Service Genie Z135

Service Manual
Serial Number Range
Z-135/70
from Z13505-101
Part No. 106783 Rev D1 July 2009
Introduction
April 2008
Introduction
Important
Read, understand and obey the safety rules and operating instructions in the Genie Z-135/70 Operator's Manual before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center.
Technical Publications
Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.
Contact Us:
http://www.genieindustries.com e-mail: techsup@genieind.com
Copyright 2005 by Genie Industries 106783 Rev D April 2008 First Edition, Fourth Printing "Genie" and "Z" are registered trademarks of Genie Industries in the USA and many other countries. Printed on recycled paper Printed in U.S.A.
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INTRODUCTION
Serial Number Legend
Model: Z-135/70 Z13505-12345 Serial number: Model year: 2005 Manufacture date: 04/12/05 Electrical schematic number: ES0366 Machine unladen weight:
Rated work load (including occupants): 600 lb / 273 kg Maximum number of platfrm occupants: 2 Maximum allowable side force : 150 lb / 670 N Maximum allowable inclination of the chassis: 0 deg Maximum wind speed : 28 mph/ 12.5 m/s Maximum platform height : 135 ft/ 41.15 m Maximum platform reach : 69 ft 9 in/ 21.26 m Gradeability: 45% Country of manufacture: USA This machine complies with: ANSI A92.5 CAN B.354.4
Z135 05 - 12345
Model Sequence number
Year of manufacture
Genie Industries 18340 NE 76th Street Redmond, WA 98052 USA

Serial label (located under cover) Serial number stamped on chassis
PN - 77055
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Section 1 Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in this manual, and the Genie Z-135/70 Operator's Manual will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
Do Not Perform Maintenance Unless:

You are trained and qualified to perform maintenance on this machine. You read, understand and obey: - manufacturers instructions and safety rules - employers safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop.
Part No. 106783
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Section 1 - Safety Rules
April 2008
SAFETY RULES
Personal Safety
Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.
Workplace Safety
Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit.
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Table of Contents
Introduction Important Information ................................................................................................... ii Serial Number Legend ................................................................................................. iii Section 1 Safety Rules General Safety Rules .................................................................................................. v Section 2 Rev G Specifications Machine Specifications .......................................................................................... 2 - 1 Performance Specifications ................................................................................... 2 - 1 Hydraulic Specifications ........................................................................................ 2 - 2 Manifold Component Specifications ....................................................................... 2 - 4 Deutz BF4L 2011 Engine ....................................................................................... 2 - 5 Deutz TD2011L04i Engine ...................................................................................... 2 - 7 Cummins B4.5L Engine ......................................................................................... 2 - 9 Cummins B3.3T Engine ....................................................................................... 2 - 10 Perkins 1104C-44 Engine ..................................................................................... 2 - 11 Perkins 804D-33T Engine .................................................................................... 2 - 13 Machine Torque Specifications ............................................................................ 2 - 14 Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 15 SAE and Metric Fasteners Torque Charts ............................................................ 2 - 16
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TABLE OF CONTENTS
Section 3
Rev
Scheduled Maintenance Procedures Introduction ............................................................................................................ 3 - 1 Pre-delivery Preparation ......................................................................................... 3 - 3 Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 Inspect the Manuals and Decals .................................................................. 3 - 7 Perform Pre-operation Inspection ................................................................. 3 - 8 Perform Function Tests ................................................................................ 3 - 8 Perform Engine Maintenance - Deutz Models ............................................... 3 - 9 Perform Engine Maintenance - Cummins Models ......................................... 3 - 9 Perform Engine Maintenance - Perkins Models .......................................... 3 - 10 Check the Hydraulic Return Filter Condition Indicator ................................. 3 - 10 Inspect the Fuel Filter/Water Separator Element - Perkins Models ............. 3 - 11 Drain the Fuel Filter/Water Separator Element Deutz and Cummins Models ...................................................................... 3 - 12
A-10 Perform 30 Day Service ............................................................................. 3 - 13 A-11 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13 A-12 Replace the Drive Hub Oil .......................................................................... 3 - 14 D Checklist B Procedures B-1 B-2 B-3 B-4 B-5 B-6 Inspect the Batteries .................................................................................. 3 - 15 Inspect the Electrical Wiring ....................................................................... 3 - 16 Test the Key Switches ............................................................................... 3 - 18 Check the Exhaust System ....................................................................... 3 - 20 Check the Engine Oil Cooler and Cooling Fins - Deutz Models ................... 3 - 21 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22
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Section 3
Rev
Scheduled Maintenance Procedures, continued B-7 B-8 B-9 Confirm the Proper Brake Configuration ...................................................... 3 - 22 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23 Test the Ground Control Override ............................................................... 3 - 24
B-10 Test the Platform Self-leveling ................................................................... 3 - 25 B-11 Test the Engine Idle Select Operation ........................................................ 3 - 26 B-12 Test the Drive Brakes ................................................................................ 3 - 27 B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 27 B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 28 B-15 Test the Alarm and Optional Flashing Beacon ............................................ 3 - 29 B-16 Perform Hydraulic Oil Analysis ................................................................... 3 - 29 B-17 Replace the Inline Fuel Filter/Water Separator Element - Perkins Models .......................................................... 3 - 30 B-18 Check and Adjust the Engine RPM ............................................................ 3 - 31 B-19 Test the Safety Envelope Limit Switches ................................................... 3 - 34 B-20 Test the Primary Boom Angle Sensor ........................................................ 3 - 37 B-21 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 38 B-22 Perform Engine Maintenance - Cummins Models ....................................... 3 - 39 D Checklist C Procedures C-1 C-2 C-3 C-4 C-5 Perform Engine Maintenance - Deutz Models ............................................. 3 - 40 Perform Engine Maintenance - Cummins Models ....................................... 3 - 40 Perform Engine Maintenance - Perkins Models .......................................... 3 - 41 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 41 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 42
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Section 3
Rev D
Scheduled Maintenance Procedures, continued Checklist D Procedures D-1 D-2 D-3 D-4 D-5 D-6 D-7 D-8 D-9 Check the Boom Wear Pads ...................................................................... 3 - 44 Check the Free-wheel Configuration ........................................................... 3 - 45 Replace the Drive Hub Oil .......................................................................... 3 - 46 Adjust the Turntable Rotation Backlash ...................................................... 3 - 48 Replace the Hydraulic Filter Elements ........................................................ 3 - 49 Perform Engine Maintenance - Deutz Models ............................................. 3 - 51 Perform Engine Maintenance - Cummins Models ....................................... 3 - 51 Perform Engine Maintenance - Perkins Models .......................................... 3 - 52 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 52
D-10 Inspect for Turntable Bearing Wear ............................................................ 3 - 54 D Checklist E Procedures E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 Test or Replace the Hydraulic Oil ............................................................... 3 - 55 Perform Engine Maintenance - Cummins Models ....................................... 3 - 57 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 57 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 58 Perform Engine Maintenance Deutz TD2011L04i and Perkins 804D-33T Models ...................................... 3 - 58 Perform Engine Maintenance - Deutz TD2011L04i Models ......................... 3 - 59 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 59 Perform Engine Maintenance - Perkins 1104C-44 Models .......................... 3 - 60 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 60
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TABLE OF CONTENTS
Section 4
Rev
Repair Procedures Introduction ............................................................................................................ 4 - 1
C C
Display Module ...................................................................................................... 4 - 2 Platform Controls 1-1 1-2 1-3 ALC-1000 Circuit Board ................................................................................ 4 - 9 Membrane Decal ........................................................................................ 4 - 10 Joysticks ................................................................................................... 4 - 11
Platform Components 2-1 2-2 2-3 2-4 Platform Leveling Cylinder .......................................................................... 4 - 19 Platform Rotator ......................................................................................... 4 - 20 Platform Level Sensor ................................................................................ 4 - 21 Platform Overload System (if equipped) ..................................................... 4 - 23
Jib Boom Components 3-1 3-2 3-3 3-4 3-5 3-6 Jib Boom Cable Track ................................................................................ 4 - 27 Jib Boom .................................................................................................... 4 - 29 Jib Boom Lift Cylinder ................................................................................ 4 - 31 Jib Boom Level Cylinder ............................................................................. 4 - 32 Jib Boom Extension Cylinder ..................................................................... 4 - 33 Jib Boom Bellcrank Angle Sensor .............................................................. 4 - 34
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Section 4
Rev F
Repair Procedures, continued Boom Components 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 Primary Boom Cable Track ........................................................................ 4 - 41 Secondary Boom Cable Track .................................................................... 4 - 44 Primary Boom ............................................................................................ 4 - 47 Primary Boom Lift Cylinder ......................................................................... 4 - 49 Secondary Boom Lift Cylinder .................................................................... 4 - 50 Primary Boom Extension Cylinder .............................................................. 4 - 53 Secondary Boom Extension Cylinders ....................................................... 4 - 54 Primary Boom Angle Sensor ...................................................................... 4 - 55 Secondary Boom Angle Sensor .................................................................. 4 - 61
Engines 5-1 5-2 RPM Adjustment ........................................................................................ 4 - 66 Flex Plate ................................................................................................... 4 - 66
Ground Controls 6-1 6-2 6-3 Service Bypass / Recovery Keyswitch ....................................................... 4 - 69 Circuit Boards ............................................................................................ 4 - 71 Membrane Decal ........................................................................................ 4 - 72
Hydraulic Pumps 7-1 7-2 Function Pump .......................................................................................... 4 - 73 Drive Pump ................................................................................................ 4 - 76
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Section 4
Rev E
Repair Procedures, continued Manifolds 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-9 Function Manifold - View 1 (before serial number 440) ................................ 4 - 78 Function Manifold - View 2 (before serial number 440) ................................ 4 - 80 Function Manifold - View 1 (after serial number 439) .................................. 4 - 82 Function Manifold - View 2 (after serial number 439) .................................. 4 - 84 Valve Adjustments - Function Manifold ...................................................... 4 - 86 Platform Manifold ....................................................................................... 4 - 88 Jib Boom Manifold ..................................................................................... 4 - 90 Function Enable Valve ............................................................................... 4 - 92 Turntable Rotation Manifolds ...................................................................... 4 - 93
8-10 Steer and Axle Manifold ............................................................................. 4 - 94 8-11 Valve Adjustments - Steer and Axle Manifold ............................................ 4 - 98 8-12 Traction Manifold - View 1 ......................................................................... 4 - 100 8-13 Traction Manifold - View 2 ......................................................................... 4 - 102 8-14 Valve Adjustments, Traction Manifold ....................................................... 4 - 104 8-15 Drive Oil Diverter Manifold (welder option) ................................................. 4 - 105 8-16 Valve Coils ................................................................................................ 4 - 106 E Turntable Rotation Components 9-1 9-2 F Turntable Rotation Assembly .................................................................... 4 - 108 Turntable Level Sensor ............................................................................. 4 - 109
Axle Components 10-1 Steer Sensors ........................................................................................... 4 - 112 10-2 Steer Cylinders .......................................................................................... 4 - 117 10-3 Axle Extension Cylinders .......................................................................... 4 - 118 10-4 Axle Angle Sensors ................................................................................... 4 - 119
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TABLE OF CONTENTS
Section 5
Rev
Fault Codes Introduction ............................................................................................................ 5 - 1
B A Section 6 Rev
Control System Fault Codes .................................................................................. 5 - 2 SCON Fault Matrix ............................................................................................... 5 - 20 Schematics Introduction ............................................................................................................ 6 - 1
C B B B B B A A A B B D C B A C
Wire Circuit Legend ................................................................................................ 6 - 2 Limit Switches and Angle Sensors ......................................................................... 6 - 9 Drive Chassis and Platform Controller Pin Legend ............................................... 6 - 11 Safety Controller Pin Legend ................................................................................ 6 - 12 Turntable Controller Pin Legend ........................................................................... 6 - 13 Engine Relay and Fuse Panel Legend .................................................................. 6 - 14 Electrical Symbols Legend .................................................................................. 6 - 15 Hydraulic Symbols Legend .................................................................................. 6 - 16 Electrical Schematic Layout ................................................................................ 6 - 18 Electrical Connector and Circuit Legend ............................................................... 6 - 19 Electrical Schematic - View 1, Drive Chassis Controller (DCON) ......................... 6 - 22 Electrical Schematic - View 2, Platform Controls (PCON) .................................... 6 - 23 Electrical Schematic - View 3, Ground Controls (TCON) ...................................... 6 - 26 Electrical Schematic - View 4, Ground Controls (TCON) ...................................... 6 - 27 Electrical Schematic - View 5, Ground Controls (TCON) ...................................... 6 - 30 Electrical Schematic - View 6, Ground Controls (TCON) ...................................... 6 - 31
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Section 6
Rev B D B D A D B B B B D B A
Schematics, continued Electrical Schematic - View 7 .............................................................................. 6 - 34 Electrical Schematic - View 8 .............................................................................. 6 - 35 Electrical Schematic - View 9 .............................................................................. 6 - 38 Electrical Schematic - View 10, Limit Switches ................................................... 6 - 39 Electrical Schematic - View 10A, Limit Switches ................................................. 6 - 41 Electrical Schematic - View 11, Deutz BF4L 2011 Engine and Deutz TD2011L04i Engine ........................... 6 - 44 Electrical Schematic - View 12 ............................................................................ 6 - 45 Electrical Schematic - View 13, Perkins 1104C-44 Engine and Perkins 804D-33T ....................................... 6 - 48 Electrical Schematic - View 14, Cummins B4.5L Engine and Cummins B3.3T Engine ................................. 6 - 49 Generator Wiring .................................................................................................. 6 - 51 Hydraulic Schematic (before serial number 180, except for serial number 102) .... 6 - 54 Hydraulic Schematic (serial number 102 and from serial number 180 to 534) ....... 6 - 55 Hydraulic Schematic (from serial number 535) ..................................................... 6 - 57
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Section 2 Specifications
REV G
Specifications
Performance Specifications
Drive speeds, maximum 445/65D22.5, FF 18 46.5 in 118.1 cm 22.5 in 57.2 cm 13 in 33 cm 10 @ 3/4 -16 420 ft-lbs 569.4 Nm 320 ft-lbs 433.9 Nm Braking distance, maximum High range on paved surface Gradeability 40 gallons 151.4 liters 65 gallons 246 liters 123 gallons 466 liters 47 fl oz 1.4 liters 40 fl oz 1.18 liters 3 to 6 ft 1 to 2 m See Operator's Manual Raised and extended Stowed position, high speed 2.8 mph 4.5 km/h 40 ft / 9.7 sec 12.2 m / 9.7 sec 0.7 mph 1.1 km/h 40 ft / 40 sec 12.2 m / 40 sec 0.4 mph 0.64 km/h 40 ft / 68.5 sec 12.2 m / 68.5 sec
Machine Specifications
Tires and wheels Tire size Tire ply rating Overall tire diameter Wheel diameter Wheel width Wheel lugs Lug nut torque, dry Lug nut torque, lubricated Fluid capacities Fuel tank Hydraulic tank Hydraulic system (including tank) Drive hubs Turntable rotation drive hub
Raised or extended
Boom function speeds, maximum from platform controls Jib boom up/down Jib boom extend/retract Primary boom up/down -60 to +70 Primary boom extend/retract Secondary boom up/down Secondary boom extend/retract Turntable rotate, 360 fully stowed Turntable rotate, 360 jib or primary booms extended Turntable rotate, 360 jib and primary booms extended 38 to 43 seconds 38 to 42 seconds 88 to 105 seconds 35 to 48 seconds 80 to 95 seconds 88 to 98 seconds 88 to 92 seconds 160 to 180 seconds 280 to 350 seconds
Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5
For operational specifications, refer to the Operator's Manual.
Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.
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SPECIFICATIONS
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Hydraulic Specifications
Hydraulic Oil Specifications Hydraulic oil type Viscosity grade Viscosity index Chevron Rykon MV equivalent Multi-viscosity 200 15/13 200 ppm
Component damage hazard. Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32F / 0C may result in component damage. Note: Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 0F / 18C. Note: Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205F / 96C. Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use.
Cleanliness level, minimum Water content, maximum
Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties. Optional fluids Biodegradable Petro Canada Environ MV 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE-S UCON Hydrolube HP-5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A
Fire resistant Mineral based
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SPECIFICATIONS
Drive pump Type: bi-directional variable displacement piston pump Displacement Flow rate @ 2350 rpm Drive pressure, maximum Charge pump Type: Displacement Flow rate @ 2350 rpm Charge pressure @ 2350 rpm Neutral position Function pumps Type: Displacement Flow rate @ 2350 rpm Pressure, maximum Pressure compensator Standby pressure Auxiliary pumps Type: Displacement fixed displacement gear pump 0.15 cu in 2.47 cc variable displacement piston pump 0 to 2.75 cu in 0 to 45 cc 0 to 28 gpm 0 to 106 L/min 2900 psi 200 bar 2900 psi 200 bar 250 psi 17 bar gerotor 0.85 cu in 13.9 cc 9 gpm 34 L/min 315 psi 21.7 bar 2.8 cu in 46 cc 28.5 gpm 108 L/min 3625 psi 250 bar
Function manifold Function relief pressure (measured at TEST port) Primary boom extend relief pressure (measured at PTEST port) Jib and platform manifolds Platform rotate and platform level flow regulator Jib manifold flow regulator Steer/Axle manifold Axle extend relief pressure Drive manifold Hot oil relief pressure Hydraulic filters High pressure filter High pressure filter bypass pressure Medium pressure filter Medium pressure filter bypass pressure Hydraulic tank return filter Drive motor case drain return filter Beta 3 200 102 psi 7 bar Beta 3 200 51 psi 3.5 bar 10 micron with 25 psi / 1.7 bar bypass Beta 10 2 250 psi 17.2 bar 2400 psi 165 bar 0.2 gpm 0.76 L/min 2 gpm 7.6 L/min 3100 psi 213.7 bar 2600 psi 179 bar
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SPECIFICATIONS
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Brakes Brake release pressure Drive motors (before serial number 180) (see note below) Displacement per revolution, high speed Displacement per revolution, low speed Drive motors (after serial number 179) Displacement per revolution, high speed Displacement per revolution, low speed (square end) Displacement per revolution, low speed (circle end) 0.8 cu in 13.3 cc 2.7 cu in 45 cc 1.5 cu in 25 cc 0.8 cu in 13.3 cc 2.7 cu in 45 cc 190 psi 13 bar
Manifold Component Specifications

Plug torque SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 SAE No. 12 36 in-lbs / 4 Nm 10 ft-lbs / 13 Nm 14 ft-lbs / 19 Nm 38 ft-lbs / 51 Nm 41 ft-lbs / 55 Nm 56 ft-lbs / 76 Nm
Valve coil resistance specifications Proportional solenoid valve (schematic items N, P, R, T, V) 3 position 4 way solenoid valve (schematic item B) 3 position 4 way solenoid valve (schematic items BN, BO, BP and BQ) 3 position 4 way solenoid valve (schematic item AH) 3 position 4 way proportional solenoid valve (schematic items Y and AI) 2 position 3 way solenoid valve (schematic items F and AD) 2 position 3 way solenoid valve (schematic items AE and AF) 2 position 3 way solenoid valve (schematic items H and J) 2 position 3 way solenoid valve (schematic items C, D, G, I, K, AX, AY, BU and BT) 2 position 2 way solenoid valve (schematic item A) 3.5 to 5.5 4 to 6 7 to 9 8 to 10 8 to 10
Note: Serial number 102 is equipped with drive motors equal to those used on machines after serial number 179.
5.5 to 7.5 8 to 10 3.5 to 5.5 7.5 to 9.5
3.5 to 5.5
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SPECIFICATIONS
Deutz BF4L 2011 Engine

Displacement Number of cylinders Bore and stroke Horsepower Continuous @ 2500 rpm Net intermittent @ 2500 rpm Firing order Low idle High idle Compression ratio 189.6 cu in 3.1 liters 4 3.7 x 4.409 inches 94 x 112 mm 69 / 51 kW 73 / 54 kW 1-3-4-2 1500 rpm 383 Hz 2350 rpm 599 Hz 17.5:1
Oil viscosity requirements -22F to 86F / -30C to 30C -4F to 90F / -20C to 32C Above 23F / -5C 5W-30 (synthetic) 10W-40 20W-50
Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil temperature switch Installation torque Oil temperature switch point Oil pressure switch Installation torque Oil pressure switch point Fuel injection system 8-18 ft-lbs 11-24 Nm 7 psi 0.48 bar 8-18 ft-lbs 11-24 Nm 275F 135C
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor Valve clearance, cold Intake Exhaust Lubrication system Oil pressure, hot (at 2000 rpm) Oil capacity (including filter) 40 to 60 psi 2.8 to 4.1 bar 11 quarts 10.4 liters 0.012 in 0.3 mm 0.020 in 0.5 mm centrifugal mechanical
Injection pump make Injection pump pressure, maximum Injector opening pressure Fuel requirement
Motorpal 15,000 psi 1034 bar 3046 psi 210 bar
For fuel requirements, refer to the engine Operator's Manual on your machine. Starter motor Current draw, normal load Cranking speed 140-200A 200-250 rpm
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Battery - Auxiliary power units Type Quantity AH rating Reserve capacity @ 25A rate 6V DC 2 285AH 745 minutes
Battery - Engine starting and control system Type Quantity Cold cranking ampere Reserve capacity @ 25A rate Alternator output Fan belt deflection 12V DC, Group 31 1 1000A 200 minutes 80A @ 14V DC
3 /8
to 1/2 inch 9 to 12 mm
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SPECIFICATIONS
Deutz TD2011L04i Engine

Displacement Number of cylinders Bore and stroke Horsepower Net intermittent @ 2400 rpm Induction system Firing order Low idle High idle Compression ratio 220.9 cu in 3.62 liters 4 3.78 x 4.92 inches 96 x 125 mm 74 / 55 kW turbocharged 1-3-4-2 1500 rpm 383 Hz 2350 rpm 599 Hz 17.5:1
Lubrication system Oil pressure, hot (at 2000 rpm) Oil capacity (including filter) Oil viscosity requirements -22F to 86F / -30C to 30C -4F to 104F / -20C to 40C Above 5F / -15C 5W-30 (synthetic) 10W-40 15W-40 40 to 60 psi 2.8 to 4.1 bar 12.8 quarts 12.1 liters
Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil temperature switch Installation torque Oil temperature switch point Oil pressure switch Installation torque 8-18 ft-lbs 11-24 Nm 22 psi 1.5 bar 8-18 ft-lbs 11-24 Nm 275F 135C
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor Valve clearance, cold Intake Exhaust 0.012 in 0.3 mm 0.020 in 0.5 mm centrifugal mechanical
Oil pressure switch point
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Fuel injection system Injection pump make Injection pump pressure, maximum Injector opening pressure Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Starter motor Current draw, normal load Cranking speed Battery - Auxiliary power units Type Quantity AH rating Reserve capacity @ 25A rate 6V DC 2 285AH 745 minutes 140-200A 250-350 rpm Motorpal 15,000 psi 1034 bar 3046 psi 210 bar
Battery - Engine starting and control system Type Quantity Cold cranking ampere Reserve capacity @ 25A rate Alternator output Fan belt deflection 12V DC, Group 31 1 1000A 200 minutes 80A @ 14V DC
3 /8
to 1/2 inch 9 to 12 mm
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SPECIFICATIONS
Cummins B4.5L Engine

Displacement Number of cylinders Bore and stroke Horsepower Firing order Low idle High idle Compression ratio 275 cu in 4.5 liters 4 4.02 x 5.42 inches 102 x 138 mm 80 @ 2200 rpm 60 kW @ 2200 rpm 1-3-4-2 1300 rpm 368 Hz 2350 rpm 666 Hz 18:1 Fuel injection system Injection pump make Injection pump pressure Injector opening pressure Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Battery - Auxiliary power units Type Quantity AH rating Reserve capacity @ 25A rate 6V DC 2 285AH 745 minutes Delphi 3480 to 3680 psi 240 to 254 bar 3480 psi 240 bar
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Valve clearance, cold Intake Exhaust Lubrication system Oil pressure, hot (at 2000 rpm) Oil capacity (including filter) Oil viscosity requirements Below 68F / 20C -10 to 68F / -23 to 20C Above 15F / -9C 5W-30 10W-30 15W-40 50 psi 3.45 bar 9.5 quarts 9 liters 0.010 in 0.254 mm 0.020 in 0.508 mm
Battery - Engine starting and control system Type Quantity Cold cranking ampere Reserve capacity @ 25A rate Starter motor Current draw, no load Brush length, minimum Engine coolant Capacity Coolant temperature sending unit Installation torque Temperature switch point Alternator output Fan belt deflection 8-18 ft-lbs 11-24 Nm 230F 110C 95A, 12V DC
3/8 to 1/2 inch 10 to 12.5 mm
12V DC, Group 31 1 1000A 200 minutes
125A 0.72 in 18.3 mm
17 quarts 16 liters
Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.
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Cummins B3.3T Engine

Displacement Number of cylinders Bore and stroke Horsepower Firing order Low idle High idle Compression ratio 199 cu in 3.26 liters 4 3.74 x 4.53 inches 95 x 115 mm 80 @ 2200 rpm 60 kW @ 2200 rpm 1-2-4-3 1300 rpm 368 Hz 2350 rpm 666 Hz 17:1 Fuel injection system Injection pump make Injection pressure Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Battery - Auxiliary power units Type Quantity AH rating Reserve capacity @ 25A rate 6V DC 2 285AH 745 minutes Zexel 12,000 psi 827 bar
Battery - Engine starting and control system Type Quantity Cold cranking ampere Reserve capacity @ 25A rate Starter motor 12V DC, Group 31 1 1000A 200 minutes
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Valve clearance, cold Intake Exhaust Lubrication system Oil pressure, hot (at 2000 rpm) Oil capacity (including filter) Oil viscosity requirements Below 68F / 20C -10 to 68F / -23 to 20C Above 14F / -10C 5W-30 10W-30 15W-40 31 to 72 psi 2 to 5 bar 9 quarts 8.5 liters 0.014 in 0.35 mm 0.020 in 0.5 mm
Current draw, maximum Engine cranking speed, minimum Engine coolant Capacity Alternator output Fan belt deflection
550A 130 rpm
9.1 quarts 8.6 liters 120A, 12V DC

3/8 to 1/2 inch 10 to 12.5 mm
Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.
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SPECIFICATIONS
Perkins 1104C-44 Engine

Displacement Number of cylinders Bore and stroke Horsepower Gross intermittent @ 2400 rpm Net intermittent @ 2400 rpm Firing order Low idle High idle Compression ratio 86 / 64 kW 83 / 62 kW 1-3-4-2 1300 rpm 316 Hz 2350 rpm 572 Hz 18.2:1 268.5 cu in 4.4 liters 4 4.13 x 5 inches 105 x 127 mm
Oil viscosity requirements Below 68F / 20C 10F to 104F / -12C to 40C Above 14F / -10C 5W-20 10W-30 15W-40
Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil pressure sending unit Installation torque Oil pressure switch point Fuel injection system Injection pump make Injector opening pressure Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Battery - Auxiliary power units Type Quantity AH rating Reserve capacity @ 25A rate 6V DC 2 285AH 745 minutes Bosch 2200 psi 152 bar 8-18 ft-lbs 11-24 Nm 8 psi 0.55 bar
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor Valve clearance, cold Intake Exhaust Lubrication system Oil pressure, hot (at 2000 rpm) Oil capacity (including filter) 40 to 60 psi 2.8 to 4.1 bar 7.3 quarts 6.9 liters 0.008 in 0.2 mm 0.018 in 0.45 mm centrifugal mechanical
Battery - Engine starting and control system Type Quantity Cold cranking ampere Reserve capacity @ 25A rate 12V DC, Group 31 1 1000A 200 minutes
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Starter motor Current draw, normal load Cranking speed Engine coolant Capacity Coolant temperature sending unit Installation torque Temperature switch point Alternator output Fan belt deflection 8-18 ft-lbs 11-24 Nm 230F 110C 85A @ 13.8V DC
3/8 in 10 mm
140-200A 200-250 rpm
14 quarts 13.2 liters
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Perkins 804D-33T Engine

Displacement Number of cylinders Bore and stroke Horsepower Gross intermittent @ 2500 rpm Induction system Firing order Low idle High idle Compression ratio 83 / 62 kW turbocharged 1-3-4-2 1300 rpm 316 Hz 2350 rpm 572 Hz 19.5:1 203 cu in 3.33 liters 4 3.7 x 4.72 inches 94 x 120 mm
Oil viscosity requirements Below 86F / 30C -4F to 104F / -20C to 40C Above 14F / -10C 5W-30 10W-30 15W-40
Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil pressure sending unit Installation torque Oil pressure switch point Fuel injection system Injection pump make Injector opening pressure Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. Battery - Auxiliary power units Bosch 2200 psi 152 bar 8-18 ft-lbs 11-24 Nm 8 psi 0.55 bar
Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder. Governor Valve clearance, cold Intake Exhaust Lubrication system Oil pressure, hot (at 2000 rpm) Oil capacity (including filter) 40 to 60 psi 2.8 to 4.1 bar 10.6 quarts 10 liters 0.0098 in 0.25 mm 0.0098 in 0.25 mm centrifugal mechanical
Type Quantity AH rating Reserve capacity @ 25A rate
6V DC 2 285AH 745 minutes
Battery - Engine starting and control system Type Quantity Cold cranking ampere Reserve capacity @ 25A rate 12V DC, Group 31 1 1000A 200 minutes
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Starter motor Current draw, normal load Cranking speed Engine coolant Capacity Coolant temperature sending unit Installation torque Temperature switch point Alternator output Fan belt deflection 8-18 ft-lbs 11-24 Nm 230F 110C 90A @ 12V DC
3/8 to 1/2 in 9 to 12 mm
Machine Torque Specifications

200A 250 rpm Platform rotator 1-8 center bolt, GR 5
3 /8
480 ft-lbs 651 Nm 44 ft-lbs 60 Nm
12.5 quarts 11.8 liters
-16 bolts, GR 8
Turntable rotate assembly Rotate bearing mounting bolts, lubricated (3/4 -10 SHC) Rotate bearing mounting bolts, lubricated (5/8 -11 SHC) Rotate drive hub mounting bolts, lubricated Drive motor mounting bolts, dry Drive motor mounting bolts, lubricated Backlash plate mounting bolts, lubricated Drive motors and hubs Drive hub mounting bolts, lubricated Drive motor mounting bolts, dry Drive motor mounting bolts, lubricated Engine vibration isolators Mounting bolts, dry Mounting bolts, lubricated 60 ft-lbs 81 Nm 45 ft-lbs 61 Nm 180 ft-lbs 217 Nm 75 ft-lbs 102 Nm 56 ft-lbs 76 Nm 320 ft-lbs 434 Nm 180 ft-lbs 244 Nm 80 ft-lbs 108 Nm 75 ft-lbs 102 Nm 56 ft-lbs 76 Nm 320 ft-lbs 434 Nm
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Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.
Seal-Lok fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been 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 are available in the O-ring field service kit (Genie part number 49612). 2 Lubricate the O-ring before installation. 3 Be sure that the face seal O-ring is seated and retained properly. 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight. 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table. 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks.
SAE O-ring Boss Port

(tube fitting - installed into Aluminum) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Torque 11 ft-lbs / 14.9 Nm 23 ft-lbs / 31.2 Nm 40 ft-lbs / 54.2 Nm 69 ft-lbs / 93.6 Nm 93 ft-lbs / 126.1 Nm 139 ft-lbs / 188.5 Nm 172 ft-lbs / 233.2 Nm 208 ft-lbs / 282 Nm
SAE O-ring Boss Port

(tube fitting - installed into Steel) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Torque 16 ft-lbs / 21.7 Nm 35 ft-lbs / 47.5 Nm 60 ft-lbs / 81.3 Nm 105 ft-lbs / 142.4 Nm 140 ft-lbs / 190 Nm 210 ft-lbs / 284.7 Nm 260 ft-lbs / 352.5 Nm 315 ft-lbs / 427.1 Nm
Seal-Lok Fittings
(hose end) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Torque 18 ft-lbs / 25 Nm 30 ft-lbs / 40 Nm 40 ft-lbs / 55 Nm 60 ft-lbs / 80 Nm 85 ft-lbs / 115 Nm 110 ft-lbs / 150 Nm 140 ft-lbs / 190 Nm 180 ft-lbs / 245 Nm
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SAE FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
SIZE
THREAD
LUBED
in-lbs
Grade 5
DRY
in-lbs Nm
Grade 8
LUBED
in-lbs Nm in-lbs
DRY
Nm
A574 High Strength Black Oxide Bolts LUBED

in-lbs Nm
Nm
1/4
20 28
80 90
ft-lbs
9 10.1 LUBED
Nm
100 120 DRY

ft-lbs
11.3 13.5
Nm
110 120
ft-lbs
12.4 13.5
Nm
140 160 DRY

ft-lbs
15.8 18
Nm
130 140 LUBED

ft-lbs
14.7 15.8
Nm
LUBED 23 25.7 42 47.4 66.4 74.5 101.6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969 18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670 24 27.1 44.7 50.1 67.8 81.3 108.4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620 25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8
1 1 1/8 1 1/4 1 1/2
18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12
13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640
17.6 19 31.2 35.2 50.1 55.5 77.3 86.7 108.4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223
17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190
33.9 36.6 59.6 66.4 94.7 108.4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826
21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000
28.4 32.5 51.5 58.3 82.7 92.1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067
METRIC FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual
Size
(m m ) 5 6 7
in- lbs
Class 4.6
LUBED
Nm in-lbs
4.6
Class 8.8
LUBED
in- lbs Nm in- lbs
8.8
Class 10.9
LUBED
in- lbs Nm in- lbs
10.9
Class 12.9
LUBED
in- lbs Nm in- lbs
12.9
DRY
Nm
DRY
Nm
DRY
Nm
DRY
Nm
16 19 45
f t - lbs
1.8 3.05 5.12

Nm
21 36 60
f t -lbs
2.4 4.07 6.83 DRY

Nm
41 69 116
f t - lbs
4.63 7.87 13.2

Nm
54 93 155
f t - lbs
6.18 10.5 17.6

Nm
58 100 167
f t - lbs
6.63 11.3 18.9

Nm
78 132 223
ft - lbs
8.84 15 25.2
Nm
68 116 1.95
f t - lbs
7.75 13.2 22.1

Nm
91 155 260
f t - lbs
10.3 17.6 29.4

Nm
LUBED 8 10 12 14 16 18 20 22 24 5.4 10.8 18.9 30.1 46.9 64.5 91 124 157 7.41 14.7 25.6 40.8 63.6 87.5 124 169 214
LUBED 14 27.9 48.6 77.4 125 171 243 331 420 19.1 37.8 66 105 170 233 330 450 570
DRY 18.8 37.2 64.9 103 166 229 325 442 562 25.5 50.5 88 140 226 311 441 600 762
LUBED 20.1 39.9 69.7 110 173 238 337 458 583 27.3 54.1 94.5 150 235 323 458 622 791
DRY 26.9 53.2 92.2 147 230 317 450 612 778 36.5 72.2 125 200 313 430 610 830 1055
LUBED 23.6 46.7 81 129 202 278 394 536 682 32 63.3 110 175 274 377 535 727 925
DRY 31.4 62.3 108 172 269 371 525 715 909 42.6 84.4 147 234 365 503 713 970 1233
7.2 14.4 25.1 40 62.5 86.2 121 166 210
9.88 19.6 34.1 54.3 84.8 117 165 225 285
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Section 3 Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions.
Observe and Obey:

Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine. Scheduled maintenance inspections shall be completed daily, quarterly, six months, annually and every two years as specified on the Maintenance Inspection Report. Failure to perform each procedure as presented and scheduled could result in death, serious injury or substantial machine damage. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating machine. Use only Genie approved replacement parts. Unless otherwise specified, perform each maintenance procedure with the machine in the following configuration: Machine parked on a firm, level surface Boom in the stowed position Turntable rotated with the boom between the circle-end (yellow arrow) wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine
Symbols Legend Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps.
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SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Note: The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below.
Pre-delivery Preparation Report The pre-delivery preparation report contains checklists for each type of scheduled inspection. Make copies of the Pre-delivery Preparation report to use for each inspection. Store completed forms as required. Maintenance Schedule
Indicates that tools will be required to perform this procedure.
Indicates that new parts will be required to perform this procedure.
Indicates that a cold engine will be required to perform this procedure.
There are five types of maintenance inspections that must be performed according to a schedule daily, quarterly, semi-annually, annual and two years. The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsectionsA, B, C, D and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.
Inspection Checklist A A+B A+B+C A+B+C+D A+B+C+D+E
Indicates that a warm engine will be required to perform this procedure.
Daily or every 8 hours Quarterly or every 250 hours
Indicates that dealer service is required to perform this procedure.
Semi-annually or every 500 hours Annual or every 1000 hours Two years or every 2000 hours
Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements.
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Pre-Deliver y Preparation Pre-Delivery

April 2008 Section 3 Scheduled Maintenance Procedures
Fundamentals
It is the responsibility of the dealer to perform the Pre-delivery Preparation. The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service. A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.
Instructions
Use the operators manual on your machine. The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests. Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operators manual. If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, completed N = no, unable to complete R = repaired Comments
Pre-Delivery Preparation 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
Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond, WA 98073-9730 (425) 881-1800 Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333
Copyright 2002 by Genie Industries. Genie is a registered trademark of Genie Industries. Rev B
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Maintenance Inspection Report

Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection. Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection: Checklist A - Rev G A-1 Manuals and decals A-2 Pre-operation inspection A-3 Function tests A-4 Engine maintenance Deutz models A-5 Engine maintenance Cummins models A-6 Engine maintenance Perkins models A-7 Hydraulic return filter condition indicator A-8 Inspect filter/separator Perkins models A-9 Drain fuel filter/ separator - Deutz and Cummins models Perform after 40 hours: A-10 30 Day Service Perform every 100 hours: A-11 Grease rotation bearing Perform after 150 hours: A+B A-12 Drive hub oil Y N R Checklist B - Rev D B-1 Batteries B-2 Electrical wiring B-3 Key switches B-4 Exhaust system B-5 Engine oil cooler and cooling fins Deutz models B-6 Tires and wheels B-7 Brake configuration B-8 Drive hub oil level B-9 Ground control override B-10 Platform self leveling B-11 Engine idle select B-12 Drive brakes B-13 Drive speed - stowed B-14 Drive speed - raised or extended B-15 Alarm and beacon B-16 Hydraulic oil analysis B-17 Replace fuel filter/ separator Perkins models B-18 Engine RPM B-19 Safety envelope limit switches B-20 Primary boom angle sensor B-21 Fuel and hydraulic tank cap venting B-22 Engine maintenance Cummins models Comments Y N R
Semi-annual or 500 hour Inspection: A+B+C Annual or 1000 hours Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E Place a check in the appropriate box after each inspection procedure is completed. Use the step-by-step procedures in this section to learn how to perform these inspections. If any inspection receives an N, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, acceptable N = no, remove from service R = repaired
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MAINTENANCE INSPECTION REPORT
Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection. Select the appropriate checklist(s) for the type of inspection to be performed. Daily or 8 hour Inspection: Quarterly or 250 hour Inspection:
Checklist C - Rev D C-1 Engine maintenance Deutz models C-2 Engine maintenance Cummins models C-3 Engine maintenance Perkins models C-4 Grease platform overload (if equipped) C-5 Test the platform overload (if equipped) Checklist D - Rev D D-1 Boom wear pads D-2 Free-wheel configuration D-3 Drive hub oil D-4 Rotation gear backlash D-5 Replace hydraulic filters D-6 Engine maintenance Deutz models D-7 Engine maintenance Cummins models D-8 Engine maintenance Perkins models D-9 Turntable rotation bolts D-10 Turntable bearing wear
Y N R
Checklist E - Rev D E-1 Replace hydraulic oil E-2 Engine maintenance Cummins models E-3 Engine maintenance Perkins 804D-33T models Perform every 2 years: E-4 Engine maintenance Perkins 804D-33T models Perform every 3,000 hours:
Y N R
Y N R
E-5 Engine maintenance Deutz models Perform every 5,000 hours: E-6 Engine maintenance Deutz TD2011L04i models Perform every 6,000 hours: E-7 Engine maintenance Perkins 804D-33T models Perform every 8,000 hours: E-8 Engine maintenance Perkins 1104C-44 models Perform every 12,000 hours: E-9 Engine maintenance Perkins 804D-33T models
A A+B
Semi-annual or 500 hour Inspection: A+B+C Annual or 1000 hours Inspection: A+B+C+D 2 Year or 2000 hour Inspection: A+B+C+D+E
Comments Place a check in the appropriate box after each inspection procedure is completed. Use the step-by-step procedures in this section to learn how to perform these inspections. If any inspection receives an N, tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the R box. Legend Y = yes, acceptable N = no, remove from service R = repaired
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Checklist A Procedures
3 Open the operator's manual to the decals inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage. Result: The machine is equipped with all required decals, and all decals are legible and in good condition. Result: The machine is not equipped with all required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced. 4 Always return the manuals to the storage container after use. Note: Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed.
A-1 Inspect the Manuals and Decals

Note: Genie specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Maintaining the operators and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 1 Check to make sure that the operator's and safety manuals are present and complete in the storage container on the platform. 2 Examine the pages of each manual to be sure that they are legible and in good condition. Result: The operator's manual is appropriate for the machine and all manuals are legible and in good condition. Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or are illegible. Remove the machine from service until the manual is replaced.
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PROCEDURES
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A-2 Perform Pre-operation Inspection

Completing a pre-operation inspection is essential to safe machine operation. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The pre-operation inspection also serves to determine if routine maintenance procedures are required. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine.
A-3 Perform Function Tests

Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine.
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CHECKLIST A
PROCEDURES
A-4 Perform Engine Maintenance Deutz Models
A-5 Perform Engine Maintenance Cummins Models
Note: Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz BF4L2011 Operation Manual (Deutz part number 0297 9929) OR the Deutz TD2011 Operation Manual (Deutz part number 0312 3547).
Deutz BF4L2011 Operation Manual Genie part number Deutz TD2011 Operation Manual Genie part number
Note: Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3 Operation and Maintenance Manual (Cummins part number 3666417-00).
Cummins B4.5 Operation and Maintenance Manual Genie part number Cummins B3.3 Operation and Maintenance Manual Genie part number
84794
107527
139320
139324
To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury. To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury.
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PROCEDURES
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A-6 Perform Engine Maintenance Perkins Models
A-7 Check the Hydraulic Return Filter Condition Indicator
Note: Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 1100 Series User's Handbook (Perkins part number TPD 1477) OR the Perkins 800 Series Operation and Maintenance Manual (Perkins part number SEBU7853-00).
Perkins 1100 Series User's Handbook Genie part number Perkins 800 Series Operation and Maintenance Manual Genie part number
Note: Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Maintaining the hydraulic filters in good condition is essential to good system performance and safe machine operation. The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter. If the filter is not frequently checked and replaced, impurities will remain in the hydraulic system and cause component damage. Note: There are four hydraulic filters on the machine: one tank return filter, one medium pressure filter, one high pressure filter and one drive motor case drain filter. Only the tank return filter has a condition indicator. 1 Start the engine from the ground controls.
107526
2 Press and release the engine idle select button to change the engine rpm to high idle.
111332
To access the engine: 1 Remove the engine tray retaining fastener located under the engine tray. Swing the engine tray out and away from the machine. 2 Install the fastener that was just removed through the engine tray and into the engine tray anchor hole in the turntable. Crushing hazard. Failure to install the fastener into the engine tray anchor hole to secure the engine tray from moving could result in death or serious injury.
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CHECKLIST A
PROCEDURES
3 Open the ground control side turntable cover and inspect the filter condition indicator gauge.
a
A-8 Inspect the Fuel Filter/ Water Separator - Perkins Models
Note: Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Proper maintenance of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and component damage. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Note: Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the fuel filter/water separator. 2 Inspect the filter bowl for water buildup. Result: If water is present in the filter bowl continue with steps 3 through 7.
filter condition indicator gauge
Result: The needle on the gauge should be operating in the green area. Result: If the needle is in the red area, this indicates that the hydraulic filter is being bypassed and the filter needs to be replaced. See D-5, Replace the Hydraulic Filter Elements.
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PROCEDURES
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3 Loosen the vent plug located on the fuel filter/ water separator head.
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A-9 Drain the Fuel Filter/ Water Separator - Deutz and Cummins Models
c b
Note: Engine specifications require that this procedure be performed daily or every 8 hours, whichever comes first. Proper maintenance of the fuel filter/water separator is essential for good engine performance. Failure to perform this procedure can lead to poor engine performance and component damage. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Note: Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the fuel filter/water separator. 2 Loosen the drain plug at the bottom of the filter. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. Do not completely drain the filter. 3 Clean up any fuel that may have spilled. 4 Start the engine from the ground controls and check the fuel filter/water separator and vent plug for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.
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vent plug drain plug filter bowl separator head
4 Loosen the drain plug located at the bottom of the bowl. Allow the water to drain into a suitable container until fuel starts to come out. Immediately tighten the drain plug. 5 Tighten the vent plug. Note: If the fuel filter/water separator is completely drained, you must prime the fuel filter/water separator before starting the engine. See B-17, Replace The Fuel Filter/Water Separator Element Perkins Models, for instructions on how to prime the fuel filter/water separator. 6 Clean up any fuel that may have spilled. 7 Start the engine from the ground controls and check the fuel filter/water separator and vent plug for leaks. Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.
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CHECKLIST A
PROCEDURES
A-10 Perform 30 Day Service
A-11 Grease the Turntable Rotation Bearing and Rotate Gear
The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage, whichever comes first. After this interval, refer to the maintenance checklists for continued scheduled maintenance. 1 Perform the following maintenance procedures: A-11 B-6 B-8 C-2 C-3 D-5 D-6 D-9 Grease the Turntable Rotation Bearing and Rotate Gear Inspect the Tires, Wheels and Lug Nut Torque Check the Drive Hub Oil Level and Fastener Torque Perform Engine Maintenance Cummins Models Perform Engine Maintenance Perkins Models Replace the Hydraulic Filter Elements Perform Engine Maintenance Deutz Models Check the Turntable Rotation Bearing Bolts
Note: Genie specifications require that this procedure be performed every 100 hours of operation. Perform this procedure more often if dusty conditions exist. Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life. Continued use of an improperly greased bearing and gear will result in component damage. 1 Locate the grease fitting below the ground control box. 2 Pump grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inches / 10 to 13 cm at a time and repeat this step until the entire bearing has been greased. 3 Apply grease to each tooth of the drive gear, located under the turntable.
Grease Specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent
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PROCEDURES
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A-12 Replace the Drive Hub Oil
Note: Drive hub specifications require that this onetime procedure be performed after the first 150 hours of usage. After this interval, refer to the maintenance checklist for continued scheduled maintenance. Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may result in component damage. See D-3, Replace the Drive Hub Oil.
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Checklist B Procedures
1 Put on protective clothing and eye wear. 2 Remove the cover from the auxiliary power unit batteries located at the ground controls side of the machine. Note: Perform the remaining steps on the auxiliary power unit batteries and the engine starting battery. 3 Be sure that the battery cable connections are free of corrosion. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 4 Be sure that the battery retainers and cable connections are tight. 5 Be sure that the battery separator wire connections are tight. 6 Fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. 7 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 8 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: Add 0.004 to the reading of each cell for every 10 / 5.5 C above 80 F / 26.7 C. Subtract 0.004 from the reading of each cell for every 10 / 5.5 C below 80 F / 26.7 C. Result: All battery cells display an adjusted specific gravity of 1.277 or higher. The battery is fully charged. Proceed to step 12. Result: One or more battery cells display a specific gravity of 1.217 or below. Proceed to step 9.
B-1 Inspect the Batteries
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. There are 3 batteries on the machine. One is used for starting the engine and powering the control system. The other two batteries are 6V DC deep cycle batteries which are wired in series to provide power for the auxiliary power units. The batteries are charged by the alternator through a battery separator. Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. Note: Perform this test after fully charging the batteries. Note: For a more accurate determination of the battery condition, fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize.
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CHECKLIST B PROCEDURES
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9 Perform an equalizing charge OR fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. 10 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. 11 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: Add 0.004 to the reading of each cell for every 10 / 5.5 C above 80 F / 26.7 C. Subtract 0.004 from the reading of each cell for every 10 / 5.5 C below 80 F / 26.7 C. Result: All battery cells display a specific gravity of 1.277 or greater. The battery is fully charged. Proceed to step 12. Result: The difference in specific gravity readings between cells is greater than 0.1 OR the specific gravity of one or more cells is less than 1.177. Replace the battery. 12 Check the battery acid level. If needed, replenish with distilled water to 1/8 inch / 3 mm below the bottom of the battery fill tube. Do not overfill. 13 Install the vent caps and neutralize any electrolyte that may have spilled. 14 Install the cover for the auxiliary power unit batteries.
B-2 Inspect the Electrical Wiring
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage. Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Open the engine side turntable cover. 2 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
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engine pivot plate anchor hole engine pivot plate retaining fastener
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3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 5 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: Engine wiring harness Battery area wiring 6 Open the ground controls side turntable cover. 7 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: Inside of the ground control box Hydraulic manifold wiring Battery area wiring Hydraulic oil cooler wiring 8 Inspect for a liberal coating of dielectric grease in the following locations: All wire harness connectors to ground control box Wire harness connectors to SCON module 9 Open the hydraulic manifold box covers at both sides of the drive chassis. 10 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: Hydraulic manifold wiring
11 Inspect for a liberal coating of dielectric grease in the following location: Wire harness connectors to DCON module 12 Start the engine from the ground controls and raise the secondary boom above the turntable covers. Component damage hazard. Be sure the hydraulic supply hoses to the function and drive pumps are not kinked before starting the engine. 13 Inspect the turntable area for burnt, chafed and pinched cables. 14 Lower the secondary boom to the stowed position and turn the engine off. 15 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires: Cable track on the boom Cables on the boom, jib boom and jib boom pivot area Jib boom/platform rotate manifold Platform control box Inside of the platform control box 16 Inspect for a liberal coating of dielectric grease in the following location: All wire harness connectors to platform control box 17 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 18 Swing the engine pivot plate in towards the machine. 19 Install the bolt that was just removed into the original hole to secure the engine pivot plate. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.
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B-3 Test the Key Switches

Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper key switch action and response is essential to safe machine operation. Failure of either key switch to function properly could cause a hazardous operating situation. There are two key switches on the machine - the Main key switch and the Service Bypass/Recovery key switch. The Main key switch controls machine operation from the ground or platform controls. When the Service Bypass/Recovery key switch is turned to the service bypass position, the primary boom can be raised while the axles are retracted. This feature of the machine is especially helpful for storage purposes or when loading the machine for transport. Note: When the boom is raised with the axles retracted, the boom cannot be rotated past either circle-end wheel. When the Service Bypass/Recovery key switch is turned and held to the recovery position, the auxiliary power units will turn on and fully retract the boom and then lower the boom. This feature of the machine is especially helpful if the operator in the platform cannot lower the boom, if the platform controls become inoperative or for returning the machine to a safe position when the safety switches have been tripped. Note: Perform this procedure with the axles retracted and the boom in the stowed position.
STOP
00000
Run Service Bypass Recovery
1 Open the ground controls side turntable side cover. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 3 At the ground controls, turn the service bypass/recovery key switch to the run position. 4 Turn the main key switch to ground control, start the engine and then turn the key switch to platform control. 5 Check any machine function from the ground controls. Result: The machine functions should not operate. 6 Turn the main key switch to ground control.
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7 Check any machine function from the platform controls. Result: The machine functions should not operate. 8 Turn the main key switch to the off position. Result: The engine should stop and no functions should operate. 9 Turn the main key switch to ground control and start the engine. 10 Attempt to raise the primary boom. Result: The boom should not raise. Note: The primary boom will not raise until the axles are fully extended. 11 Remove the key from the main key switch and insert the key into the service bypass/recovery key switch. Note: The main key switch should remain in the ground control position. 12 Turn the service bypass/recovery key switch to the service bypass position. 13 Raise the boom. Result: The boom should raise. 14 Remove the key from the service bypass/recovery key switch and insert the key into the main key switch. 15 Turn the main key switch to the off position.
16 Remove the key from the main key switch and insert the key into the service bypass/recovery key switch. 17 Turn and hold the service bypass/recovery key switch to the recovery position. Result: The boom should return to the stowed position. 18 Turn the service bypass/recovery key switch to the run position. 19 Remove the key from the service bypass/recovery key switch and insert the key into the main key switch. 20 Turn the main key switch to the off position. 21 Close the turntable side cover.
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B-4 Check the Exhaust System
2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving.
Note: Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the exhaust system is essential to good engine performance and service life. Operating the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Bodily injury hazard. Beware of hot engine components. Contact with hot engine components may cause severe burns. 1 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 4 Be sure that all nuts and bolts are tight. 5 Inspect all welds for cracks. 6 Inspect for exhaust leaks (i.e., carbon buildup) around seams and joints. 7 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 8 Swing the engine pivot plate in towards the machine. 9 Install the bolt that was just removed into the original hole to secure the engine pivot plate. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.
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B-5 Check the Engine Oil Cooler and Cooling Fins - Deutz Models
Cooling and blower fins: 5 Inspect the fan blower fins for physical damage. 6 Clean the fan blower fins of debris and foreign material. 7 Using a flashlight, inspect the head cooling passages and fins for physical damage or foreign material. 8 If needed, clean the cylinder head cooling passages and fins of debris and foreign material. 9 Install the engine side cover and tighten the retaining fasteners.
Note: Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the oil cooler in good condition is essential for good engine performance. Operating a machine with a damaged oil cooler may result in engine damage. Also, restricting air flow through the oil cooler will affect the performance of the cooling system. Bodily injury hazard. Do not inspect while the engine is running. Remove the key to secure from operation. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 1 Open the engine side turntable cover. Oil cooler: 2 Remove the retaining fasteners from the engine side cover. Remove the cover. 3 Inspect the oil cooler for leaks and physical damage. 4 Clean the oil cooler of debris and foreign material.
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B-6 Inspect the Tires, Wheels and Lug Nut Torque
B-7 Confirm the Proper Brake Configuration
Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the tires and wheels, including proper wheel fastener torque, is essential to safe operation and good performance. Tire and/or wheel failure could result in a machine tip-over. Component damage may also result if problems are not discovered and repaired in a timely fashion. Note: The tires on this machine are foam filled and do not need air added to them. 1 Check all tire treads and sidewalls for cuts, cracks, punctures and unusual wear. 2 Check each wheel for damage, bends and cracked welds. 3 Check each lug nut for proper torque. Refer to Section 2, Specifications.
Note: Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake configuration is essential to safe operation and good machine performance. Hydrostatic brakes and hydraulically-released, spring-applied individual wheel brakes can appear to operate normally when they are actually not fully operational. 1 Check each drive hub disconnect cap to be sure it is in the engaged position.
disengaged position
engaged position
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2 Be sure the free-wheel valve on the drive pump is closed (clockwise). Note: The free-wheel valve is located on the drive pump.
B-8 Check the Drive Hub Oil Level and Fastener Torque
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Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage. Drive hubs: 1 Drive the machine to rotate the hub until the plugs are located one at the side and the other at the other side.
a
a b c d
drive pump screwdriver lift pump free-wheel valve
Note: The free-wheel valve should always remain closed.
drive hub plugs
2 Remove both plugs and check the oil level. Result: The oil level should be even with the bottom of the plug holes. 3 If necessary, add oil until the oil level is even with the bottom of the plug holes. Refer to Section 2, Specifications. 4 Install the plugs in the drive hub. 5 Check the torque of the drive hub mounting fasteners. Refer to Section 2, Specifications. 6 Repeat this procedure for each drive hub.
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Turntable rotate drive hubs: 1 Remove the fixed turntable cover at the ground controls side of the machine. 2 Remove the plug located on the side of the hub and check the oil level. Result: The oil level should be even with the bottom of the plug hole.
B-9 Test the Ground Control Override

Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the on or off position. This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position. 1 Push in the platform red Emergency Stop button to the off position. 2 Start the engine from the ground controls. 3 At the ground controls, operate each boom function through a partial cycle. Result: All boom functions should operate.
drive hub plugs
3 If necessary, add oil until the oil level is even with the bottom of the plug hole. Refer to Section 2, Specifications. 4 Apply pipe thread sealant to the plug, and install the plug in the drive hub. 5 Repeat steps 2 through 4 for the other turntable rotate drive hub.
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B-10 Test the Platform Self-leveling
4 Press and hold a function enable/speed select button and adjust the platform to zero degrees using the platform level up/down buttons. 5 Push and hold a function enable/speed select button and fully raise the primary boom while observing the platform angle shown on the LCD display. Result: The platform should remain level at all times to within 2 degrees. Note: If the platform becomes out of level, the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls. The platform level up/down buttons will only work in the direction that will level the platform. Level the platform until the indicator light turns off. 6 Push and hold a function enable/speed select button and fully lower the primary boom. Result: The platform should remain level at all times to within 2 degrees. Note: If the platform becomes out of level, the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls. The platform level up/down buttons will only work in the direction that will level the platform. Level the platform until the indicator light turns off. Note: If the platform does not level properly, see Repair Procedure 2-3, How to Calibrate the Platform Level Sensor.
Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Automatic platform self-leveling throughout the full cycle of primary boom raising and lowering is essential for safe machine operation. The platform is maintained level by the communication between the platform level sensor and the turntable level sensor. If the platform becomes out of level, the computer at the ground controls will open the appropriate solenoid valve(s) at the platform manifold to maintain a level platform. A platform self-leveling failure creates an unsafe working condition for platform and ground personnel. 1 Start the engine from the ground controls. 2 Press and hold a function enable/speed select button and fully retract the primary boom. 3 Push one of the LCD screen buttons shown until platform angle is displayed.
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B-11 Test the Engine Idle Select Operation

Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly operating engine idle select function is essential to good engine performance and safe machine operation. There are three settings. Low idle (turtle symbol) allows the operator to control multiple boom and/or drive functions simultaneously, though at reduced speed. This setting maintains a consistent low idle. High idle (rabbit symbol) allows the operator to control multiple boom and/or drive functions simultaneously. This setting maintains a consistent high idle. Foot switch activated high idle (rabbit and foot switch symbols) should be used for normal machine operation. This selection activates high idle only when the foot switch is pressed down. 1 Turn the key switch to ground controls. 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. 3 Start the engine from the ground controls. 4 Push and release the rpm select button until high rpm is selected (rabbit symbol). Result: The engine should change to high idle.
5 Push and release the rpm select button until low rpm is selected (turtle symbol). Result: The engine should return to low idle. 6 Turn the key switch to platform controls. 7 At the platform controls, press the engine idle select button until high idle (rabbit symbol) is selected. Result: The engine should change to high idle.
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d a b c d foot switch activated high idle indicator light low idle indicator light high idle indicator light engine rpm select button
8 Press the engine idle select button until low idle (turtle symbol) is selected. Result: The engine should change to low idle. 9 Press the engine idle select button until the foot switch activated high idle (rabbit and foot switch symbol) is selected. Result: The engine should not change to high idle. 10 Press down the foot switch. Result: The engine should change to high idle.
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B-12 Test the Drive Brakes
B-13 Test the Drive Speed Stowed Position
Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydraulically-released individual wheel brakes can appear to operate normally when they are actually not fully operational. Collision hazard. Be sure that the machine is not in free-wheel or partial free-wheel configuration. Refer to B-7, Confirm the Proper Brake Configuration. Note: Select a test area that is firm, level and free of obstructions. 1 Mark a test line on the ground for reference. 2 Start the engine from the platform controls. 3 Press the engine rpm select button until the foot switch activated high idle (rabbit and foot switch symbol) is selected, then lower the boom into the stowed position. 4 Choose a point on the machine (i.e., contact patch of a tire) as a visual reference for use when crossing the test line. 5 Bring the machine to top drive speed before reaching the test line. Release the drive controller when your reference point on the machine crosses the test line. 6 Measure the distance between the test line and your machine reference point. Refer to Section 2, Specifications.
Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Note: Select a test area that is firm, level and free of obstructions. Note: Perform this procedure with the boom in the stowed position. 1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. 2 Start the engine from the platform controls. 3 Press the engine rpm select button until the foot switch activated high idle (rabbit and foot switch symbol) is selected. 4 Choose a point on the machine; i.e., contact patch of a tire as a visual reference for use when crossing the start and finish lines. 5 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 6 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Specifications.
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B-14 Test the Drive Speed Raised or Extended Position
7 Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Specifications. 8 Lower the boom to the stowed position. 9 Extend the primary boom 12 inches / 0.3 m.
Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control. Drive performance should also be free of hesitation, jerking and unusual noise over the entire proportionally controlled speed range. Note: Select a test area that is firm, level and free of obstructions. 1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. 2 Start the engine from the platform controls. 3 Press the engine rpm select button until the foot switch activated high idle (rabbit and foot switch symbol) is selected. 4 Press down the foot switch and raise the boom greater than 5 degrees. 5 Choose a point on the machine; i.e., contact patch of a tire as a visual reference for use when crossing the start and finish lines. 6 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line.
10 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. 11 Bring the machine to top drive speed before reaching the start line. Begin timing when your reference point on the machine crosses the start line. 12 Continue at top speed and note the time when the machine reference point crosses the finish line. Refer to Section 2, Specifications.
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B-15 Test the Alarm and Optional Flashing Beacon

Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. An alarm and optional flashing beacon are installed to alert operators and ground personnel of machine proximity and motion. There are four alarm option modes that can be activated based on user preference or requirement. Refer to Display Module in the Repair Section for information. 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. Result: The alarm should sound twice. The flashing beacon (if equipped) should be on and flashing.
B-16 Perform Hydraulic Oil Analysis
Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and a clogged suction strainer or hydraulic filters may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often. Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil.
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B-17 Replace the Inline Fuel Filter/ Water Separator Element Perkins Models
3 Loosen the vent plug located on the inline fuel filter/water separator head. 4 Place a suitable container under the filter bowl. 5 Loosen the drain plug located at the bottom of the bowl. Completely drain the fuel from the bowl.
e a
Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacing the inline fuel filter/water separator element is essential for good engine performance and service life. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Note: Perform this procedure with the engine off. 1 Open the engine side turntable cover and locate the fuel filter/water separator next to the medium pressure filter. 2 Tag, disconnect and plug the fuel line from the fuel tank at the inline fuel filter/water separator head.
b
a b c d e
vent plug filter element filter bowl drain plug fuel filter/water separator head
6 Remove the filter element from the filter head. 7 Remove the filter bowl from the old filter element and install the bowl onto the new filter element. Tighten the drain plug. 8 Fill the element and bowl with clean diesel fuel. 9 Apply a thin layer of oil onto the element gasket.
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10 Install the filter/bowl assembly onto the filter head and tighten it securely by hand. Note: The filter/bowl assembly must be full of fuel when it is installed onto the filter head or the fuel system will have to be bled. 11 Tighten the vent plug. 12 Clean up any diesel fuel that may have spilled during the procedure. 13 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter. 14 Install the fuel tank line onto the fuel filter/water separator head. Tighten the hose clamp.
B-18 Check and Adjust the Engine RPM
Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life. The machine will not operate properly if the rpm is incorrect and continued use may cause component damage. Deutz models: 1 Start the engine from the ground controls. 2 Push one of the LCD screen buttons shown until engine rpm is displayed. Result: Low idle should be 1500 rpm. Skip to step 5 if the low idle rpm is correct.
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3 Loosen the locknut on the low idle adjustment screw.
Cummins and Perkins models: 1 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
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2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate.
a
a low idle adjustment screw
3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 4 Start the engine from the ground controls. Component damage hazard. Be sure the hydraulic supply hoses to the function and drive pumps are not kinked before starting the engine. 5 Push one of the LCD screen buttons shown until engine rpm is displayed. Result: Low idle should be 1300 rpm. Skip to step 7 if the low idle rpm is correct.
4 Adjust the low idle adjustment screw until low idle is 1500 rpm. Tighten the locknut. 5 Push and hold the function enable/high speed button. Note the engine rpm on the display. Result: High idle should be 2350 rpm. If the high idle is correct, disregard adjustment step 6. 6 Loosen the yoke lock nut. Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Note: Be sure the solenoid fully retracts when activating high idle.
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6 Loosen the low idle lock nut. Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm. Tighten the low idle lock nut and confirm the rpm.
a
7 Push and hold the function enable/high speed button. Note the engine rpm on the display. Result: High idle should be 2350 rpm. If the high idle is correct, disregard adjustment step 8. 8 Perkins models: Loosen the yoke lock nut. Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Tighten the yoke lock nut and recheck the rpm. Cummins models: Turn the high idle solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm. Recheck the rpm. Note: Be sure the solenoid fully retracts when activating high idle.
Perkins models a low idle adjustment screw b solenoid boot c yoke lock nut
9 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 10 Swing the engine pivot plate in towards the machine. 11 Install the bolt that was just removed into the original hole to secure the engine pivot plate. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.
Cummins models a low idle adjustment screw b solenoid cable c rpm solenoid
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B-19 Test the Safety Envelope Limit Switches

Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Testing the machine envelope safety limit switches is critical to safe machine operation. If the boom is allowed to operate when a safety switch is not functioning correctly, the machine stability could be compromised and may tip over. Note: Perform this procedure with the axles extended and the boom in the stowed position. Note: This procedure may require two people. Secondary Boom #1 Retracted Safety Limit Switch, LSS1RS 1 Working at the platform end of the turntable, support and secure the lower turntable riser end cover to a suitable lifting device. 2 Remove the lower cover retaining fasteners and remove the lower cover from turntable. Crushing hazard. The turntable riser lower cover could become unbalanced and fall when removed from the turntable if not properly supported and secured to the lifting device. 3 Support and secure the upper turntable riser end cover to a suitable lifting device.
4 Remove the upper cover retaining fasteners and remove the upper cover from turntable. Crushing hazard. The turntable riser lower cover could become unbalanced and fall when removed from the turntable if not properly supported and secured to the lifting device. 5 Locate the secondary boom #1 retracted safety limit switch (LSS1RS) inside the secondary boom tube. Note: The secondary boom #1 retracted safety limit switch (LSS1RS) is attatched to the number 2 boom tube and can easily be identified by the blue and red tie wraps attached to the limit switch cable. 6 Start the engine from the ground controls. 7 Fully raise the secondary boom. Do not extend the boom. Turn the machine off. 8 Locate and disconnect the deutsch connector to LSS1RS. 9 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the deutsch connector of the limit switch cable. Result: The limit switch should not have continuity. Result: The limit switch does have continuity. The limit switch is faulty and needs to be replaced. 10 Remove the multimeter leads and connect the deutsch connector to LSS1RS.
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11 Start the engine from the ground controls. 12 Extend the secondary boom while visually inspecting the roller arm of the limit switch. Continue to extend the boom until the limit switch arm is released by the limit switch ramp bracket. Turn the machine off. Result: The roller arm of the limit switch remains centered with the limit switch ramp bracket through the entire length of travel. Result: The roller arm of the limit switch does not remain centered with the limit switch ramp bracket through the entire length of travel. Adjust or replace the limit switch ramp bracket to ensure the limit switch roller arm remains centered with the limit switch ramp bracket through the entire length of travel. Note: The limit switch ramp bracket is attached to the number 4 boom tube. 13 Locate and disconnect the deutsch connector to LSS1RS. 14 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the deutsch connector of the limit switch cable. Result: The limit switch should have continuity. Result: The limit switch does not have continuity. The limit switch is faulty and needs to be replaced. 15 Remove the multimeter leads and connect the deutsch connector to LSS1RS. 16 Install the secondary boom end covers.
Turntable Rotate Safety Limit Switch, LST1S 17 Locate the turntable rotate safety limit switch (LST1S) at the center of the turntable. Note: The turntable rotate safety limit switch (LST1S) is located between the two operational turntable rotate limit switches. It can easily be identified by the orange and red tie wraps attached to the limit switch cable. 18 Locate and disconnect the deutsch connector to LST1S. 19 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the deutsch connector of the limit switch cable. Result: The limit switch should have continuity. Result: The limit switch does not have continuity. The limit switch is faulty and needs to be replaced. 20 Remove the multimeter leads and connect the deutsch connector to LST1S. 21 Start the engine and rotate the turntable more than 15. Turn the engine off 22 Locate and disconnect the deutsch connector to LST1S. 23 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the deutsch connector of the limit switch cable. Result: The limit switch should not have continuity. Result: The limit switch does have continuity. The limit switch is faulty and needs to be replaced OR the mounting position of the limit switch needs to be adjusted until it activates when the turntable is rotated more than 15. 24 Remove the multimeter leads and connect the deutsch connector to LST1S.
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Axle Extended Safety Limit Switches, LSFA1ES and LSRA1ES 25 Start the engine from the ground controls and lower the boom to the stowed postion. 26 Turn the key switch to platform controls. 27 From the platform controls, drive the machine in either direction and fully retract the axles. Turn the machine off. 28 Choose an axle extend safety limit switch to test. 29 Locate and disconnect the deutsch connector to the axle extend limit switch. 30 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the deutsch connector of the limit switch cable. Result: The limit switch should not have continuity. Result: The limit switch does have continuity. The limit switch is faulty and needs to be replaced. 31 Remove the multimeter leads and connect the deutsch connector to the limit switch. 32 Repeat steps 29 through 31 for the other axle extend safety limit switch. 33 Start the engine from the platform controls and fully extend the axles. Turn the machine off. 34 Choose an axle extend safety limit switch to test. 35 Locate and disconnect the deutsch connector to the axle extend limit switch.
36 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the deutsch connector of the limit switch cable. Result: The limit switch should have continuity. Result: The limit switch does not have continuity. The limit switch is faulty and needs to be replaced. 37 Remove the multimeter leads and connect the deutsch connector to the limit switch. 38 Repeat steps 35 through 37 for the other axle extend safety limit switch.
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B-20 Test the Primary Boom Angle Sensor

Note: Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly functioning primary boom angle sensor is essential to safe machine operation. The ECM at the ground controls (TCON) monitors the position and angle of the primary boom using the signal from the primary boom angle sensor. The primary boom angle sensor signal is used to control the ramping of the primary boom, limiting the speed of the primary boom to 2.3 feet / 0.7 meters per second. Note: Perform this procedure with the axles fully extended, the boom fully stowed and the machine on a firm, level surface within 2 degrees. 1 Turn the key switch to ground control and pull out the red Emergency Stop buttons out to the on position at both the ground and platform controls. 2 Start the engine from the ground controls. 3 Push one of the LCD screen buttons shown until PRIMARY BOOM ANGLE TO GRAVITY DEGREES is displayed. 4 Raise the primary boom while watching the display screen.
5 Continue to raise the primary boom until it stops at 58. Tip-over hazard. If the boom does not stop at 58, release the function enable button immediately and lower the primary boom. Contact Genie Industries Service Department. Failure to lower the boom could cause the machine to tip over resulting in death or serious injury.
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B-21 Inspect the Fuel and Hydraulic Tank Cap Venting Systems
3 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 2. 4 Install the fuel tank cap onto the fuel tank. 5 Remove the breather cap from the hydraulic tank. 6 Check for proper venting. Result: Air passes through the fuel tank cap. Proceed to step 8. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 7. Note: When checking for positive tank cap venting, air should pass freely through the cap. 7 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 6. 8 Install the breather cap onto the hydraulic tank.
Note: Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist. Free-breathing fuel and hydraulic tank caps are essential for good machine performance and service life. A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the caps be inspected more often. Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, wellventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Note: Perform this procedure with the engine off. 1 Remove the cap from the fuel tank. 2 Check for proper venting. Result: Air passes through the fuel tank cap. Proceed to step 4. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 3. Note: When checking for positive tank cap venting, air should pass freely through the cap.
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B-22 Perform Engine Maintenance Cummins Models
Note: Engine specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3 Operation and Maintenance Manual (Cummins part number 3666417-00).
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Checklist C Procedures
C-1 Perform Engine Maintenance Deutz Models
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C-2 Perform Engine Maintenance Cummins Models
Note: Engine specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz BF4L2011 Operation Manual (Deutz part number 0297 9929) OR the Deutz TD2011 Operation Manual (Deutz part number 0312 3547).
Note: Engine specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3 Operation and Maintenance Manual (Cummins part number 3666417-00).
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CHECKLIST C PROCEDURES
C-3 Perform Engine Maintenance Perkins Models
C-4 Grease the Platform Overload Mechanism (if equipped)
Note: Engine specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 1100 Series User's Handbook (Perkins part number TPD 1477) OR the Perkins 800 Series Operation and Maintenance Manual (Perkins part number SEBU7853-00).
Note: Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Perform this procedure more often if dusty conditions exist. Application of lubrication to the platform overload mechanism is essential to safe machine operation. Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage. 1 Locate the grease fittings on each pivot pin of the platform overload assembly. 2 Thoroughly pump grease into each grease fitting.
Grease Specification
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Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent
111332
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C-5 Test the Platform Overload System (if equipped)
As weight is added to the platform, the spring will compress until, when the platform is overloaded, the lower arm contacts a limit switch and thereby activating the overload signal. When adjusted correctly, the platform overload system will deactivate normal boom operation at platform capacity. Note: Perform this procedure with the machine on a firm, level surface. 1 Turn the key switch to platform control. Start the engine from the platform controls. 2 Level the platform. 3 Determine the maximum platform capacity. Refer to the machine serial plate. 4 Using a suitable lifting device, place an appropriate test weight equal to that of the maximum platform capacity in one of the locations shown. Result: The platform overload indicator light should be off at both the ground and platform controls.
Note: Genie specifications require that this procedure be performed every 500 hours or six months. Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stablity could be compromised resulting in the machine tipping over. The platform overload system is designed to detect an overloaded platform and prevent machine operation anytime the machine is turned on. When activated, the system halts all normal boom operation, giving visual and audible warning to the operator. Models equipped with the platform overload option are provided with additional machine components: an adjustable spring-loaded platform support subassembly, a limit switch, an electronic module which receives the overload signal and interrupts power, and an audio/visual warning indication to alert the operator of the overload. The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link. This isolates platform loads into a shear or vertical state, which translates into a compressive load. A spring in the parallelogram link supports this purely compressive load regardless of where the load is placed in the platform.
5 Carefully move the test weight to each remaining location. Result: The platform overload indicator light should be off at both the ground and platform controls.
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6 Add an additional 12 lbs / 5.4 kg test weight to the original test weight to overload the platform. Result: The alarm should be sounding. The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls. Result: If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations, the platform overload system needs to be calibrated. Refer to repair procedure 2-4, How to Calibrate the Platform Overload System (if equipped). Note: There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. 7 Carefully move the test weights to each remaining location in the platform. Result: The alarm should be sounding. The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls. Result: If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations, the platform overload system needs to be calibrated. Refer to repair procedure 2-4, How to Calibrate the Platform Overload System (if equipped). Note: There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds.
8 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 9 Turn the key switch to ground control. 10 Test all machine functions from the ground controls. Before serial number 471: Result: All ground control functions should not operate. After serial number 470: Result: All ground control functions should operate using the auxiliary pump. 11 Lift the test weights off the platform floor using a suitable lifting device. Result: The platform overload indicator light and alarm should turn off at both the ground and platform controls. Note: There may be an approximate 2 second delay before the overload indicator light and alarm turn off. 12 Test all machine functions from the ground controls. Result: All ground control functions should operate normally. 13 Turn the key switch to platform control. 14 Test all machine functions from the platform controls. Result: All platform control functions should operate. Note: If the platform overload system is not operating properly, refer to repair procedure 2-4, How to Calibrate the Platform Overload System (if equipped).
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Checklist D Procedures
D-1 Check the Boom Wear Pads
Secondary boom wear pad specifications Top wear pads (extension end of boom)
REV D
Minimum inch 9.5 mm

1/2 inch 12.7 mm 7 /8 3 /8
Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining the boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions. 1 Measure each wear pad. Replace the wear pad once it reaches the minimum allowable thickness. If the wear pad is still within specification, shim as necessary to obtain minimum clearance with zero binding. Note: The minimum shim clearance for the secondary boom wear pads is 0.070 inch / 1.8 mm and the maximum allowable shim clearance is 0.25 inch / 6.4 mm. Note: The minimum shim clearance for the jib boom and primary boom wear pads is 0.070 inch / 1.8 mm and the maximum allowable shim clearance is 0.188 inch / 4.8 mm.
Primary boom wear pad specifications Top, bottom and side wear pads (platform end of boom) Top and bottom wear pads (pivot end of boom) Side wear pads (pivot end of boom)
Side wear pads (extension end of boom) Bottom wear pads (extension end of boom) Top and bottom wear pads (pivot end of boom) Side wear pads (pivot end of boom) Jib boom wear pad specifications Bottom and side wear pads (platform end of boom) Top wear pads (platform end of boom) Top and side wear pads (pivot end of boom) Bottom wear pads (pivot end of boom)
inch 22 mm
5/8 inch 15.9 mm 1/2 inch 12.7 mm
Minimum
5/8 inch 15.9 mm 1/2 inch 12.7 mm
inch 9.5 mm
5/8 inch 15.9 mm
3 /8
2 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom. Note: Always maintain squareness between the outer and inner boom tubes.
Minimum
5/8 inch 15.9 mm 1/2 inch 12.7 mm
inch 9.5 mm
3 /8
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CHECKLIST D PROCEDURES
D-2 Check the Free-wheel Configuration
5 Manually rotate each wheel at the square-end of the machine. Result: Each wheel at the square-end of the machine should rotate with minimum effort. 6 Re-engage the drive hubs by turning over the drive hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the blocks. Lower the machine. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury and property damage. 7 Chock both of the wheels at the square-end of the machine to prevent the machine from rolling. 8 Place a lifting jack of ample capacity (35,000 lbs / 16000 kg) under each of the steer yokes at the circle-end of the machine. 9 Lift the wheels off the ground and place blocks under the drive chassis for support. 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the circle-end of the machine.
disengaged position
Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing. A machine configured to free-wheel without operator knowledge may cause death or serious injury and property damage. Collision hazard. Select a work site that is firm and level. Component damage hazard. If the machine must be towed, do not exceed 2 mph / 3.2 km/h. 1 Chock both of the wheels at the circle-end of the machine to prevent the machine from rolling. 2 Place a lifting jack of ample capacity (35,000 lbs / 16000 kg) under each of the steer yokes at the square-end of the machine. 3 Lift the wheels off the ground and place blocks under the drive chassis for support. 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the square-end of the machine.
disengaged position
engaged position
11 Manually rotate each wheel at the circle-end of the machine. Result: Each wheel at the circle-end of the machine should rotate with minimum effort.
engaged position
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12 Re-engage the drive hubs by turning over the drive hub disconnect caps. Rotate each wheel to check for engagement. Lift the machine and remove the blocks. Lower the machine. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury and property damage. All models: 13 Be sure the free-wheel valve on the drive pump is closed (clockwise). Note: The free-wheel valve is located on the drive pump, and should always remain closed.
D-3 Replace the Drive Hub Oil
Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Replacing the drive hub oil is essential for good machine performance and service life. Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage. Drive Hubs: 1 Select the drive hub to be serviced. Drive the machine until one of the two plugs is at the lowest point.
b
c d
2 Remove both plugs and drain the oil into a suitable container. 3 Drive the machine to rotate the hub until the plugs are located one at the side and the other at the other side.
a
a b c d
drive pump screwdriver lift pump free-wheel valve
drive hub plugs
4 Fill the hub with oil from either plug hole until the oil level is even with the bottom of both plug holes. Install the plugs. Refer to Section 2, Specifications. 5 Repeat steps 1 through 4 for all the other drive hubs.
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Turntable Rotate Drive Hub: 1 Secure the turntable from rotating with the turntable rotation lock pin. 2 Tag, disconnect and plug the hydraulic hoses to the drive hub drive motor and brake for each drive hub assembly. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Attach a suitable lifting device to the lifting eye of one turntable rotate drive hub assembly.
4 Remove the drive hub mounting bolts from one drive hub assembly. Carefully remove the turntable rotate drive hub assembly from the machine. Do not remove both turntable rotate drive hub assemblies at the same time. Crushing hazard. The turntable rotate drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported by the lifting device.
a
a b
b
drive hub mounting bolts drive hub plugs
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5 Remove the plug from the side of the drive hub. Drain the oil from the hub into a suitable container. 6 Install the drive hub assembly onto the machine. Lubricate and torque the drive hub mounting bolts to specification. Refer to Section 2, Specifications. 7 Fill the drive hub with oil from the side hole until the oil level is even with the bottom of the hole. Apply pipe thread sealant to the plug. Install the plug. Refer to Section 2, Specifications. 8 Repeat steps 3 through 7 for the other turntable rotate drive hub assembly. 9 Adjust turntable rotation gear backlash. See D-4, Adjust the Turntable Rotation Gear Backlash.
D-4 Adjust the Turntable Rotatation Gear Backlash

Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Properly adjusted turntable rotation gear backlash is essential for good machine performance and service life. Improperly adjusted turntable rotation gear backlash will cause the machine to perform poorly and continued use will cause component damage. The turntable rotation drive hubs are mounted on an adjustable plate on the swing chassis behind the fixed side cover at the ground controls side of the machine. Note: Perform this procedure with the machine fully stowed and the counterweight at the square end of the machine. Note: Select a test area that is firm, level and free of obstructions. 1 Secure the turntable from rotating with the turntable rotation lock pin. 2 Remove the fixed turntable cover at the ground controls side of the machine. 3 Loosen the backlash pivot plate mounting bolts. 4 Push the backlash pivot plate towards the turntable as far as possible (this will push the rotation pinion gears into the turntable bearing ring gear).
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5 Loosen the lock nut on the adjustment bolt. 6 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate.
D-5 Replace the Hydraulic Filter Elements
Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Perform this procedure more often if dusty conditions exist. Replacement of the hydraulic filters is essential for good machine performance and service life. A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. Note: Perform this procedure with the engine off. Hydraulic return filter:
a b
a b c
c
backlash pivot plate adjustment bolt with lock nut backlash pivot plate mounting bolts
1 Open the ground controls side turntable cover and locate the hydraulic return filter mounted on the hydraulic tank. 2 Place a suitable container under the hydraulic tank return filter. 3 Remove the filter with an oil filter wrench. 4 Apply a thin layer of fresh oil to the gasket of the new oil filter. 5 Install the new hydraulic return filter element and tighten it securely by hand. Clean up any oil that may have spilled during the installation procedure. 6 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter.
7 Turn the adjustment bolt 1/4 turn counterclockwise. Tighten the lock nut on the adjustment bolt. 8 Pull the backlash pivot plate away from the turntable until it contacts the adjustment bolt. Then lubricate the mounting fasteners on the backlash pivot plate and torque to specification. Refer to Section 2, Specifications. 9 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary.
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High pressure filter and drive motor case drain filter: Note: The high pressure filter is for all machine functions except the drive functions. The drive motor case drain filter is used to filter oil returning to the hydraulic tank from the drive motors.
12 Remove the filter element from the housing. 13 Inspect the housing seal and replace it if necessary. 14 Install the new high pressure filter element into the housing. Install the filter housing onto the filter head and tighten it securely. 15 Clean up any oil that may have spilled during the installation procedure. 16 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings. Medium pressure filter: Note: The medium pressure filter is for the charge pump. 17 Open the engine side turntable cover and locate the medium pressure filter mounted to the engine tray near the hydraulic pumps.
18 Place a suitable container under the filter. 19 Remove the medium pressure filter housing by using a wrench on the nut provided on the bottom of the housing. 20 Remove the filter element from the housing. 21 Inspect the housing seal and replace it if necessary. 22 Install the new medium pressure filter element into the housing. Install the filter housing onto the filter head and tighten it securely. 23 Clean up any oil that may have spilled during the installation procedure. 24 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housing. 25 Start the engine from the ground controls. 26 Inspect the all of the filter housings and related components to be sure that there are no leaks.
a b
drive motor case drain filter high pressure filter
7 Locate the high pressure filter and the drive motor case drain filter near the auxillary power units. 8 Place a suitable container under the filters. 9 Use a filter wrench to remove the drive motor case drain filter element. 10 Install the new drive motor case drain filter element onto the filter head and tighten it securely. 11 Remove the high pressure filter housing by using a wrench on the nut provided on the bottom of the housing.
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D-6 Perform Engine Maintenance Deutz Models
D-7 Perform Engine Maintenance Cummins Models
Note: Engine specifications require that this procedure be performed every 1000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz BF4L2011 Operation Manual (Deutz part number 0297 9929) OR the Deutz TD2011 Operation Manual (Deutz part number 0312 3547).
Note: Engine specifications require that this procedure be performed every 1000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3 Operation and Maintenance Manual (Cummins part number 3666417-00).
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D-8 Perform Engine Maintenance Perkins Models
D-9 Check the Turntable Rotation Bearing Bolts
Note: Engine specifications require that this procedure be performed every 1000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 1100 Series User's Handbook (Perkins part number TPD 1477) OR the Perkins 800 Series Operation and Maintenance Manual (Perkins part number SEBU7853-00).
Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque could result in an unsafe operating condition and component damage. 1 Raise the secondary boom to the point where it begins to extend. Turn the machine off. 2 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
107526
111332
a b
3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate.
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4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 5 Confirm that each turntable mounting bolt is torqued in sequence to specification. Refer to Section 2, Specifications.
10 1 28 8 20 16 12 24 6
6 Lower the secondary boom to the stowed position. 7 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 8 Swing the engine pivot plate in towards the machine. 9 Install the bolt that was just removed into the original hole to secure the engine pivot plate. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 10 Confirm that each bearing mounting bolt under the drive chassis is torqued in sequence to specification. Refer to Section 2, Specifications.
36 23 1 9 25
22 13 26 3
18
13 29 7
5 23 15 19 11 7 25 2 9 17 21 14 4 27
15 5 33 28 20 11 3 26 34 17
18 31 27 12 4 21 35 16 6 32 24 10 2 19 30 22 14 8
Bolt torque sequence (from above turntable)
Bolt torque sequence (from above turntable)
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D-10 Inspect for Turntable Bearing Wear
Note: Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first. Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life. Continued use of a worn turntable bearing could create an unsafe operating condition, resulting in death or serious injury and component damage. Note: Perform this procedure with the machine on a firm, level surface and the boom in the stowed position. 1 Grease the turntable bearing. See A-10, Grease the Turntable Bearing and Rotate Gear. 2 Torque the turntable bearing bolts to specification. See D-9, Check the Turntable Rotation Bearing Bolts. 3 Start the machine from the ground controls and raise the boom to full height. Do not extend the boom. 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under, or inline with, the boom and no more than 1 inch / 2.5 cm from the bearing. Note: To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing.
a b c d
turntable dial indicator drive chassis turntable rotation bearing
5 At the dial indicator, adjust it to "zero" the indicator. 6 Fully extend the boom and lower to a horizontal position. 7 Note the reading on the dial indicator. Result: The measurement is less than 0.063 inch / 1.6 mm. The bearing is good. Result: The measurement is more than 0.063 inch / 1.6 mm. The bearing is worn and needs to be replaced. 8 Fully retract the boom and raise the boom to full height. Visually inspect the the dial indicator to be sure the needle returns to the "zero" position. 9 Remove the dial indicator and rotate the turntable 90. 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart. 11 Lower the boom to the stowed position and turn the machine off. 12 Remove the dial indicator from the machine.
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Checklist E Procedures
1 Close the two hydraulic tank shut-off valves at the hydraulic tank. Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 2 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Section 2, Specifications. 3 Tag, disconnect and plug the two suction hoses from the hydraulic tank. 4 Tag, disconnect and plug the two supply hoses for the auxiliary power units. Cap the fittings on the hydraulic tank. 5 Tag, disconnect and plug the hydraulic hose from the drive motor case drain filter at the hydraulic tank. Cap the fitting on the hydraulic tank. 6 Disconnect and plug the hydraulic hose at the return filter. Cap the fitting on the return filter housing. 7 Remove the turntable cover using a suitable lifting device. Crushing hazard. The turntable cover may become unbalanced and fall if not properly supported and secured to a suitable lifting device.
E-1 Test or Replace the Hydraulic Oil
Note: Genie specifications require that this procedure be performed every 2000 hours or every two years, whichever comes first. Perform this procedure more often if dusty conditions exist. Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and a clogged suction strainer or hydraulic filters may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more frequently. Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the boom in the stowed position.
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CHECKLIST E PROCEDURES
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8 Remove the ground control box mounting fasteners. Move the ground control box out of the way. 9 Remove the cover from the auxiliary power unit batteries. 10 Tag and disconnect the cables from the auxiliary power unit batteries. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 11 Tag and disconnect the cables from the engine starting battery located on the engine side of the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 12 Attach an overhead crane or similar lifting device to the battery box for the auxiliary power unit batteries. 13 Remove the battery box retaining fasteners and carefully remove the battery box from the machine. Crushing hazard. The battery box could become unbalanced and fall when removed from the machine if not properly supported. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
14 Remove the hydraulic tank retaining fasteners. 15 Support the hydraulic tank with 2 lifting straps. Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate lifting device. 16 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank could become unbalanced and fall when removed from the machine if not properly supported. 17 Remove the suction strainers from the tank and clean them using a mild solvent. 18 Rinse out the inside of the tank using a mild solvent. 19 Install the suction strainers using pipe thread sealant on the threads. 20 Install the drain plug using pipe thread sealant on the threads. 21 Install the hydraulic tank onto the machine. 22 Install the ground control box and mounting fasteners. 23 Install the two suction hoses, return filter hose, drive motor case drain filter hose and the supply hoses for the auxiliary power units. 24 Install the turntable cover. 25 Fill the tank with hydraulic oil until the level is within the top 2 inches / 5 cm of the sight gauge. Do not overfill. 26 Open the two hydraulic tank shut-off valves at the hydraulic tank. 27 Clean up any oil that may have spilled. 28 Start the engine and check for leaks.
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E-2 Perform Engine Maintenance Cummins Models
E-3 Perform Engine Maintenance Perkins 804D-33T Models
Note: Engine specifications require that this procedure be performed every 2000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Cummins B4.5 Operation and Maintenance Manual (Cummins part number 4021389-01) OR the Cummins B3.3 Operation and Maintenance Manual (Cummins part number 3666417-00).
Note: Engine specifications require that this procedure be performed every 2000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 800 Series Operation and Maintenance Manual (Perkins part number SEBU7853-00).
Perkins 800 Series Operation and Maintenance Manual Genie part number
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E-5 Perform Engine Maintenance Deutz TD2011L04i and Perkins 804D-33T Models
Note: Engine specifications require that this procedure be performed every 2 years. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 800 Series Operation and Maintenance Manual (Perkins part number SEBU7853-00).
Note: Engine specifications require that this procedure be performed every 3000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz TD2011 Operation Manual (Deutz part number 0312 3547) OR the Perkins 800 Series Operation and Maintenance Manual (Perkins part number SEBU7853-00).
Deutz TD2011 Operation Manual Genie part number Perkins 800 Series Operation and Maintenance Manual Genie part number
111332 139320
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E-6 Perform Engine Maintenance Deutz TD2011L04i Models
Note: Engine specifications require that this procedure be performed every 5000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Deutz TD2011 Operation Manual (Deutz part number 0312 3547).
Deutz TD2011 Operation Manual Genie part number
Note: Engine specifications require that this procedure be performed every 6000 hours or 3 years, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 800 Series Operation and Maintenance Manual (Perkins part number SEBU7853-00).
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E-8 Perform Engine Maintenance Perkins 1104C-44 Models
Note: Engine specifications require that this procedure be performed every 8000 hours. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 1100 Series User's Handbook (Perkins part number TPD 1477).
Perkins 1100 Series User's Handbook Genie part number
Note: Engine specifications require that this procedure be performed every 12,000 hours or 6 years, whichever comes first. Proper engine maintenance, following the engine manufacturer's maintenance schedule, is essential to good engine performance and service life. Failure to perform the maintenance procedures can lead to poor engine performance and component damage. Required maintenance procedures and additional engine information are available in the Perkins 800 Series Operation and Maintenance Manual (Perkins part number SEBU7853-00).
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Section 4 Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.
Observe and Obey:

Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine.
Perform disassembly procedures to the point where repairs can be completed. To re-assemble, perform the disassembly steps in reverse order. Symbols Legend Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. With safety alert symbolused to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps.
Before Repairs Start:

Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine. Be sure that all necessary tools and parts are available and ready for use. Use only Genie approved replacement parts. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Machine parked on a firm, level surface Boom in the stowed position Turntable rotated with the boom between the circle-end (yellow arrow) wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Part No. 106783 Z-135/70
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Display Module
The key switch must be in the off position before entering the programming mode. Activation of the setting, use the or
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This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters.
buttons scrolls through the screens. To change parameter values or select a button (to decrease or scroll
button (to increase or scroll forward) and the
backwards). Then press the to memory. Use the and use the
Screen or Menu
button to save new value to memory. An audible beep will indicate a save buttons to scroll to the EXIT menu. Use the button to change to YES
and
button to exit.
Procedure Default Description Hour meter (on power up) Engine speed Engine oil pressure PSI* (English) Engine oil pressure kPa* (metric) Engine temperature F** (English) Engine temperature C** (metric) TT level sensor X TT level sensor Y Platform angle Primary boom angle to gravity Battery volts Hydraulic pressure PSI (English) Hydraulic pressure kPa (metric) Primary boom to secondary boom angle* Primary boom length Secondary boom angle Secondary boom length Jib bellcrank angle* Range or Selection
Operator
* automatically displayed while engine is running ** engine temperature will not be displayed until coolant temperature reaches a minimum of 100 F / 38 C 0-4500 psi 0-31000 kPa -60 deg to +75 deg =0, >0 0-80 deg =0 ft, >0 ft -10 deg to +10 deg * referenced to chassis tilt angle Use +/- buttons to change English, German, French, Spanish, Portuguese, Italian, Dutch and Swedish. Deutz, Perkins, Cummins
Machine Status
With key switch on, press the and at the same time.
Unit of Measure, Language and engine selection
With the key switch OFF , press and hold the button and turn the key switch to the ON position. Release the button and press .
Metric/English measurements Language selection
Engine selection
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DISPLAY MODULE
S c re e n o r M enu D riv e F u n c tio n s
P ro c e d u re
W ith th e k e y s w itc h O F F , p re s s a n d h o ld th e b u tto n a n d tu rn th e k e y s w itc h to th e O N p o s itio n . R e le a s e th e b u tto n a n d . p re s s F o rw a rd F o rw a rd F o rw a rd F o rw a rd
D e s c rip tio n
e x te n d e d d riv e s p e e d % n o t s to w e d d riv e s p e e d % lo w d riv e s p e e d % h ig h d riv e s p e e d %
R a n g e o r S e le c tio n
120% 120% 120% 120% 100% 120% 100% 120% 100% 120% 100% (d e fa u lt) 5 0 % m in (d e fa u lt) 5 0 % m in (d e fa u lt) 5 0 % m in m a x , 5 0 % m in , (d e fa u lt) m a x , 5 0 % m in , (d e fa u lt) m a x , 5 0 % m in , (d e fa u lt) m a x , 5 0 % m in , (d e fa u lt)
R e v e rs e n o t s to w e d d riv e sp e e d % R e v e rs e lo w d riv e s p e e d % R e v e rs e h ig h d riv e s p e e d % D riv e a c c e le ra tio n % D riv e d e c e le ra tio n % S p e e d lim it o n s te e r a n g le
1 5 0 % m a x , 5 0 % m in , 1 0 0 % (d e fa u lt) 1 5 0 % m a x , 5 0 % m in , 1 0 0 % (d e fa u lt) 1 0 0 % m a x , 0 % m in , 7 5 % (d e fa u lt)
Boom F u n c tio n Speeds
W ith th e k e y s w itc h O F F , p re s s a n d h o ld th e b u tto n a n d tu rn th e k e y s w itc h to th e O N p o s itio n . R e le a s e th e b u tto n a n d . p re s s
P rim a ry b o o m u p s p e e d s to w e d % P rim a ry b o o m u p s p e e d n o t s to w e d % P rim a ry b o o m d o w n s p e e d s to w e d % P rim a ry b o o m d o w n s p e e d n o t s to w e d % P rim a ry b o o m e x te n d s p e ed % P rim a ry b o o m re tra c t s p e ed % S e c o n d a ry b o o m u p s p e e d s to w e d % S e c o n d a ry b o o m u p s p e e d n o t s to w e d % S e c o n d a ry b o o m d o w n s p e e d s to w e d % S e c o n d a ry b o o m d o w n s p e e d n o t s to w e d % S e c o n d a ry b o o m e x te n d s pe e d % S e c o n d a ry b o o m re tra c t s pe e d % T T ro ta te s p e e d re tra c te d % T T ro ta te s p e e d n o t re tra c te d % T T ro ta te s p e e d e x te n d e d % J ib u p s p e e d re tra c te d % J ib u p s p e e d n o t re tra c ted % J ib d o w n s p e e d re tra c te d % J ib d o w n s p e e d n o t re tra c te d %
1 2 0 % m a x , 5 0 % m in , 1 0 0 % (d e fa u lt)
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Screen or Menu
Procedure With the key switch OFF, press and hold the button and turn the key switch to the ON position. Release the button . and press
Description Primary boom up/down ramp acceleration % Primary boom up/down ramp deceleration % Primary boom extend/retract ramp acceleration % Primary boom extend/retract ramp deceleration % Secondary boom ramp acceleration % Secondary boom ramp deceleration % TT rotate ramp acceleration % TT rotate ramp deceleration % Jib boom up/down ramp deceleration %
Range or Selection
Lift Function Ramp Settings
150% max, 50% min, 100% (default), 5% increment
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DISPLAY MODULE
Screen or Menu
Procedure
Description
Range or Selection
Valve Calibration
With the key switch OFF, press and hold the button and turn the key switch to the ON position. Release the button . and press
Reset drive valve defaults Reset primary boom up/down valve defaults Reset primary boom extend/retract valve defaults Reset secondary boom valve defaults Reset turntable rotate valve defaults Allow primary boom up/down speed calibration Allow primary boom extend/retract speed calibration Allow secondary boom up/down speed calibration Allow turntable rotate speed calibration Reset drive joystick defaults Reset primary boom up/down joystick defaults Reset primary boom extend/retract joystick defaults Reset secondary boom joystick defaults Reset turntable rotate joystick defaults Reset steer joystick defaults Reset jib up/down joystick
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S cre en o r M enu S enso r C alibration
P ro c e d u re
W ith the key sw itch O F F , pre ss and hold the butto n and turn the key sw itch to the O N position . button R eleas e the . and pre ss
D e s c rip tio n
S et unit X -axis to gravity S et unit Y -axis to gravity S et platform lev el to gravity (Y E S /N O ) Y E S : S et pla tform level to gravity (Y E S /N O ) P latform level se nsor m illivolts per deg ree R eset axle angle sensors (Y E S /N O ) Y E S : A xle an gle fully retracted (Y E S /N O ) Y E S : A xle an gle fully extended (Y E S /N O ) R eset all steer s ensors (Y E S /N O ) R eset blue end blue side steer sensor (F L) (Y E S /N O ) R eset yellow en d blue side steer sensor (R L) (Y E S /N O ) R eset blue end yellow side steer sensor (F R ) (Y E S /N O ) R eset yellow en d yellow side steer sensor (R R ) (Y E S /N O ) C alibrate secon dary boom angle sensor (Y E S /N O )
secondary secondary secondary secondary secondary secondary boom boom boom boom boom boom ang le ang le ang le ang le angle ang le to to to to to to gravity gravity gravity gravity gravity gravity -3.5 deg 20 deg 35 deg 50 deg 65 deg 76 deg
R an g e o r S e le c tio n
U se +/- buttons to adjust
C alibrate prim a ry boom angle sensor (Y E S /N O )

prim ary prim ary prim ary prim ary prim ary prim ary boom boom boom boom boom boom angle angle angle angle angle angle to to to to to to gravity gravity gravity gravity gravity gravity 0 deg -50 deg -20 deg 10 deg 40 deg 70 deg
R eset level angle sensor (Y E S /N O )

jib jib jib jib jib jib level level level level level level calibration calibration calibration calibration calibration calibration de g de g de g de g de g de g to to to to to to gravity gravity gravity gravity gravity gravity 60 deg 34 deg 8 deg -18 deg -44 deg -70 deg
D efau lt R eset
W ith the key sw itch O F F , pre ss and hold the butto n and turn the key sw itch to the O N position . button R eleas e the . and pre ss
R eset drive func tions R eset boom fun ctions R eset lift functio n ram ps R eset all
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DISPLAY MODULE
Screen or Menu
Procedure
With the key switch OFF, press and hold the button and turn the key switch to the ON position. Release the button . and press
Description
Boom function limit:
NO LT / EXT LT
Range or Selection
NO LT: no limit EXT LT: secondary
Options
boom
extend inhibited.
AC Generator: NONE/BELT/HYDAC Alarm: No (NO AL), motion (MO AL), travel (TR AL), descent (DE AL), travel and descent (TD AL) Lift/drive OPT: No (NO CO), drive cutout while not stowed (DCONS), lifting or driving (LORDR) Proximity kill switch OR platform: (NONE, PROX, PLTFS) Chassis switch: (YES/NO) Flashing beacon: (NO/YES) Drive lights: (NO/YES) Disable steer mode change while driving: (NO/YES) Rocker switch: (NO/YES) Chassis tilt cutout: (NO/YES) Foot switch lockout: 0 to 30 minutes
0- 30 minutes, 10.0 (default) Holding + or button will cause display to scroll through options or increment number settings automatically in 0.2 min inc./dec.
Platform level to gravity: (NO/YES) Axle whl drv: (NO/YES)
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Platform Controls
The platform controls contains two printed circuit boards: The LED circuit board is mounted to the underside of the control box lid which contains the LEDs. The LED circuit board sends the input from the operator to the platform controls circuit board (PCON). The circuit board (PCON) sends the data to the turntable control box (TCON) for processing. The platform controls ECM circuit board (ALC-1000) communicates with the turntable controls. The joystick controllers at the platform controls utilize Hall Effect technology (non-contact) and require no adjustment. The operating parameters of the joysticks are stored in memory at the turntable controls. If a joystick controller error occurs or if a joystick is replaced, it will need to be calibrated before that particular machine function will operate. See 1-3, How to Calibrate a Joystick. Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion. For further information or assistance, consult the Genie Industries Service Department.
a
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a b
c d e f
platform controls ALC-1000 circuit board jib boom up/down, jib boom extend/ retract and platform rotate left right joystick secondary boom up/extend and down/retract joystick drive/steer joystick controller LED circuit board primary boom up/down, primary boom extend/retract and turntable rotate left/right joystick
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PLATFORM CONTROLS
1-1 ALC-1000 Circuit Board

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: When the ALC-1000 circuit board is replaced, the joystick controllers will need to be calibrated. See 1-3, How to Calibrate a Joystick.
7 Attach a grounded wrist strap to the ground screw inside the platform control box. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 8 Tag and carefully disconnect the wire connectors from the circuit board. 9 Tag and disconnect the ribbon cable from the LED circuit board. 10 Remove the ALC-1000 circuit board mounting fasteners. 11 Carefully remove the ALC-1000 circuit board from the platform control box.
How to Remove the ALC-1000 Circuit Board

1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Locate the cables that connect to the bottom of the control box. Number each cable and its location at the control box. 3 Disconnect the cables from the bottom of the platform control box. 4 Remove the control cable plug retaining fasteners from the bottom of the platform control box. 5 Remove the platform control box lid retaining fasteners. Open the control box lid. 6 Locate the ALC-1000 circuit board mounted to the inside of the platform control box.
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How to Remove the LED Circuit Board

1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the platform control box lid retaining fasteners. Open the control box lid. 3 Locate the LED circuit board mounted to the inside of the platform control box lid. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 4 Tag and carefully disconnect the ribbon cables from the membrane circuit board. 5 Remove the LED circuit board retaining fasteners. 6 Carefully remove the LED circuit board from the platform control box lid. Do not lose the plastic spacers. Note: When installing the LED circuit board, be sure the plastic spacers are installed between the circuit board and the control box lid.
1-2 Membrane Decal How to Replace the Membrane Decal

The membrane decal is a special decal that incorporates an electronic membrane on the backside. The membrane contains touch sensitive areas that, when pushed, activates the machine functions. The membrane buttons function similar to toggle switches, but do not have any moving parts. 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the platform control box lid retaining fasteners. Open the control box lid. 3 Tag and carefully disconnect the two ribon cables from the membrane circuit board. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.
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PLATFORM CONTROLS
4 Close the control box lid. 5 Remove the platform controls decal from the platform control box. 6 Carefully remove the membrane decal from the platform control box while guiding the ribbon cables out of the control box lid. 7 Remove any decal adhesive from the control box lid with a mild solvent. Note: Do not allow any solvent to come in contact with the membrane circuit board. 8 Install the new membrane decal while guiding the ribbon cables through the control box lid. Note: Be sure that all LED locations on the membrane decal align with the LEDs on the membrane circuit board. 9 Install a new platform controls decal over the membrane decal. 10 Open the control box lid and carefuly connect the ribbon cables from the membrane decal to the membrane circuit board.
1-3 Joysticks How to Calibrate a Joystick

The joystick controllers on this machine utilize digital Hall Effect technology for proportional control. If a joystick controller is disconnected or replaced, it must be calibrated before that particular machine function will operate. Note: The joystick must be calibrated before the threshold, max-out or ramping can be set. Note: After each joystick is calibrated, check the display at the ground control box. There should be no calibration faults shown on the display. If calibration faults exist, repeat steps 1 through 8 for that joystick controlled function. Note: Perform this procedure with the engine off. Drive functions: 1 Turn the key switch to the off position. on the 2 Press and hold the enter button ground control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds. 3 Press the minus button enter button twice. twice, then press the
4 Use the scroll button to scroll through the menu until RESET DRIVE JOYSTICK DEFAULTS is displayed. Press the button to select YES, then press the button.
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5 Do not start the engine. 6 Locate the drive/steer joystick. 7 Move the drive/steer joystick full stroke in the forward direction and hold for 5 seconds, then return to the center or neutral position. 8 Move the drive/steer joystick full stroke in the reverse direction and hold for 5 seconds, then return to the center or neutral position. Result: The alarm at the ground controls should sound for a successful calibration. Steer functions: 1 Turn the key switch to the off position. on the 2 Press and hold the enter button ground control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds. 3 Press the minus button enter button twice. twice, then press the
Primary boom extend/retract functions: 1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds. 3 Press the minus button enter button twice. twice, then press the
to scroll through the 4 Use the scroll button menu until RESET PRIMARY BOOM EXTEND/RETRACT JOYSTICK DEFAULTS is displayed. Press the button to select YES, then press the button. 5 Do not start the engine. 6 Locate the thumb rocker switch on top of the primary boom/turntable rotate joystick. 7 Move the primary boom extend/retract thumb rocker switch full stroke in the extend direction and hold for 5 seconds, then return to the center or neutral position. 8 Move the primary boom extend/retract thumb rocker switch full stroke in the retract direction and hold for 5 seconds, then return to the center or neutral position. Result: The alarm at the ground controls should sound for a successful calibration.
to scroll through the 4 Use the scroll button menu until RESET STEER JOYSTICK DEFAULTS is displayed. Press the button to select YES, then press the button. 5 Do not start the engine. 6 Locate the drive/steer joystick. 7 Move the drive/steer joystick or thumb rocker switch (if equipped) full stroke in the left direction and hold for 5 seconds, then return to the center or neutral position. 8 Move the drive/steer joystick or thumb rocker switch (if equipped) full stroke in the right direction and hold for 5 seconds, then return to the center or neutral position. Result: The alarm at the ground controls should sound for a successful calibration.
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Secondary boom up/down and extend/retract functions: 1 Turn the key switch to the off position. on the 2 Press and hold the enter button ground control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds. 3 Press the minus button enter button twice. twice, then press the
Primary boom up/down functions: 1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds. 3 Press the minus button enter button twice. twice, then press the
to scroll through the 4 Use the scroll button menu until RESET SECONDARY BOOM JOYSTICK DEFAULTS is displayed. Press the button to select YES, then press the button. 5 Do not start the engine. 6 Locate the secondary boom up/down and extend/retract joystick. 7 Move the secondary boom up/down and extend/ retract joystick full stroke in the up/extend direction and hold for 5 seconds, then return to the center or neutral position. 8 Move the secondary boom up/down and extend/ retract joystick full stroke in the down/retract direction and hold for 5 seconds, then return to the center or neutral position. Result: The alarm at the ground controls should sound for a successful calibration.
to scroll through the 4 Use the scroll button menu until RESET PRIMARY BOOM UP/DOWN JOYSTICK DEFAULTS is displayed. Press the button to select YES, then press the button. 5 Do not start the engine. 6 Locate the primary boom/turntable rotate joystick. 7 Move the boom/turntable rotate joystick full stroke in the up direction and hold for 5 seconds, then return to the center or neutral position. 8 Move the boom/turntable rotate joystick full stroke in the down direction and hold for 5 seconds, then return to the center or neutral position. Result: The alarm at the ground controls should sound for a successful calibration.
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Jib boom up/down functions: 1 Turn the key switch to the off position. on the 2 Press and hold the enter button ground control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds. 3 Press the minus button enter button twice. twice, then press the
Turntable rotate functions: 1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds. 3 Press the minus button enter button twice. twice, then press the
to scroll through the 4 Use the scroll button menu until RESET JIB BOOM UP/DOWN JOYSTICK DEFAULTS is displayed. Press the button to select YES, then press the button. 5 Do not start the engine. 6 Locate the jib boom joystick. 7 Move the jib boom joystick full stroke in the up direction and hold for 5 seconds, then return to the center or neutral position. 8 Move the jib boom joystick full stroke in the down direction and hold for 5 seconds, then return to the center or neutral position. Result: The alarm at the ground controls should sound for a successful calibration.
to scroll through the 4 Use the scroll button menu until RESET TURNTABLE ROTATE JOYSTICK DEFAULTS is displayed. Press the button to select YES, then press the button. 5 Do not start the engine. 6 Locate the primary boom/turntable rotate joystick. 7 Move the boom/turntable joystick full stroke in the left direction and hold for 5 seconds, then return to the center or neutral position. 8 Move the boom/turntable joystick full stroke in the right direction and hold for 5 seconds, then return to the center or neutral position. Result: The alarm at the ground controls should sound for a successful calibration.
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How to Reset a Proportional Valve Coil Default

Note: This procedure only needs to be performed if a proportional valve has been replaced. Note: After the valve coil defaults have been set, each machine function threshold and default function speed must be set. See How to Set the Function Thresholds and Default Function Speeds. 1 Turn the key switch to the off position. on the 2 Press and hold the enter button ground control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds. 3 Press the minus button enter button twice. twice, then press the
How to Set the Function Thresholds and Default Functions Speeds

Note: Before the threshold and default function speeds can be set, the boom function proportional valve coil defaults must be set first. See How to Reset a Proportional Valve Coil Default. Note: If a boom function proportional valve coil has not been replaced and just want to reset the function speed to original factory settings, begin with step 12. 1 Start the engine from the platform controls. 2 Press down the foot switch. Note: Be sure the engine rpm is set to foot switch activated high idle. Function threshold: 3 Select a joystick controlled function that needs to have the threshold set. 4 Slowly move the joystick off center in either direction just until the machine function starts to move, then move the joystick very slowly towards the neutral or center position just before the machine function stops. Do not let go of the joystick. 5 While holding the joystick in position, press the engine start button at the platform controls to set the joystick controller threshold. 6 Slowly move the joystick off center in the opposite direction just until the machine function starts to move, then move the joystick very slowly towards the neutral or center position just before the machine function stops. Do not let go of the joystick.
to scroll through the 4 Use the scroll button menu until the function valve that needs to be reset is displayed. Press the button to select YES, then press the button to save the setting. 5 Push one of the LCD screen buttons shown until EXIT is displayed. 6 Press the plus button or minus button select YES and then press the enter button to .
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7 While holding the joystick in position, press the at the platform controls engine start button to set the joystick controller threshold. 8 Repeat steps 3 through 7 for each joystick controlled machine function (primary boom up/ down and turntable rotate left/right, primary boom extend/retract, secondary up/down and extend/retract, drive forward/reverse). 9 Once the threshold has been set, press and hold the engine start button until the engine shuts off. Do not press the red Emergency Stop button. Note: Approximately 3 seconds after the engine shuts off, the alarm at the ground controls will sound to indicate the threshold settings are being saved in memory. 10 At the ground controls, turn the key switch to the off position, wait a moment and then turn the key switch to platform controls. 11 Check the display at the ground controls to be sure there are no calibration faults. Note: There should be no calibration faults shown on the display. If calibration faults exist, repeat this procedure.
Function speeds: Note: Be sure the machine is in the stowed position and the boom is rotated between the circle end tires. Note: Perform this procedure with the machine parked on a firm, level surface which is free of obstructions. 12 Start the engine from the platform controls. 13 Select a boom function that needs the function speed set. 14 Primary boom up/down and extend/retract functions: Move the joystick full stroke in the up or extend direction. When the alarm sounds, move the joystick in the opposite direction full stroke until the alarm sounds again. Return the joystick to center. Secondary boom up/extend and down/retract functions: Move the joystick full stroke in the up or extend direction. When the alarm sounds, move the joystick in the opposite direction full stroke until the alarm sounds again. Return the joystick to center. Turntable rotate functions: Move the joystick full stroke in either the left or right direction. When the alarm sounds, move the joystick in the opposite direction full stroke until the alarm sounds again. Return the joystick to center.
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15 Once the function speeds have been set, press until the and hold the engine start button engine shuts off. Do not press the red Emergency Stop button. Note: Approximately 3 seconds after the engine shuts off, the alarm at the ground controls will sound to indicate the speed settings are being saved in memory. 16 At the ground controls, turn the key switch to the off position, wait a moment and then turn the key switch to platform controls. 17 Check the display at the ground controls to be sure there are no calibration faults. Note: There should be no calibration faults shown on the display. If calibration faults exist, repeat this procedure.
How to Adjust the Function Speeds

Note: Perform this procedure with the boom in the stowed position. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. on the 2 Press and hold the enter button ground control panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds. 3 Press the plus button minus button twice. twice, then press the
4 Press the scroll button until the function to be adjusted is displayed. 5 Press the plus button to increase the speed to decrease the to save the setting in
or press the minus button speed. 6 Press the enter button memory. 7 Push one of the LCD screen buttons shown until EXIT is displayed.
8 Press the plus button or minus button select YES and then press the enter button
to .
9 Continue to perform this procedure until the machine function speed meets specification. Refer to Section 2, Specifications for function speeds.
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How to Adjust the Function Ramp Rate Setting

The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output, when moved out of the neutral position. The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine. Note: Perform this procedure with the boom in the stowed position. 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. on the 2 Press and hold the enter button ground control panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds. 3 Press the plus button scroll button twice. twice, then press the
until the function to 4 Press the scroll button be adjusted is displayed. 5 Press the plus button to increase the ramp to decrease
rate or press the minus button the ramp rate. 6 Press the enter button memory. 7 Push one of the LCD screen buttons shown until EXIT is displayed.
to save the setting in
8 Press the plus button or minus button select YES and then press the enter button
to .
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Platform Components
4 Place a block under the platform leveling cylinder for support. 5 Remove the external snap rings from the barrelend pivot pin. Use a soft metal drift to remove the barrel-end pivot pin. 6 Support the rod end of the platform level cylinder. 7 Remove the pin retaining fasteners from the platform leveling cylinder rod-end pivot pin. Use a soft metal drift to remove the barrel-end pivot pin. 8 Carefully pull the platform leveling cylinder out of the boom to access the hydraulic hoses. 9 Tag, disconnect and plug the hydraulic hoses from the platform leveling cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 10 Remove the platform leveling cylinder from the machine. Crushing hazard. The platform leveling cylinder may fall if not properly supported when removed from the machine.
2-1 Platform Leveling Cylinder

The platform leveling cylinder keeps the platform level through the entire range of boom motion. The platform is maintained level to the turntable. To accomplish this, the ECM at the ground controls compares the difference in readings between the platform angle sensor and the turntable level sensor, which then sends a signal to the platform controls to open or close the appropriate platform level proportional valve on the platform manifold to maintain a level platform. The platform leveling cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.
How to Remove the Platform Leveling Cylinder

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Extend the jib boom until the platform leveling cylinder barrel-end pivot pin is accessible. 2 Raise the jib boom slightly and place blocks under the platform. 3 Lower the jib boom until the platform is resting on the blocks just enough to support the platform. Note: Do not rest the entire weight of the boom on the blocks.
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2-2 Platform Rotator

The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees.
3 Remove the platform angle sensor retaining fasteners. Remove the platform angle sensor from the platform rotator. Component damage hazard. The platform angle sensor is a very sensitive instrument. It can be damaged internally if is dropped or sustains any physical shock, even if the damage is not visible. 4 Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Tag, disconnect and plug the hydraulic hoses from the platform manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 6 Remove the power to platform electrical outlet box bracket mounting fasteners. Do not disconnect the wiring. 7 Remove the hose and cable guide retaining fasteners and remove the guide from the platform support.
How to Remove the Platform Rotator

Component damage hazard. Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment. The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal. If a new rotator is installed or the rotator is disassembled, proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform. 2 Tag and disconnect the electrical connector from the platform angle sensor.
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8 Remove the weld cable from the platform (if equipped). Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 9 Support the platform mounting weldment, but do not apply any lifting pressure. 10 Remove the eight mounting bolts from the platform mounting weldment. 11 Remove the center bolt and slide the platform mounting weldment off of the platform rotator. Crushing hazard. The platform mounting weldment could become unbalanced and fall if not properly supported. 12 Support the platform rotator with a suitable lifting device. Do not apply any lifting pressure. 13 Place a block under the platform leveling cylinder rod for support. 14 Remove the pin retaining fasteners from the platform leveling cylinder rod-end pivot pin. Do not remove the pin. 15 Remove the pin retaining fasteners from the jib boom to platform rotator pivot pin. Do not remove the pin. 16 Use a soft metal drift to remove both pins and remove the platform rotator from the machine. Crushing hazard. The platform rotator could fall when removed from the machine if not properly supported.
2-3 Platform Level Sensor

The platform level sensor is mounted to the side of the platform rotator. The platform level sensor is monitored by the control system to maintain a level platform throught boom range of motion. If a platform level sensor is replaced, it must be calibrated prior to machine operation.
How to Calibrate the Platform Level Sensor

Note: Perform this procedure with the machine on a firm, level surface and in the stowed position. 1 Secure a digital level to one of the side railings of the platform. 2 Start the machine and level the platform to gravity. Turn the machine off. 3 Open the ground control box. Before serial number 321: 4 Locate the 2 pin connector in the lower left hand area of the ground control box. 5 Remove the connector plug and insert a jumper wire between the two pins of the connector. After serial number 320: 4 Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left direction. 5 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine.
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All models: on the 6 Press and hold the enter button ground control panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds. 7 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: . 8 Push one of the LCD screen buttons shown until RESET PLATFORM LEVEL SENSOR TO GRAVITY is displayed. 9 Press the plus button press the enter button. to select YES, then
12 Press the plus button or minus button to correct the display to match the data sheet. Then press the enter button to save the setting in memory. 13 Push one of the LCD screen buttons shown until EXIT is displayed. 14 Press the plus button or minus button select YES and then press the enter button Before serial number 321: 15 Remove the wire jumper from the 2 pin connector in the lower left hand area of the ground control box that was installed in step 5. Install the connector plug. Tip-over hazard. Failure to remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over causing death or serious injury. The jumper wire must be removed before operating the machine. 16 Close the ground control box and install the door retaining fasteners. After serial number 320: 15 Remove the fastener that was temporarily installed in step 5. Close the control box door and install the door retaining fasteners. Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode. to .
10 Push one of the LCD screen buttons shown until PLATFORM LEVEL SENSOR MV PER DEGREE is displayed. 11 Confirm that the number shown on the display is the same as that shown on the data sheet supplied with the new platform level sensor. Result: If the number shown on the display is the same as that shown on the data sheet supplied with the new platform level sensor, continue to step 13. Result: If the number shown on the display is not the same as that shown on the data sheet supplied with the new platform level sensor, continue to step 12.
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2-4 Platform Overload System (if equipped)

Proper calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over.
Determine the limit switch trigger point: 4 Gently move the platform up and down by hand, so it bounces approximately 1 to 2 inches / 2.5 to 5 cm. Allow the platform to settle. Result: The overload indicator light and the alarm is on. Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off. Note: The platform will need to be moved up and down and allowed to settle in between adjustments. Note: There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. Result: The overload indicator light and alarm is off. Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on. Note: There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. Note: The platform will need to be moved up and down and allowed to settle in between adjustments. Confirm the setting: 5 Turn the key switch to platform control. Start the engine from the platform controls. 6 Lift the test weight off the platform floor using a suitable lifting device.
How to Calibrate the Platform Overload System (if equipped)

Note: Perform this procedure with the machine on a firm, level surface. 1 Level the platform. 2 Determine the maximum platform capacity. Refer to the machine serial plate. 3 Using a suitable lifting device, place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor.
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7 Place the test weight back onto the center of the platform floor using a suitable lifting device. Result: The alarm should be off. The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls. Note: There may be an approximate 2 second delay before the overload indicator light and alarm turn off. 8 Add an additional 12 lb / 5.4 kg test weight to the original test weight to overload the platform. Result: The alarm should be sounding. The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls. Note: There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds. 9 Test all machine functions from the platform controls. Result: All platform control functions should not operate. 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls. Result: All ground control functions should not operate.
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Jib Boom Components

a b c d
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Jib boom components a b c d e f g h i j k l primary extension boom jib boom manifold bellcrank cable track tube platform rotator platform leveling cylinder jib boom jib extension boom hose and cable junction box jib boom lift cylinder jib boom cable track jib boom leveling cylinder
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JIB BOOM COMPONENTS
3-1 Jib Boom Cable Track

The jib boom cable track guides the cables and hoses running up the jib boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire jib boom cable track is only necessary when performing major repairs that involve removing the jib boom.
5 Pull the hoses out of the plastic hose guide located on the primary extension boom near the jib boom manifold. 6 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Remove the hose and cable clamp retaining fasteners from the jib boom cable track junction box. Remove the clamps. 8 Pull the jib boom lift cylinder hydraulic hoses out of the jib boom cable track junction box. 9 Remove the hose and cable clamp retaining fasteners at the platform end of the jib boom cable track tube. Remove the clamps. 10 Tag and disconnect the electrical connectors from the platform manifold. 11 Tag and disconnect the electrical connectors from the platform box. 12 Tag and disconnect the electrical connector from the foot switch. 13 Tag and disconnect the electrical connector from the platform angle sensor. 14 Tag, disconnect and plug the hydraulic hoses from the "P" and "T" ports on the platform manifold.
How to Remove the Jib Boom Cable Track

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation.Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom to a horizontal position. Turn the machine off. 2 Remove the cover from the hose and cable junction box under the jib boom cable track. 3 Tag and disconnect the electrical connectors inside the cable track junction box. 4 Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to the platform manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Note: The jib boom manifold is located at the platform end of the primary extension boom.
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15 Pull the two hydraulic hoses just removed and all of the cables through the hose and cable guide at the platform support. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 16 Remove the cotter pin from the upper cable track tube at the platform end of the jib boom. Do not discard the washer. Note: Always replace the cotter pin with a new one. 17 Remove the fasteners from the cable track tube guide at the platform end of the jib boom. Remove the cable track tube guide from the jib boom. 18 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 19 Attach a lifting strap from an overhead crane to the cable track. 20 Remove the mounting fasteners that attach the lower cable track to the jib boom. 21 Remove the cable track from the machine and place it on a structure capable of supporting it. Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
How to Repair the Cable Track

Component damage hazard. The boom cable track can be damaged if it is twisted. Note: A cable track repair kit is available through the Genie Industries Service Parts Department, part no. 77896. The kit includes a 4-link section of cable track. 1 Visually inspect the cable track and determine which 4-link section needs to be replaced. 2 Carefully remove the snap rings and pins from each end of the damaged section of cable track. 3 Remove the retaining fasteners from the upper black rollers from the 4-link section of cable track to be replaced. Remove the rollers. 4 Lift up the hoses and cables and carefully remove the damaged 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 5 Remove the upper rollers from the replacement section of cable track. 6 Lift up the hoses and cables and carefully insert the new 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 7 Connect the ends of the replacement cable track section to the existing cable track using the pins and snap rings. 8 Install the rollers onto the new section of cable track. 9 Operate the jib boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track.
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3-2 Jib Boom How to Remove the Jib Boom

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform mounting weldment and the platform rotator. See 2-2, How to Remove the Platform Rotator. 2 Tag, disconnect and plug the the two hydraulic hoses from the jib boom manifold that lead to the platform manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
3 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses from the jib boom manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Remove the cotter pin from the upper cable track tube at the platform end of the jib boom. Note: Always replace the cotter pin with a new one. 5 Remove the cable track guide fasteners from the cable track guide at the platform end of the jib boom and remove the cable track guide from the jib boom. 6 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 7 Attach a lifting strap from an overhead crane to the cable track. 8 Remove the mounting fasteners that attach the lower cable track to the jib boom. 9 Remove the cable track from the machine and lay to the side. Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
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10 Disconnect the electrical connector from the jib boom angle sensor located at the jib boom pivot pin on the engine side of the machine. 11 Remove the cover retaining fasteners from the jib boom angle sensor. Remove the cover. 12 Remove the jib boom angle sensor mounting bracket fasteners from the side of the primary extension boom. 13 Carefully remove the bracket and sensor assembly. Note the location of the springs. Do not lose the springs. Note: There is one spring inside the jib boom pivot pin and one inside the angle sensor. Note: When the jib boom is installed, the jib boom angle sensor will need to be calibrated. See 3-6, Jib Boom Bellcrank Angle Sensor for the calibration procedure. 14 Attach a lifting strap from an overhead crane to the platform end of the jib boom. 15 Support the barrel end of the jib boom lift cylinder with another suitable lifting device. 16 Remove the pin retaining fasteners from the jib boom lift cylinder barrel-end pivot pin. 17 Use a soft metal drift to remove the jib boom lift cylinder barrel-end pivot pin. Crushing hazard. The jib boom could fall when the jib boom lift cylinder barrel-end pivot pin is removed if not properly supported. Crushing hazard. The jib boom lift cylinder could fall when the barrel-end pivot pin is removed if not properly supported.
18 Secure the jib boom lift cylinder to the jib boom with a strap or other suitable device. 19 Raise the jib boom to a horizontal position using the overhead crane. 20 Attach a second lifting strap from the overhead crane to the pivot end of the jib boom. 21 Remove the pin retaining fastener from the jib boom pivot pin. Do not remove the pin. 22 Place a block under the jib boom level cylinder for support. Protect the cylinder rod from damage. 23 Use a soft metal drift to tap the pin halfway out in one direction and lower one side of the jib boom bellcrank. Tap the pin in the other direction and lower the other side of the jib boom bellcrank. 24 Use a soft metal drift to remove the jib boom pivot pin. Remove the jib boom from the machine and place it on a structure capable of supporting it. Crushing hazard. The jib boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.
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3-3 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder
Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Lower the jib boom until the platform is resting on the blocks just enough to support the platform. Note: Do not rest the entire weight of the boom on the blocks. 2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
3 Support the rod end of the jib boom lift cylinder with a suitable lifting device. 4 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin and let the cylinder hang down. 5 Attach a lifting strap from an overhead crane to the barrel end of jib boom lift cylinder. 6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. 7 Remove the jib boom lift cylinder from the machine. Crushing hazard. The jib boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.
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3-4 Jib Boom Level Cylinder How to Remove the Jib Boom Level Cylinder
Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Extend the primary boom until the jib boom level cylinder barrel-end pivot pin is accessible. 2 Raise the jib boom above horizontal. 3 Attach an overhead crane to the jib boom assembly for support. 4 Place a block under the jib boom level cylinder for support. Protect the cylinder rod from damage. 5 Remove the pin retaining fasteners from the jib boom level cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The jib boom could fall if not properly supported when the jib boom level cylinder rod-end pivot pin is removed. 6 Remove the external snap rings from the jib boom level cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin.
7 Tag, disconnect and plug the jib boom level cylinder hydraulic hoses from the jib boom manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 8 Attach an overhead crane or other suitable device to the jib boom level cylinder for support. 9 Carefully remove the jib boom level cylinder from the machine. Crushing hazard. The jib boom level cylinder could become unbalanced and fall when removed from the machine if not properly supported.
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3-5 Jib Boom Extension Cylinder How to Remove the Jib Boom Extension Cylinder
Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the jib boom lift cylinder. See 3-3, How to Remove the Jib Boom Lift Cylinder. 2 Attach a lifting strap from an overhead crane to the platform end of the jib boom for support. Raise the jib boom to a horizontal position using the overhead crane. 3 Extend the jib boom until the jib boom extension cylinder rod-end pivot pin is accessible.
4 Tag, disconnect and plug the the two hydraulic hoses from the jib boom manifold that lead to the platform manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Tag, disconnect and plug the jib boom lift cylinder and jib boom extension cylinder hydraulic hoses from the jib boom manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 6 Remove the cover from the lower jib boom cable track. 7 Tag and disconnect the electrical connectors inside the lower cable track. 8 Remove the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom. Remove the clamps. 9 Pull the electrical cables out of the lower cable track that lead to the primary boom. 10 Attach a lifting strap from a second overhead crane to the pivot end of the jib boom for support. Do not apply any lifting pressure.
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11 Place a block under the jib boom level cylinder for support. Protect the cylinder rod from damage. 12 Remove the pin retaining fastener from the jib boom pivot pin. Do not remove the pin. 13 Use a soft metal drift to tap the jib boom pivot pin halfway out in one direction and lower one side of the jib boom bellcrank. Tap the pin in the other direction and lower the other side of the jib boom bellcrank. 14 Use a soft metal drift to remove the jib boom pivot pin. Remove the jib boom and platform assembly from the machine and place it on a structure capable of supporting it. Crushing hazard. The jib boom and platform assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. 15 Remove the pin retaining fasteners from the jib boom extension cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. 16 Attach a lifting strap from an overhead crane to the barrel end of the jib boom extension cylinder. 17 Remove the pin retaining fasteners from the jib boom extension cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin. 18 Carefully slide the jib boom extension cylinder out of the jib boom and place it on a structure capable of supporting it. Crushing hazard. The jib boom extension cylinder could become unbalanced and fall when removed from the jib boom if not properly supported. Note: During removal of the extension cylinder, the overhead crane strap will need to be carefully adjusted for proper balancing.
3-6 Jib Boom Bellcrank Angle Sensor

The jib boom bellcrank angle sensor is monitored by the control system to keep the jib boom bellcrank vertical and to help maintain a level platform through boom range of motion. If a jib boom bellcrank angle sensor is replaced, it must be calibrated prior to machine operation. The jib boom bellcrank angle sensor is mounted to the bellcrank pivot pin on the engine side of the machine.
How to Replace the Jib Boom Bellcrank Angle Sensor

Note: Perform this procedure on a firm, level surface with the boom in the stowed position. 1 Locate the jib boom bellcrank angle sensor where the jib boom bellcrank connects to the primary boom. 2 Disconnect the electrical connector from the sensor. Remove any tie wraps securing the wiring. 3 Remove the retaining fasteners from the angle sensor guard. Remove the guard from the machine. 4 Remove the angle sensor cover retaining fastener. Remove the cover. 5 Remove the angle sensor mounting bracket retaining fasteners.
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6 Remove the angle sensor and bracket assembly. Do not lose the two springs or the hex-shaped key. 7 Remove the sensor retaining fasteners from the mounting bracket. Remove the angle sensor. Note: Note the sensor orientation on the bracket during removal so the new sensor will be installed in the same position. 8 Install the new angle sensor onto the mounting bracket. 9 Install one spring, removed in step 6, into the hex-shaped hole in the angle sensor. Install the other spring into the hex-shaped hole in the center of the boom pivot pin. 10 Insert the hex-shaped key into the angle sensor. 11 Align the side of the sensor with flat area of the boom pivot pin as shown below.
12 Insert the hex-shaped key into the bellcrank pivot pin allowing free clockwise rotation of the angle sensor mounting bracket. Note: Be sure the hex-shaped key remains engaged in the sensor. 13 Rotate the angle sensor mounting bracket, while holding the key in the sensor, clockwise until the mounting bracket fits into the machined pocket. 14 Install the angle sensor bracket retaining fasteners. 15 Install the angle sensor cover and install the cover retaining fasteners. 16 Connect the electrical connector to the new sensor. 17 Install the angle sensor guard over the angle sensor. 18 Calibrate the jib boom bellcrank angle sensor. See How to Calibrate the Jib Boom Bellcrank Angle Sensor.
b
a b c flat area angle sensor hex-shaped hole
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How to Calibrate the Jib Boom Bellcrank Angle Sensor

Note: If the secondary boom and/or primary boom angle sensors have been removed or replaced, they will need to be calibrated before the jib boom bellcrank angle sensor. See 4-9, Secondary Boom Angle Sensor and/or 4-8, Primary Boom Angle Sensor for the calibration procedures. Note: Perform this procedure with the machine on a firm, level surface and in the stowed position with the axles extended. Note: A digital level will be required to perform this procedure. Note: A kit is available through the Genie Industries Service Department (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses. Digital levels with alternate zero function: 1 Prepare the digital level by placing it vertically on a known surface that is perpendicular to gravity. Zero out the level with the alternate zero function. Note: When the level is calibrated correctly, it should read 0 on a vertical surface. Digital levels without alternate zero function: Note: If your digital level does not have an alternate zero function, it will read 90 on a vertical surface. During calibration, the measured value will need to be subtracted from 90 degrees to get the correct number to enter into the system.
2 Raise the jib boom to a slightly less than horizontal position. 3 Push in the ground controls red Emergency Stop button to the off position. Do not turn the key switch to the off position. 4 Open the ground control box Before serial number 321: 5 Locate the 2 pin connector in the lower left hand area of the ground control box. 6 Remove the connector plug and insert a jumper wire between the two pins of the connector. After serial number 320: 5 Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left direction. 6 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine. All models: 7 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine. 8 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position. Hold the enter button for approximately 5 seconds and then release it. 9 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: .
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10 Remove the key from the main key switch. 11 Insert the key into the service/bypass key switch and turn it to the service/bypass position. Note: The angle sensor calibration values will not be saved correctly unless the key switch is in the service/bypass position.
STOP
15 Press and hold a function enable/speed select button and the platform level up button. Fully extend the jib boom level cylinder. Note: When in service/bypass mode, the platform level buttons are used to adjust the jib boom level cylinder. Note: With the jib boom level cylinder is fully extended, the jib boom bellcrank angle should be at approximately 60 5 degrees. 16 Attach the digital level to the surface of the jib boom bellcrank as shown.
00000
12 Push one of the LCD screen buttons shown until RESET JIB LEVEL ANGLE SENSOR is displayed. 13 Press the plus button press the enter button to select YES, then to accept.
a b c
jib boom angle sensor jib boom bellcrank place level on this surface
17 At the ground controls, press the plus button or minus button to adjust the display to to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.
14 At the JIB LEVEL CALIBRATION DEG 60.0DEG screen, start the engine. Note: If the system exits out of calibration mode when the engine is started, repeat step 9 and continue to step 15.
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18 Press and hold a function enable/speed select button and the platform level down button until the digital level displays approximately 34 5 degrees. 19 At the ground controls, press the plus button or minus button to adjust the display to to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 20 Press and hold a function enable/speed select button and the platform level down button until the digital level displays approximately 8 5 degrees. 21 At the ground controls, press the plus button or minus button to to adjust the display to to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.
22 Press and hold a function enable/speed select button and raise the jib boom above horizontal to provide additional ground clearance for the remaining calibration points. 23 Press and hold a function enable/speed select button and the platform level down button until the digital level displays approximately 18 5 degrees. 24 At the ground controls, press the plus button or minus button to adjust the display to to the exact value shown on the digital level and press the enter button . Note: Be sure the number entered at the ground controls is a negative number. Note: If the measured angle already matches the angle shown on the display at the ground controls, or minus button to press the plus button change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 25 Press and hold a function enable/speed select button and the platform level down button until the digital level displays approximately 44 5 degrees. 26 At the ground controls, press the plus button or minus button to adjust the display to to the exact value shown on the digital level and press the enter button . Note: Be sure the number entered at the ground controls is a negative number. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.
-70 60 34 -44 8 0 -18
Calibration angles
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27 Press and hold a function enable/speed select button and the platform level down button until the digital level displays approximately 70 5 degrees. The jib boom level cylinder should be fully retracted at this point. 28 At the ground controls, press the plus button or minus button to adjust the display to to the exact value shown on the digital level and press the enter button . Note: Be sure the number entered at the ground controls is a negative number. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. Note: With the jib boom level cylinder fully retracted, the jib boom bellcrank angle should be at approximately 70 degrees. 29 Push one of the LCD screen buttons shown until EXIT is displayed. 30 Press the plus button press the enter button to select YES, then to accept.
Before serial number 321: 33 Remove the wire jumper from the 2 pin connector in the lower left hand area of the ground control box that was installed in step 6. Install the connector plug. Tip-over hazard. Failure to remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over causing death or serious injury. The jumper wire must be removed before operating the machine. 34 Close the ground control box and install the door retaining fasteners. After serial number 320: 33 Remove the fastener that was temporarily installed in step 6. 34 Close the control box door and install the door retaining fasteners. Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode. All models: 35 Use the key to turn the service/bypass key switch to the run postion. Note: Be sure that the service/bypass key switch is in the run position before attempting to operate the machine.
31 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings. Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved. 32 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in to the off position or by turning the main key switch to the off position.
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Boom components a b c d e f g h i j k l m upper primary boom lift cylinder linkage arm primary boom cable track primary extension boom jib boom manifold secondary boom lift cylinder secondary boom cable track (inside of secondary boom) primary boom lift cylinder number 1 secondary boom tube number 2 secondary boom tube number 3 secondary boom tube lower primary boom lift cylinder linkage arm number 4 secondary boom tube
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4-1 Primary Boom Cable Track

The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom.
5 Tag and disconnect the electrical connectors from the jib boom manifold located at the platform end of the primary extension boom. 6 Tag, disconnect and plug the two hydraulic hoses from the side of the jib boom manifold that lead to the primary boom cable track. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 7 Remove the retaining fasteners from the hose and cable guide at the platform end of the primary boom. Remove the hose and cable guide. 8 Tag and disconnect the electrical connector from the limit switch on the side of the primary boom. Do not remove the limit switch. 9 Remove the cotter pin from the upper cable track tube at the platform end of the primary extension boom. Note: Always replace the cotter pin with a new one. 10 Remove the retaining fasteners from the cable track guide at the platform end of the boom. Remove the cable track guide from the machine. 11 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.
How to Remove the Cable Track

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the machine on a firm, level surface and the boom in the stowed position. 1 Remove the cover from the lower jib boom cable track. 2 Tag and disconnect the electrical connectors inside the lower cable track. 3 Remove the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom. Remove the clamps. 4 Pull the electrical cables out of the lower cable track that lead to the primary boom. Component damage hazard. Cables can be damaged if they are kinked or pinched.
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12 Remove the hose and cable clamps from the primary boom lift cylinder. 13 At the counterweight end of the secondary boom, support and secure the secondary boom lower end cover to a suitable lifting device. 14 Remove the cover retaining fasteners and remove the cover from the end of the secondary boom. Crushing hazard. The secondary boom lower end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device. 15 Locate the two hydraulic hoses inside the end of the secondary boom that lead to the primary boom cable track. 16 Tag, disconnect and plug the hydraulic hoses from the unions. Cap the fittings on the unions. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 17 Disconnect the electrical connectors for the electrical cables that lead to the cable track at the end of the secondary boom.
18 Pull all hydraulic hoses and electrical cables that lead to the cable track out of the secondary boom riser. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 19 Attach a lifting strap to each end of the cable track from an overhead crane for support. Do not apply any lifting pressure. 20 Remove the mounting fasteners that attach the lower cable track to the primary boom lift cylinder. 21 Remove the mounting fasteners that attach the cable track to the primary boom. 22 Carefully remove the cable track from the machine and lay it on a structure capable of supporting it. Crushing hazard. The primary boom cable track could become unbalanced and fall when removed from the primary boom if not properly supported by the overhead crane. Component damage hazard. The boom cable track can be damaged if it is twisted. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
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How to Repair the Primary Boom Cable Track

Component damage hazard. The boom cable track can be damaged if it is twisted. Note: A cable track repair kit is available through the Genie Industries Service Parts Department, part no. 77896. The kit includes a 4-link section of cable track. 1 Visually inspect the cable track and determine which 4-link section needs to be replaced. 2 Carefully remove the snap rings and pins from each end of the damaged section of cable track. 3 Remove the retaining fasteners from the upper black rollers from the 4-link section of cable track to be replaced. Remove the rollers. 4 Lift up the hoses and cables and carefully remove the damaged 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 5 Remove the upper rollers from the replacement section of cable track. 6 Lift up the hoses and cables and carefully insert the new 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched.
7 Connect the ends of the replacement cable track section to the existing cable track using the pins and snap rings. 8 Install the rollers onto the new section of cable track. 9 Operate the primary boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track.
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4-2 Secondary Boom Cable Track

The secondary boom cable track guides the cables and hoses running up through the inside of the secondary boom. It can be repaired link by link without removing the cables and hoses that run through it. Removal of the secondary boom cable track is required to repair it.
4 Remove the cover retaining fasteners and remove the cover from the secondary boom. Crushing hazard. The secondary boom end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device. 5 Working at the platform end of the secondary boom, remove the hose and cable U-bolt fasteners near the upper cable track tube. 6 Working at the platform end of the secondary boom, remove the upper cable track tube retaining fasteners. Remove the curved hose guide. 7 Working at the platform end of the secondary boom, remove the lower cable track retaining fasteners. 8 Working at the counterweight end of the secondary boom, remove the lower cable track retaining fasteners. 9 Tag, disconnect and plug the hydraulic hoses from the following ports of the function manifold: PE, PR, P2, T1, PU and PD. Cap the fittings on the manifold. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
How to Remove the Secondary Boom Cable Track

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Working at the counterweight end of the secondary boom, support and secure the secondary boom end cover to a suitable lifting device. 2 Remove the cover retaining fasteners and remove the cover from the secondary boom. Crushing hazard. The secondary boom end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device. 3 Working at the platform end of the secondary boom, support and secure the secondary boom end cover to a suitable lifting device.
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10 Pull the hydraulic hoses just removed through the turntable bulkhead. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 11 Working at the counterweight end of the secondary boom, tag, disconnect and plug the hydraulic hoses from the unions that lead to the cable track. 12 Working at the counterweight end of the secondary boom, tag and disconnect the electrical connectors to all of the cables that lead to the secondary boom cable track. 13 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. 14 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses at the unions located above the primary boom lift cylinder. Cap the fittings on the unions. 15 Pull the hydraulic hoses for the primary boom lift cylinder and extension cylinder out through the hole in the number 4 secondary boom tube. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 16 Working at the platform end of the secondary boom, place blocks between the upper and lower cable tracks for support.
17 Working at the counterweight end of the secondary boom, attach a lifting strap from an overhead crane to the secondary boom cable track. 18 Carefully pull the secondary boom cable track out of the counterweight end of the boom. 19 Remove the secondary boom cable track from the machine and place it on a structure capable of supporting it. Crushing hazard. The secondary boom cable track could become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. Component damage hazard. The secondary boom cable track can be damaged if it is twisted. Note: The lifting strap from the overhead crane will need to be adjusted during removal for proper balancing of the cable track.
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How to Repair the Secondary Boom Cable Track

Component damage hazard. The boom cable track can be damaged if it is twisted. Note: A cable track repair kit is available through the Genie Industries Service Parts Department, part no.107717. The kit includes a 4-link section of cable track. 1 Remove the secondary boom cable track. See How to Remove the Secondary Boom Cable Track. 2 Visually inspect the cable track and determine which 4-link section needs to be replaced. 3 Carefully remove the snap rings and pins from each end of the damaged section of cable track. 4 Remove the retaining fasteners from the upper black rollers from the 4-link section of cable track to be replaced. Remove the rollers. 5 Lift up the hoses and cables and carefully remove the damaged 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. Note: If the section of cable track being replaced has clamps or wear pads, those items will need to be transferred to the replacement section of cable track.
6 Remove the upper rollers from the replacement section of cable track. 7 Lift up the hoses and cables and carefully insert the new 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 8 Connect the ends of the replacement cable track section to the existing cable track using the pins and snap rings. 9 Install the rollers onto the new section of cable track. 10 Install the secondary boom cable track into the secondary boom. 11 Operate the secondary boom up/extend and down/retract functions through a full cycle to ensure smooth operation of the new section of cable track.
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4-3 Primary Boom How to Remove the Primary Boom

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the boom in the stowed position. 1 Remove the platform. 2 Remove the platform mounting weldment and the platform rotator. See 2-2, How to Remove the Platform Rotator. 3 Remove the jib boom. See 3-2, How to Remove the Jib Boom. Note: When the jib boom is installed, the jib boom angle sensor will need to be calibrated. See 3-6, Jib Boom Bellcrank Angle Sensor for the calibration procedure.
4 Remove the primary boom cable track. See 4-1, How to Remove the Cable Track. 5 Remove the end cover from the pivot end of the primary boom. 6 Remove the limit switch mounting fasteners from the limit switch on the ground controls side of the primary boom. Do not disconnect the wiring. Remove the limit switch. 7 Disconnect the electrical connector from the primary boom angle sensor. Note: The primary boom angle sensor is located inside the primary boom at the pivot end. 8 Remove the primary boom angle sensor bracket mounting fasteners and remove the primary boom angle sensor from the primary boom. Do not remove the angle sensor from the bracket. Note the location of the springs. Do not lose the springs. Note: There is one spring inside the primary boom pivot pin and one inside the angle sensor. Note: When the primary boom is installed, the primary boom angle sensor will need to be calibrated. See 4-8, Primary Boom Angle Sensor for the calibration procedure. 9 Remove the hose and cable guide fasteners at the primary boom pivot pin. Remove the hose and cable guide.
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10 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 11 Place blocks under both ends of the primary boom lift cylinder for support. 12 Attach a lifting strap from an overhead crane to the rod end of the primary boom lift cylinder. 13 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. 14 Use a soft metal drift to remove the rod-end pivot pin. Rest the rod end of the primary boom lift cylinder on the blocks. 15 Support both upper primary boom lift cylinder linkage arms with a suitable lifting device. Do not apply any lifting pressure. 16 Remove the pin retaining fasteners from the upper primary boom lift cylinder linkage arm pivot pin where it connects to the primary boom. 17 Use a soft metal drift to tap the pin halfway out and lower one of the linkage arms down. Tap the pin in the other direction and lower the other linkage arm down. Crushing hazard. The upper primary boom lift cylinder linkage arms could fall if not properly supported when the pivot pins are removed.
18 Attach a 5 ton / 5000 kg overhead crane to both ends of the primary boom. Do not apply any lifting pressure. 19 Remove the pin retaining fasteners from the primary boom pivot pins. 20 Use a soft metal drift to remove the primary boom pivot pins. 21 Carefully remove the primary boom from the machine and place it on a structure capable of supporting it. Crushing hazard. The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.
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4-4 Primary Boom Lift Cylinder

The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure.
4 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 5 Attach a lifting strap from an overhead crane to the rod end of the primary boom lift cylinder. Do not apply any lifting pressure. 6 Remove the pin retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin and rest the cylinder on the block. 7 Attach a lifting strap from a second overhead crane to the barrel end of the primary boom lift cylinder. Do not apply any lifting pressure. 8 Remove the primary boom lift cylinder barrel-end pivot pin retaining fasteners. 9 Use a soft metal drift to remove the barrel-end pivot pin. Carefully remove the primary boom lift cylinder from the machine. Crushing hazard. The lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Crushing hazard. The primary boom lift cylinder linkage arms may fall if not properly supported when the barrel-end pivot pin is removed.
How to Remove the Primary Boom Lift Cylinder

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the boom in the stowed position. 1 Remove the hose and cable clamps from the primary boom lift cylinder. 2 Remove the cable track retaining fasteners at the primary boom lift cylinder. 3 Place blocks under both ends of the primary boom lift cylinder. Place another block under the cylinder linkage arms under the primary boom lift cylinder barrel-end pivot pin.
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4-5 Secondary Boom Lift Cylinder How to Remove the Secondary Boom Lift Cylinder
Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the boom in the stowed position and the axles extended. 1 Tag, disconnect and plug the hydraulic hoses from the secondary boom lift cylinder. The hoses can be accessed from under the turntable. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
2 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.
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3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving. Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 5 Remove the retaining fasteners from the fixed turntable cover at the ground controls side of the machine. Remove the fixed turntable cover from the machine. 6 Tag, disconnect and plug the fuel hoses from the fuel tank. Clean up any fuel that may have spilled.
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7 Close the two hydraulic tank shut-off valves at the hydraulic tank. Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 8 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Section 2, Specifications. 9 Tag, disconnect and plug the two suction hoses from the hydraulic tank. 10 Tag, disconnect and plug the two supply hoses for the auxiliary power units. Cap the fittings on the hydraulic tank. 11 Tag, disconnect and plug the hydraulic hose from the drive motor case drain filter at the hydraulic tank. Cap the fitting on the hydraulic tank. 12 Tag, disconnect and plug the hydraulic hose at the return filter. Cap the fitting on the return filter housing. 13 Remove the turntable cover using a suitable lifting device. Crushing hazard. The turntable cover may become unbalanced and fall if not properly supported and secured to a suitable lifting device.
14 Remove the ground control box mounting fasteners. Move the ground control box out of the way. 15 Remove the hydraulic tank retaining fasteners. 16 Remove the cover from the auxiliary power unit batteries. 17 Tag and disconnect the cables from the auxiliary power unit batteries. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 18 Tag and disconnect the cables from the engine starting/controls battery located on the engine side of the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 19 Attach an overhead crane or similar lifting device to the battery box for the auxiliary power unit batteries. 20 Remove the battery box retaining fasteners and carefully remove the battery box from the machine. Crushing hazard. The battery box could become unbalanced and fall when removed from the machine if not properly supported. Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
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21 Support the hydraulic tank with 2 lifting straps. Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate lifting device. 22 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank could become unbalanced and fall when removed from the machine if not properly supported. 23 Place a block under the secondary boom lift cylinder for support. 24 Remove the secondary boom lift cylinder rod-end pivot pin retaining fasteners. Use a soft metal drift to remove the pin through the access holes in the turntable bulkheads. 25 Attach an overhead crane with a minimum capacity of 7 tons / 7000 kg to the counterweight end of the secondary boom. 26 Raise the boom assembly with the overhead crane approximately 20 feet / 6 m. Crushing hazard. The boom assembly can fall if not properly supported by the overhead crane. 27 Remove the secondary boom lift cylinder barrel-end pivot pin retaining fasteners. Do not remove the pin. 28 Attach a lifting strap from a second overhead crane to each end of the secondary boom lift cylinder. Note: Protect the hoses and cables underneath the cylinder from damage.
29 Use a slide hammer to remove the barrel-end pivot pin. Component damage hazard. Hoses and cables can become damaged if the barrel end of the secondary boom lift cylinder is allowed to fall when the barrel-end pivot pin is removed. 30 Carefully remove the secondary boom lift cylinder from the machine. Crushing hazard. The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Component damage hazard. Hoses and cables can be damaged if the secondary boom lift cylinder is pulled across them.
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4-6 Primary Boom Extension Cylinder

The primary boom extension cylinder extends and retracts the primary boom extension tube.The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.
3 Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 At the platform end, remove the external snap rings from the extension cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. 5 Remove the extension cylinder retainers from the saddle blocks. 6 Attach a lifting strap from an overhead crane to the barrel end of the primary boom extension cylinder. 7 Using the overhead crane, lift the extension cylinder to clear the saddle blocks. 8 Support and slide the primary boom extension cylinder out of the primary boom and place it on a structure capable of supporting it. Crushing hazard. The extension cylinder could fall when removed from the primary boom if not properly supported. Note: The lifting strap from the overhead crane will need to be adjusted during removal for proper balancing of the extension cylinder. Note: Note the length of the cylinder after removal. The cylinder must be at the same length for installation.
How to Remove the Primary Boom Extension Cylinder

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the axles extended and the boom in the stowed position. 1 Extend the primary boom until the primary boom extension cylinder rod-end pivot pin is accessible in the primary boom extension tube. 2 Remove the access cover from the pivot end of the primary boom.
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4-7 Secondary Boom Extension Cylinders

The secondary boom extension cylinders extend and retract the secondary boom. The secondary boom extension system consists of 3 hydraulic cylinders and each are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.
3 Remove the cover retaining fasteners and remove the cover from the secondary boom. Crushing hazard. The secondary boom end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device. 4 Remove the retaining fasteners from both secondary boom extend limit switches and remove the limit switches. Do not disconnect the wiring. Note: Label the location of each limit switch as they are not the same and their mounting locations cannot be exchanged. 5 Tag, disconnect and plug all hydraulic hoses for the 3 secondary boom extension cylinders. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 6 Remove the upper extension cylinder retainers from the saddle blocks. 7 Attach a lifting strap from an overhead crane to the rod end of the upper extension cylinder. 8 Using the overhead crane, lift the extension cylinder to clear the saddle blocks.
How to Remove the Secondary Boom Extension Cylinders

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the axles extended and the boom in the stowed position. 1 Raise the primary boom approximately 10 feet / 3 m. Turn the machine off. 2 Working at the platform end of the secondary boom, support and secure the secondary boom end cover to a suitable lifting device.
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9 Support and slide the upper extension cylinder out of the secondary boom and place it on a structure capable of supporting it. Crushing hazard. The extension cylinder could fall when removed from the secondary boom if not properly supported. Note: The lifting strap from the overhead crane will need to be adjusted during removal for proper balancing of the extension cylinder. 10 Repeat steps 6 through 9 for the remaining secondary boom extension cylinders. Note: The secondary boom extension cylinders must be installed in the same order they were removed. Note: When installing the middle and upper secondary boom extension cylinders, be sure the grooved wear pads are correctly aligned with the channels on the top of the cylinders.
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4-8 Primary Boom Angle Sensor

The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity.
How to Replace the Primary Boom Angle Sensor

Note: Perform this procedure on a firm, level surface with the boom in the stowed position. 1 Remove the retaining fasteners from the boom end cover at the pivot end of the primary boom. Remove the cover from the machine. 2 Locate the primary boom angle sensor inside the primary boom at the boom pivot pin. 3 Disconnect the electrical connector from the sensor. 4 Remove the angle sensor mounting bracket retaining fasteners. 5 Remove the angle sensor and bracket assembly. Do not lose the two springs or the hex-shaped key. 6 Remove the sensor retaining fasteners from the bracket. Remove the angle sensor. Note: Note the sensor orientation on the bracket during removal so the new sensor will be installed in the same position.
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upper extension cylinder (#1) middle extension cylinder (#2) bottom extension cylinder (#3) cylinder grooved wear pads channels
7 Install the new angle sensor onto the mounting bracket.
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8 Install one spring, removed in step 5, into the hex-shaped hole in the angle sensor. Install the other spring into the hex-shaped hole in the center of the boom pivot pin. 9 Insert the hex-shaped key into the angle sensor. 10 Align the side of the sensor with flat area of the boom pivot pin shown as shown below while holding the bracket away from key insertion.
12 Insert the hex-shaped key into the boom pivot pin and the bracket into the machined pocket. Note: Be sure the hex-shaped key remains engaged in the sensor. 13 Install the angle sensor bracket retaining fasteners. 14 Connect the electrical connector to the new sensor. 15 Install the primary boom end cover. 16 Calibrate the primary boom angle sensor. See How to Calibrate the Primary Boom Angle Sensor.
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flat area angle sensor hex-shaped hole
11 While holding the hex-shaped key in position, rotate the angle sensor mounting bracket clockwise until it aligns with the machined pocket. Do not allow the key to rotate while holding it.
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How to Calibrate the Primary Boom Angle Sensor

Note: If the secondary boom angle sensor has been removed or replaced, it will need to be calibrated first. See 4-9, Secondary Boom Angle Sensor for the calibration procedure. Note: Perform this procedure with the machine on a firm, level surface with the axles extended and in the stowed position. Note: A digital level will be required to perform this procedure. Note: A kit is available through the Genie Industries Service Department (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses. 1 Push in the ground controls red Emergency Stop button to the off position. 2 Turn the key switch to ground controls. 3 Open the ground control box. Before serial number 321: 4 Locate the 2 pin connector in the lower left hand area of the ground control box. 5 Remove the connector plug and insert a jumper wire between the two pins of the connector. After serial number 320: 4 Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left direction. 5 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine.
All models: 6 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position. Hold the enter button for approximately 5 seconds and then release it. 7 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: . 8 Remove the key from the main key switch. Insert the key into the service/bypass key switch and turn it to the service/bypass position. Note: The angle sensor calibration values will not be saved correctly unless the key switch is in the service/bypass position.
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9 Start the engine from the ground controls. Note: If the system exits out of calibration mode when the engine is started, repeat step 7 and continue to step 10. 10 Push one of the LCD screen buttons shown until RESET PRIMARY BOOM ANGLE SENSOR is displayed. 11 Press the plus button press the enter button to select YES, then to accept.
16 Measure the angle of the primary boom with the digital level. Note: The angle of the primary boom must be between -45 and -55 degrees. If the primary boom angle is not within this range, adjust the primary boom until the digital level displays approximately -50 5 degrees. 17 At the ground controls, press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button . Note: Be sure the number entered at the ground controls is a negative number. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 18 Press and hold a function enable/speed select button and the primary boom up button until the digital level displays approximately -20 5 degrees.
12 Place the digital level on top of the primary boom and note the angle displayed on the digital level. 13 At the PRIMARY BOOM ANGLE TO GRAVITY 0.0 DEG screen, press the plus button or minus to adjust the display to the exact button value shown on the digital level, then press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 14 Fully raise the secondary boom. Stop before the secondary boom begins to extend. 15 Press and hold a function enable/speed select button and the primary boom down button and lower the primary boom down as far as it will go.
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19 At the ground controls, press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button . Note: Be sure the number entered at the ground controls is a negative number. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 20 Press and hold a function enable/speed select button and the primary boom up button until the digital level displays approximately 10 5 degrees. 21 At the ground controls, press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 22 Press and hold a function enable/speed select button and the primary boom up button until the digital level displays approximately 40 5 degrees.
23 At the ground controls, press the plus button or minus button to to adjust the display to the exact value shown on the digital level and . press the enter button Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 24 Press and hold a function enable/speed select button and the primary boom up button until the primary boom is fully raised. The angle will be approximately 70 5 degrees. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 25 Push one of the LCD screen buttons shown until EXIT is displayed. 26 Press the plus button press the enter button to select YES, then to accept.
27 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings. Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved. 28 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in to the off position or by turning the main key switch to the off position.
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Before serial number 321: 29 Remove the wire jumper from the 2 pin connector in the lower left hand area of the ground control box that was installed in step 5. Install the connector plug. Tip-over hazard. Failure to remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over causing death or serious injury. The jumper wire must be removed before operating the machine. 30 Close the ground control box and install the door retaining fasteners. After serial number 320: 29 Remove the fastener that was temporarily installed in step 5. 30 Close the control box door and install the door retaining fasteners. Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode.
All models: 31 Use the key to turn the service/bypass key switch to the run postion. Note: Be sure that the service/bypass key switch is in the run position before attempting to operate the machine. 32 Start the engine and lower the boom to the stowed position. Be sure there are no calibration faults shown on the display.
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4-9 Secondary Boom Angle Sensor

The secondary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity.
8 Install one spring, removed in step 5, into the hex-shaped hole in the angle sensor. Install the other spring into the hex-shaped hole in the center of the boom pivot pin. 9 Insert the hex-shaped key into the angle sensor. 10 Align the side of the sensor with flat area of the boom pivot pin as shown below. Hold the bracket out to clear the side of the turntable side plate.
How to Replace the Secondary Boom Angle Sensor

Note: Perform this procedure on a firm, level surface with the boom in the stowed position. 1 Locate the secondary boom angle sensor on the turntable riser bulkhead at the ground controls side of the machine. 2 Disconnect the electrical connector from the sensor. Remove any tie wraps securing the wiring. 3 Remove the angle sensor cover retaining fastener. Remove the cover. 4 Remove the angle sensor mounting bracket retaining fasteners. 5 Remove the angle sensor and bracket assembly. Do not lose the two springs or the hex-shaped key. 6 Remove the sensor retaining fasteners from the bracket. Remove the angle sensor. Note: Note the sensor orientation on the bracket during removal so the new sensor will be installed in the same position. 7 Install the new angle sensor onto the mounting bracket.
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flat area angle sensor hex-shaped hole
11 While holding the hex-shaped key in position, rotate the angle sensor mounting bracket clockwise until it aligns with the machined pocket. Do not allow the key to rotate while holding it. Note: Be sure the hex-shaped key remains engaged in the sensor only.
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12 Insert the hex-shaped key into the boom pivot pin and the bracket into the machined pocket. 13 Install the angle sensor bracket retaining fasters. 14 Install the angle sensor cover and install the cover retaining fastener. 15 Connect the electrical connector to the new sensor. 16 Calibrate the secondary boom angle sensor. See How to Calibrate the Secondary Boom Angle Sensor.
Before serial number 321: 4 Locate the 2 pin connector in the lower left hand area of the ground control box. 5 Remove the connector plug and insert a jumper wire between the two pins of the connector. After serial number 320: 4 Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left direction. 5 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine. All models: 6 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position. Hold the enter button for approximately 5 seconds and then release it. 7 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: .
How to Calibrate the Secondary Boom Angle Sensor

Note: If the primary boom angle sensor and/or jib boom angle sensor has been removed or replaced, the secondary boom angle sensor will need to be calibrated first. Note: Perform this procedure with the machine on a firm, level surface with the axles extended and in the stowed position. Note: A digital level will be required to perform this procedure. Note: A kit is available through the Genie Industries Service Department (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses. 1 Push in the ground controls red Emergency Stop button to the off position. 2 Turn the key switch to ground controls. 3 Open the ground control box.
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8 Remove the key from the main key switch. Insert the key into the service/bypass key switch and turn it to the service/bypass position. Note: The angle sensor calibration values will not be saved correctly unless the key switch is in the service/bypass position.
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12 At the SECONDARY BOOM ANGLE TO GRAVITY -3.5DEG screen, press the plus button or minus to adjust the display to the exact button value shown on the digital level and press the enter button . Note: Be sure the number entered at the ground controls is a negative number. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 13 Start the engine from the ground controls. Note: If the system exits out of calibration mode when the engine is started, repeat step 7 and continue to step 14. 14 Press and hold a function enable/speed select button and the secondary boom up button until the digital level displays approximately 20 5 degrees. 15 At the ground controls, press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.
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9 Push one of the LCD screen buttons shown until RESET SECONDARY BOOM ANGLE SENSOR is displayed. 10 Press the plus button press the enter button to select YES, then to accept.
11 Place the digital level on top of the secondary boom.
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16 Press and hold a function enable/speed select button and the secondary boom up button until the digital level displays approximately 35 5 degrees. 17 At the ground controls, press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 18 Press and hold a function enable/speed select button and the secondary boom up button until the digital level displays approximately 50 5 degrees. 19 At the ground controls, press the plus button or minus button to to adjust the display to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 20 Press and hold a function enable/speed select button and the secondary boom up button until the digital level displays approximately 65 5 degrees.
21 At the ground controls, press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 22 Press and hold a function enable/speed select button and the secondary boom up button. Fully raise the secondary boom. Stop before the secondary boom begins to extend. The angle will be approximately 76 5 degrees. 23 At the ground controls, press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 24 Push one of the LCD screen buttons shown until EXIT is displayed. 25 Press the plus button press the enter button to select YES, then to accept.
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26 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings. Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved. 27 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in to the off position or by turning the main key switch to the off position. Before serial number 321: 28 Remove the wire jumper from the 2 pin connector in the lower left hand area of the ground control box that was installed in step 5. Install the connector plug. Tip-over hazard. Failure to remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over causing death or serious injury. The jumper wire must be removed before operating the machine. 29 Close the ground control box and install the door retaining fasteners. After serial number 320: 28 Remove the fastener that was temporarily installed in step 5. 29 Close the control box door and install the door retaining fasteners. Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode.
All models: 30 Use the key to turn the service/bypass key switch to the run postion. Note: Be sure that the service/bypass key switch is in the run position before attempting to operate the machine. 31 Start the engine and lower the boom to the stowed position. Be sure there are no calibration faults shown on the display.
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Engines
5-1 RPM Adjustment
Refer to Maintenance Procedure B-18, Check and Adjust the Engine RPM.
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How to Remove the Flex Plate

1 Disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 2 Support the drive pump with an appropriate lifting device. Then remove all of the pump mounting plate to engine bell housing bolts. 3 Carefully pull the pump away from the engine and secure it from moving. 4 Remove the flex plate mounting fasteners, then remove the flex plate from the engine flywheel.
5-2 Flex Plate

The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump. Two different styles of flex plates have been used in the production of your machine model. Type "A" flex plates utilize a flex plate installed onto the flywheel of the engine and a separate coupler installed onto the pump splined shaft. Type "B" flex plates combines the pump coupler, as part of the flex plate, which is installed onto the engine flywheel.
Type "A"
(flexplate with separate coupler)
Type "B"
(flexplate with coupler combined)
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ENGINES
How to Install a Type "A" Flex Plate

1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. 2 Ford models: Torque the flex plate mounting bolts in sequence to 14 ft-lbs / 19 Nm. Then torque the flex plate mounting bolts in sequence to 20 ft-lbs / 27 Nm. Deutz models: Torque the flex plate mounting bolts in sequence to 28 ft-lbs / 38 Nm. Then torque the flex plate mounting bolts in sequence to 40 ft-lbs / 54 Nm. Perkins models: Torque the flex plate mounting bolts in sequence to 49 ft-lbs / 66 Nm. Then torque the flex plate mounting bolts in sequence to 70 ft-lbs / 95 Nm.
1
3 Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between coupler and pump end plate for your engine.
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f a b c d e f pump pump shaft pump coupler flex plate with raised spline engine flywheel 0.188 inch / 4.8 mm gap Deutz models 0.25 inch / 6.4 mm gap Cummins and Perkins models
4 Cummins and Perkins models: Apply Loctite removable thread sealant to the pump coupler set screw. Torque the set screw to 22 ft-lbs / 30 Nm. Deutz models: Apply Loctite removable thread sealant to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm. Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged.
Ford and Deutz models
2
Perkins models
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ENGINES
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How to Install a Type "B" Flex Plate

1 Deutz and Perkins models: Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the pump. Cummins models: Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the engine flywheel. 2 Apply Loctite removable thread sealant to the flex plate fasteners and loosely install the fasteners. 3 Deutz and Perkins models: Torque the flex plate mounting bolts in sequence to 28 ft-lbs / 38 Nm. Then torque the flex plate mounting bolts in sequence to 40 ft-lbs / 54 Nm. Cummins models: Torque the flex plate mounting bolts in sequence to 14 ft-lbs / 19 Nm. Then torque the flex plate mounting bolts in sequence to 20 ft-lbs / 27 Nm. 4 Apply a high viscosity coupling grease (Genie part number 128025) to the splines of the pump shaft and flex plate.
Grease Specification Shell Alvania Grease CG, NLGI 0/1 or equivalent.
Deutz and Perkins models
4 2
Cummins models
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Ground Controls
How to Use the Service Bypass Mode
Tip-over hazard. Operating the machine outside of the operating envelope while in Service Bypass mode will result in death or serious injury if proper operating procedures and safety precautions are not followed. Do not use this mode if you are not trained and familiar with the operating envelope of the machine. Note: Before using the Service Bypass mode, make sure you understand the fault code or issue affecting the operation of the machine to be sure the use of service bypass is required. The Service Bypass mode will allow the platform to be manually leveled when an out-of-envelope condition exists. In the event that the platform angle is greater than 10 from level, the boom angle and platform level functions are disabled. Use of the Service Bypass mode will allow the platform to be manually adjusted to within the normal operating envelope, 4.5. Only auxiliary power can be used to correct an out of level platform fault. 1 Turn the engine off. 2 Turn the main key switch to ground controls. Remove the key from the main key switch and insert the key into the service bypass/recovery key switch. Note: The main key switch must remain in the ground control position.
6-1 Service Bypass/Recovery Key Switch

The ground control box contains two key switches. The main key switch towards the top of the control box is for selection of ground or platform controls. The key switch at the bottom of the control box is the Service Bypass/Recovery key switch. Service Bypass and Recovery modes are only intended for certain circumstances and are not part of normal machine operation. If either the Service Bypass or the Recovery function is required, this indicates there may be faults with the machine. Contact trained personnel immediately. Service Bypass is used for a platform out-ofenvelope condition and certain service situations. Recovery is only to be used as a last attempt to lower the platform when the operator in the platform is unable to do so, system failure or in emergency situations.
STOP
00000
Service Bypass / Recovery Key Switch
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3 Turn the service bypass/recovery key switch to the service bypass position. 4 Using auxiliary power, operate the platform level toggle switch to level the platform. Note: Only the auxiliary power unit can be used to correct an out of level platform fault. 5 Turn the service bypass/recovery key switch to the run position. 6 Remove the key from the service bypass/ recovery key switch and insert the key into the main key switch. Note: If the Service Bypass function has been used, there may be faults with the machine. Check the LCD screen on the ground control box for machine faults, then contact trained service personnel.
The Recovery mode allows the platform to be lowered in the event the operator in the platform is unable to lower the platform using the platform controls, system failure or emergency situations. The recovery sequence will automatically retract the primary boom and then lower the primary boom using the auxiliary power unit to allow the operator at the platform controls to exit the platform. 1 Turn the main key switch to the off position. Remove the key from the main key switch and insert the key into the service bypass/recovery key switch. 2 Turn and hold the service bypass/recovery key switch to the recovery position. The switch must be held in the recovery position. Result: The auxiliary power unit will turn on and the boom will begin the following recovery sequence. The primary boom will retract The primary boom will lower Note: The key switch must be held in the recovery position until the recovery sequence is complete or until the operator in the platform can safely exit the platform. Note: If any boom safety limit switches are faulty, the boom will only retract and not lower and the operator will need to be recovered from that point. Note: If the Recovery function has been used, this may indicate there may be faults with the machine. Tag and remove the machine from service until the fault has been corrected by trained personnel.
How to Use the Recovery Mode

Recovery is only to be used as a last attempt to lower the platform when the operator in the platform is unable to do so, system failure or in emergency situations. Bodily injury hazard. When using recovery mode, the platform may not fully lower to the ground when the recovery mode is completed. Failure to use only suitable equipment and/or practices to allow the operator to safely exit the platform could result in death or serious injury. Bodily injury hazard. Platform leveling is not active when using recovery mode. The platform could reach high out-of-level conditions when using this mode. The operator will need to secure themself to the platform to prevent falling injury.
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GROUND CONTROLS
The ground control box (TCON) is the communication and operations center for the machine. The ground control box contains two key switches. The key switch towards the top of the control box is for selection of ground or platform controls. The key switch at the bottom of the control box is the Service Bypass key switch. It is used when calibrating certain machine parameters and also to correct an out-of-level platform. If the machine trips an envelope safety switch, an operator at the ground controls can turn and hold the Service Bypass key switch in the recover position, which will automatically retract the boom and lower the platform close to the ground. The ground control box contains a replaceable membrane decal with touch sensitive buttons for various machine functions. The ground control box also contains two printed circuit boards: The LCD (Liquid Crystal Display) circuit board is mounted to the inside of the control box lid which controls the LCD display screen. The ECM circuit board is the main circuit board for the machine. All operating parameters and configuration of options for the machine are stored in the ECM memory. Note: When the ECM circuit board is replaced, the joysticks will need to be calibrated. See 1-3, How to Calibrate a Joystick. Note: When the ECM circuit board is replaced, all the boom, platform and axle angle sensors will need to be calibrated and in a specific order. Contact the Genie Industries Service Department.
6-2 Circuit Boards How to Remove the LCD Display Screen Circuit Board
1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the ground control box lid fasteners. Open the control box lid. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap. 3 Carefully disconnect the LCD circuit board ribbon cable from the ECM circuit board. 4 Remove the LCD display circuit board retaining fasteners. 5 Carefully remove the LCD display circuit board from the ground control box lid.
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6-3 Membrane Decal

The membrane decal is a special decal that consists of a decal with an electronic membrane on the backside. The membrane contains touch sensitive areas that, when pushed, activates the machine functions. The membrane buttons activate machine functions similar to toggle switches, but do not have any moving parts.
5 Remove the membrane decal from the control box lid while guiding the ribbon cables out of the control box lid. 6 Remove any decal adhesive from the control box lid with a mild solvent. Note: Do not allow any solvent to come in contact with the LCD display screen. 7 Install the new membrane decal while guiding the ribbon cables through the control box lid. 8 Connect the ribbon cables to the ECM circuit board. 9 Close the control box lid and install the retaining fasteners.
How to Replace the Membrane Decal

1 Turn the key switch at the ground controls to the off position. 2 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 3 Remove the ground control box lid fasteners. Open the control box lid. 4 Tag and disconnect the two ribbon cables from the membrane decal at the ECM circuit board. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.
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Hydraulic Pumps
2 Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Support the pump with a suitable lifting device. 4 Remove the two pump mounting fasteners. Carefully remove the pump. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.
7-1 Function Pump

The function pump is a pressure compensated, variable displacement piston pump. Any internal service to the pump should be performed at an authorized Sauer-Danfoss service center. Contact the Genie Industries Service Department to locate your local authorized service center.
How to Remove the Function Pump

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Locate the two hydraulic tank valves at the hydraulic tank. Close the valves.
open
closed
Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition.
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How to Prime the Function Pump

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the case drain hydraulic hose from the top of the function pump. Note: The case drain hose is the smaller of the two hoses on top of the function pump and closest to the drive pump. 2 Locate and open the hydraulic tank shut-off valve at the hydraulic tank that supplies hydraulic oil to the function pump. Do not open the valve for the drive pump. 3 When hydraulic fluid begins to come out of the case drain port of the function pump, install the function pump case drain hose. 4 Clean up any oil that may have spilled. 5 Start the engine from the ground controls and check for hydraulic leaks.
How to Adjust the Function Pump Standby Pressure

1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST port on the function manifold. 2 Start the engine from the ground controls and allow the engine to run at low idle. 3 Observe the pressure reading on the pressure gauge. Result: The gauge should show 250 psi / 17 bar. Result: If the gauge does not show 250 psi / 17 bar, proceed with step 4 to adjust the function pump standby pressure. 4 Loosen the set screw for the standby pressure adjustment screw.
a
a b
standby pressure set screw standby pressure adjustment screw
5 Adjust the function pump standby pressure. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. 6 Turn the engine off and remove the pressure gauge.
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HYDRAULIC PUMPS
How to Adjust the Function Pump Pressure Compensator

Note: Two people will be required to perform this procedure. 1 Confirm the system relief pressure is set to specification. See 8-3, Valve Adjustments Function Manifold. 2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST port on the function manifold. 3 Start the engine from the ground controls and change the rpm to high idle. 4 Push and hold the high speed function enable button (rabbit symbol). Do not activate any boom functions. 5 Observe the pressure reading on the pressure gauge. Result: The gauge should show 2900 psi / 200 bar. Result: If the gauge does not show 2900 psi / 200 bar, proceed with step 6 to adjust the function pump pressure compensator.
6 Loosen the set screw for the pressure compensator adjustment screw.
a b
pressure compensator set screw pressure compensator adjustment screw
7 Adjust the pressure compensator pressure. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. Component damage hazard. Do not adjust the pressure compensator higher than specified. 8 Turn the engine off and remove the pressure gauge.
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7-2 Drive Pump

The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should be performed at an authorized SauerDanfoss service center. Contact the Genie Industries Service Department to locate your local authorized service center.
2 Locate the two hydraulic tank valves at the hydraulic tank. Close the valves.
open
closed
How to Remove the Drive Pump

Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended. Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. 1 Disconnect the electrical connection at the electronic displacement controller (EDC) located on the drive pump.
Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 3 Tag, disconnect and plug the hydraulic hoses from the drive and function pumps. Cap the fittings on the pumps. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners.
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HYDRAULIC PUMPS
5 Carefully pull the drive pump out until the pump coupler separates from the flex plate. 6 Remove the drive pump from the machine. Component damage hazard. The pumps may become unbalanced and fall if not properly supported. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.
How to Prime the Drive Pump

Component damage hazard. Be sure to open the two hydraulic tank valves before performing this procedure. 1 Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to either the "A" or "B" test port on the drive pump. 2 Perkins and Cummins models: Disconnect the engine wiring harness from the fuel shutoff solenoid at the injector pump. Deutz models: Hold the manual fuel shutoff valve clockwise to the closed position. 3 Have another person crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the pressure reaches approximately 250 psi / 17 bar. 4 Perkins and Cummins models: Connect the engine wiring harness to the fuel solenoid. Deutz models: Release the manual fuel shutoff valve. 5 Start the engine from the ground controls and check for hydraulic leaks.
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Manifolds
8-1 Function Manifold - View 1 (before serial number 440)
The function manifold is located next to the ground control box.
Index No. 1 Description Schematic Item Function Torque
REV E
Check valve ....................................... W .......... Prevents the draining of hydraulic oil from the jib manifold and platform manifold ............................................ 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... C ........... Primary boom up .............................. 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... G ........... Primary boom retract ........................ 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... J ............ Secondary boom extend .................. 50-55 ft-lbs / 68-75 Nm Solenoid valve, 2 position 3 way ...... H ........... Secondary boom up ......................... 50-55 ft-lbs / 68-75 Nm Plug, 16 SAE .................................................... Port plug ................................... 130-140 ft-lbs / 176-190 Nm Relief valve, 3100 psi / 214 bar ........ L ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... I ............ Secondary boom down .................... 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... K ........... Secondary boom retract ................... 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... F ........... Primary boom extend ....................... 30-35 ft-lbs / 41-47 Nm Solenoid valve, 3 position 4 way ...... B ........... Turntable rotate left/right .................. 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... D ........... Primary boom down ......................... 30-35 ft-lbs / 41-47 Nm
2 3 4 5 6 7 8 9 10 11 12
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MANIFOLDS
1 W
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D C
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10
G 9 K J
L 7 6
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8-2 Function Manifold - View 2 (before serial number 440)

Check valve ....................................... DB ........ Prevents hydraulic pressure from flowing back into auxiliary pump #1 Check valve ....................................... DC ........ Prevents hydraulic pressure from flowing back into auxiliary pump #2 Differential sensing valve, 150 psi / 6.9 bar ................................. M .......... Turntable rotate circuit, regulates pressure drop across turntable rotate proportional valve ... 30-35 ft-lbs / 41-47 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. O ........... Primary boom up/down circuit, regulates pressure drop across primary boom up/down proportional valve ............................. 30-35 ft-lbs / 41-47 Nm Relief valve, 2600 psi / 179 bar ........ E ........... Primary boom extend ....................... 20-25 ft-lbs / 27-34 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. Q ........... Primary boom extend/retract circuit, regulates pressure drop across primary boom extend/retract proportional valve ............................. 30-35 ft-lbs / 41-47 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. U ........... Secondary boom extend/retract circuit, regulates pressure drop across secondary boom extend/retract proportional valve ............................. 50-55 ft-lbs / 68-75 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. S ........... Secondary boom up/down circuit, regulates pressure drop across secondary boom up/down proportional valve ............................. 50-55 ft-lbs / 68-75 Nm Proportional solenoid valve .............. T ........... Secondary boom up/down circuit ..... 50-55 ft-lbs / 68-75 Nm Check valve ....................................... DD ........ Prevents hydraulic pressure from flowing back into the function pump ........................... 130-140 ft-lbs / 176-190 Nm Proportional solenoid valve .............. V ........... Secondary boom extend/ retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm Proportional solenoid valve .............. R ........... Primary boom extend/ retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm Proportional solenoid valve .............. P ........... Primary boom up/down circuit .......... 50-55 ft-lbs / 68-75 Nm Proportional solenoid valve .............. N ........... Turntable rotate left/right circuit ........ 50-55 ft-lbs / 68-75 Nm
5 6
9 10
11 12 13 14
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1
DB
2
DC M
3
O
14
N E
13 12 11 10
P Q R U V DD S
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8-3 Function Manifold - View 1 (after serial number 439)

Index No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Schematic Item Function Torque
Solenoid Valve, 2 position 3 way ...... D ........... Primary boom down ......................... 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way ...... C ........... Primary boom up .............................. 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way ...... G ........... Primary boom retract ........................ 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way ...... F ........... Primary boom extend ....................... 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way ...... K ........... Secondary boom retract ................... 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way ...... J ............ Secondary boom extend .................. 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way ...... I ............ Secondary boom down .................... 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way ...... H ........... Secondary boom up ......................... 30-35 ft-lbs / 41-47 Nm Check valve ....................................... DF ......... Tank return circuit ..................... 130-140 ft-lbs / 176-190 Nm Solenoid valve, 3 position 4 way ...... B ........... Turntable rotate left/right .................. 30-35 ft-lbs / 41-47 Nm Relief valve, 3100 psi / 214 bar ........ L ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. S ........... Secondary boom up/down circuit, regulates pressure drop across secondary boom up/down proportional valve ............................. 50-55 ft-lbs / 68-75 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. U ........... Secondary boom extend/retract circuit, regulates pressure drop across secondary boom extend/retract proportional valve ............................. 50-55 ft-lbs / 68-75 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. Q ........... Primary boom extend/retract circuit, regulates pressure drop across primary boom extend/retract proportional valve ............................. 30-35 ft-lbs / 41-47 Nm
13
14
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MANIFOLDS
1 D
G F K J I H DF
3 4 5
14
6 7 8 9
13
B L
10
11
12
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8-4 Function Manifold - View 2 (after serial number 439)

Check valve ....................................... DB ........ Prevents hydraulic pressure from flowing back into auxiliary pump #1 Check valve ....................................... W .......... Prevents the draining of hydraulic oil from the jib manifold and platform manifold ............................................ 30-35 ft-lbs / 41-47 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. O ........... Primary boom up/down circuit, regulates pressure drop across primary boom up/down proportional valve ............................. 30-35 ft-lbs / 41-47 Nm Relief valve, 2600 psi / 179 bar ........ E ........... Primary boom extend ....................... 20-25 ft-lbs / 27-34 Nm Proportional solenoid valve .............. P ........... Primary boom up/down circuit .......... 50-55 ft-lbs / 68-75 Nm Proportional solenoid valve .............. R ........... Primary boom extend/ retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm Proportional solenoid valve .............. V ........... Secondary boom extend/ retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm Proportional solenoid valve .............. T ........... Secondary boom up/down circuit ..... 50-55 ft-lbs / 68-75 Nm Proportional solenoid valve .............. N ........... Turntable rotate left/right circuit ........ 50-55 ft-lbs / 68-75 Nm Differential sensing valve, 150 psi / 10.3 bar .............................. M .......... Turntable rotate circuit, regulates pressure drop across turntable rotate proportional valve ... 30-35 ft-lbs / 41-47 Nm Check valve ....................................... DD ........ Prevents hydraulic pressure from flowing back into the function pump ........................... 130-140 ft-lbs / 176-190 Nm Check valve ....................................... DC ........ Prevents hydraulic pressure from flowing back into auxiliary pump #2
4 5 6 7 8 9 10
11
12
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1 DB W
P 12 DC
V DD T
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10
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8-5 Valve Adjustments Function Manifold How to Adjust the System Relief Valve (before serial number 440)
Note: Perform this procedure with the boom in the stowed position. Note: Auxiliary power will be used to perform this procedure. Do not start the engine. 1 Locate the system relief valve on the function manifold (item L). Hold the relief valve and remove the cap. 2 Turn the internal hex socket counterclockwise several turns. Do not allow the relief valve to come apart. Install the relief valve cap. 3 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST port on the function manifold. 4 Simultaneously push and hold the auxiliary power button and the primary boom retract button with the primary boom fully retracted. Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 5 Use a wrench to hold the relief valve and remove the cap (item L). 6 Adjust the internal hex socket. Turn it clockwise to increase the pressure. Install the relief valve cap. Component damage hazard. Do not adjust the relief valve higher than specified. 7 Repeat step 4 to confirm relief valve pressure. 8 Remove the pressure gauge.
How to Adjust the System Relief Valve (after serial number 439)
Note: Perform this procedure with the boom in the stowed position. Note: Auxiliary power will be used to perform this procedure. Do not start the engine. 1 Locate the system relief valve on the function manifold (item L). Hold the relief valve stem with a hex wrench and loosen the lock nut. 2 Turn the valve stem counterclockwise several turns. Do not allow the relief valve to come apart. Tighten the lock nut. 3 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST port on the function manifold. 4 Simultaneously push and hold the auxiliary power button and the primary boom retract button with the primary boom fully retracted. Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 5 Hold the relief valve stem with a hex wrench and loosen the lock nut. 6 Adjust the valve stem. Turn it clockwise to increase the pressure. Tighten the lock nut. Component damage hazard. Do not adjust the relief valve higher than specified. 7 Repeat step 4 to confirm relief valve pressure. 8 Remove the pressure gauge.
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MANIFOLDS
How to Adjust the Primary Boom Extend Relief Valve

Note: Perform this procedure with the axles extended. 1 Remove the primary boom end cover from the pivot end of the boom. 2 Locate the primary boom extend limit switch on the side of the primary boom. 3 Follow the wiring from the switch to the pivot end of the primary boom. Locate and disconnect the wire connector for the primary boom extend limit switch. Note: The correct wire connector will be a 2 pin connector with a yellow marker on the cable. 4 Start the engine and fully extend the primary boom. Turn the engine off. 5 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the PETST port on the function manifold. 6 Start the engine from the ground controls and press and release the rpm select button until the engine changes to high idle. 7 Simultaneously push and hold the function enable/high speed button and the primary boom extend button with the primary boom fully extended. Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 8 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item E).
9 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Component damage hazard. Do not adjust the relief valve higher than specified. 10 Repeat step 7 to confirm relief valve pressure. 11 At the pivot end of the primary boom, connect the primary boom extend limit switch connector, that was disconnected in step 3. 12 Install the primary boom end cover and remove the pressure gauge. 13 Start the engine and fully retract the primary boom. Turn the engine off.
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8-6 Platform Manifold

The platform manifold is mounted to the platform mounting weldment.
Index No. 1 2 3 Description Schematic Item Function Torque
Solenoid valve, 3 position 4 way ......... AH ......... Platform rotate left/right ................. 20-25 ft-lbs / 27-34 Nm Proportional solenoid valve, 3 position 4 way .................................... AI .......... Platform level up/down ................. 20-25 ft-lbs / 27-34 Nm Flow control valve, 0.2 gpm / 0.76 L/min ............................. AG ......... Platform rotate left/right circuit ...... 20-25 ft-lbs / 27-34 Nm
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1 AH AI
AG
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8-7 Jib Boom Manifold

The jib boom manifold is mounted inside the primary extension boom at the platform end.
Pressure compensator valve, 150 psi / 10.3 bar .................................. X ........... Jib boom up/down circuit, regulates pressure drop across jib boom up/down proportional valve ......................... 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ......... AE .......... Jib boom retract ............................ 20-25 ft-lbs / 27-34 Nm Solenoid valve, 2 position 3 way ......... AD ......... Jib boom extend ........................... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 2 gpm / 7.6 L/min .................................. AC ......... Jib boom extend/retract circuit ...... 20-25 ft-lbs / 27-34 Nm Orifice, 0.040 inch / 1 mm ..................... AB .......... Jib boom extend/retract circuit Check valve, 25 psi / 1.7 bar ................ AA .......... Holds oil in jib boom manifold ...... 20-25 ft-lbs / 27-34 Nm Shuttle valve .......................................... Z ........... Jib boom up/down circuit .............. 10-12 ft-lbs / 14-16 Nm Proportional solenoid valve, 3 position 4 way .................................... Y ........... Jib boom up/down ........................ 20-25 ft-lbs / 27-34 Nm Proportional solenoid valve, 3 position 4 way ................................... AF .......... Jib boom bellcrank level up/down ................................ 20-25 ft-lbs / 27-34 Nm
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1 X
2 AE
3 AD
4 AC
AB
AF
AA
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8-8 Function Enable Valve

The function enable valve is mounted behind the medium pressure filter.
Solenoid valve, 2 position 2 way ..... A ............ Enables lift pump to provide hydraulic pressure for all boom and steer/axle functions .................. 20-25 ft-lbs / 27-34 Nm
1 A
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8-9 Turntable Rotation Manifold

The turntable rotation manifolds are mounted to the turntable rotation drive hub motors.
Index No. 1 2 3 4 Description Schematic Item Function Torque
Counterbalance valve .................... CA ........... Turntable rotate right ....................... 25-30 ft-lbs / 34-41 Nm Counterbalance valve .................... CB ........... Turntable rotate left .......................... 25-30 ft-lbs / 34-41 Nm Shuttle valve, 2 position 3 way ...... CC ........... Turntable rotation brake release ....... 8-10 ft-lbs / 11-14 Nm Orifice plug, 0.030 inch / 0.76 mm . CD ........... Turntable rotation brake release
1 CA
2 CB
CD
CC
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8-10 Steer and Axle Manifold

The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine.
Flow regulator valve, 1.5 gpm / 5.7 L/min ............................ BI .......... Right front steer cylinder retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm Check valve ....................................... BC ........ Prevents right front steer cylinder from moving when not steering ........ 20-25 ft-lbs / 27-34 Nm Check valve ....................................... BB ......... Prevents left front steer cylinder from moving when not steering ........ 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 2.1 gpm / 8 L/min ............................... BL ......... Right rear steer cylinder extend circuit .................................... 20-25 ft-lbs / 27-34 Nm Solenoid valve, 3 position 4 way ...... BQ ........ Steer left/right, right rear steer cylinder ..................... 20-25 ft-lbs / 27-34 Nm Check valve ....................................... BE ......... Prevents right rear steer cylinder from moving when not steering ........ 20-25 ft-lbs / 27-34 Nm Check valve ....................................... BD ........ Prevents left rear steer cylinder from moving when not steering ........ 20-25 ft-lbs / 27-34 Nm Solenoid valve, 3 position 4 way ...... BP ......... Steer left/right, left rear steer cylinder ....................... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 2.1 gpm / 8 L/min ............................... BJ ......... Left rear steer cylinder extend circuit .................................... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 7 gpm / 26.5 L/min ............................. BS ......... Axle extend/retract circuit ................. 20-25 ft-lbs / 27-34 Nm Solenoid valve, 2 position 3 way ...... BU ........ Axle retract ........................................ 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... BT ......... Axle extend ....................................... 30-35 ft-lbs / 41-47 Nm Pressure reducing valve, 2400 psi / 165 bar ............................. BR ........ Axle extend/retract circuit ................. 30-35 ft-lbs / 41-47 Nm
2 3 4
5 6 7 8 9
10 11 12 13
This list continues. Please turn the page.
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MANIFOLDS
1 BI
2 BC
3 BB
BC BB
20
BO
19
BN BL BQ 4 5
18 17
BH BF BE
16 BG 15 6 14 7 13 BM BE
BD BK BD BR BP
BT 12
BU 11
BS 10
BJ 9
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Steer and Axle Manifold, continued

Flow regulator valve, 1.5 gpm / 5.7 L/min ............................ BK ......... Left rear steer cylinder retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 1.5 gpm / 5.7 L/min ............................ BM ........ Right rear steer cylinder retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 1.5 gpm / 5.7 L/min ............................ BG ........ Left front steer cylinder retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 2.1 gpm / 8 L/min ............................... BF ......... Left front steer cylinder extend circuit .................................... 20-25 ft-lbs / 27-34 Nm Flow regulator valve, 2.1 gpm / 8 L/min ............................... BH ........ Right front steer cylinder extend circuit .................................... 20-25 ft-lbs / 27-34 Nm Solenoid valve, 3 position 4 way ...... BN ........ Steer left/right, left front steer cylinder ...................... 20-25 ft-lbs / 27-34 Nm Solenoid valve, 3 position 4 way ...... BO ........ Steer left/right, right front steer cylinder .................... 20-25 ft-lbs / 27-34 Nm
15
16
17
18
19 20
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MANIFOLDS
1 BI
2 BC
3 BB
BC BB
20
BO
19
BN BL BQ 4 5
18 17
BH BF BE
16 BG 15 6 14 7 13 BM BE
BD BK BD BR BP
BT 12
BU 11
BS 10
BJ 9
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8-11 Valve Adjustments Steer and Axle Manifold How to Adjust the Axle Relief Valve
Note: Perform this procedure with the boom in the stowed position and the axles fully extended. Note: This procedure will require 2 people. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the TEST port on the steer and axle manifold. 2 Locate the axle relief valve on the steer and axle manifold (item BR). Hold the relief valve with a wrench and remove the cap. 3 Start the engine from the platform controls and press down the footswitch. Press and hold the axle extend button at the plaform controls. Observe the pressure reading on the pressure gauge. Refer to Section 2, Specifications. 4 Turn the engine off. 5 Adjust the internal hex socket clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. Component damage hazard. Do not adjust the relief valve higher than specified. 6 Repeat steps 3 through 5 to confirm relief valve pressure. 7 Remove the pressure gauge.
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8-12 Traction Manifold - View 1

The traction manifold is mounted inside the manifold box at the blue triangle side of the machine. Index No.
1 2 3 4 5 6
Description
Schematic Item Function
Torque
Check valve, 5 psi / 0.3 bar ............... BA ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm Check valve, 5 psi / 0.3 bar ............... AZ ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm Check valve, 5 psi / 0.3 bar ............... AJ ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm Check valve, 5 psi / 0.3 bar ............... AT ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm Check valve, 5 psi / 0.3 bar ............... AW ........ Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm Shuttle valve, 3 position 3 way ......... AO ........ Charge pressure circuit that directs hot oil out of low pressure side of drive pump ............................ 50-55 ft-lbs / 68-75 Nm Relief valve, 250 psi / 17.2 bar ......... AN ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way ...... AY ......... Brake release ................................... 20-25 ft-lbs / 27-34 Nm Solenoid valve, 2 position 3 way ...... AX ......... 2-speed drive motor shift .................. 20-25 ft-lbs / 27-34 Nm Flow divider/combiner valve ............. AR ........ Controls flow to square end drive motors in forward and reverse ................................. 90-100 ft-lbs / 122-136 Nm Flow divider/combiner valve ............. AM ........ Controls flow to circle end drive motors in forward and reverse ................................. 90-100 ft-lbs / 122-136 Nm Flow divider/combiner valve ............. AP ......... Controls flow to flow divider/ combiner valves AR and AM in forward and reverse .............. 90-100 ft-lbs / 122-136 Nm
7 8 9 10
11
12
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MANIFOLDS
1 BA AZ
12 11
AP AM
AJ
10
AR
AT 9 AX
AY
AW AN 7 AO 6
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8-13 Traction Manifold - View 2

The traction manifold is mounted inside the manifold box at the blue triangle side of the machine. Index No.
1
Description
Schematic Item Function
Torque
Orifice, 0.063 in / 1.6 mm (before serial number 180 except for serial number 102) ........... AL ......... Equalizes pressure on both sides of flow divider/combiner AM Orifice, 0.039 in / 1 mm (serial number 102 and after serial number 179 ..................... AL ......... Equalizes pressure on both sides of flow divider/combiner AM Orifice, 0.052 in / 1.3 mm .................. AQ ........ Equalizes pressure on both sides of flow divider/combiner AP Orifice, 0.063 in / 1.6 mm .................. AS ......... Equalizes pressure on both sides of flow divider/combiner AR Orifice, 0.030 in / 0.76 mm ................ AV ......... Brake release and 2-speed motor shift circuit Check valve, 5 psi / 0.3 bar ............... AU ........ Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm Check valve, 5 psi / 0.3 bar ............... AK ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
2 3 4 5 6
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AK
AL AU
AQ
AS
AV 4
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8-14 Valve Adjustments, Traction Manifold How to Adjust the Hot Oil Relief Valve
Note: The hydraulic oil temperature must be 100F to 150F / 38C to 65.5C before performing this procedure. 1 Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to either the "A" or "B" test port on the drive pump. 2 Locate the hot oil relief valve on the traction manifold (item AN). Hold the relief valve and remove the cap. 3 Turn the internal hex socket clockwise fully until it stops. Install the cap. 4 Start the engine from the ground controls. 5 Press and hold the function enable/high rpm select button (rabbit symbol) position. Note the reading on the pressure gauge. 5 Turn the engine off. 6 Remove the pressure gauge from the drive pump. Connect the gauge to the test port located on the traction manifold. 7 Hold the hot oil relief valve and remove the cap (item AN).
8 Start the engine from the ground controls. 9 Press and hold the function enable/high rpm select button (rabbit symbol) position. 10 Adjust the internal hex socket until the pressure reading on the gauge is 40 psi / 2.8 bar less than the pressure reading on the pump. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. 11 Turn the engine off and remove the pressure gauge.
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8-15 Drive Oil Diverter Manifold Components (welder option)

The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index No. 1 2 3 4 5 Description Schematic Item Function Torque
Directional valve ............................ BV ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm Orifice disc, 0.030 inch / 0.080 cm ..................... BW ........... Delays shift to drive Solenoid valve ............................... BX ........... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm Relief valve, 270 psi / 18.6 bar ....... BZ ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm Check valve .................................... BY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
CY
CU
CV
CW
CX
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8-16 Valve Coils How to Test a Coil

A properly functioning coil provides an electromotive force which operates the solenoid valve. Critical to normal operation is continuity within the coil that provides this force field. Since coil resistance is sensitive to temperature, resistance values outside specification can produce erratic operation. When coil resistance decreases below specification, amperage increases. As resistance rises above specification, voltage increases. While valves may operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Tag and disconnect the wiring from the coil to be tested. 2 Test the coil resistance. Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil.Valve Coil Resistance Specification
Valve Coil Resistance Specification

Note: The following coil resistance specifications are at an ambient temperature of 68F / 20C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18F / 10C that your air temperature increases or decreases from 68F / 20C.
Valve coil resistance specifications Proportional solenoid valve (schematic items N, P, R, T, V) 3 position 4 way solenoid valve (schematic item B) 3 position 4 way solenoid valve (schematic items BN, BO, BP and BQ) 3 position 4 way solenoid valve (schematic item AH) 3 position 4 way proportional solenoid valve (schematic items Y and AI) 2 position 3 way solenoid valve (schematic items F and AD) 2 position 3 way solenoid valve (schematic items AE and AF) 2 position 3 way solenoid valve (schematic items H and J) 2 position 3 way solenoid valve (schematic items C, D, G, I, K, AX, AY, BU and BT) 2 position 2 way solenoid valve (schematic item A) 3.5 to 5.5 4 to 6 7 to 9 8 to 10 8 to 10
5.5 to 7.5 8 to 10 3.5 to 5.5 7.5 to 9.5
3.5 to 5.5
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MANIFOLDS
How to Test a Coil Diode

Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Test the coil for resistance. See, How to Test a Coil. 2 Connect a 10 resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil.
Resistor, 10 Genie part number
d
COIL MULTI METER
+
b
10 W RESISTOR 9V BATTERY
a b c d multimeter 9V DC battery 10 resistor coil
Note: Dotted lines in illustration indicate a reversed connection as specified in step 6
3 Set a multimeter to read DC current. Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA. 4 Connect the negative lead to the other terminal on the coil. 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery. Note and record the current reading. 6 At the battery or coil terminals, reverse the connections. Note and record the current reading. Result: Both current readings are greater than 0 mA and are different by a minimum of 20%. The coil is good. Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced.
27287
Note: The battery should read 9V DC or more when measured across the terminals.
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Turntable Rotation Components

9-1 Turntable Rotation Assembly How to Remove a Turntable Rotation Assembly
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the primary boom between the circle-end tires and with the machine on a firm, level surface. 1 Secure the turntable from rotating with the turntable rotation lock pin. 2 Remove the ground controls side fixed turntable cover. 3 Tag, disconnect the hydraulic hoses from the turntable rotation motor. Cap the fittings on the motor. 4 Attach a lifting strap from an overhead crane or other suitable lifting device to the lifting eye on the turntable rotation assembly. 5 Remove the drive hub mounting bolts and remove the turntable rotation assembly from the machine.
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6 Repeat steps 3 through 5 for the other turntable rotation assembly. Tip-over hazard. If the turntable rotation lock pin is not properly installed, machine stability is compromised and the machine could tip over when the drive hub is removed from the machine, which could result in death or serious injury. Crushing hazard. The drive hub could become unbalanced and fall if not properly supported by the overhead crane or lifting device when removed from the machine. Note: When installing a turntable rotation assembly, the rotation gear backlash must be adjusted. See Maintenance Procedure D-4, Adjust the Turntable Rotation Gear Backlash.
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TURNTABLE ROTATION COMPONENTS
9-2 Turntable Level Sensor How to Calibrate the Turntable Level Sensor
Note: If the Safety Controller (SCON) has been replaced, the entire machine needs to be calibrated in a specific order. Consult the Genie Industries Service Department. Note: Perform this procedure with the machine on a firm, level surface and in the stowed position. Note: A digital level will be required to perform this procedure. Note: A kit is available through the Genie Industries Service Department (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses. 1 Push in the ground controls red Emergency Stop button to the off position.
All models: 5 Turn the key switch to ground controls. on the 6 Press and hold the enter button ground control panel while pulling out the ground controls red Emergency Stop button to the on position. Hold the enter button for approximately 5 seconds and then release it. 7 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: . 8 Remove the key from the main key switch. Insert the key into the service/bypass key switch and turn it to the service/bypass position. Note: The angle sensor calibration values will not be saved correctly unless the key switch is in the service/bypass position.
STOP
00000
2 Open the ground control box. Before serial number 321: 3 Locate the 2 pin connector in the lower left hand area of the ground control box. 4 Remove the connector plug and insert a jumper wire between the two pins of the connector. After serial number 320: 3 Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left direction. 4 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine.
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9 Push one of the LCD screen buttons shown until SET UNIT X AXIS LEVEL TO GRAVITY is displayed. 10 Place the digital level along the X axis of the turntable.
13 Place the digital level along the Y axis of the turntable.

+Y axis -Y axis
-X axis
or minus button to 14 Press the plus button adjust the display to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, or minus button to press the plus button change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 15 Push one of the LCD screen buttons shown until EXIT is displayed. 16 Press the plus button press the enter button to select YES, then to accept.
Platform
+X axis
or minus button to 11 Press the plus button adjust the display to the exact value shown on the digital level and press the enter button . Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value. 12 Push one of the LCD screen buttons shown until SET UNIT Y AXIS LEVEL TO GRAVITY is displayed.
17 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in to the off position or by turning the main key switch to the off position.
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Before serial number 321: 18 Remove the wire jumper from the 2 pin connector in the lower left hand area of the ground control box that was installed in step 4. Install the connector plug. Tip-over hazard. Failure to remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over causing death or serious injury. The jumper wire must be removed before operating the machine. 19 Close the ground control box and install the door retaining fasteners. After serial number 320: 18 Remove the fastener that was temporarily installed in step 4. 19 Close the control box door and install the door retaining fasteners. Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode.
All models: 20 Use the key to turn the service/bypass key switch to the run postion. Note: Be sure that the service/bypass key switch is in the run position before attempting to operate the machine. 21 Use the key to turn the service/bypass key switch to the run postion. Note: Be sure that the service/bypass key switch is in the run position before attempting to operate the machine. 22 Start the engine. Be sure there are no calibration faults shown on the display.
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Axle Components
10-1 Steer Sensors
The steer sensors measure steer angle and communicates that information to the ground controls ECM. The steer sensor on the ground controls side of the machine at the square-end acts as the lead sensor when in front wheel steer mode. In rear wheel steer mode, the steer sensor on the ground controls side of the machine at the circleend acts as the lead sensor. The other three sensors follow the position, or steer angle, of the lead sensor. There is a steer sensor mounted to the top of each steer yoke upper pivot pin.
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How to Replace a Steer Sensor

Note: Perform this procedure with the axles fully retracted and the boom in the stowed position. 1 Align the remaining wheels on the machine so they are visually parallel to the chassis as close as possible. 2 Disconnect the steer sensor assembly cable from the main harness to be replaced. 3 Remove the steer sensor cover retaining fasteners. Remove the steer sensor assembly. Note: Inspect the sensor activator pin to make sure it is not broken or twisted. Note: If the sensor activator pin needs to be replaced, install the new activator pin per Illustration 1
Illustration 1 (square end, yellow side and circle end, blue side shown)
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AXLE COMPONENTS
Left front (square-end, blue side) and right rear (circle-end, yellow side) angle sensors:
a
6 Rotate the sensor housing in a clockwise direction until the sensor cable is pointing away from the machine. Refer to Illustration 2. 7 Install the steer sensor cover retaining fasteners. Do not tighten the cover retaining fasteners. 8 Connect the steer sensor assembly cable to the main harness. 9 Calibrate the steer sensor. See How to Calibrate a Replacement Steer Sensor. Note: Be sure the yoke pivot pin retaining plate is fully engaged into the pivot pin and that the fasteners are securely tightened.
b c d
Illustration 2 a starting position b installed position c sensor cover d rotation arrow
4 Position the new steer sensor assembly over the sensor activator pin with the sensor cable angled towards the tire. Refer to Illustration 2. 5 Align the sensor with the pin and install the sensor on to the pin. Note: Be sure the sensor activator pin is engaged into the sensor.
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Right front (square-end, yellow side) and left rear (circle-end, blue side) angle sensors:
a b c d
12 Rotate the sensor housing in a clockwise direction until the sensor cable is pointing away from the machine. Refer to Illustration 2. 13 Install the steer sensor cover retaining fasteners. Do not tighten the cover retaining fasteners. 14 Connect the steer sensor assembly cable to the main harness. 15 Calibrate the steer sensor. See How to Calibrate a Replacement Steer Sensor. Note: Be sure the yoke pivot pin retaining plate is fully engaged into the pivot pin and that the fasteners are securely tightened.
Illustration 3 a installed position b starting position c sensor cover d rotation arrow
10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable angled away from the tire. Refer to Illustration 3. 11 Align the sensor with the pin and install the sensor on to the pin. Note: Be sure the sensor activator pin is engaged into the sensor.
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AXLE COMPONENTS
How to Calibrate a Replacement Steer Sensor

Note: If a steer angle sensor has been removed or replaced, the steer angle sensors will need to be calibrated first. Note: Perform this procedure with the axles retracted and the tires straightened. Note: This procedure will require two people. Note: Be sure the yoke pivot pin retaining plate is fully engaged into the pivot pin and that the fasteners are securely tightened. 1 Start the engine from the platform controls. 2 Select the proper steer mode. If a front (squareend) steer angle sensor has been replaced, select rear steer mode. If a rear (circle-end) steer angle sensor has been replaced, select front steer mode. 3 Have another person press down the foot switch. 4 At the new steer angle sensor, loosen the steer angle sensor cover retaining fasteners. Do not remove the fasteners or the sensor cover. 5 Rotate the sensor cover clockwise or counterclockwise until the tire is straight in relation with the other tires. Tighten the sensor cover fasteners. Note: If available, WebGPI can also be used for this procedure. 6 Push in the red Emergency Stop button to the off position.
How to Calibrate All Steer Sensors

Note: This procedure will only need to be performed if the ground controls circuit board (TCON) has been replaced. Note: Perform this procedure with the axles retracted and the tires straightened. Before serial number 321: 1 Locate the 2 pin connector in the lower left hand area of the ground control box. 2 Remove the connector plug and insert a jumper wire between the two pins of the connector. After serial number 320: 1 Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left direction. 2 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine. All models: 3 Turn the key switch to ground controls and pull out the ground controls red Emergency Stop button to the on position. 4 Loosen the steer angle sensor cover retaining fasteners. Do not remove the fasteners or the sensor cover.
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5 Using a voltmeter set to DC voltage, probe the back of the electrical connector at pins B and C. 6 Left front (square-end, blue side) and right rear (circle-end, yellow side) angle sensors: Rotate the sensor cover clockwise or counterclockwise until the voltage reading is between 1.4 to 1.6V DC. Tighten the sensor cover fasteners. Right front (square-end, yellow side) and left rear (circle-end, blue side) angle sensors: Rotate the sensor cover clockwise or counterclockwise until the voltage reading is between 3.4 to 3.6V DC. Tighten the sensor cover fasteners. Note: If available, WebGPI can also be used for this procedure. 7 Push in the red Emergency Stop button to the off position. 8 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position. Hold the enter button for approximately 5 seconds and then release it.
STOP
00000
10 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: . 11 Push one of the LCD screen buttons shown until RESET ALL STEER SENSORS is displayed. 12 Press the plus button press the enter button to select YES, then to accept.
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AXLE COMPONENTS
13 Push one of the LCD screen buttons shown until EXIT is displayed. 14 Press the plus button press the enter button to select YES, then to accept.
10-2 Steer Cylinders How to Remove a Steer Cylinder

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the axles extended. 1 Tag, disconnect and plug the hydraulic hoses from the steer cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Support the steer cylinder with a suitable lifting device. Protect the cylinder rod from damage. 3 Remove the pin retaining fasteners from both steer cylinder pivot pins. 4 Use a soft metal drift to remove the pins. 5 Remove the steering cylinder from the machine. Crushing hazard. The steer cylinder may become unbalanced and fall if not properly supported by the lifting device when removed from the machine.
15 Turn the machine off by pushing in the red Emergency Stop button to the off position. Before serial number 321: 16 Remove the wire jumper from the 2 pin connector in the lower left hand area of the ground control box that was installed in step 2. Install the connector plug. Tip-over hazard. Failure to remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over causing death or serious injury. The jumper wire must be removed before operating the machine. 17 Close the ground control box and install the door retaining fasteners. After serial number 320: 16 Remove the fastener that was temporarily installed in step 2. 17 Close the control box door and install the door retaining fasteners. Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode. All models: 18 Use the key to turn the service/bypass key switch to the run postion. Note: Be sure that the service/bypass key switch is in the RUN position before attempting to operate the machine.
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10-3 Axle Extension Cylinders How to Remove an Axle Extension Cylinder

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the machine on a firm, level surface and the axles extended. Note: This procedure will require the use of a portable hydraulic power unit. 1 Tag, disconnect and plug the hydraulic hoses from the axle extension cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 2 Remove the axle extension limit switch cover fasteners. Remove the cover. 3 Remove the limit switch mounting fasteners and remove the limit switch. Do not disconnect the wiring.
4 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension cylinder. Note: Connect the pressure hose from the power unit to the "R" port of the cylinder and the return hose from the power unit to the "E" port on the cylinder. 5 Support the axle extension cylinder with a suitable lifting device. Protect the cylinder rod from damage. 6 Remove the pin retaining fasteners from both axle extension cylinder pivot pins. 7 Use a soft metal drift to remove the pins. 8 Using the portable hydraulic power unit, retract the axle extension cylinder until the ends of the cylinder clears the axles. 9 Remove the axle extension cylinder from the machine. Crushing hazard. The axle extension cylinder may become unbalanced and fall if not properly supported by the lifting device.
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AXLE COMPONENTS
10-4 Axle Angle Sensors

The axle angle sensors measure the axle angle and communicates that information to the ground controls ECM. There are two axle angle sensors. They are located on opposite axle pivot pins at each end of the chassis.
How to Install an Axle Angle Sensor

Note: Perform this procedure with the machine in the stowed position and the axles fully retracted. 1 Locate the axle angle sensor to be replaced. 2 Tag and disconnect the angle sensor electrical connector from the chassis harness. 3 Remove the angle sensor cover retaining fasteners. Remove the angle sensor assembly. Note: Inspect the sensor activator pin to make sure it is not broken or twisted. Note: If the sensor activator pin needs to be replaced, install the new activator pin parallel with the drive chassis side plate. Refer to Illustration 1.
Illustration 1 a drive chassis side plate b activator pin
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3 Position the new axle angle sensor assembly over the sensor activator pin as shown. Refer to Illustration 2.
5 Rotate the sensor housing in a clockwise direction until the sensor cable is parallel with the drive chassis side plate. Refer to Illustration 2. 6 Install the axle sensor cover retaing fasteners. Do not tighten the cover retaining fasteners. 7 Connect the axle sensor assembly cable to the main harness. 8 Calibrate the axle angle sensor. See How to Calibrate the Axle Angle Sensors.
b c
Illustration 2 a starting position b installed position c sensor cover d rotation arrow e drive chassis side plate
4 Align the sensor with the pin and install the sensor on to the pin. Note: Be sure the sensor activator pin is engaged into the sensor.
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AXLE COMPONENTS
How to Calibrate the Axle Angle Sensors

Note: If an axle angle sensor has been removed or replaced, the axle angle sensors will need to be calibrated first. Note: Perform this procedure with the machine in the stowed position and the axles fully retracted. Note: This procedure will require two people. 1 Turn the key switch to ground controls and pull out the ground controls red Emergency Stop button to the on position. 2 Loosen an axle angle sensor cover retaining fasteners. Do not remove the fasteners or the sensor cover. 3 Using a voltmeter set to DC voltage, probe the back of the electrical connector at pins 2 and 3. Note: If available, WebGPI can also be used for this procedure. 4 Rotate the sensor cover clockwise or counterclockwise until the voltage reading is between 4.2 to 4.4V DC. Tighten the sensor cover fasteners. 5 Repeat steps 2 through 4 for each remaining axle angle sensor. 6 Turn the machine off by pressing the ground controls red Emergency Stop button to the off position. Do not turn the key switch to the off position.
Before serial number 321: 7 Locate the 2 pin connector in the lower left hand area of the ground control box. 8 Remove the connector plug and insert a jumper wire between the two pins of the connector. After serial number 320: 7 Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left direction. 8 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine. All models: 9 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position. Hold the enter button for approximately 5 seconds and then release it. 10 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: .
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STOP
15 When the AXLE ANGLES FULLY EXTENDED screen is displayed, start the engine and fully extend the axles. Note: If the system exits out of calibration mode when the engine is started, repeat step 9. 16 Press the plus button press the enter button 17 Push one of the LCD screen buttons shown until EXIT is displayed. 18 Press the plus button press the enter button to select YES, then to accept. to select YES, then to accept.
00000
19 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings.
Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved. 20 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in to the off position or by turning the main key switch to the off position.
12 Push one of the LCD screen buttons shown until RESET AXLE ANGLE SENSORS is displayed. 13 Press the plus button press the enter button to select YES, then to accept.
14 At the AXLE ANGLES FULLY RETRACTED screen, press the plus button to select YES, then press the enter button to accept.
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AXLE COMPONENTS
Before serial number 321: 21 Remove the wire jumper from the 2 pin connector in the lower left hand area of the ground control box that was installed in step 8. Install the connector plug. Tip-over hazard. Failure to remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over causing death or serious injury. The jumper wire must be removed before operating the machine. 22 Close the ground control box and install the door retaining fasteners. After serial number 320: 21 Remove the fastener that was temporarily installed in step 8. 22 Close the control box door and install the door retaining fasteners. Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode. All models: 23 Use the key to turn the service/bypass key switch to the run postion. Note: Be sure that the service/bypass key switch is in the run position before attempting to operate the machine.
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Section 5 Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and operating instructions printed in the Genie Z-135/70 Operator's Manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Read each appropiate fault code thoroughly. Attempting shortcuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Perform all troubleshooting on a firm, level surface. Two persons will be required to safely perform some troubleshooting procedures.
Observe and Obey:

Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Machine parked on a firm, level surface Boom in the stowed position Turntable rotated with the boom between the circle-end wheels (yellow arrow) Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Welder disconnected from the machine (if equipped with the weld cable to platform option) Wheels chocked All external AC power supply disconnected from the machine
Part No. 106783
Z-135/70
5-1
April 2008
Control System Fault Codes

Error Source Error Type Effects Corrective Action Limited Speed and Value at 5.0 V Direction frozen at zero and neutral, Alarm sounds Primary Up/Down Joystick Value too high Value too low Value at 0, Joystick Speed and Not calibrated Direction frozen at zero and neutral Just calibrated Initiate one second beep of audible warning device.
REV B
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
Limited Speed and Value at 5.0 V Direction frozen at zero and neutral, Alarm sounds Primary Extend/Retract Joystick Value too high Value too low Value at 0, Joystick Speed and Not calibrated Direction frozen at zero and neutral Just calibrated Primary Boom Up/Down switches on TCON Primary Boom Ext/Ret switches on TCON Primary Boom Length Fault Check, (both buttons pressed) Fault Check, (both buttons pressed) Fault check (unknown length) Initiate one second beep of audible warning device. Check ribbon and connector from Primary boom up/dwn disabled, display message membrane switch. If necessary replace membrane switch. on LCD. Check ribbon and connector from Primary boom Ext/Ret disabled, display message membrane switch. If necessary replace on LCD. membrane switch. Check primary boom retracted and Default to low speed drive, extended switches for proper contact display message on LCD. with the boom. Readjust or shim switch as necessary. Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
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REV B
CONTROL SYSTEM FAULT CODES
Error Source
Primary Boom Up/Down Flow Valve
Effects Corrective Action Normal function except threshold for one or the Not calibrated Perform calibration procedure. other direction is zero. Display message on LCD. Initiate one second beep Just calibrated No action required. of audible warning device. Limited Speed and Direction frozen at zero Value Too High and neutral, Alarm sounds. Limited Speed and Direction frozen at zero Value Too Low and neutral, Alarm sounds. Check for opens in the wiring or a bad ground. Replace coil if necessary.
Error Type
Check for shorts to ground in the wiring. Replace coil if necessary.
Normal function except threshold for one or the Not calibrated Perform calibration procedure. other direction is zero. Display message on LCD. Just calibrated Primary Boom Ext/Ret Flow Valve Initiate one second beep No action required. of audible warning device. Check for opens in the wiring or a bad ground. Replace coil if necessary.
Limited Speed and Direction frozen at zero Value Too High and neutral, Alarm sounds. Limited Speed and Direction frozen at zero Value Too Low and neutral, Alarm sounds.
Check for shorts to ground in the wiring. Replace coil if necessary.
PRI BOOM EXT VALVE PRI BOOM RET VALVE PRI BOOM UP VALVE PRI BOOM DOWN VALVE
fault check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary.
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Z-135/70
5-3
April 2008
REV B
Error Source
Error Type Value at 5.0 V
Effects
Value too high
Value too low OPERATIONAL PRIMARY BOOM ANGLE SENSOR
Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds
Value at 0,
Corrective Action Check for an open ground circuit going to the sensor. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary. Recalibrate sensor.
Out of Tolerance Not calibrated Just calibrated Value at 5.0 V
Primary Up only active Perform calibration procedure per from TCON activate alarm service manual or Z135 training CD. Initiate one second beep No action required. of audible warning device. Check for an open ground circuit going to the sensor. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary. Recalibrate sensor. Primary Up only active Perform calibration procedure per from TCON activate alarm service manual or Z135 training CD. Initiate one second beep No action required. of audible warning device.
Value too high
Value too low SAFETY PRIMARY BOOM ANGLE SENSOR
Value at 0,
Out of Tolerance Not calibrated Just calibrated
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REV B
Error Source
Error Type
Effects
Corrective Action
Limited Speed and Value at 5.0 V Direction frozen at zero and neutral, Alarm sounds Secondary Boom Joystick Value too high Value too low Value at 0, Joystick Speed and Not calibrated Direction frozen at zero and neutral Initiate one second beep Just calibrated of audible warning device. Sec Boom Up/Ext/Dwn/Ret switches on TCON Fault Check, (both buttons pressed)
Sec Boom Check ribbon and connector from Up/Ext/Dwn/Ret disabled, membrane switch. If necessary replace display message on LCD. membrane switch.
Display message on LCD SEC BOOM See service manual on how to perform Not calibrated and allow operation at UP/DOWN SPEED this procedure. default speed. Normal function except threshold for one or the Not calibrated Perform calibration procedure. other direction is zero. Display message on LCD. SEC BOOM UP/DOWN/EXT/R ET FLOW VALVE Just calibrated Initiate one second beep No action required. of audible warning device. Check for opens in the wiring or a bad ground. Replace coil if necessary. Check for shorts to ground in the wiring. Replace coil if necessary.
Value Too High Limited Speed and Direction frozen at zero and neutral, Alarm Value Too Low sounds. SEC BOOM EXT VALVE SEC BOOM RET VALVE SEC BOOM UP VALVE SEC BOOM DOWN VALVE SEC EXT SEQ VALVE SEC DWN SEQ VALVE
fault check
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary.
Part No. 106783
Z-135/70
5-5
April 2008
REV B
Error Source
Effects
Corrective Action Check for an open ground circuit going to the sensor. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too high
OPERATIONAL SECONDARY BOOM ANGLE SENSOR
Value too low Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Out of Tolerance Not calibrated
Recalibrate sensor. Secondary Up only active Perform calibration procedure per from TCON activate alarm service manual or Z135 training CD. Initiate one second beep No action required. of audible warning device.
Just calibrated
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REV B
Error Source
Effects
Corrective Action Check for an open ground circuit going to the sensor. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary. Recalibrate sensor.
Value too high
Value too low SAFETY SECONDARY BOOM ANGLE SENSOR
Value at 0,
Out of Tolerance Not calibrated Just calibrated
Secondary Up only active Perform calibration procedure per from TCON activate alarm service manual or Z135 training CD. Initiate one second beep No action required. of audible warning device.
Part No. 106783
Z-135/70
5-7
April 2008
REV B
Error Source Engine Speed
Error Type range check (underspeed) range check (low oil pressure) range check (high temperature) fault check Fault Check, (both buttons pressed)
Effects
Corrective Action Engine is running below 50 RPM check fuel system.
Display message on LCD. Oil pressure is low check sender and oil level. Engine is overheating check sender, Display message on LCD. water or oil level, or radiator/heat exchanger. Display message on LCD. Check wiring to senders for opens or shorts. Repair or replace senders.
Oil Pressure
Water/Oil Temp Oil Pressure Sensor Oil Temp Sender AXLE EXT/RET BUTTONS
Axle Extend/Retract Check ribbon and connector from disabled, display message membrane switch. If necessary replace on LCD. membrane switch. Limited Speed and Direction frozen at zero and neutral, Alarm sounds. Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary.
AXLE VALVE
fault check
DCON CAN BUS
fault check
Check CAN Bus wiring from TCON to Display message on LCD. DCON through rotator. Repair or Disable propel replace wiring or DCON. Check CAN Bus wiring from TCON to Display message on LCD. SCON/PCON. Repair or replace wiring or SCON/PCON.
CAN BUS
fault check
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Part No. 106783
April 2008
REV B
Error Source SAFETY SWITCH P3
Error Type
Effects
Corrective Action
Display message on LCD. P3 SAFETY SWITCH Internal Fault Not on Z135 FAULT Check wiring for circuit P53LS Display message on LCD. (White/Black wire) for damage resulting P6R1 SAFETY SWITCH in shorts or opens. Repair wiring or FAULT replace TCON Check wiring for circuit P54ENG Display message on LCD. (black/white wire) for damage resulting P6R2 SAFETY SWITCH in shorts or opens. Repair wiring or FAULT replace TCON Display message on LCD. Check wiring for circuit S56PRV (red P7 SAFETY SWITCH wire) for damage resulting in shorts or FAULT opens. Repair wiring or replace TCON Display message on LCD. Function enable button was held down P7R SAFETY SWITCH during startup. Recycle power with the FAULT function enable button released Display message on LCD. Check wiring for circuit S56PRV (red DCON P7R SAFETY wire) for damage resulting in shorts or SWITCH FAULT opens. Repair wiring or replace DCON Check wiring for circuit P53LS Display message on LCD. (White/Black wire) for damage resulting P9A SAFETY SWITCH in shorts or opens. Repair wiring or FAULT replace TCON Boom has violated the safety limits resulting in the engine being shutoff as a Display message on LCD. safety feature. Use aux to get the boom P9B SAFETY SWITCH back into operational limits. Check FAULT P54ENG and P58LS between SCON and TCON for damage. Check SCON chart for possible fault conditions. Display message on LCD. P10 SAFETY SWITCH Recycle Power FAULT
SAFETY SWITCH P6R1
fault check
SAFETY SWITCH P6R2
SAFETY SWITCH P7
SAFETY SWITCH P7R
fault check
SAFETY SWITCH DCON P7R
SAFETY SWITCH P9A
SAFETY SWITCH P9B
fault check
SAFETY SWITCH P10
Part No. 106783
Z-135/70
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April 2008
REV B
Error Source SAFETY SWITCH P11
Error Type
Effects
Corrective Action
fault check
Recycle Power and check wiring on Display message on LCD. circuit S140ENL (orange/black) between P11 SAFETY SWITCH SCON and TCON. Check SCON chart FAULT for possible fault conditions. Display message on LCD. P14 SAFETY SWITCH Recycle Power FAULT Display message on LCD. P18 SAFETY SWITCH Recycle Power FAULT Display message on LCD. Re-level platform check for wiring P22 SAFETY SWITCH damage on circuit P56PRV (red/white) FAULT Display message on LCD. Re-level platform, Repair or Replace P22R SAFETY SWITCH PCON FAULT Recycle Power and check wiring on Display message on LCD. circuit S140ENL (orange/black) between P30 SAFETY SWITCH SCON and TCON. Check SCON chart FAULT for possible fault conditions. Recycle Power and check wiring on Display message on LCD. circuit S137PLL (red/wht) between P38 SAFETY SWITCH SCON and TCON. Check SCON chart FAULT for possible fault conditions. Recycle Power and check wiring on Display message on LCD. circuit S139TRF (white/red) between P39 SAFETY SWITCH SCON and TCON. Check SCON chart FAULT for possible fault conditions. Check for an overload in the platform. Display message on LCD. Check the overload switch mounted on the platform support. Display message on LCD Check footswitch wiring for damage or display remove blocking item on the footswitch.
SAFETY SWITCH P14 SAFETY SWITCH P18 SAFETY SWITCH P22 SAFETY SWITCH P22R
fault check
fault check
fault check
fault check
SAFETY SWITCH P30
fault check
SAFETY SWITCH P38
fault check
SAFETY SWITCH P39
fault check
PLATFORM OVERLOAD FOOTSWITCH TIMEOUT
fault check (if active)
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REV B
Error Source
TURNTABLE ROTATE JOYSTICK
Error Type Effects Value at 5.0 V Limited Speed and Value too high Direction frozen at zero Value too low and neutral, Alarm sounds Value at 0, Joystick Speed and Not calibrated Direction frozen at zero and neutral Just calibrated Initiate one second beep of audible warning device.
Corrective Action
TURNTABLE ROTATE BUTTONS TURNTABLE ROTATE SPEED
Fault Check, (both buttons pressed)
Check ribbon and connector from TT rotate disabled, display membrane switch. If necessary replace message on LCD. membrane switch.
Display message on LCD Calibrate turntable rotate speed in Not calibrated and allow operation at accordance with the service manual default speed. Normal function except threshold for one or the Not calibrated Perform calibration procedure other direction is zero. Display message on LCD.
TURNTABLE ROTATE FLOW VALVE
Just calibrated
Initiate one second beep No action required of audible warning device. Check for opens in the wiring or a bad ground. Replace coil if necessary. Check for shorts to ground in the wiring. Replace coil if necessary.
Value Too High Limited Speed and Direction frozen at zero and neutral, Alarm Value Too Low sounds. TURNTABLE ROTATE CW VALVE TURNTABLE ROTATE CCW VALVE MULTI-FUNCTION VALVE
fault check
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary
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5 - 11
April 2008
REV B
Error Type Effects Corrective Action Value at 5.0 V Check that the SCON is grounded. Value too high Flash unit out of level icon Value too low OPERATIONAL and LED and activate Replace SCON Value at 0, TURNTABLE Alarm Out of LEVEL SENSOR XTolerance DIRECTION Initiate one second beep Just calibrated No action required of audible warning device. Value at 5.0 V Value too high Flash unit out of level icon Value too low SAFETY and LED and activate Value at 0, TURNTABLE Alarm Out of LEVEL SENSOR XTolerance DIRECTION Initiate one second beep Just calibrated of audible warning device. Value at 5.0 V Value too high Primary & Secondary Up Value too low OPERATIONAL and Extend disabled, Value at 0, TURNTABLE Alarm sounds Out of LEVEL SENSOR YTolerance DIRECTION Just calibrated Check that the SCON is grounded.
Error Source
Replace SCON
No action required Check that the SCON is grounded. Replace SCON
Initiate one second beep No action required of audible warning device.
Value at 5.0 V Check that the SCON is grounded. Value too high Primary & Secondary Up Value too low SAFETY and Extend disabled, Replace SCON Value at 0, TURNTABLE Alarm sounds Out of LEVEL SENSOR YTolerance DIRECTION Initiate one second beep Just calibrated No action required of audible warning device. Value at 5.0 V Check that the SCON is grounded. Primary & Secondary Up Value too high and Extend disabled, PLATFORM Replace SCON Value too low Alarm sounds LEVEL SENSOR Y- Value at 0, DIRECTION Initiate one second beep Just calibrated No action required of audible warning device.
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Part No. 106783
April 2008
REV B
Error Source PLAT ROT CW VALVE PLAT ROT CCW VALVE JIB UP VALVE JIB DN VALVE JIB LEVEL UP VALVE JIB LEVEL DN VALVE JIB EXTEND VALVE JIB RETRACT VALVE
Error Type
Effects
Corrective Action
fault check
fault check
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary
Normal function except threshold for one or the Perform calibration procedure Not calibrated other direction is zero. Display message on LCD. JIB UP/DWN FLOW VALVE Just calibrated Value Too High Initiate one second beep No action required of audible warning device. Check for opens in the wiring or a bad ground. Replace coil if necessary. Check for shorts to ground in the wiring. Replace coil if necessary.
Limited Speed and Direction frozen at zero and neutral, Alarm Value Too Low sounds.
Normal function except threshold for one or the Not calibrated Perform calibration procedure other direction is zero. Display message on LCD. JIB LEVEL UP/DWN FLOW VALVE Just calibrated Initiate one second beep No action required of audible warning device. Check for opens in the wiring or a bad ground. Replace coil if necessary. Check for shorts to ground in the wiring. Replace coil if necessary.
Value Too High Limited Speed and Direction frozen at zero and neutral, Alarm Value Too Low sounds.
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Z-135/70
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April 2008
REV B
Error Source
Error Type
Effects
Corrective Action
Normal function except threshold for one or the Perform calibration procedure Not calibrated other direction is zero. Display message on LCD. PLATFORM LEVEL UP FLOW VALVE Just calibrated Initiate one second beep No action required of audible warning device. Check for opens in the wiring or a bad ground. Replace coil if necessary. Check for shorts to ground in the wiring. Replace coil if necessary.
Value Too High Limited Speed and Direction frozen at zero and neutral, Alarm Value Too Low sounds.
Normal function except threshold for one or the Perform calibration procedure Not calibrated other direction is zero. Display message on LCD. PLATFORM LEVEL DWN FLOW VALVE Just calibrated Initiate one second beep No action required of audible warning device. Check for opens in the wiring or a bad ground. Replace coil if necessary. Check for shorts to ground in the wiring. Replace coil if necessary.
Value Too High Limited Speed and Direction frozen at zero and neutral, Alarm Value Too Low sounds. JIB UP/DWN SWITCHES JIB EXT/RET SWITCHES PLAT ROT SWITCHES
Fault Check, (both closed)
Affected functions Check ribbon and connector from disabled, display message membrane switch. If necessary replace membrane switch. on LCD.
JIB UP/DWN JOYSTICK
Value at 5.0 V Limited Speed and Value too high Direction frozen at zero Value too low and neutral, Alarm sounds Value at 0, Joystick Speed and Not calibrated Direction frozen at zero and neutral Just calibrated Initiate one second beep of audible warning device.
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REV B
Error Source
JIB EXT/RET JOYSTICK
Error Type Effects Value at 5.0 V Limited Speed and Value too high Direction frozen at zero Value too low and neutral, Alarm sounds Value at 0, Joystick Speed and Not calibrated Direction frozen at zero and neutral Just calibrated Initiate one second beep of audible warning device.
Corrective Action Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
PLATFORM ROTATE JOYSTICK
Value at 5.0 V Limited Speed and Check for damaged wiring to the Value too high Direction frozen at zero joystick. Check the connectors to Value too low and neutral, Alarm sounds ensure the connector terminals have not Value at 0, backed out. Substitute a known good Joystick Speed and joystick. If necessary replace and Not calibrated Direction frozen at zero recalibrate joystick. and neutral Value at 5.0 V Check for an open ground circuit going to the sensor Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary. Display message at TCON Recalibrate sensor activate alarm Initiate one second beep Perform calibration procedure per of audible warning device. service manual or Z135 training CD
Value high Primary Up, Secondary Up/Dwn and Extend Value too low disabled, Alarm sounds FRONT AXLE ANGLE SENSOR Value at 0,
Not calibrated Just calibrated
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Z-135/70
5 - 15
April 2008
REV B
Error Source
Effects
Corrective Action Check for an open ground circuit going to the sensor Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Value too high Primary Up, Secondary Up/Dwn and Extend Value too low disabled, Alarm sounds REAR AXLE ANGLE SENSOR Value at 0,
Not calibrated Just calibrated
Display message at TCON Recalibrate sensor activate alarm Initiate one second beep Perform calibration procedure per of audible warning device. service manual or Z135 training CD
PROPEL JOYSTICK
Value at 5.0 V Value too high Limited Speed and Value too low Direction frozen at zero and neutral, Alarm sounds Check for damaged wiring to the Value at 0, joystick. Check the connectors to ensure the connector terminals have not Joystick Speed and backed out. Substitute a known good Not calibrated Direction frozen at zero joystick. If necessary replace and and neutral recalibrate joystick Initiate one second beep Just calibrated of audible warning device. Normal function except threshold for one or the Perform calibration procedure Not calibrated other direction is zero. Display message on LCD. Initiate one second beep No action required of audible warning device. Check for opens in the wiring or a bad ground. Replace coil if necessary. Check for shorts to ground in the wiring. Replace coil if necessary.
PROPEL VALVES FWD PROPEL VALVES REV Just calibrated PROPEL EDC FWD PROPEL EDC Value Too High REV
Limited Speed and Direction frozen at zero and neutral, Alarm Value Too Low sounds.
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April 2008
REV B
Error Source MOTOR SPEED VALVE BRAKE VALVE AUX PROPEL VALVE
Error Type
Effects
Corrective Action Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary
fault check
fault check
STEERING JOYSTICK
Value at 5.0 V Limited Speed and Value too high Direction frozen at zero Value too low and neutral, Alarm sounds Value at 0, Joystick Speed and Not calibrated Direction frozen at zero and neutral Just calibrated Value at 5.0 V Initiate one second beep of audible warning device.
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick
Check for an open ground circuit going to the sensor Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too high
LF STR ANG SNSR
Limited Speed and Sensor is out of range check sensor and Direction frozen at zero actuating pin for proper installation. Value too low and neutral, Alarm sounds Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Value at 0,
Part No. 106783
Z-135/70
5 - 17
April 2008
REV B
Error Source
Effects
Corrective Action Check for an open ground circuit going to the sensor Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too high
RF STR ANG SNSR
Limited Speed and Sensor is out of range check sensor and Direction frozen at zero actuating pin for proper installation. Value too low and neutral, Alarm sounds Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary. Check for an open ground circuit going to the sensor Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Value at 5.0 V
Value too high
LR STR ANG SNSR
Limited Speed and Sensor is out of range check sensor and Direction frozen at zero actuating pin for proper installation. Value too low and neutral, Alarm sounds Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Value at 0,
5 - 18
Z-135/70
Part No. 106783
April 2008
REV B
Error Source
Effects
Corrective Action Check for an open ground circuit going to the sensor Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too high
RR STR ANG SNSR
Value too low
Limited Speed and Sensor is out of range check sensor and Direction frozen at zero actuating pin for proper installation. and neutral, Alarm sounds Repair or replace sensor and recalibrate. Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Value at 0,
LF STEER VALVE RF STEER VALVE fault check LR STEER VALVE RR STEER VALVE Limited Speed and Direction frozen at zero and neutral, Alarm sounds. Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary
Part No. 106783
Z-135/70
5 - 19
April 2008
SCON Fault Matrix

P_11 Primary/Secondary Up P_30 Secondary Extend/Down P_39 Turntable Rotate P_10 Primary boom extend P_38 Propel
REV A
X = circuit power is turned off
Turntable tilt Y axis (+5 degrees, sec boom not stowed) Primary Boom Angle (crosscheck) Secondary Boom Angle (crosscheck) Secondary Boom safety (not retracted & not raised) Axle Safety not stowed (not faulted primary & secondary stowed) Axles crosscheck Angle sensor vs. safety switch Axle (not fully extended) and Turntable Rotate (stowed and in drive disable zone) Axle safety stowed (not faulted) Turntable Tilt Angle (crosscheck SCON internal sensors 3 in a delta configuration) Primary Boom Safety (max angle) Boom Not Stowed (not faulted) Loss of CAN LSS1RS Disconnected (SCON pin #2) Platform Overload (SCON pin #1) Secondary Boom Length (crosscheck LSS1RS and LSS1RO)
X X X
X X X X
X X X X
X X X X X X X
X X X X
X X
X X
X X X X X X X X X X X
X X
X X
5 - 20
Z-135/70
Part No. 106783
P_9B Ignition/Fuel
X X
April 2008
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Hydraulic Schematics Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. General Repair Process
Observe and Obey:

Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules and operating instructions printed in the Genie Z-135/70 Operator's Manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use.
Malfunction discovered
Identify symptoms
Troubleshoot
problem still exists
Return to service
problem solved
Inspect and test
Perform repair
Part No. 106783
Z-135/70
6-1
April 2008
Wire Circuit Legend

REV C
Circuit numbering
1 Circuit numbers consist of three parts: the circuit prefix, circuit number and circuit suffix. The circuit prefix indicates the type of circuit. The circuit number describes the function of the circuit. The circuit suffix provides an abbreviation for the number or may be used to further define the function of this portion of the circuit. It also may be used to indicate the final end of the circuit, i.e., LS or limit sw. 2 The circuit number may be used more than once in a circuit.
Circuit prefix
C .... Control D .... Data E .... Engine G ... Gauges N .... Neutral P .... Power R .... Relay Output S .... Safety V .... Valve
For Example: C 74 PL This is the circuit for the lockout valve #1. C stands for control, 74 is the number of the circuit for the primary #1 lock out valve. PL stands for Primary Lockout. S 62 BST This is the circuit that communicates to the onboard computers of the machine that the boom is fully stowed. S stands for safety, 62 is the number of the circuit for boom stowed and BST stands for Boom Stowed. P 48 LP P stands for power. 48 is the circuit number for work lamps and LP stands for Lamp. R 48 LP R stands for relay. In this case it is the wire that feeds the relay coil for the work lamp. All other numbers remain the same. V61AXR V stands for valve power. Number 61 stands for axle retracted circuit; AXR stands for Axle retracted. R46HN R stands for Relay output, supplying power to the horn (HN). Number 46 is the circuit number for the horn.
Circuit suffix
Definition AC Generator Alternator Field Angle Auxiliary Boom Valve Auxiliary Forward Valve Auxiliary Hydraulic Pump Auxiliary Platform Valve Auxiliary Reverse Valve Auxiliary Steer/Drive Valve Axle Extend Valve Axle Oscillate Axle Retract Valve Axle Front Position Axle Rear Position Battery Boom Extended Boom Stowed Brake Bypass Valves Calibrate CAN Signal CAN Shield CATS Module Chain Break Data High Data Low Drive Chassis Controller suffix GEN AF ANG ABV AFV AH APV ARV ASV AXE AXO AXR FAP RAP BAT BEX BST BRK BV CAL CAN SHD CAT CNK DTH DTL DCN
6-2
Z-135/70
Part No. 106783
April 2008
REV C
WIRE CIRCUIT LEGEND
Drive Enable Drive Enable Left Drive Enable Right Electrical Displacement Control Envelope Light Engine Speed Select Engine Status Lamp Envelope Lockout Extend/Retract Lockout Filter Restricted Filter Switch Flashing Beacon Float Switch Foot switch Signal Forward Fuel Pump Fuel Select (gas/LP) Fuel Solenoid Function Enable Ground Control Ground Horn High RPM Hydraulic Generator Ignition Jib Bellcrank Down Jib Bellcrank Up Jib Sensor Jib Up/Down Control Jib Down Jib Up/Down Flow Control Jib Select Valve Jib Up Jib Extend/Retract Control Jib Extend Jib Retract Jib Rotate Left (CCW) Jib Rotate Right (CW) Joystick 5V DC Power Lamps Left Front Left Front Steer Sensor Left Rear Left Rear Steer Sensor Limit Switch Lift Speed Reduction Load Sensor Lockout
DE DEL DER EDC ENV ESP ESL ENL ERL FLR FLT FB FS FTS FWD FP FL FSL FE TCN GND HRN HS HG IGN JBD JBU JBS JUD JD JFC JSV JU JER JBE JBR JRL JRR JPW LPS LF LFS LR LRS LS LSR LDS LO
Low RPM Low fuel Motor Shift (Speed) Multi Function Valve Platform Control Primary Ext/Ret Lockout Platform Level Down Platform Level Flow Control Platform Level Up Platform Rotate Flow Control Platform Rotate Control Platform Rotate Left (CCW) Platform Rotate Right (CW) Platform Tilt Alarm Platform Tilt Sensor Power Power to Length Sensor Pressure Comp Enable Pressure Sender Pressure Switches Primary Boom Angle Sensor Primary Boom Down Primary Boom Extend/Retract Lockout Valve Primary Boom Extend Primary Boom Extend/Retract Flow Control Primary Boom Retract Primary Boom Up Primary Boom Up/Down Flow Control Primary Boom Extend/Retract Signal Primary Boom Up/Down Signal Primary Lockout Propel Signal Program Setup Enable Propel Lockout Proportional Valve Proximity Sensor Receptacle Recovery Retract Lockout Return Reverse Right Front Right Front Steer Sensor Right Rear Right Rear Steer Sensor RPM
LS LOF MS MFV PCN PEL PLD PLF PLU PRF PRC PRL PRR PTA PTS PWR PSL PCE PSR PS PBS PBD PBL PBE PER PBR PBU PUD PLS PES PL JPL PSE PLL PRV PXS REC RCV RL RET REV RF RFS RR RRS RPM
Part No. 106783
Z-135/70
6-3
April 2008
WIRE CIRCUIT LEGEND
REV C
Sec Boom Angle Sensor SBS Sec Boom Elevated SBL Sec Boom Down SBD Sec Boom Extend SBE Sec Boom Extend/Retract Flow Control SER Sec Boom Retract SBR Sec Boom Up SBU Sec Boom Up/Down Flow Control SUD Secondary Boom SB Secondary Boom Lockout Valve (extend) SLE Secondary Boom Lockout Valve (riser down) SLD Sensor SEN Spare SP Speed Sensor SS Start Aid (Glow Plug or choke) SA Starter STR Steer Control Signal STC Steering Valve (CW) SCW Steering Valve (CCW) SCC Temp Sender TSR Temp Switches TS Tether TET Tilt Alarm X axis TAX Tilt Alarm Y axis TAY Ground Control Panel TCN Turntable Rotate Flow Control TRF Turntable Rotate Right (CW) TRR Turntable Tilt Alarm TTA Turntable Tilt Sensor TTS Test Switch TSW
6-4
Z-135/70
Part No. 106783
April 2008
REV C
WIRE CIRCUIT LEGEND
Wire Coloring
1 All cylinder extension colors are solid and all retract functions are striped black. When using black wire, the stripe shall be white. 2 All rotations that are LEFT or CW are solid, RIGHT or CCW are striped and black. When the wire is black, the stripe is white. 3 All proportional valve wiring is striped.
Color, Circuit #, and Primary function

RD RD/BK RD/WH 1 2 3 Primary boom up driver Primary boom down driver Primary boom up/down flow control proportional valve driver Turntable rotate left valve driver Turntable rotate right valve driver Turntable rotate flow control proportional valve driver Primary boom extend Primary boom retract Primary boom Extend/Retract proportional valve driver Secondary boom up valve driver Secondary boom down valve driver Secondary boom up/down flow control proportional valve driver Drive enable Platform level up valve Platform level down valve Platform up/down flow control proportional valve driver Platform rotate left valve driver Platform rotate right valve driver Jib select valve driver circuit 12V DC battery supply 12V DC ignition supply Key switch power to platform Power to platform Power to warning senders Power to oil pressure sender Power to temp sender Auxiliary Power Platform level alarm Drive Motor shift (speed) Forward/EDC-A Reverse/EDC-B
WH WH/BK WH/RD BK BK/WH BK/RD BL BL/BK BL/WH
4 5 6 7 8 9 10 11 12
Wire Color Legend

BL BL/BK BL/RD BL/WH BK BK/RD BK/WH BK/YL BR GR GR/BK GR/WH RD RD/BK RD/WH OR OR/BK OR/RD WH WH/BK WH/RD Blue Blue/Black Blue/Red Blue/White Black Black/Red Black/White Black/Yellow Brown Green Green/Black Green/White Red Red/Black Red/White Orange Orange/Black Orange/Red White White/Black White/Red
BL/RD OR OR/BK OR/RD
13 14 15 16
GR GR/BK GR/WH RD WH BK WH RD WH/BK
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Power Circuits
P10 .... Primary boom extend valve P11 .... Primary boom up valve P30 .... Secondary boom down and extend valves P38 .... Propel (drive) valves P39 .... Turntable rotate flow control valve
WH/RD RD RD/BK RD/WH WH WH/BK
Part No. 106783
Z-135/70
6-5
April 2008
WIRE CIRCUIT LEGEND
REV C
WH/RD BK BK/WH BK/RD BL BL/BK BL/WH BL/RD OR OR/BK OR/RD GR GR/BK GR/WH WH WH/BK WH/RD WH/BK BL BL/WH BL/RD WH/BK BK/WH
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Brake Start Start Aid (glow plug or choke) High Engine speed select Steer clockwise Steer counterclockwise
OR/BK BL/WH BL BL RD
64 65 66 67 68
Power for operational switches Low fuel indication Drive Enable Secondary boom not stowed Primary Boom lowered (operational) Primary boom #1 extended Primary boom #2 retracted Primary boom #2 extended Secondary boom extended Secondary boom retracted Primary #1 Lockout Primary #2 Lockout Primary boom #3 extended Lower Angle #1 operational Upper Angle #2 operational Power from TCON ESTOP Can 2.0/J1939 Shield Can 2.0/J1939 Low Can 2.0/J1939 High Tilt signal X axis Tilt signal Y axis Tilt sensor power Hydraulic Filter restricted Platform Level Safety Power Platform Level Safety Output Platform Level Safety Ground Proximity Kill Gate Interlock Motor Speed (LO/HI) Motor Bypass Load Sensor Tether ESTOP return Tether Power
BL Gasoline BL/WH LPG BL/BK Limit switch signal stowed BL/WH RPM signal Boom retracted signal Jib Up Jib Down AC Generator Horn Output Power Enable Work Lamp Motion Lamp Auxiliary Boom Auxiliary Steer Auxiliary Platform Boom envelope safety valve cutoff Power to safety interlock switches (engine) Axle oscillation Foot switch/TCON estop power Boom down safety interlock Safety interlock to engine Chain break circuit Axle extend Axle retract Boom stowed (safety) Power to boom envelope safety switch BL/RD RD RD/WH BL WH WH/BK BK N/A GR YL GR/WH GR/BK GR OR RD RD/BK BR RD/BK RD/WH WH/BK WH/RD WH OR RD
69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
GR/BK RD RD/WH RD/BK GR/WH GR/WH GR OR OR/RD
55 56 57 58 59 60 61 62 63
6-6
Z-135/70
Part No. 106783
April 2008
REV C
WIRE CIRCUIT LEGEND
BK WH BK WH/RD WH/BK OR OR/RD BK/WH BK/RD
97 98 99 100 101 102 103 104 105
Tether ESTOP Power J1708 + (high) J1708- (low) Outrigger lowered Outrigger raised Pothole protector up Pothole protector down Proprietary Data buss (I.e. ITT or AP) Proprietary Data buss + (I.e. ITT or AP) Spare Alternator Field Engine Status Sensor Power Sensor Return Steer Signal Steer Signal to Solenoid Valve Multi-function Valve Load Moment Overweight Load Moment Underweight Hydraulic Oil Cooler Flashing Beacon Lift Speed Reduction Hydraulic Pressure Sensor Output Oil Cooler Fan Axle Oscillate Left Axle Oscillate Right Primary Boom Angle Signal Operational Secondary Boom Angle Signal Operational Secondary Boom Lockout (Extend Enable) Secondary Boom Lockout (Riser Down Enable) ECU Test Switch Low Engine Speed Descent Alarm
WH/RD BL GR GR/WH GR/BK BL/WH RD RD/WH RD/BK WH/RD OR/RD
130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165
Travel Alarm Motion Alarm Platform Load Input Platform Load Alarm Key Switch power Fuel Pump Power to Safety Module Drive Power (P_38) Primary Boom Up/Secondary Boom Down-Extend (P_11/30) Turntable Rotate Flow Control Safety (P_39) Boom Envelope Safety Primary Boom Angle Signal Safety Secondary Boom Angle Signal Safety Drive Enable Left Drive Enable Right Calibrate Jib Bellcrank Up Flow Control Jib Bellcrank Down Flow Control Jib Bellcrank Sensor Jib Up/Down Flow Control Hydraulic Generator Bypass Hydraulic EDC Output Injector Retard Jib Extend Jib Retract Pressure Comp. Enable Jib Up/Down Jib Extend/Retract Steer Signal Rocker Steer Joystick Signal Propel Joystick Signal Secondary Boom Joystick Signal Joystick 5V DC power Primary Extend/Retract Signal Primary Up/Down Signal TT Rotate Signal
GR RD BL/WH GR/WH BK OR RD OR/RD BK/RD RD/BK OR RD OR BL OR GR GR/BK RD/BK RD/WH WH/RD WH/BK GR OR/RD RD/BK
106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129
RD OR BL/RD BL/WH RD/WH BL BL/BK BL/WH GR/WH GR/BK GR BK BK BK/WH OR/RD GN/WH BK/RD BL/RD BL/WH WH/RD WH/BK OR BL/WH RD/WH WH/RD
Part No. 106783
Z-135/70
6-7
April 2008
WIRE CIRCUIT LEGEND
REV C
OR OR/BK BL/RD GN WH/RD WH/BK BL BK WH WH/BK GN/WH BL/RD BK GN BK OR RD BL WH WH BL BL GR BK BK/WH WH/RD WH/BK WH/RD WH/RD OR/RD YL WH RD WH/RD BR
166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 N/A
Boom Length Signal Safety Boom Length Signal Operational Primary Boom Hydraulic Valve Lockout Envelope Active LED Load Sense Relay Source Load Sense Relay Sink UP/DN Flow Control Ground Ext/Ret Flow Control Ground Key Switch Power, Ground Position Load Sensor Signal Operational Secondary Extend/Retract FC Extend/Retract Lockout Control Module Status Light Drive Power Relay Lift Power Relay 48 Volt Alternator field (or Battery) 24 Volt Battery Envelope or Load Sense Recovery Program setup Enable Encode A Encode B Bootstrap or Program Enable Safety cross check Data Receive Data Transmit Multi-Function Pressure Relief Jib Rotate Left Jib Rotate Right Speed Select Input Electric Brake Source 2.5V Sensor Power Hour Meter +12V Sensor Power Thermal Switch Ground or Return
6-8
Z-135/70
Part No. 106783
April 2008
Limit Switches and Angle Sensors

REV B
Types of Limit Switches

There are two types of limit switches, found in various locations throughout the machine: mechanical-type operational/safety switches and rotation or angle sensors. As in aircraft, which features redundant safety systems, each mechanical operational switch is backed up with a separate, independently functioning safety switch. The mechanical-type operational or safety switches are used to sense a positive displacement or movement of the limit switch actuator, or arm, as the machine moves through its range of operational functions. The rotation or angle sensors utilize Hall Effect technology and must be calibrated when replaced. Included in this group are envelope limit switches which sense the extended length and angle of the booms and rotational position of the turntable. For example, when the secondary boom is fully raised and the operational sensor is activated, it tells the ECM at the ground controls to start extending the secondary boom. Another example is the drive enable limit switch, which disables the drive function anytime the boom is rotated past the rear tires, indicated by the 'circle' end of the drive chassis. In some cases, the engine will be stopped if safety parameters are exceeded.
RSP1AO RSP1AS
1
Limit Switch and Sensor Numbering

LSP1RO LSP1EO LSS1RO LSS1RS LSJ1RO LST1O LST2O LST1S LSFA1ES LSRA1ES RSP1AO RSP1AS RSJ1AO RSS1AO RSS1AS RSFA1O RSRA1O RSLF1SO RSRF1SO RSLR1SO RSRR1SO Primary boom length retracted Primary boom length fully extended Secondary boom fully retracted Secondary boom fully retracted, safety Jib boom length fully retracted Drive enable, left direction Drive enable, right direction Drive enable safety, retracted axles Front axle fully retracted Rear axle fully retracted Primary boom angle sensor Primary boom angle sensor, safety Jib boom angle sensor Secondary boom angle sensor Secondary boom angle sensor, safety Front axle postioning sensor Rear axle positioning sensor Left front wheel positioning sensor Right front wheel positioning sensor Left rear wheel positioning sensor Right rear wheel positioning sensor
Numbering Legend
AX Axle B Boom T Turntable LS Limit switch Circuit number D Down A Angle L Load moment E Extend O Operational R Retract S Safety
LSP1RO
LSS1RO RSS1AO
LSP1EO
LS AX 1 R O
1
PRIMARY BOOM
SECONDARY BOOM
4 3
GROUND CONTROL BOX
RSJ1AO
LSS1RS RSFA1SO RSLF1SO RSRF1SO LSFA1ES

LST10 LST20
SAFETY CONTROLLER (SCON)

LST1S
JIB
RSS1AS RSLR1SO RSRR1SO
PLATFORM ANGLE SENSOR 2
LSJ1RO CONTROL
BOX
PLATFORM
DRIVE CHASSIS CONTROLLER (DCON)
RSRA1SO LSRA1ES
Part No. 106783
Z-135/70
6-9
April 2008
LIMIT SWITCHES AND ANGLE SENSORS
REV B
Platform Angle Sensor: Measures the angle of the platform. The range of measurement is +/- 20 degrees. The safety cutout is set at +/- 10 degrees from gravity and will disable the primary and secondary boom up/ down functions and the platform level up/down functions. Jib Bell Crank Angle Sensor: Measures the angle of the jib bell crank. The range of measurement is + 60 / -70 degrees. Safety Controller (SCON): Redundant dual axis tilt sensors measuring the X and Y tilt angles of the turntable. Also provides safety switch logic for function cut-off. Alarm sounds at 4.5 degrees. LSFA1ES: Limit switch, Front Axle #1 Extended Safety. Prevents boom functions with the axles retracted. Switch closes when axles are fully extended. LSRA1ES: Limit switch, Rear Axle #1 Extended Safety. Prevents boom functions with the axles retracted. Switch closes when axles are fully extended. LST1O: Limit switch, Turntable #1 Operational. Activates the drive enable zone when the turntable is rotated in the left direction. LST2O: Limit switch, Turntable #2 Operational. Activates the drive enable zone when the turntable is rotated in the right direction. LST1S: Limit switch, Turntable #1 Safety. Prevents the turntable from rotating out past either rear tire when axles are retracted. LSS1RO: Limit switch, Secondary Boom #1 Retracted Operational. NOHC when secondary boom is fully retracted. Used to reduce turntable rotate speed when secondary boom is extended and to disable secondary boom down unitl fully retracted. LSS1RS: Limit switch, Secondary Boom #1 Retract Safety Switch. Backup switch for LSS1RO. Used to cut circuits P9B, P_11 and P_30. LSJ1RO: Limit Switch, Jib Boom #1 Retract Operational. Switch is held closed when the jib boom fully retracted. Used to limit turntable rotate speed and drive speed when jib boom is extended. LSP1EO: Limit Switch, Primary Boom #1 Extend Operational. Switch closes when the primary boom is fully extended. NOHC when fully extended.
LSP1RO: Limit Switch, Primary Boom #1 Retract Operational. Switch closes when the primary boom is extended. NCHO when fully retracted RSP1AO: Rotary Sensor, Primary #1 Angle Operational. Provides operational primary boom angle positioning relative to secondary boom angle. RSP1AS: Rotary Sensor, Primary #1 Angle Safety. Provides safety primary boom angle positioning relative to secondary boom angle. RSJ1AO: Rotary Sensor, Jib #1 Angle Operational. Used to level jib bell crank relative to the primary, secondary and turntable angles. RSS1AO: Rotary Sensor, Secondary #1 Angle Operational. Used to measure the angle of the secondary boom. Lowers drive speed when elevated, sequences secondary boom up/extend and down/retract. RSS1AS: Rotary Sensor, Secondary #1 Angle Safety. Backup safety angle sensor for RSS1AO. Cuts power to circuits P9B, P_11 and P_30 if the secondary boom drifts down while still extended. RSFA1O: Rotary Sensor, Front Axle #1 Operational. Provides front axle positioning information for adjusting steering neutral setting during axle extension. RSRA1O: Rotary Sensor, Rear Axle #1 Operational. Provides front axle positioning information for adjusting steering neutral setting during axle extension. RSLF1SO: Rotary Sensor, Left Front #1 Steer Operational. Provides wheel position information during steering. Master wheel in all steer modes except rear steer. RSRF1SO: Rotary Sensor, Right Front #1 Steer Operational. Provides wheel position information during steering. RSLR1SO: Rotary Sensor, Left Rear #1 Steer Operational. Provides wheel position information during steering. Master wheel for rear steer mode. RSRR1SO: Rotary Sensor, Right Rear #1 Steer Operational. Provides wheel position information during steering.
6 - 10
Z-135/70
Part No. 106783
April 2008
Drive Chassis and Platform Controller Pin Legend

REV B
J22 J21
WHITE 35 PIN CONNECTOR
BLACK 23 PIN CONNECTOR
PLATFORM CONTROLLER
PCON
J22
J31 J32
PLATFORM CONTROLLER
PCON
J21
1 = GNDPCON - BR 2 = P52PCON - WH 3 = (UNUSED) 4 = S56PRV - RD 5 = (UNUSED) 6 = (UNUSED) 7 = P56PRV - RD/WH 8 = (UNUSED) 9 = (UNUSED) 10 = (UNUSED) 11 = (UNUSED) 12 = (UNUSED) 13 = (UNUSED) 14 = (UNUSED) 15 = C47OUT - WH/BK 16 = C46HN - WH 17 = D81CAN(-) - GR 18 = D82CAN(+) - YL 19 = (UNUSED) 20 = (UNUSED) 21 = (UNUSED) 22 = (UNUSED) 23 = P23PCON - BK
1 = VLVRET1 - BR 2 = V153JBE - BK 3 = V18PRR - GR/BK 4 = V17PRL - GR 5 = V43JU - GR 6 = V44JD - GR/BK 7 = V14PLU - OR 8 = V15PLD - OR/BK 9 = V154JBR - BK/WH 10 = R90PXS - RD/BK 11 = C90PXS - RD/BK 12 = P110LDS - GR 13 = C94LDS - WH 14 = P109LDS - BK 15 = C88PTS - RD/BK 16 = C64LS -OR/BK 17 = C56FTS - RD 18 = C154JBR - BK/WH 19 = P85RET - BR 20 = C84TAY - GR/BK 21 = P85PTS - GR 22 = P87RET - BR 23 = P87PTS - RD 24 = (UNUSED) 25 = (UNUSED) 26 = (UNUSED) 27 = (UNUSED) 28 = V146JBU - BL 29 = V147JBD - BL/BK 30 = P109JBS - GR/WH 31 = P110JBS - BK 32 = C148JBS - BL/WH 33 = (UNUSED) 34 = VLVRET2 - BR 35 = (UNUSED)
DRIVE CHASSIS CONTROLLER
DCON
J32
DRIVE CHASSIS CONTROLLER
DCON
J31
1 16
8 23
PIN NUMBERING FOR 23 PIN CONNECTORS
1 = VLVRET1 - BR 2 = V61AXRT - GR 3 = V60AXEX - GR/WH 4 = V29MS - RD/WH 5 = (UNUSED) 6 = (UNUSED) 7 = (UNUSED) 8 = V36RRS - BL 9 = V37RRS - BL/BK 10 = C111RRS - OR 11 = C111LRS - OR 12 = C111RFS - OR 13 = C111LFS - OR 14 = VLVRET2 - BR 15 = V32BRK - WH/RD 16 = V36LRS - BL 17 = V37LRS - BL/BK 18 = V36RFS - BL 19 = P110RT - BK 20 = P109ANG - GR/WH 21 = V37RFS - BL/BK 22 = V36LFS - BL 23 = V37LFS - BL/BK
1 = GND-DCON - BR 2 = P21DCON - WH 3 = P53LS - WH/BK 4 = (UNUSED) 5 = S56PRV - RD 6 = C61AXRT - GR 7 = (UNUSED) 8 = (UNUSED) 9 = (UNUSED) 10 = (UNUSED) 11 = (UNUSED) 12 = (UNUSED) 13 = (UNUSED) 14 = (UNUSED) 15 = (UNUSED) 16 = (UNUSED) 17 = D81CAN(-) - GR 18 = D82CAN(+) - YL 19 = (UNUSED) 20 = C60FAP - GR/WH 21 = C60RAP - GR/WH 22 = (UNUSED) 23 = P61LSA - GR
Part No. 106783
Z-135/70
6 - 11
April 2008
Safety Controller Pin Legend

REV B
GRAY 12 PIN CONNECTOR
J121
J122
SAFETY CONTROLLER
SCON
J121
SAFETY CONTROLLER
SCON
J122
1 = S132LDS - BL/WH 2 = S73SLE - BL/RD 3 = (UNUSED) 4 = C145CAL - RD/WH 5 = (UNUSED) 6 = D82CAN (+) - YL 7 = D81CAN (-) - GR 8 = S59CNBK - GR/WH 9 = S56PRV - RD 10 = S137PLL - RD/WH 11 = S139TRF - WH/RD 12 = GNDSCON - BR
6 7
1 12
1 = P21DCON - WH 2 = C142SBS - OR 3 = C141PBS - RD 4 = C60AXEX - GR/WH 5 = S12SB - BL/WH 6 = S13DE - BL/RD 7 = P53LS - WH/BK 8 = S140ENL - OR/RD 9 = P54ENG - BK/WH 10 = P58LS - RD/BK 11 = S56PRV - RD 12 = C61AXRT - GR
6 - 12
Z-135/70
Part No. 106783
April 2008
Turntable Controller Pin Legend

REV B
STOP
24
1 16
4 19
8 23
J14
29 35
6 12
00000
J13
16 19 23
1 4 8
4 PIN CONNECTOR
24
J15
4 1 1
3 2
1 24
6 29
12 35
J12
29 35
6 12
J11
16 19 23
1 4 8
4 3
1 2
TURNTABLE CONTROLLER
TCON
J11
TCON
J12
TCON
J13
TCON
J14
PIN NUMBERING FOR 4 PIN CONNECTOR
1 = GNDPCON - BR 2 = P52PCON - WH 3 = C46HN - WH 4 = C47OUT - WH/BK 5 = P23PCON - BK 6 = S56PRV - RD 7 = P56PRV - RD/WH 8 = (UNUSED) 9 = C117FB - RD 10 = (UNUSED) 11 = C145CAL - RD/WH 12 = (UNUSED) 13 = (UNUSED) 14 = (UNUSED) 15 = (UNUSED) 16 = (UNUSED) 17 = D81CAN(-) - GR 18 = D82CAN(+) - YL 19 = (UNUSED) 20 = (UNUSED) 21 = (UNUSED) 22 = (UNUSED) 23 = (UNUSED)
1 = GNDSCON - BR 2 = P21DCON - WH 3 = P53LS - WH/BK 4 = P54ENG - BK/WH 5 = S56PRV - RD 6 = P53LS - WH/BK 7 = P58LS - RD/BK 8 = S59CNBK - GR/WH 9 = S140ENL - OR/RD 10 = C61AXRT - GR 11 = (UNUSED) 12 = (UNUSED) 13 = C64LS - OR/BK 14 = C65LOFL - BL/WH 15 = C144DER - BL/WH 16 = C73SBR - BL/RD 17 = C67SBD - BL 18 = C64LS - OR/BK 19 = C70PBR - BL/WH 20 = C71PBE - BL/BK 21 = (UNUSED) 22 = (UNUSED) 23 = (UNUSED) 24 = (UNUSED) 25 = SNSR GND - BR 26 = P109PSR - GR/WH 27 = (UNUSED) 28 = C143DEL - BL/RD 29 = (UNUSED) 30 = (UNUSED) 31 = (UNUSED) 32 = C123PBS - RD/BK 33 = C124SBS - OR/BK 34 = S140ENL - OR/RD 35 = GND16 - BR
1 = (UNUSED) 2 = C35RPM - BK/RD 3 = C21IGN - WH 4 = C34SA - BK/WH 5 = (UNUSED) 6 = (UNUSED) 7 = C46HRN - WH 8 = (UNUSED) 9 = C33STR - BK 10 = C30EDC - WH 11 = C31EDC - WH/BK 12 = C25PSR - WH/BK 13 = C26TSR - WH/RD 14 = (UNUSED) 15 = (UNUSED) 16 = (UNUSED) 17 = S137PLL - RD/WH 18 = C41RPM - OR/BK 19 = S139TRF - WH/RD 20 = (UNUSED) 21 = (UNUSED) 22 = C45GEN - GR/WH 23 = (UNUSED)
TCON
J15
1 = B1BAT - RD 2 = GND - BR 3 = GND - BR 4 = (UNUSED)
1 = VLVRET4 - BR 2 = V03PUD - RD/WH 3 = V09PER - BK/RD 4 = V06TRF - WH/RD 5 = V12SUD - BL/WH 6 = V176SER - GR/WH 7 = VO1PBU - RD 8 = V02PBD - RD/BK 9 = V07PBE - BK 10 = V08PBR - BK/WH 11 = (UNUSED) 12 = V11SBD - BL/BK 13 = C49LP - WH/BK 14 = VLVRET5 - BR 15 = (UNUSED) 16 = (UNUSED) 17 = VLVRET5 - BR 18 = VLVRET5 - BR 19 = V10SBU - BL 20 = V73SBR - GR/BK 21 = V72SBE - GR 22 = (UNUSED) 23 = (UNUSED) 24 = (UNUSED) 25 = V04TRL - WH 26 = V05TRR - WH/BK 27 = VLVRET7 - BR 28 = (UNUSED) 29 = (UNUSED) 30 = VLVRET6 - BR 31 = (UNUSED) 32 = C27AUX - RD 33 = (UNUSED) 34 = V155PSE - OR/RD 35 = V150HG - GR/BK
Part No. 106783
Z-135/70
6 - 13
April 2008
Engine Relay and Fuse Panel Legend

REV B
CB10
F23
B1PBAT
LABEL CR1 CR5
Deutz BF4L 2011 Deutz TD2011L04i

DESCRIPTION START RELAY HORN RELAY GLOW PLUG RELAY HYDRAULIC OIL COOLER FAN RELAY ENGINE / FUEL RELAY FLASHING BEACON RELAY FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN CIRCUIT BREAKER, 20A, RPM SOLENOID FUSE, 60A, GLOW PLUG FUSE, 30A, ENG/STR/ALT
CR28
CR17
F22
1 2 3
F7
4
B3PBAT
CR15 CR17 CR28 CR41
R21PIGN
CR41
CR5
02PGND
CR1
CR15
F7 CB10 F22 F23
CB10
F23
B1PBAT
CR28
CR17
F22
1 2 3
LABEL CR1 CR5 CR15 CR17 CR28 CR41
Perkins 1104C-44 Perkins 804D-33T

DESCRIPTION START RELAY HORN RELAY GLOW PLUG RELAY HYDRAULIC OIL COOLER FAN RELAY ENGINE / FUEL RELAY FLASHING BEACON RELAY FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN CIRCUIT BREAKER, 20A, RPM SOLENOID FUSE, 60A, GLOW PLUG FUSE, 30A, ENG/STR/ALT
F7
4
B3PBAT
R21PIGN
CR41
CR5
02PGND
CR1
CR15
F7 CB10 F22 F23
Cummins B4.5L Cummins B3.3T

B1PBAT
CB10
F23
LABEL CR1 CR5 CR17 CR28 CR41 F7
DESCRIPTION START RELAY HORN RELAY HYDRAULIC OIL COOLER FAN RELAY ENGINE RUN/ALT RELAY FLASHING BEACON RELAY FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN CIRCUIT BREAKER, 20A, RPM SOLENOID FUSE, 60A, GLOW PLUG FUSE, 30A, ENG/STR/ALT
CR28
CR17
F22
1 2 3
F7
4
B3PBAT
R21PIGN
CR41
CR5
02PGND
CR1
CB10 F22 F23
6 - 14
Z-135/70
Part No. 106783
April 2008
Electrical Symbols Legend

REV A
BLK
CB1 15A PR1
FS1
OPS1 N.C.
BLK
WHT
Quick disconnect terminal
Circuit breaker with amperage
Foot switch Power relay Oil pressure switch normally closed

P1
H1
T-circuits connect Horn or alarm
Toggle switch
FB
Sending unit
Emergency Stop button normally closed
Connection no terminal Flashing beacon
PULL IN
HOLD
CR4 N.O.
FAN
Circuits crossing no connection
G1
Control relay contact normally open

OTS2 N.O.
Hydraulic oil cooling fan
Fuel or RPM solenoid

Aux Pump
Gauge
Diode
HM
Oil temperature switch normally open
Auxiliary pump
Coil
KS2
Hour meter
+
CTS1 N.O.
SERVICE BYPASS/ RECOVERY KEY SWITCH
RUN SERVICE BYPASS 1 RECOVERY 2 A-A
Battery LED
F1
RD
BK
BL
25A
Fuse with amperage
STARTER
PCON 1 TCON A-A 2
Starter motor
AUX MAIN
Battery separator
Part No. 106783
L3
Coolant temperature switch normally open
A-B 4
B-B 3 4
Tilt sensor
2
86
C-B 3 4
1
30 87a 87
C-A 2
B C
1 2
85
B-A
Starting aid: glow plug or flame ignitor

Steer sensor
D1
ALTERNATOR
Service bypass/ recovery key switch
Relay
OFF
KS1
MAIN KEYSWITCH
Power relay
A-B 3 4
Chassis ground
BAT
EXCT BAT
B-A 2
STA.
B-B 3 4
LS3
N.O.H.C N.C.H.O
REGULATOR
IND.
Limit switch
ALTERNATOR
Main key switch
Current limiting device
Z-135/70
6 - 15
April 2008
Hydraulic Symbols Legend

REV A
25 psi
Filter with bypass valve relief setting
Motor 2-speed, bi-directional
Solenoid operated 2 position, 3 way, directional valve

Pressure reducing valve
3000 psi (206.8 bar) 3:1
Pilot operated 3 position, 3 way, shuttle valve
Pump fixed displacement
Pump stroke piston
Counterbalance valve with pressure and pilot ratio 50% 50%
E
Pump prime mover (engine or motor) Pump variable displacement
Double acting cylinder
Flow divider/combiner valve with pressure balancing orifice and flow percentages
Directional valve pilot operated 2 position, 2 way Differential sensing valve
.035"
Motor
Orifice with size Solenoid operated 3 position, 4 way, directional valve Solenoid operated proportional valve
Shut off valve
Pump bi-directional, variable displacement
2 position, 3 way, shuttle valve Pilot operated check valve

Flow regulator valve
Check valve
200 psi
Hydraulic oil cooler
Motor bi-directional
Relief valve with pressure setting 2 position, 2 way solenoid valve
Brake
6 - 16
Z-135/70
Part No. 106783
April 2008
Electrical Schematic Layout
6 - 17
6 - 18
REV A
C26TSR-WT/RD WATER TEMP SENDER
J153
J153
C25PSR-WT/BK
OIL PRESSURE
TO AUX HYDPPUMP RELAYS
MANIFOLD HARNESS
MANIFOLD HARNESS
ENGINE HARNESS
ENGINE HARNESS
1
HOLD FUEL SHUTDOWN TO MICRO
TCON MEMBRANE PANEL
R21IGN-WH
HYD WELDER PROPEL BYPASS PRESS COMP ENABLE VLV

CR28PENG FUELPRELAY
P14-35 P14-34 V155PSE OR/RD V155PSE OR/RD P14-33 P14-32 P14-31 C27AUX-RD C27AUX-RD V155PSE-OR/RD FUNCTION ENABLE VALVE (Y74)
V150HG GR/BK
V150HG GR/BK
WELDER GEN BYPASS VLV (Y75)
2
BOOM CW TO MICRO SPARE AUX_RELAY
3
PLTFRM CW
SEE OPTIONS SHEETPFOR BELT DRIVEN PAC GENERATORPWELDMASTER
4
TO MICRO VALVE_RTN6 P14-29
87a
JIB DOWN
P14-30
VLVRET6-BR VLVRTN6-BR
TO PLD
5
PLTFRM DOWN VALVE_RTN7
87
PROPEL POWER INPUT P14-28 P14-27 CR2 RELAY

85
VLVRET7-BR VLVRTN7-BR C05TRR WH/BK BAT GND-BR C04TRL-WH TT ROT CW VLV (J70) TT ROT CCW VLV (J71)
86
6
PLTFRM UP ROTATE_CW_VLV P14-25 P14-24
R21IGN-WH
TO MICRO ROTATE_CCW_VLV V04TRL-WH
P14-26
V05TRR-WH/BK
7
JIB UP MULTI_FUNCT_VLV P14-23 P14-22 V72SBE-BL/WH V72SBE-BL/WH TO MICRO UNUSED
View 12
TO SHEET 5
FAN
PLTFRM CCW
30
UNUSED SEC_EXT_VLV V10SBU-BL V10SBU-BL

CR17POILPCOOLERPRELAY
87
P14-21 V72SBE-BL/WH R116HYD-OR BAT GND-BR V73SBR-BL/RD B3BAT/14-RD

OTS1PN.O.
9
TO PLD TO MICRO SEC_UP_VLV
86
BOOM CCW P14-19 C21IGN-WH C116HYD-OR

85
SEC_RET_VLV V10SBU-BL BAT GND-BR TEMPPSW VLVRET5-BR VLVRET5-BR SEC RET VLV (J66) SEC UP VLV (J67)
J32-ENG HARN
P14-20 COOLERPRELAY
10
TURTLE BOOM REVERSE LOAD DI P14-17 P14-16 P14-15
C45GEN-GR/WH
TO MICRO BOOM OVERLOAD DI SEC EXT VLV (J65) P14-18
11
SEC. DOWN TO MICRO TO MICRO
P_30 PR15PGRIDPHEATERPRELAY
TO PLD HYD_FILTER2 DI HYD_FILTER1 DI TO MICRO

B2BAT-RD
12
RABBIT DRIVE LIGHT RELAY P14-13 C49LP - WH/BK C49LP - WH/BK V11SBD-BL/BK VLVRET5-BR
C26TSR-WH/RD C21IGN-WH GND-BR
VALVE_RTN5 GRID HEATER
P14-14 VLVRET5-BR
SEC DWN VLV (J68)
87a
TO MICRO
V73SBR-BL/RD V73SBR-BL/RD HYDRAULICPOIL COOLER FAN
30
J56
R34SA/4-RD
View 6
BOOM EXT
C25PSR-WH/BK
13
SEC_DWN_VLV TO PLD TO MICRO PRI_RET_VALVE P14-10 V08PBR-BK/WH V08PBR-BK/WH PRI RET VLV (J63) UNUSED P14-11 P14-12 V11SBD-BL/BK
14
DUETZ BF4L2011 PENGINE SHOWNPSEE: DETAIL A PFOR PERKINS PDETAIL BPFOR FORD
B1ENG-RD
BOOM DOWN
TO AUX HYD BATTERYPPOS TERM (B2)
PRI_EXTEND_VLV
15
BOOM RET TO MICRO PRI_DOWN_VLV PRI_UP_VLV C34SA-BK/WH VLVRET-BR
J120
P14-08 P14-07 V01PBU-RD V01PBU-RD PRI UP VLV (J59) GLOW PLUG
V02PBD-RD/BK V02PBD-RD/BK PRI DWN VLV (J60)
P11 J11
P
TO MICRO SEC BM E/R FC VLV P14-06 V09SER-BK/RD V09SER-BK/RD SEC. BM ER F.C. (J64) SEC. BM UD
C
TT ROT FC VLV
P14-04
V06TRF-WH/RD
V06TRF-WH/RD
TT ROT CW/CCW F.C. (J69) PRI BM EXT/RET F.C. (J61) GND04-BR C30EDC-WH
A B
C31EDC-WH/BK DUAL PCOILPEDC
TO MICRO
TO MICRO
PRI BM E/R FC VLV
P14-03
V09PER-BK/RD
V09PER-BK/RD
PRI BM U/D FC VLV

1
P14-02
J14 WHITE 35 PINPMANIFOLD HARNESS
V03PUD-RD/WH VLVRET4-BR GND04-BR

B1ENG-RD
V03PUD-RD/WH VLVRET4-BR VALVE RTN#3 P1-23 P1-22 P1-21 BATGND(A)

B3BAT/14-RD P34SA/4-RD
PRI BM UP/DWN F.C. (J58)
VALVE_RTN4 P14-01 TO MICRO
TO PLD
AC GENERATOR TT_TILT_Y_AXIS
C45GEN-GR/WH
C49LP - WH/BK
TO MICRO TO PLD
CR5PHORNPRELAY
WH-PULL IN RD-HOLD
HOLD
P_38 PWR TO PROPEL VALVE RTN#2 P1-16 P1-15 SERVICEPHORN

86 85
P1-17
S137PLL-RD/WH
BOOM UP
B1ENG-RD
6
TT_TILT_SNSR_PWR TT_TILT_SNSR_GND P1-14 VLVRET2-BR

87 30
SEC. UP R46HRN-WH HORNPRELAY BAT GND-BR C41RPM-OR/BK C107AF-RD

BATGND(A) RD-HOLD
87a
7
OIL/WATER_TEMP P1-13 P1-12 P1-11 P1-10 P1-09 P1-08

WH-PULL IN
C26TSR-WH/RD C25PSR-WH/BK C31EDC-WH/BK C30EDC-WH C33STR-BK B3BAT/14-RD
OIL_PRESSURE EDC REV EDC FWD STARTER RELAY LP
AUXILIARY
8
ENG SPEED
9
CR23PDRIVE LPSPRELAY
GAS/LP
SERVICE HRN P1-07 C46HRN-WH
REGULATOR
10
ALTERNATOR
REV PWM P1-06 P1-05 P1-04 P1-03

F7 OIL COOLERPF20 HI/LO COOLERPFXX NOT USEDPF23 ENG/ST/ALT
+ BUTTON
11
FWD PWM CHOKE/GLOW PLUG RELAY C34SA-BK/WH C21IGN-WH C35RPM-BK/RD

B3BAT/14-RD P34SA/4-RD TIME DELAY
ALTERNATOR
86
85
12
THROTTLE P1-02 P1-01

TROMBETTA MOM N.O.
87
SCRL F/ENT
VALVE RTN#1
BAT. +
- BUTTON
B A C
IGN/FUEL
S-500
TO J4-32PWHITE 35 PIN C27AUX-RD
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
ENGINE HARN
AUXILIARY HYD RECOVERY SIGNAL
STRT ASST
BOOM RET RECOVERY SIGNAL BOOM DWN RECOVERY SIGNAL
15
S137PLL-RD/WH
S139TRF-WH/RD
START
J10
WORK LPPON/OFFPTOGGLEPSWITCH
P9A
P6R1
P11
BAT GND-BR
86 85
P_22R
P_30
P_39
P7R
P10
C33STR-BK
87
30
WORKPLAMP
BATECU GND P1-03 F7 BAT STARTER 10 A 20 A

ENG HARN
GND-BR F23 GND-BR B2BAT-RD F20 P35RPM-BK/RD

12-3 CABLE
SYS BAT GND P1-02 P1-01

BLACK 4 PIN
C26TSR-WT/RD OIL TEMP SENDER ENGINEPBLOCK &PELECTRONICS

D3
SYS_BAT_PWR
20 A
INTEGRAPCABLE
POWER HARN
F22
87a
B1ENG-RD
B1ENG-RD
CR1PSTARTERPRELAY
P1-04
R33STR-BK STARTER RELAY
AUX. PUMP
P10
D5
275 A F7
AUX MAIN
B1BAT-RD B1BAT-RD
86 SEE OPTIONS SHEETPFOR BELT DRIVEN PAC GENERATORPWELDMASTER 85
87
INTEGRAPCABLE
20 A
POWERPHARN
B1BAT-RD
TWO 6 VOLTPBATTERIES
SPARE
J15
B1
C25PSR-WT/BK
OIL PRESSURE
SEPARATEP4 GA WIRE
SEPARATEP4 GA WIRE
SEPARATEP4 GA WIRE
CR28PENG FUELPRELAY
30
87a
B1ENG-RD
D7 D8 POWERPHARN
B1BAT-RD B1BAT-RD
FAN
HYDRAULICPOIL COOLER FAN BAT GND-BR S139TRF-WH/RD
87a
87
C21IGN-WH
86
C116HYD-OR BAT GND-BR TEMPPSW

85
LOWER LS PHARNESS ENGINEPHARNESS
OTS1PN.O.
COOLERPRELAY
C26TSR-WH/RD
J32-ENG HARN
C25PSR-WH/BK
B1ENG-RD
C21IGN-WH
R21IGN-WH
87a
30
PRELAY GLOW PLUG R34SA-BK/WH
C45GEN-GR/WH
CR15PGLOWPPLUGPRELAY
87
B1ENG-RD
GLOW PLUG
86
C34SA-BK/WH VLVRET-BR
85
J120
C31EDC-WH/BK DUAL PCOILPEDC
GND04-BR C30EDC-WH
B1ENG-RD
VALVE RTN#3 P1-23 P1-22 P1-21

P34SA-BK/WH
TOPMICRO
P_22R P_39 P_7R P_10
AC GENERATOR TT_TILT_Y_AXIS 07GND-BR BK

B3BAT/14-RD
C45GEN-GR/WH
GND04-BR
TT_TILT_X_AXIS P1-20 WH-PULL IN P1-19 RD-HOLD RD

CR5PHORNPRELAY
HOLD
HI/LO SPEEDP SOLENOID

PULL IN
P_39 POWER TO TTROT FC
S139TRF-WH/RD
P_38 PWR TO PROPEL TOPMICRO VALVE RTN#2 P1-16 P1-15

86
P1-17
S137PLL-RD/WH
TOPMICRO TT_TILT_SNSR_PWR TT_TILT_SNSR_GND

B1ENG-RD
J57
ALTERNATOR RPM P1-18 C41RPM-OR/BK
WH
SERVICEPHORN
P1-14 VLVRET2-BR
87 30
P_10
87a
TOPMICRO R46HRN WH HORNPRELAY BAT GND-BR C26TSR-WT/RD WATER TEMP SENDER C41RPM-OR/BK
D1
OIL/WATER_TEMP P1-13 P1-12 P1-11 P1-10 P1-09

WH-PULL IN
C26TSR-WH/RD C25PSR-WH/BK C31EDC-WH/BK C30EDC-WH C33STR-BK

RD-HOLD D2
OIL_PRESSURE P_7R EDC REV (P15)+(ECU POWER) TO HORN BUTTON TOPMICRO STARTER RELAY
(P15)+(ECU POWER)
B3BAT/14-RD
EDC FWD C107AF-RD C25PSR-WT/BK

SW28 = ENGINE CYLINDER HEAD TEMPERATURE
View 11
85
H1
J146 ENGINE HARN
B3BAT/14-RD S137PLL-RD/WH
30
R116HYD-OR
B2
BAT GND-BR B2BAT-RD B2BAT-RD
FUEL SOLENOID
LP P1-08
EXCT.
BAT. -
ALTERNATOR
P_7R
REGULATOR
REV PWM P1-06 P1-05 P1-04 R21IGN-WH HOLD FUEL SHUTDOWN

F7 OIL COOLERPF20 HI/LO COOLERPF22 GLOW PLUGPF23 ENG/ST/ALT
STA.
IND.
P_7 FWD PWM P_6R1 CHOKE/GLOW PLUG RELAY C34SA-BK/WH C21IGN-WH C35RPM-BK/RD
P34SA-BK/WH B3BAT/14-RD TIME DELAY P22R
4~SLP MODE (~SM)
ALTERNATOR
TO MICRO
AUX HYD (AH)
IGN/FUEL P1-03 P1-02 P1-01

TROMBETTA
C21IGN-WH
P_7
THROTTLE VALVE RTN#1

TCON MODE(TM)
BAT. +
S-500

B1BAT-RD CR28PENG FUELPRELAY
View 5
FUNC ENABLE (FE)
TOPMICRO
SUPPLIEDPBY DEUTZ ENGINE HARN
J13 WHITE 23 PIN
MOM N.O.
J56
PR1
R21IGN-WH
AUX+
GND-
(~SM)+(AH)
5V 12V GND
P_7R
P_7
P_10
AUX. PUMP
(SM)+(AH)
BAT+
B1ENG-RD
FUEL
PUMP
(OE)
S137PLL-RD/WH
S139TRF-WH/RD
AUX HYD PUMP

SEE OPTIONS SHEETPFOR BELT DRIVEN PAC GENERATOR
R21IGN-WH
87a
C35RPM-BK/RD
30
PR1
12
13
10
AUX. PUMP
87
74HC08
74HC08
74HC08
74HC08
(SM)+(AH)
86
85
14
14
74HC08
BAT GND-BR
86 85
((~SM)+(AH))(P_22)
TOPMICRO C33STR-BK
87
((~SM)+(AH))(P_7)
((~SM)+(AH))(OE)
(TM)(FE)
F7 B1ENG-RD
OUT PWR ENABLE (OE)
P1-03
87a
TO SHEET 5
FAN
BATECU GND GND-BR 10 A

POWER HARN
CR1PSTARTERPRELAY
P1-04 HYDRAULICPOIL COOLER FAN BAT GND-BR
F23 STARTER
87
30
B1ENG-RD R33STR-BK STARTER RELAY
R21IGN-WH
P22R
P_22
P7R
P1-02 P1-01
INTEGRA
P_7
Vbb BTS621 IN1 OUT 1 IN2 OUT 2 ST Vbb BTS621 IN1 OUT 1 IN2 OUT 2 ST
P_1 P35RPM-BK/RD
86
BTS650 Vbb
BTS650 Vbb
BTS650 Vbb
OUT
OUT
ENG HARN
85
20 A
BLACK 4 PIN INTEGRA
ENGINE BLOCK ELECTRONICS BATTERY C116HYD-OR BAT GND-BR TEMPPSW
C21IGN-WH
OUT
P_6R2
F22
GND
GND
IN
IS
IN
IS
POWER HARN
60 A START BATP B1BAT-RD F7

CR15PGLOWPPLUGPRELAY
B1
IN
IS
J15
AUX
MAIN
20 A B1BAT-RD B1BAT-RD
C45GEN-GR/WH
B1BAT-RD
B2
GND-BR
SEPARATEP4 GA WIRE
B2BAT-RD
C26TSR-WH/RD C25PSR-WH/BK R21IGN-WH
SEPARATEP4 GA WIRE
AUX HYDPBATTERY
B2BAT-RD
P_6R2 R34SA-BK/WH
U32
J32-ENG HARN
B1ENG-RD
C21IGN-WH
87a
OTS1PN.O.
20A ENGINE BLOCK
SYS_BAT_PWR B1BAT-RD F20 COOLERPRELAY
B1BAT-RD
20 A B3BAT/14-RD
30
CB SYS BAT GND GND-BR B1ENG-RD
R116HYD-OR
TO AUX HYD BATTERYPNEG TERM (B2)
30
U95
87
S139TRF-WH/RD C34SA-BK/WH
86
VLVRET-BR
85
S137PLL-RD/WH C31EDC-WH/BK DUAL PCOILPEDC
GND04-BR C30EDC-WH
GND04-BR
B1ENG-RD
VALVE RTN#3 P1-23 P1-22

P34SA/10-BK/WH
AC GENERATOR TT_TILT_Y_AXIS P1-21 BATGND(A)

B3BAT/14-RD
C45GEN-GR/WH
BK WH RD
HOLD PULL IN
TT_TILT_X_AXIS P1-20 WH-PULL IN RD-HOLD

CR5PHORNPRELAY J146 ENGINE HARN
HI/LO SPEEDP SOLENOID
LOWER LS PHARNESS ENGINEPHARNESS
P_39 POWER TO TTROT FC P1-19
S139TRF-WH/RD
J57
P_38 PWR TO PROPEL VALVE RTN#2 P1-16 P1-15

86
P1-17
S137PLL-RD/WH
TT_TILT_SNSR_PWR TT_TILT_SNSR_GND
B1ENG-RD
P1-14 VLVRET2-BR
87 30
10
74HC08
OIL/WATER_TEMP
13 NO
C64LS-OR/BK RD
NO 23 1
P1-13 R46HRN-WH HORNPRELAY BAT GND-BR C41RPM-OR/BK C107AF-RD

BATGND(A) RD-HOLD
87a

WH-PULL IN
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
C67SBD-BL C64LS-OR/BK C73SBR-BL/RD BR P1-12 P1-11 P1-10 P1-09 P1-08

14 24 2
OIL_PRESSURE PERPJ49 EDC REV EDC FWD STARTER RELAY
B3BAT/14-RD
BK WH
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
PWR TO TCON ESTOP
((~SM)+(AH))(BM STOWED)
EXCT.
BAT. -
(P15)+(ECU POWER)
OUT PWR ENABLE
BR
22 14
BOOM STOWED
TO HORN BUTTON
PCON POWER
BK
ALTERNATOR
TCON MODE
WH
LST20PDRV ENABLE LEFTPJ48
Vbb BTS621 IN1 OUT 1 IN2 OUT 2 ST GND
REGULATOR
REV PWM P1-06 P1-05 P1-04

F7 OIL COOLERPF20 HI/LO COOLERPF22 GLOW PLUGPF23 ENG/ST/ALT
P_9A
P_6R1
STA.
IND.
C64LS-OR/BK C143DEL-BL/RD
NC 2 21 13 1
RD
NO
LP
85
H1
SERVICEPHORN
P_6R2
P_11
P_7R
P_22
P_9B
P_30
P_10
P_7
FWD PWM CHOKE/GLOW PLUG RELAY C34SA-BK/WH C21IGN-WH

P34SA/10-BK/WH ENGINEPHARNESS
ALTERNATOR
22
14
WH
TIME DELAY TROMBETTA
LST10PDRV ENABLE RIGHTPJ48 VALVE RTN#1 P1-01

MOM N.O.
B3BAT/14-RD
BK
THROTTLE P1-02 C35RPM-BK/RD
BR
BAT. +
C64LS-OR/BK C144DER-BL/WH
21
RD
NC 13 NO
IGN/FUEL P1-03
S-500
C64LS-OR/BK
ENGINE HARN
C65LOFL-BL/WH PR1
BAT+
J13 WHITE 23 PIN
FST1SPLOW FUEL FS
C124SBS-OR/BK YL BR OR S19-SEC BM ANGLE OPER

WORK LPPON/OFFPTOGGLEPSWITCH S137PLL-RD/WH S139TRF-WH/RD
AUX. PUMP
AUX+
GND-
VLVRET BR
B1ENG-RD
SNSR GND-BR P109PSR-GR/WH C35RPM-BK/RD PR1
AUX HYD PUMP
BOOM STOWED
PCON POWER
SNSR GND-BR
TCON MODE
BK RD BAT GND-BR
86 85
P_9A
P_6R1
P_7R
P_11
J154
P109PSR-GR/WH
S20-SEC BM ANGLE SAFETY C33STR-BK

87
30
P_7
P_10
21
C64LS-OR/BK
NC 13 1
RD
NO
B1ENG-RD B1ENG-RD PBATTERY STARTER

WORKPLAMP
S13DE-BL/RD BR
22 14
BATECU GND P1-03 F7 10 A 20 A F20 P35RPM-BK/RD

12-3 CABLE POWERPHARN
GND-BR F23 GND-BR B2BAT-RD ENGINE BLOCK ENGINE BLOCK
BK
YEL
WH SYS_BAT_PWR P1-01
BLACK 4 PIN
LST1SP DRV ENPJ126 P1-02
SYS BAT GND
21
13
C64LS-OR/BK RD
NC NO 1
20 A F22 ENG STARTPCONTROLS
POWER HARN
22
14
S12SB-BL/WH C64LS-OR/BK BR
2
CR1PSTARTERPRELAY
P1-04
R33STR-BK STARTER RELAY
AUX. PUMP
C142SBS-OR BL
B1BAT-RD F7
AUX MAIN
B1BAT-RD B1BAT-RD 20 A B1BAT-RD B1BAT-RD
21
VLV RET P12-35 C70PBR-BL/WH

2
8 3
C70PBR-BL
BR
22 14 3
P_30 P12-34 S140ENL-OR/RD

4
BK WH
13
C64LS-OR/BK C64LS-WH
1 NC NO
RD
LSP1R0P3' EXTPJ44
View 10
J15
INTEGRA
RED
S73SLE-BL/RD WH
4
LSS1RSP 3' EXTPJ46
60 A
B1
BK
SEPARATEP4 GA WIRE
NC
BOOM STOWED P12-31
BR
9 4
LSB14AO P12-30
2
C64LS-OR/BK C71PBE-BL/BK
22 1
C64LS-WH/BK C71PBE-BL/BK
BK WH
14
21
13
NO
PRI ANG INPUT P12-32 C123PBS-RD/BK

RD
B2BAT-RD
LSP1E0P3'FROM FULLY PEXTENDEDPJ45
LSB13AO P12-29 P12-28 C143DEL-BL/RD S139TRF-WH/RD P12-27 P12-26 P12-25 P12-24 SNSR GND-BR C123PBS-RD/BK C123PBS-GR/BK YL BR OR S17-PRI BM ANGLE OPER
1 2 LOWER LS PHARNESS ENGINEPHARNESS
LST20 DR ENBL L PRESSURE GA SNSR PWR P109PSR-GR/WH SNSR GND TO MICRO P2 SEQ
J146 ENGINE HARN
TO MICRO S137PLL-RD/WH
View 4
TO PLD
12
LSS2EO P12-21 SNSR GND-BR C71PBE-BL/BK

J114 J20
LSS2AO P12-22 C141PBS-RD BL BK RD S18-PRI BM ANGLE SAFETY SNSR GND-GR S64LS-OR C141PBS-RD
LSP1EO P12-20 P12-19 C70PBR-BL/WH C64LS-OR/BK C67SBD-BL C73SBR-BL/RD C144DER-BL/WH C65LOF-BL/WH C64LS-OR/BK
P12 J122-BK 12 PINPSCON MODULE
LSP1RO TO PLD LSB2RO LSP1AO TO MICRO LSS1RO TO PLD TO PLD LST10 DR ENBL R FST1S-LOW FUEL P12-14 P12-13 P12-12 P12-11 P12-10 C61AXRT-GR C61AXRT-GR S56PRV-RD P58LS-RD/BK P9B P6R2 P11+P30 P6R1 DRV. ENA. SEC. BOOM RET AXLE EXTENDED RSP1AS RSS1AS ECU PWR P54ENG-BK/WH S140ENL-OR/RD P122-08 P122-07 P122-06 P122-05 P122-04 P122-03 P122-02 P122-01 P53LS-WH/BK S13DE-BL/RD S12SB-BL/WH C60AXEX-GR/WH C141PBS-RD C142SBS-OR P21DCON-WH P122-09 P122-10 P122-11 P7R P122-12 P12 S140ENL-OR/RD S59CNBK-GR/WH P58LS RD/BK P53LS-WH/BK S56PRV-RD P54ENG-BK/WH P53LS-WH/BK P21DCON-WH GNDDCON-BR P12-09 P12-08 P12-07 P12-06 P12-05 P12-04 P12-03
J12 BLACK 35 PINPLIMIT SWITCH HARN
. P12-18 P12-17 P12-16 P12-15
TO MICRO
OPER SW PWR
P_22 P_9B TCON MODE PCON POWER OUT PWR ENABLE
P_18
P6R1 P9A P11
P7R
P_7
P10
P_14 P_12 P_11 P_10 P_9B P_9A U32 P_7R P_6R2 P_6R1 DCON ECU PWR DCON ECU GND P12-01 P12-02 U31 U30
11
TO MICRO
GND-BR S139TRF-WH/RD S137PLL-RD/WH S56PRV-RD S59CNBK-GR/WH D81CAN- -GR P121-07 CANCAN+ RD 232 CALIBRATION IN TD RS232 DIG IN DIG IN P121-06 P121-05 C145CAL-RD/WH P121-03
J121-GR 12 PINPSCON MODULE
P121-12 P121-11 P39 P38 P7R P10 P121-10 P121-09 P121-08
GND
D82CAN+ -YL
P121-04
S73SLE-BL/RD
P121-02 P121-01
S132LDS-BL/WH
BOOM EXT/RET FC RECOVERY SIGNAL BOOM UP/DWN FC RECOVERY SIGNAL PCON POWER
P109PSR-GR/WH
2 10
P1 SEQ P12-23 P109PSR-GR/WH P109PSR-RD/BK
SNSR GND-BR
SNSR GND-BK
PRI BOOM LENGTH 100' STATUS
PRI BOOM LENGTH 3' STATUS
PRI BOOM RETRACTED STATUS
(P15)+(ECU POWER)
PWR TO TCON ESTOP
OUT PWR ENABLE
TO HORN BUTTON
LOCKOUT VALVE #1 SIG
P_22
View 3
C145CAL-RD/WH
S132LDS-BL/WH
BC BC BB BA BB
J129-02
J129-01
BA
AA
AB
C145CAL-RD/WH
S132LDS-BL/WH
AC
J152B
C60AXEX-GR/WHT
TO MICRO TO MICRO
GNDDCON-BR
D82CAN+ -YL
ECU POWER
TO HORN BUTTON
OUT PWR ENABLE
BM DWN O
P15 PCON POWER
PWR TO TCON ESTOP
BM E/R FC O
GND-BR
BM U/D FC O
PLD
TCON MODE
D81CAN- -GR
BM RET O MLT FNC VLV O

P_22 P11
P21DCON-WH
S56PRV-RD
P53LS-WH/BK
C61AXRT-GR
N MODULE
TCON MODE
P_7
P7R
P6R1
P11
AUX HYD O OPER. REC. PRI BM RET ST I

TO FLASHING BEACON R117FB-RD P117FB-RD
View 9
P6R1
P_7
P7R
SEPARATEP4 GA WIRE
SEC ANG INPUT P12-33 C124SBS-OR/BK
B2
AUX HYD
DETAIL A PPERKINS 1104C ENGINE
View 13
J120
(BM STOWED)
(~SM)+(AH)
SERV. OR PROVIDES PWR TO MINIMAL HARDWARE IN SERV OR RECOVERY VICE OR RECOVERY MODE
BM 3' I BM 100' I PRI LO#1 O
TCON ESTOP
J11 BLACK 23 PINPBOOM HARN
BL/BK
G-P MODE GR/BK WH/BK

1 1 1 1
1 PWR TO TCON ESTOP-BL/BK TCON ESTOP-BL/WH TET ESTOP RET DIAG/TETHER PWR DIAG/TETHER GND
AA AB AC
PLAT
PLAT
PLAT
PLAT
2
PLAT
P11-23 P11-22 P11-21 P11-20 P11-19 P11-18 D82CAN+ -YL D81CAN- -GR BB
J152A
BL/WH
3 C47OUT WH/BK C47OUT GR/BK P23PCON-BK 5 6 7 BA S56PRV-RD/BK 8 9 SERV. OR OPER. REC. BA P11-15
BA BB BC
SERV/CAL MODE ECU POWER PCON MODE TETHER FUNC ENBL NOT USED CAN HIGH CAN LOW P11-17 P11-16 P15 CAL FREQ 2 OUTPUT PWR ENABLE P6R1 P7R
P23PCON-BK TCON MODE C47OUT WH/BK P53LS-BK/WH
SRV REC-WH P56PRV-RD 10

RS232_GND
P22 OPER. REC.

D82CAN+ -YL D81CAN- -GR
TET ESTOP PWR CAL FREQ 1 NOT USED P11-13 P11-12 P11-11 P11-10 P11-09 R117FB-RD P11-08
D82CAN+ -YL S56PRV-RD C60AXEX-GR/WHT
OR/BK 11 12
RS232_TXDP5
P11-14
GR/WH OR 13 14
ON CIRCUIT BOARDPDB9 CONNECTOR
P7-GN/WH P11 TCON MODE SERV/CAL MODE CAN SHIELD (1939-11) FLASHING BEACON RLY SPARE P_22 P11-07 P56PRV-RD/WH S56PRV-RD P23PCON-BK C47OUT-WH/BK
SEE ES0385PFOR HYD GENERATOR/PWELDER OPTION D81CAN- -GR
NOT USED C145CAL-RD/WH

P53LS-WH/BK GNDDCON-BR P21DCON-WH C61AXRT-GR
RD/WH BL 15 16
RS232_RXDP3
ALARM PWR ALARM GND
S1 PBU-OR U30
P2
P_7 PLAT-GR/WH
CKT #P
P_7 P11-06 P11-05 P11-04 P11-03 C46HN-WH P52PCON-WH J147C-1 PCON GND P11-01 GNDPCON-BR J148C-1 P11-02 PWR-PCON ESTOP OUT PWR ENBL HORN RELAY COIL PCON POWER
C47OUT WH/BK P_15-OR/BK

PIN
ALM PWR-BL ALM-GND-BR
S56PRV-RD
S132LDS-BL/WH
C60AXEX-GR/WHT
P56PRV-RD/WH
TCON
C47OUT-WH/BK D82CAN+ -YL GNDDCON-BR P21DCON-WH D82CAN+ -YL D81CAN- -GR S56PRV-RD C61AXRT-GR P53LS-WH/BK D81CAN- -GR P52PCON-WH P23PCON-BK GNDPCON-BR S56PRV-RD C46HN-WH
WORK LPPON/OFFPTOGGLEPSWITCH
J156
J21 23 PIN BLACKPBOOM HARNESSPHARNESS
J155
J149B-2
J150B-2
J150B-4
J148B-1
J147B-1
J151B-A
J151B-B
J149B-1
CR45PWORK LPPRELAY 30
87a 87
GND-BR
P56PRV-RD/WH
S132LDS-BL/WH
P2
C47OUT-WH/BK D82CAN+ -YL P23PCON-BK P52PCON-WH D81CAN- -GR GNDPCON-BR S56PRV-RD
FUEL TYPE P2 J156 P48LPS-WH/RD J155 J150A-1 NOT USED P2 NOT USED CRAB STEER P2 NOT USED P21-19 J151A-C CAN H P2 J151A-A
MEMBRANE/LED INTERFACE CARD
SPARE 2 P2 PWR-PCON ESTOP P23PCON-BK COORD STEER P21-21 P21-20 7 P21-22 P21-23
6 NOT USED
REAR STEER CAN L P21-17 J151A-B HRN RLY CNTRL P21-16 J150A-3 OUT PWR ENBL P21-15 C47OUT-WT/BK J150A-2 J150A-4 BOOT P21-13 P21-12 P21-11 P21-10 P21-09 P21-08 P21-07 P56PRV-RD/WH J149A-2
OUT S132LDS-BL/WH
5 P21-18 D81CAN-GR C46HN-WH D82CAN+ -YL
FRONT STEER P2
DRIVE SPEED P2
3 NOT USED P21-14
P2 NOT USED CAN SHIELD 10 NOT USED 9
ENGINE SPEED P2
J24B 10PIN
AXLE EXTEND
2 NOT USED
10 8
J24A 10PIN BTS650 Vbb
NOT USED
U21
U22
7 NOT USED
IS
Vbb BTS621 IN1 OUT 1 IN2 ST OUT 2
P1 P_22 P21-06 P21-05 P21-04 S56PRV-RD J149A-1 NOT USED P21-03

P6
IN
5 SPARE 1 P1 3
RS232_TXDP5 J23 10PIN
RS232_GND
P1 NOT USED P_7
8 4
GND
AXLE RETRACT
P7R
9 6
C46HN-WH
GND-BR
10
WORKPLAMP
P20BAT-RD
J150B-3
J151B-C
J150B-1
86
85
P1 PCON GND GNDPCON-BR J148A-1

OPTIONAL SWINGPGATE WIRING
P21-01
START
RS232_RXDP3
P1
SWING GATE INTERLOCK
START ASSIST P1
FOOTSWITCH
J34-LIMIT SW HARN 1
S56PRV-RD
DRIVE ENABLE
GNDDCON-BR
AUXILIARY
CKT #P
4 P1
2 1 ON CIRCUIT BOARDPDB9 CONNECTOR
NC
J35-LIMIT SW HARN
P2
J33-BOOM HARN
P21DCON-WH
J147A-1
C61AXRT-GR
P53LS-WH/BK
PCON PWR P52PCON-WH
P21-02
C60AXEX-GR/WH
PCON MEMBRANE PANEL (MS1)
4 3
PIN
74HC08
74HC08
P1 C23PTS-WH WH
22
14
HORN
4 5 1
J22 35 PIN WHITEPPCON MANIFOLDPHARNESS
S132LDS-BL/WH
P1
YEL
GRN
BK
OR
BR
BL
YL
P1
SLP_MODE
CAN HIGH
CAN LOW
DCON GND
DCON PWR
RD
P9A
P12
View 2
P7R
P RING
P RING
88
88
88
88
88
88
88
88
88
P7R
P22
P6
P7
J157-1
88
BL
BK
RD
WH
BR
YL
YEL
DRIVE & STEERINGPJOYSTICK (JC3)
6 5 4
NOT USED P1-35 P1-34 VLVRET2-BR P1-33 P1-32 C148JBS-BL/WH P110JBS-BK P109JBS-GR/WH V147JBD-BL/BK V146JBU-BL
PLATFORM PTILT SENSORPASSEMBLY S132LDS-BL/WH
GND1-BR C158STC-BL/RD C160JPL-WH/RD C159STC-BL/WH VALVE RETURN P162JPW-OR JIB ELEVATED JSGND1-BR
ECU
VLVRET3-BL/BK
1 1 2 2 3 P16 P18 P17
GRN
OR
VLVRET2-BL VLVRET1-BK/WH
J37-DRIVE CHASSIS HARN
SEC BM UP/DWNPEXT/RET JOYSTICKP(JC5)
JIB SENSOR GROUND
P1-31 P1-30 P1-29 P1-28 P1-27 P1-26

J55
J147
J25 JSGND1-BR 16 JIB SENSOR POWER JSGND4-BR 15 JIB BELLCRANK LEVEL DOWN P162JPW-OR 14 JIB BELLCRANK LEVEL UP P162JPW-OR 13 NOT USED C165TRS-WH/RD 12 NOT USED 11 NOT USED 10 NOT USED C161SB-WH/BK 9 SAFE PL TILT PWR P87PTS-RD P87RET-BR P85PTS-GR C84TAY-GR/BK P85RET-BR C154JBR-BK/WH C56FTS-RD C64LS-OR/BK C88PTS-RD/BK P1-14 P1-13 P1-12 P1-11 PROX KILL CMD PROX KILL GND JIB RETRACT PLAT LEVEL DOWN PLAT LEVEL UP JIB DWN JIB UP PLAT ROT CCW ESTOP PWR-RD/BK 20 PWR-PCN ES ALARM PLAT ROT R PLAT ROT L GND JIB DN JIB UP GND GND BOOT! OUT PWR ENBL GND PLAT LVL DN 19 18 17 ESTOP PWR-RD
E-STOP (P2) OVERLOAD PLIMIT SWPLSP1OLS
JIB SENSOR SIGNAL
J149
WH
RD
S21 JIB BELLCRANK SENSOR
6 5 4
C161SB-WH/BK
GND2-BR
RD/BK RD
JIB BELLCRANK DOWN (J136) JIB BELLCRANK UP (J135)
3 2
JIB EXT/RET, UP/DOWNPPLAT ROT JOYSTICK (JC6)
P162JPW-OR C164PLS-RD/WH JSGND2-BR C163PES-BL/WH P1-24 P1-23 P1-22 P1-21 P1-20 P1-19 P1-18 P1-17 P1-16 P1-15 P1-25
1
J28
POWER FET
POWER FET
PRIMARY BOOM UP/DOWN,PEXT/RET AND TURNTABLEPROTATE JOYSTICK (JC7)
J119
LSP1PROXPPROXIMITYPKILL SWITCHP(NOHC)POPTIONAL
2
P6
P162JPW-OR 4 JIB NOT RETRACTED FOOT SW RTN JSGND3-BR 2 LIMIT SWITCH PWR 1 J7 C163PES-BL/WH C165TRS-WH/RD C164PLS-RD/WH P162JPW-OR JSGND4-BR LOAD SNSR PWR LOAD SNSR IN LOAD SNSR GND SAFE PL TILT OUT JSGND2-BR 3 JSGND3-BR P162JPW-OR
P162JPW-OR
1
J128
J84
C56FTS-RD C64LS-OR/BK
FOOTSW (FS1)
C154JBR-BK/WH
PL TILT SNSR GND
PLAT TILT SNSR
C156JUD-GR/WH 5
WH
22
14
6 5 4 3 2 1
J127
GND4-BR
P109LDS-BK C94LDS-WH P110LDS-GR C90PXS-RD/BK GR
BK WH RD
NO NC
Electrical Schematic Layout
P1-10 P1-09 P1-08 P1-07 P1-06 P1-05 P1-04 PLAT ROT CW JIB EXTEND VLV RTN P1-03 P1-02 P1-01
R90PXS-RD/BK V154JBR-BK/WH V15PLD-OR/BK V14PLU-OR V44JD-GR/BK V43JU-GR
10
OR/BK PLAT LEVEL DN (J81) PLAT LEVEL UP (J80) GR/BK

12
JIB RETRACT (J141)

D82CAN+ -YL D81CAN- -GR P21DCON-WH GNDDCON-BR S56PRV-RD C61AXRT-GR
JIB DWN (J79) GR

J147
JIB UP(J78) V17PRL-GR V18PRR-GR/BK V153JBE-BK VLVRET1-BR PLAT ROT CCW (J77) PLAT ROT CW (J76)
11
ALARM+ RD/BK
16 15 14 GND1-BR 13 12 11 ESTOP RET-BK 10 9 8 7 6 GND GND JIB EXT/RET 5 4 3 2 1 J8 GND2-BR PLAT LVL DN-OR/BK
PCON
OR
JIB EXTEND (J140)
PJ138
ESTOP RET-BK GND12-BR
SENSOR AXLE REAR C60AXEX-GR/WH PJ137 LSRA1ESP

NC NO
BR
22
21
RD
13
PLATFORM LEVEL
GND6-BR GND6-BR GND3-BR C157JER-BK/RD C156JUD-GR/WH GND4-BR C16PRL-OR/RD PLAT LVL UP-OR
WH
14
PLAT LVL DN-OR/BK PLAT LVL UP-OR
PLAT LVL UP
BK
SENSOR AXLE
FRONT
NC
22
PLAT ROT
WH
14
GND
J2-GR/BK
BK
NO
BR
21
JIB UP/DWN
RD
13
LSFA1ESP
D82CAN+ -YL
GND12-BR
BK
BL
RD AXLE NOT EXT PWR NOT USED REAR AXLE POSITION SENSOR FRONT AXLE POSITION SENSOR RS232 GND CAN + CAN NOT USED AXLE NOT EXT SIG NOT USED BOOT RS232 TXD RS232 RXD CAN SHIELD AXLE NOT RET RTN DIGIN AXLE RET GND NOT USED NOT USED P12 P_7R NOT USED P_6R1 DCON ECU PWR DCON ECU GND P1-23 P1-22 P1-21 P1-20 P1-19 P1-18 P1-17 P1-16 P1-15 P1-14 P1-13 P1-12 P1-11 P1-10 P1-09 P1-08 P1-07 P1-06 P1-05 P1-04
J31 23 PIN BLACKPDRIVE CHASSISPHARNESS
S16 REAR AXLE POS P61LSA-GR
C60RAP-GR/WH
BK
C60FAP-GR/WH
BL
RD D82CAN+ -YL D81CAN- -GR
S15 FRT AXLE POS
P21DCON-WH
GNDDCON-BR
PCON ALARM
S56PRV-RD
ALARM+ RD/BK
P53LS-WH/BK
D81CAN- -GR
C61AXRT-GR
C61AXRT-GR S56PRV-RD
C61AXRT-GR
P1-03 P1-02 P1-01
P53LS-WH/BK P21DCON-WH GND-DCON-BR
Y62-LF STEER LEFT (J98)

J32 23 PIN WHITEPDRIVE CHASSISPHARNESS
View 1
Y61-LF STEER RIGHT (J97) Y60-RF STEER LEFT (J96) Y59-RF STEER RIGHT (J95)
P_6R1 P_7R P12
Y58-LR STEER LEFT (J94) Y57-LR STEER RIGHT (J93) Y56-RR STEER LEFT (J92) Y55-RR STEER RIGHT (J91)
LF STEER LEFT LF STEER RIGHT RF STEER LEFT STEER SNSR PWR (5.0 VDC) STEER SNSR GND RF STEER RIGHT LR STEER LEFT LR STEER RIGHT BRAKE VALVE RTN2 LF STEER SNSR RF STEER SNSR LR STEER SNSR RR STEER SNSR RR STEER LEFT RR STEER RIGHT SPARE SPARE SPARE MOTOR SPEED AXLE EXTEND AXLE RETRACT VALVE RTN1
P32-23 P32-22 P32-21 P32-20 P32-19 P32-18 P32-17 P32-16 P32-15 P32-14 P32-13 P32-12 P32-11 P32-10 P32-09 P32-08 P32-07 P32-06
V37LFS-BL/BK V36LFS-BL V37RFS-BL/BK

B C
BK BL P109ANG-GR/WH P110RT-BK V36RFS-BL V37LRS-BL/BK V36LRS-BL

B C J110 A
RD
S14-LF STEER RIGHT
BK BL V32BRK-WH/RD VLVRET2-BRN C111LFS-OR C111RFS-OR C111LRS-OR

B C J109 A
RD
S13-RF STEER RIGHT
BK BL C111RRS-OR V37RRS-BL/BK V36RRS-BL BK

C J108 A
RD
S12-LR STEER RIGHT
BL
B
P32-05
J107
RD P32-04 P32-03 P32-02 P32-01 V29MS-RD/WH V60AXEX-GR/WH V61AXRT - GR VLVRET1-BR

A
S11-RR STEER RIGHT SNSR
View 7
Y2-BRAKE RELEASE (J106)
Y27-TWO SPEED MOTOR STROKE (J87) AXLE EXTEND AXLE RETRACT
6 - 18 1
N EN7
Z-135/70
J82
C60AXEX-GR/WHT
P53LS-WH/BK
PL TILT SNSR
4
C16PRL-OR/RD C158STC-BL/RD
BK
LSJ1RO
0-20 DEG Y AXIS
BR
JIB NOT
PL TILT SNSR PWR
21
13
SAFETY CUTOUT
RD
RETRACTED
NC
NO
5
C157JER-BK/RD C159STC-BL/WH
U20
SAFE PL TILT GND
10 DEG
6
C160JPL-WH/RD
GND3-BR 8
10 DEG
(RETRACTED POS)
BK WH/BK
BL BK
GR
88
P6R1
P18
P11
GR
WH
AC GENERATOR
6 3
3 BK
C56PTS-RD
BR
21
NO
13
RD
View 8
Part No. 106783
April 2008
OFF
OFF
OFF
OFF
OFF
GROUND
GROUND
GROUND
GROUND
GROUND
J17
P15
RUN
SERV BYPASS
RECOVERY
R117FB-RD
PR1
C35RPM-BK/RD AUX HYD PUMP
BAT+
AUX. PUMP
AUX+
GND-
14
BOOM UP/DWN FC RECOVERY SIGNAL
B1ENG-RD
PR1
SCROLL R AUX HYD PUMP
J13 WHITE 23 PIN
13
30
87a
WORKPLAMP
START
AUX HYDPBATTERY
OIL PRESSURE
BAT GND-BR
COLD START ADVANCE
BAT GND-BR
FUEL LIFT PUMP
CR2 RELAY BAT GND-BR
PRELAY GLOW PLUG
GLOW PLUG
DETAIL A CUMMINS ENGINE
J57
EXCT.
H1
BAT. -
STA.
IND.
RD
P_39 POWER TO TTROT FC P1-19
S139TRF-WH/RD
WH
TT_TILT_X_AXIS P1-20 HI/LO SPEEDP SOLENOID
PULL IN
SEC BM U/D FC VLV
P14-05
V12SUD-BL/WH
V12SUD-BL/WH
F.C. (J64)
TO AUX HYD BATTERYPNEG TERM (B2)
P14-09
V07PBE-BK V07PBE-BK
PRI EXT VLV (J62)
PRELAY
View 14
R21IGN-WH
BK
+
+ + -
+
+ + -
+
+ + -
P56PRV-RD S56PRV-RD SJ2-WH SJ2-WH/BK SJ3-WH P56PRV-RD
SJ3-WH
SJ3-WH
April 2008 REV B
Electrical Connector and Circuit Legend

M L K J I H G F E D C B A 1
Conn No. J9 J10 J11 J12 J13 J14 J15 J17 J20 J21 J22 J23 J24A J24B J25 J28 J29 J31 J32 J46 J49 J55 J57 J58 J59 J60 J61 J62 J63 J65 J66 J67 J68 J69 J70 J71 J78 J79 J82 J84 J87
Description Ribbon connector from TCON to membrane #1 Ribbon connector from TCON to membrane #2 Black 23 pin AMP connector on TCON Black 35 pin AMP connector on TCON White 23 pin AMP connector on TCON White 35 pin AMP connector on TCON Black 4 pin DTP connector on PCON 16 pin Molex mini fit circuit board to key switch 12 pin Deutsch connector lower/upper limit switch harness Black 23 pin AMP connector on PCON White 35 pin AMP connector on PCON 10 pin ribbon connector PCON to membrane driver board 10 pin ribbon conn. mem driver board to membrane switch 10 pin ribbon conn. mem driver board to membrane switch 6 pin Deutsch connector on drive/steer joystick 6 pin Deutsch connector on secondary boom up/extend and down/retract joystick 16 pin Molex mini fit circuit board to joystick and switches Black 23 pin AMP connector on DCON White 23 pin AMP connector on DCON 4 pin Deutsch connector on LSS1RS 4 pin Deutsch connector on sec boom retract (LSS1RO) 6 pin Deutsch connector on platform tilt sensor 3 pin Deutsch connector on RPM solenoid 2 pin Deutsch connector for pri boom up/down flow control 2 pin Deutsch connector for primary boom up valve 2 pin Deutsch connector for primary boom down valve 2 pin Deutsch connector for primary boom ext/ret flow control valve 2 pin Deutsch connector for primary boom extend valve 2 pin Deutsch connector for primary boom retract valve 2 pin Deutsch connector for secondary boom extend valve 2 pin Deutsch connector for secondary boom retract valve 2 pin Deutsch connector for secondary boom up valve 2 pin Deutsch connector for secondary boom down valve 2 pin Deutsch connector for turntable rotate flow control 2 pin Deutsch connector for turntable rotate CW valve 2 pin Deutsch connector for turntable rotate CCW valve 2 pin Deutsch connector for jib boom up valve 2 pin Deutsch connector for jib boom down valve 2 pin Deutsch connector for prox kill 2 pin Deutsch connector for platform footswitch 2 pin Deutsch connector for two-speed motor stroke valve
Conn No. Description 2 pin Deutsch connector for J91 right rear steer right valve J92 J93 J94 J95 J96 J97 J98 J99 J100 J106 J107 J108 J109 J110 J114 J119 J120 J121 J122 J124 J125 J126 2 pin Deutsch connector for right rear steer left valve 2 pin Deutsch connector for left rear steer right valve 2 pin Deutsch connector for left rear steer left valve 2 pin Deutsch connector for right front steer right valve 2 pin Deutsch connector for right front steer left valve 2 pin Deutsch connector for left front steer right valve 2 pin Deutsch connector for left front steer left valve 2 pin Deutsch connector for axle extend valve 2 pin Deutsch connector for axle retract valve 2 pin Deutsch connector for brake release valve 3 pin Deutsch connector for right rear steer sensor 3 pin Deutsch connector for left rear steer sensor 3 pin Deutsch connector for right front steer sensor 3 pin Deutsch connector for left front steer sensor 6 pin Deutsch connector for primary boom angle sensor (PBAS) 2 pin Deutsch connector for jib not retracted 4 pin Weatherpack EDC connection 12 pin Deutsch gray SCON connector 12 pin Deutsch black SCON connector 2 pin Deutsch connector for drive enable right limit switch (LST1O) 2 pin Deutsch connector for drive enable left limit switch (LST2O) 4 pin Deutsch connector for drive enable safety limit switch (LST1S)
Conn No. Description 6 pin Deutsch connector for primary boom J127 up/down, ext/ret and turntable joystick J128 J129 J135 J136 J137 J138 J140 J141 J146 J147 J148 J149 J150 J151 J152 J153 J154 J157 J160 J161 J162 J163 J164 6 pin Deutsch connector for jib boom up/down, ext/ret and platform rotate 2 pin Deutsch connector for boom composite/lower limit switch harness 2 pin Deutsch connector for jib boom bellcrank up 2 pin Deutsch connector for jib boom bellcrank down 2 pin Deutsch connector for front axle safety switch 2 pin Deutsch connector for rear axle safety switch 2 pin Deutsch connector for jib extend 2 pin Deutsch connector for jib retract 2 way Deutsch connector for lower limit switch harness/engine harness 1 way Deutsch connector for platform power jib/primary 1 way Deutsch connector for platform ground jib/primary 2 pin Deutsch connector, boom composite 4 pin Deutsch connector, boom composite 3 pin Deutsch connector, CAN connector, jib/primary 3 pin SAE Deutsch tee 2 pin Deutsch connector for engine and manifold harness 6 pin Deutsch connector for secondary boom angle sensor 2 pin Deutsch connector for PCON manifold/boom composite harness 4 pin Deutsch connector for front axle angle sensor 4 pin Deutsch connector for rear axle angle sensor 3 pin Deutsch connector for jib bellcrank angle sensor 2 pin Deutsch connector for secondary boom up/down flow control 2 pin Deutsch connector for secondary boom extend/retract flow control
Conn No. Description 12 pin Deutsch connector located at PCON J165 J166 J168 J169 J175 6 pin Deutsch connector for jib bellcrank sensor 1 way 0.25 inch slide terminal for belt generator excite 20 pin Molex connector for circuit board to joystick and switches #2 2 pin Deutsch connector
Part No. 106783
Z-135/70
6 - 19
April 2008
Electrical Connector and Circuit Legend
6 - 19
6 - 20
April 2008
Electrical Schematic - View 1

Drive Chassis Controller (DCON)
6 - 21
6 - 22
REV B
DCON EN7
Continued on View 2
AXLE NOT EXT PWR P1-23 P1-22 P1-21 P1-20 P1-19 P1-18 P1-17 P1-16 P1-15 P1-14 P1-13 P1-12 P1-11 P1-10 P1-09 P1-08 P1-07 P1-06 P1-05 P1-04 P1-03 P1-02 P1-01 GND-DCON-BR P21DCN-WH P53LS-WH/BK S56PRV-RD C61AXRT-GR D81CAN- -GR D82CAN+ -YL C60FAP-GR/WH C60RAP-GR/WH P61LSA-GR NOT USED REAR AXLE POSITION SENSOR FRONT AXLE POSITION SENSOR RS232 GND CAN + CAN NOT USED AXLE NOT EXT SIG NOT USED BOOT RS232 TXD RS232 RXD CAN SHIELD AXLE NOT RET RTN DIGIN AXLE RET GND NOT USED NOT USED
P12 P_7R NOT USED P_6R1 DCON ECU PWR
DCON ECU GND
J31 23 PIN BLACK DRIVE CHASSIS HARNESS
LF STEER LEFT
J32 23 PIN WHITE DRIVE CHASSIS HARNESS
P32-23 LF STEER RIGHT RF STEER LEFT P32-22 P32-21
V37LFS-BL/BK V36LFS-BL V37RFS-BL/BK
Continued on View 7
P_6R1 P_7R
P12
STEER SNSR PWR (5.0 VDC)
P32-20 STEER SNSR GND RF STEER RIGHT LR STEER LEFT LR STEER RIGHT BRAKE P32-19 P32-18 P32-17 P32-16 P32-15 VALVE RTN2 LF STEER SNSR RF STEER SNSR LR STEER SNSR RR STEER SNSR P32-14 P32-13 P32-12 P32-11 P32-10 RR STEER LEFT P32-09 RR STEER RIGHT SPARE SPARE P32-08 P32-07 P32-06 SPARE MOTOR SPEED AXLE EXTEND AXLE RETRACT VALVE RTN1 P32-05 P32-04 P32-03 P32-02 P32-01
P109ANG-GR/WH P110RT-BK V36RFS-BL V37LRS-BL/BK V36LRS-BL V32BRK-WH/RD VLVRET2-BRN C111LFS-OR C111RFS-OR C111LRS-OR C111RRS-OR
Drive Chassis Controller (DCON)
V36RRS-BL
V29MS-RD/WH V60AXEX-GR/WH V61AXRT - GR VLVRET1-BR
6 - 22 1 2 3 4 5 6 7 8
Z-135/70
V37RRS-BL/BK
Part No. 106783
April 2008

Platform Controls (PCON)
Continued on View 3
10 P2
FUEL TYPE 9 P2
SPARE 2 8 P2 PWR-PCON ESTOP COORD STEER 7 P2 NOT USED CRAB STEER 6 P2 NOT USED P21-19 P21-18 P21-17 P21-16 P21-15 P21-14 P21-13 P21-12 P21-11 P21-10 P21-09 P21-08 P21-07 P21-06 P21-05 P21-04 S56PRV-RD P21-03 P21-02 P52PCON-WH GNDPCON-BR P21-01
J21 23 PIN BLACK BOOM HARNESS
P21-23 P21-22 P21-21 P21-20
P23PCON-BK
NOT USED
NOT USED
REAR STEER 5 P2 CAN L D81CAN-GR C46HN-WH C47OUT-WT/BK

MEMBRANE/LED INTERFACE CARD
CAN H D82CAN+ -YL
FRONT STEER 4 P2 OUT PWR ENBL NOT USED BOOT NOT USED NOT USED CAN SHIELD 10 NOT USED 9 NOT USED 10
Vbb BTS621 IN1 OUT 1 IN2 OUT 2 ST J24A 10PIN BTS650
HRN RLY CNTRL
TO TERM #86 CR45 WORK LIGHT RELAY
DRIVE SPEED 3 P2
AXLE EXTEND 2
J24B 10PIN
P2
ENGINE SPEED 1 P2
8 7
OUT U21
U22
P1 P_22 NOT USED NOT USED P_7 P56PRV-RD/WH
P7R
Vbb
IN
5 SPARE 1 8 P1 NOT USED 3 PCON PWR P1 PCON GND 1

J23 10PIN
DRIVE ENABLE 7
START 6 P1
START ASSIST 5 P1
IS
P1
GND
P6
AXLE RETRACT 9
AUXILIARY 4 P1
74HC08
74HC08
P1
AC GENERATOR 3
HORN
4 5 1
2 P1
2
1 P1
DRIVE JOYSTICK WITH STEER ROCKER SWITCH (JC3)
6 5
P6
GND1-BR
C158STC-BL/RD
P22
4
J22 35 PIN WHITE MANIFOLDPHARNESS
C160JPL-WH/RD C159STC-BL/WH P162JPW-OR JSGND1-BR
3 2 1
J25
6
DUAL AXIS DRIVE AND STEER JOYSTICK (JC3)
GND1-BR
ECU
NOT USED VALVE RETURN JIB ELEVATED JIB SENSOR SIGNAL JIB SENSOR GROUND JIB SENSOR POWER JIB BELLCRANK LEVEL DOWN JSGND1-BR 16 15 14 13 12 11 10 9 8 7
P6
P1-35 P1-34 P1-33 P1-32 P1-31 P1-30 P1-29 C148JBS-BL/WH P110JBS-BK P109JBS-GR/WH V147JBD-BL/BK VLVRET2-BR
5 4 3
C159STC-BL/WH P162JPW-OR JSGND1-BR C160JPL-WH/RD
C158STC-BL/RD
2 1
J25
SECONDARY BOOM UP/DOWN AND EXTEND/RETRACT JOYSTICK (JC5)
6
JSGND4-BR
GND2-BR
JIB BELLCRANK LEVEL UP NOT USED NOT USED NOT USED NOT USED SAFE PL TILT PWR
P1-28 P1-27 P1-26 P1-25 P1-24 P1-23
5
P162JPW-OR
4
P162JPW-OR
C161SB-WH/BK
3
C165TRS-WH/RD
2
C164PLS-RD/WH JSGND2-BR C163PES-BL/WH C161SB-WH/BK
P162JPW-OR
1
J28
U20
SAFE PL TILT GND PL TILT SNSR PWR PL TILT SNSR PL TILT SNSR GND JIB NOT RETRACTED FOOT SW RTN LIMIT SWITCH PWR SAFE PL TILT OUT LOAD SNSR PWR LOAD SNSR IN
P1-22 P1-21 P1-20 P1-19 P1-18 P1-17 P1-16 P1-15 P1-14 P1-13 LOAD SNSR GND PROX KILL CMD P1-12 P1-11 P1-10 JIB RETRACT PLAT LEVEL DOWN PLAT LEVEL UP JIB DWN JIB UP PLAT ROT CCW P1-09 P1-08 P1-07 P1-06 P1-05 P1-04
JIB BOOM EXTEND/RETRACT, UP/DOWN AND PLATFORM ROTATE JOYSTICK (JC6)
6
C160JPL-WH/RD C159STC-BL/WH C158STC-BL/RD 5 P162JPW-OR 4 3 2 1
J29
GND3-BR
5 4 3 2 1
J128
C157JER-BK/RD C16PRL-OR/RD 6 C156JUD-GR/WH P162JPW-OR JSGND3-BR JSGND3-BR JSGND2-BR P162JPW-OR
PRIMARY BOOM UP/DOWN, EXTEND/RETRACT AND TURNTABLE ROTATE JOYSTICK (JC7)
6 5 4 3 2 1
J127
GND4-BR
C163PES-BL/WH C165TRS-WH/RD C164PLS-RD/WH P162JPW-OR JSGND4-BR
ESTOP PWR-RD ALARM+ RD/BK
20 19 18 17
PWR-PCN ES ALARM PLAT ROT R PLAT ROT L 16 15 14

GND1-BR
PLAT ROT CW JIB EXTEND VLV RTN
P1-03 P1-02 P1-01
ESTOP PWR-RD
PCON EMERGENCY STOP BUTTON (P2)
GND JIB DN JIB UP 13 GND12-BR 12 11 ESTOP RET-BK

GND2-BR
GND GND BOOT! 10 9 PLAT LVL DN-OR/BK 8 PLAT LVL UP-OR GND6-BR
GND3-BR C157JER-BK/RD C156JUD-GR/WH GND4-BR
ESTOP RET-BK
OUT PWR ENBL GND PLAT LVL DN 7 6 5 4 3 2

C16PRL-OR/RD
PLATFORM LEVEL
PLAT LVL DN-OR/BK GND6-BR PLAT LVL UP-OR
PLAT LVL UP GND GND JIB EXT/RET JIB UP/DWN GND 1

J169
REV D
PLAT ROT
PCON ALARM
ALARM+ RD/BK GND12-BR
Continued on View 1
Continued on View 8
PCON MEMBRANE PANEL (MS1)
SLP_MODE
P7R
P7
ON CIRCUIT BOARD DB9 CONNECTOR
V146JBU-BL
P87PTS-RD P87RET-BR P85PTS-GR C84TAY-GR/BK P85RET-BR C154JBR-BK/WH C56FTS-RD C64LS-OR/BK C88PTS-RD/BK P109LDS-BK C94LDS-WH P110LDS-GR C90PXS-RD/BK R90PXS-RD/BK V154JBR-BK/WH V15PLD-OR/BK V14PLU-OR V44JD-GR/BK V43JU-GR V17PRL-GR V18PRR-GR/BK V153JBE-BK VLVRET1-BR
Part No. 106783
April 2008
PIN CKT # 2 RS232_RXD 3 RS232_TXD 5 RS232_GND
Z-135/70
6 - 23
April 2008

Platform Controls (PCON)
6 - 23
6 - 24
April 2008

Ground Controls (TCON)
6 - 25
6 - 26
April 2008 REV C

A 1
KEY SWITCH NC ESTOP
PANEL PANEL
RECOVERY
C
RUN SERVICE BYPASS 2
E
BL/WH OFF
U
1
GROUND 2 PLAT
C
1
NC A
C NC B 1
NC D NC E 2
4
EMERGENCY STOP BUTTON OFF
X
3
NC
1 2
GROUND 2 PLAT
E
1
G-P MODE GR/BK
LOCKOUT VALVE #1 SIG PRI BOOM LENGTH 3' STATUS PRI BOOM LENGTH 100' STATUS PRI BOOM RETRACTED STATUS AUXILIARY HYD RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL
OFF
2
RECOVERY 1 V 2 NC 2 NC 4 3 NO X Y 3 NO Z 3 NO
P_15-OR/BK P_7 PLAT-GR/WH C47OUT WH/BK
Y
4 3
GROUND 2 PLAT
D
1
P23PCON-BK
OFF
Z
4 3
1 U 2 NC PANEL
GROUND 2 PLAT
A
1
WH/BK
BOOM RET RECOVERY SIGNAL BOOM DWN RECOVERY SIGNAL BOOM EXT/RET FC RECOVERY SIGNAL BOOM UP/DWN FC RECOVERY SIGNAL
1 W
OFF
W
4
TCON MODE
GROUND 2 PLAT
B
1
(P15)+(ECU POWER)
C47OUT WH/BK
V
2 1
TO HORN BUTTON
ALM PWR-BL
ALM-GND-BR
PWR TO TCON ESTOP P_22
BL/BK
4
C47OUT WH/BK C47OUT WH/BK S56PRV-RD/BK P53LS-BK/WH
INSTALL WIRE JUMPER TO CALIBRATE SENSORS
OUT PWR ENABLE
AUX HYD O
BM 3' I
PRI BM RET ST I
BM 100' I
BM U/D FC O
BM E/R FC O
BM RET O
MLT FNC VLV O
BM DWN O
PRI LO#1 O
Continued on View 2
16 ALARM GND
SRV REC-WH
P23PCON-BK
P56PRV-RD
GR/WH
RD/WH 14 TCON MODE 13 P11
OR/BK
Continued on View 4
PLD
BL 15 ALARM PWR
12 P7-GN/WH
11 OPER. REC.
9 SERV. OR OPER. REC.
10 P22
J17
ECU POWER
SERV/CAL MODE
TCON ESTOP-BL/WH
PCON MODE
PWR TO TCON ESTOP-BL/BK
OUTPUT PWR ENABLE
P7R
P6R1
ON CIRCUIT BOARD DB9 CONNECTOR
SERVICE OR RECOVERY MODE
PIN CKT # 2 RS232_RXD 3 RS232_TXD 5 RS232_GND
P15
P15
P15 ECU POWER TCON MODE
6
TO HORN BUTTON PWR TO TCON ESTOP
TO MICRO
P_7 P7R
PCON POWER
OUT PWR ENABLE TCON MODE P_7 P6R1 P11
7
U30
P_22 P7R PCON POWER P6R1 P11
FLASHING BEACON RLY
CAN SHIELD (1939-11)
TETHER FUNC ENBL
DIAG/TETHER PWR
DIAG/TETHER GND
PWR-PCON ESTOP
HORN RELAY COIL
SERV/CAL MODE
TET ESTOP PWR
TCON
J11 BLACK 23 PIN BOOM HARNESS
TET ESTOP RET
OUT PWR ENBL
PCON POWER
CAL FREQ 2
CAL FREQ 1
PCON GND
NOT USED
NOT USED
NOT USED
CAN HIGH
CAN LOW
SPARE
P_22
P_7
P11-10
P11-12
P11-13
P11-15
P11-17
P11-18
P11-02 P52PCON-WH
P11-03
P11-05
P11-07
P11-08
P11-20
P11-22
P11-23
P11-11
P11-01 GNDPCON-BR
P11-21
P11-16
P11-19
P11-14
P11-06
P11-09
P11-04 C47OUT-WH/BK
Continued on View 9
R117FB-RD
C46HN-WH
P23PCON-BK
D81CAN- -GR
P56PRV-RD/WH
C145CAL-RD/WH
S56PRV-RD
D82CAN+ -YL
6 - 26
Z-135/70
Part No. 106783
April 2008 REV B

LOCKOUT VALVE #1 SIG PRI BOOM LENGTH 3' STATUS PRI BOOM LENGTH 100' STATUS PRI BOOM RETRACTED STATUS AUXILIARY HYD RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL BOOM RET RECOVERY SIGNAL BOOM DWN RECOVERY SIGNAL BOOM EXT/RET FC RECOVERY SIGNAL BOOM UP/DWN FC RECOVERY SIGNAL AUXILIARY HYD RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL BOOM RET RECOVERY SIGNAL BOOM DWN RECOVERY SIGNAL BOOM EXT/RET FC RECOVERY SIGNAL BOOM UP/DWN FC RECOVERY SIGNAL
(P15)+(ECU POWER)
(P15)+(ECU POWER) P_30
TO HORN BUTTON
TO HORN BUTTON
PWR TO TCON ESTOP P_22 P_22 P_9B OUT PWR ENABLE OUT PWR ENABLE
PWR TO TCON ESTOP P_22 P_9B OUT PWR ENABLE P_6R2
Continued on View 3
Continued on View 5
BOOM STOWED TCON MODE P_7 P7R TCON MODE P_7 P7R P10 TCON MODE P_7 P_7R P_10
PCON POWER
PCON POWER
PCON POWER
P9A P6R1 P11 P6R1 P11
P_9A P_6R1 P_11
TO MICRO
TO MICRO
TO MICRO
TO MICRO
TO PLD
TO PLD
TO PLD
TO MICRO
U30
U31
U32
TO PLD
7
LST20 DR ENBL L SEC ANG INPUT
FST1S-LOW FUEL
LST10 DR ENBL R
DCON ECU PWR
DCON ECU GND
BOOM STOWED
PRI ANG INPUT
OPER SW PWR
PRESSURE GA
Continued on View 10
J12 BLACK 35 PIN LIMIT SWITCH HARNESS
SNSR PWR
SNSR GND
LSB13AO
LSB14AO
VLV RET
. LSB2RO
LSS1RO
LSP1RO
LSP1EO
LSP1AO
LSS2EO
LSS2AO
P2 SEQ
P1 SEQ
P_6R2
P_6R1
P_7R
P_9A
P_9B
P_14
P_18
P_30
P_10
P_12
P_11
P12-01 GNDDCON-BR
P12-21
P12-31
P12-16
P12-19
P12-14
P12-06
P12-09
P12-26
P12-29
P12-04
P12-24
P12-34
P12-10
P12-12
P12-13
P12-15
P12-17
P12-18
P12-02 P21DCON-WH
P12-03 P53LS-WH/BK
P12-05 S56PRV-RD
P12-07 P58LS RD/BK
P12-08
P12-20
P12-22
P12-23
P12-25
P12-27
P12-28
P12-30
P12-32
P12-33
P12-35
P12-11
C123PBS-RD/BK
SNSR GND-BR
C70PBR-BL/WH
C64LS-OR/BK
P53LS-WH/BK
C143DEL-BL/RD
S140ENL-OR/RD
C65LOF-BL/WH
C124SBS-OR/BK
S59CNBK-GR/WH
C144DER-BL/WH
P54ENG-BK/WH
C67SBD-BL
C61AXR-GR
S140ENL-OR/RD
P109PSR-GR/WH
C73SBR-BL/RD
C64LS-OR/BK
C71PBE-BL/BK
Part No. 106783
Z-135/70
6 - 27
April 2008

6 - 27
6 - 28
April 2008

6 - 29
6 - 30
April 2008 REV A

A 1
AUXILIARY HYD RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL BOOM RET RECOVERY SIGNAL BOOM DWN RECOVERY SIGNAL BOOM EXT/RET FC RECOVERY SIGNAL BOOM UP/DWN FC RECOVERY SIGNAL
2
(P15)+(ECU POWER) P_30 TO HORN BUTTON AUXILIARY HYD RECOVERY SIGNAL (P15)+(ECU POWER)
U95
PWR TO TCON ESTOP
MULTI FUNCTION VLV RECOVERY SIGNAL BOOM RET RECOVERY SIGNAL
P_22
P_22
BOOM DWN RECOVERY SIGNAL BOOM EXT/RET FC RECOVERY SIGNAL
P_9B OUT PWR ENABLE P_6R2 Vbb IN1 IN2 ST GND BTS621 OUT 1 OUT 2 P_22R ((~SM)+(AH))(P_22) BTS650 Vbb OUT IN
8 9 10 14 12
OUT PWR ENABLE (OE) (SM)+(AH)
TO MICRO
BOOM UP/DWN FC RECOVERY SIGNAL P_30
P22R
P22R P_22R P7R P10
P_6R2
Vbb IN1 IN2 ST GND
BTS621 OUT 1 OUT 2
P_7R
74HC08 13
P7R
P_10
IS (~SM)+(AH) (BM STOWED) Vbb OUT IN IS P_6R2 BTS650 Vbb OUT IN IS ((~SM)+(AH))(OE) Vbb IN1 IN2 BTS621 OUT 1 OUT 2 (TM)(FE) BTS650 ((~SM)+(AH))(P_7)
9 8 10
((~SM)+(AH))(BM STOWED)
P_7
TO HORN BUTTON
(P15)+(ECU POWER)
74HC08
74HC08
(SM)+(AH)
P_7
P_7R
P_7R
P_10
P_39 P_39
4 5 74HC08
(OE)
4
(~SM)+(AH)
5
~SLP MODE (~SM) AUX HYD (AH)
5
BOOM STOWED TCON MODE P_7 P_7R P_10 U32
P_6R1
ST GND
74HC08
FUNC ENABLE (FE)
P_7
74HC08
TCON MODE(TM) P_7 P_7R P_10 P9A P6R1 P11
TO MICRO
14 PCON POWER 5V 12V GND

7
TO MICRO
TO MICRO
6
P_9A P_6R1 P_11
P_1
TO MICRO
CB 20A
Continued on View 6
TO MICRO TO MICRO TO MICRO
Continued on View 4
CHOKE/GLOW PLUG RELAY
P_39 POWER TO TTROT FC
P_38 PWR TO PROPEL
TT_TILT_SNSR_PWR
TT_TILT_SNSR_GND
ALTERNATOR RPM
OIL/WATER_TEMP
STARTER RELAY
AC GENERATOR
TT_TILT_Y_AXIS
TT_TILT_X_AXIS
OIL_PRESSURE
SYS_BAT_PWR P1-01
J15 BLACK 4 PIN POWER HARNESS
SERVICE HRN
SYS BAT GND P1-02
VALVE RTN#3
VALVE RTN#2
BATECU GND P1-03 P1-04

J13 WHITE 23 PIN ENGINE HARNESS
VALVE RTN#1 P1-01
THROTTLE P1-02
FWD PWM
REV PWM
EDC FWD
IGN/FUEL P1-03
EDC REV
LP P1-08
P1-19
P1-04
P1-06
P1-07
P1-10
P1-11
P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-20
P1-21
P1-22
P1-23
P1-09
P1-05
8
C45GEN-GR/WH S139TRF-WH/RD S137PLL-RD/WH GND-BR GND-BR B1BAT-RD C35RPM-BK/RD C41RPM-OR/BK C26TSR-WH/RD C25PSR-WH/BK C31EDC-WH/BK C30EDC-WH C33STR-BK C46HRN-WH C34SA-BK/WH C21IGN-WH
6 - 30
Z-135/70
Part No. 106783
1
TO MICRO
TCON MEMBRANE PANEL
HYD WELDER PROPEL BYPASS P14-35 P14-34 P14-33 P14-32 P14-31 C27AUX-RD V155PSE-OR/RD PRESS COMP ENABLE VLV
V150HG GR/BK
2
TO MICRO SPARE AUX_RELAY
BOOM CW
PLTFRM CW
4
TO MICRO VALVE_RTN6 P14-29 PROPEL POWER INPUT P14-28 P14-27 P14-26 P14-25 P14-24 P14-23 V04TRL-WH V05TRR-WH/BK VLVRET7-BR VALVE_RTN7 P14-30 VLVRET6-BR TO PLD JIB DOWN
PLTFRM DOWN
6
TO MICRO ROTATE_CCW_VLV ROTATE_CW_VLV
PLTFRM UP
7
TO MICRO MULTI_FUNCT_VLV UNUSED
JIB UP
TO MICRO
PLTFRM CCW TO MICRO
SEC_EXT_VLV SEC_RET_VLV SEC_UP_VLV P14-19 P14-18 VLVRET5-BR VLVRET5-BR P14-17 P14-16 P14-15 P14-14 VLVRET5-BR C49LP - WH/BK V11SBD-BL/BK P14-13 P14-12 P14-11 P14-10 P14-09 P14-08 P14-07 P14-06 P14-05 P14-04 P14-03 P14-02 P14-01 VLVRET4-BR V03PUD-RD/WH V09PER-BK/RD V06TRF-WH/RD V12SUD-BL/WH V176SER-GR/WH V01PBU-RD V02PBD-RD/BK V07PBE-BK V08PBR-BK/WH V10SBU-BL P14-20 V73SBR-GR/BK
P14-21 V72SBE-GR
9
TO PLD
BOOM CCW
10
BOOM OVERLOAD DI BOOM REVERSE LOAD DI
TO MICRO
TURTLE
11
HYD_FILTER2 DI TO MICRO SEC. DOWN
P_30
TO PLD
HYD_FILTER1 DI
12
TO MICRO DRIVE LIGHT RELAY VALVE_RTN5
TO MICRO
RABBIT
13
SEC_DWN_VLV TO PLD UNUSED PRI_RET_VALVE PRI_EXTEND_VLV BOOM EXT
14
TO MICRO BOOM DOWN
15
TO MICRO PRI_DOWN_VLV PRI_UP_VLV TO MICRO SEC BM U/D FC VLV SEC BM E/R FC VLV
J9
BOOM RET
P9
TO MICRO PRI BM U/D FC VLV
TO MICRO
PRI BM E/R FC VLV
April 2008
1
TO MICRO
VALVE_RTN4
TO PLD
TO MICRO TO PLD
BOOM UP
SEC. UP
AUXILIARY
ENG SPEED
GAS/LP
10
+ BUTTON
11
- BUTTON
12
SCRL F/ENT
13
SCROLL R
14
MULTI FUNCTION VLV RECOVERY SIGNAL BOOM EXT/RET FC RECOVERY SIGNAL BOOM UP/DWN FC RECOVERY SIGNAL
15
P10
STRT ASST
J10
START
REV C
Continued on View 5
P_22R
P6R1
P_30
P_39
P7R
P9A
P10
P11
Part No. 106783
TT ROT FC VLV
J14 WHITE 35 PIN MANIFOLD HARNESS
Z-135/70
8
TO MICRO UNUSED P14-22
6 - 31
April 2008

6 - 31
6 - 32
April 2008
6 - 33
6 - 34
REV B
Continued on View 1
Continued on View 8
C60AXE-GR/WH
21
RD
NC NO
13
BR
22 14
C60AXE-GR/WH
J2-GR/BK
WH
BK
LSRA1ES REAR AXLE SAFETY SWITCH J138
21
RD
NC NO
13
BR
22 14
J2-GR/BK
P61LSA-GR
WH
BK
LSFA1ES FRONT AXLE SAFETY SWITCH J137
GNDDCON-BR
P21DCON-WH
D82CAN+ -YL
D81CAN- -GR
BK
BL
RSRA10 REAR AXLE SENSOR J161
RD P1-23 P1-22 P1-21 BK C60RAP-GR/WH P61LSA-GR
P1-20 C60FAP-GR/WH P1-19 RD D82CAN+ -YL D81CAN- -GR P1-18 P1-17 P1-16 P1-15 P1-14 P1-13
BL
RSFA10 FRONT AXLE SENSOR J160
P1-12 P1-11 P1-10 P1-09 P1-08 P1-07 P1-06 C61AXRT-GR S56PRV-RD P1-05 C61AXRT-GR
P1-04 P1-03 P53LS-WH/BK P21DCN-WH GND-DCN-BR
P53LS-WH/BK
C61AXR-GR
S56PRV-RD
P1-02 P1-01
J31 23 PIN BLACK DRIVE CHASSIS HARNESS
Y62-LF STEER LEFT (J98)

1 2
Y61-LF STEER RIGHT (J97)

1 2
Y60-RF STEER LEFT (J96)

1 2
Y59-RF STEER RIGHT (J95)

1 2
J32 23 PIN WHITE DRIVE CHASSIS HARNESS
Y58-LR STEER LEFT (J94)

1 2
Y57-LR STEER RIGHT (J93)

1 2
Y56-RR STEER LEFT (J92) Y55-RR STEER RIGHT (J91)

1 2
P32-23 P32-22 V36LFS-BL V37RFS-BL/BK P109ANG-GR/WH P110RT-BK V36RFS-BL V37LRS-BL/BK V36LRS-BL V32BRK-WH/RD VLVRET2-BRN C111LFS-OR C111RFS-OR C111LRS-OR C111RRS-OR V37RRS-BL/BK V36RRS-BL P32-21 P32-20 P32-19 P32-18 P32-17
V37LFS-BL/BK BK
C
BL RD
J110 A
S14-LF STEER RIGHT
P32-16 P32-15
BK BL
P32-14 P32-13 P32-12 P32-11 P32-10 P32-09
BK BL
B
RD
J108 A
S12-LR STEER RIGHT
P32-08 P32-07 P32-06 P32-05 P32-04 P32-03 P32-02
BK BL
B
RD V29MS-RD/WH V60AXEX-GR/WH V61AXRT - GR

1 2 J107 A
S11-RR STEER RIGHT SNSR
Y2-BRAKE RELEASE (J106) P32-01 VLVRET1-BR

1 2
Y27-TWO SPEED MOTOR STROKE (J87)

1 2
AXLE EXTEND AXLE RETRACT

1 2
6 - 34 1 2 3 4 5 6 7 8
Z-135/70
J109 A
RD
S13-RF STEER RIGHT
Part No. 106783

1 2
April 2008
April 2008 REV D

WORK LIGHT ON/OFF TOGGLE SWITCH
V18PRR-GR/BK P23PCN-BK C64LS-OR/BK V17PRL-GR P110JBS-BK P110LDS-GR D82CAN+ -YL V15PLD-OR/BK P85RET-BR P56PRV-RD/WH C148JBS-BL/WH P52PCN-WH C90PXS-RD/BK P85PTS-GR P87PTS-RD D81CAN-GR VLVRET2-BR C94LDS-WH C46HN-WH V43JU-GR V154JBR-BK/WH V44JD-GR/BK V153JBE-BK V14PLU-OR V147JBD-BL/BK C56FTS-RD C154JBR-BK/WH P109LDS-BK V146JBU-BL P109JBS-GR/WH P87RET-BR GNDPCN-BR C84TAY-GR/BK VLVRET1-BR C47OUT-WT/BK C88PTS-RD/BK S56PRV-RD
J22 35 PIN WHITE PCON MANIFOLD HARNESS
J21 23 PIN BLACK BOOM HARNESS
P21-10
P21-12
P21-17
P21-18
P21-13
P21-15
P21-22
P21-03
P21-05
P21-07
P21-08
P21-20
P21-23
P21-02
P21-11
P21-01
P21-21
P21-19
P21-16
P21-14
P21-09
P21-06
P21-04
P1-04
P1-24
P1-34
P1-18
P1-12
P1-10
P1-13
P1-15
P1-17
P1-25
P1-27
P1-28
P1-30
P1-02
P1-03
P1-07
P1-08
P1-20
P1-22
P1-23
P1-32
P1-33
P1-35
P1-05
P1-11
P1-21
J82
Continued on View 7
9
OR JIB EXTEND (J140)
P1-01
P1-31
P1-19
P1-16
P1-14
P1-26
P1-06
P1-29
P1-09
Continued on View 2
J157-1 S132LDS-BL/WH
P48LPS-WH/RD
30 87a 87
86 85
CR45 WORK LIGHT RELAY
S132LDS-BL/WH
S132LDS-BL/WH
2
WORKPLAMP
GR
OVERLOAD LIMIT SWITCH LSP1OLS
BK WH RD
1
NO
J55
J148A-1
J147A-1
J150A-4
J150A-2
J151A-B
J151A-A
J151A-C
J150A-1
J149A-1
J150A-3
J149A-2
NC
J156
J155
GND-BR
PLAT TILT SNSR
0-20 DEG Y AXIS
POWER FET
SAFETY CUTOUT
10 DEG
C154JBR-BK/WH
PLAT ROT CCW (J77)

11 12
PLAT LEVEL UP (J80)
PLAT ROT CW (J76)
PLAT LEVEL DN (J81)

R90PXS-RD/BK
C64LS-OR/BK
Continued on View 9
J147
C56FTS-RD
POWER FET
J147
PLATFORM TILT SENSOR ASSEMBLY J119 J84
10 DEG
10
J82
GND-BR P20BAT-RD
J156 J155
4
S56PRV-RD P56PRV-RD/WH C46HN-WH P23PCON-BK C47OUT-WH/BK S132LDS-BL/WH
C23PTS-WH
C56PTS-RD
VLVRET2-BL
VLVRET3-BL/BK
VLVRET1-BR
YL/BK
RD
RD/BK
1 1
2
2
BR BK RD
BR/BK
OR/BK
PLATFORM LEVEL RECOVERY SWITCH (ANSI/CSA ONLY)
YL
GR/BK JIB DWN (J79)
GR JIB UP(J78)
WH
LSP1PROX PROXIMITY KILL SWITCH (NOHC) OPTIONAL
FOOTSWITCH (FS1) 22 21 NC 14 13 NO
J165 1 2 3
S56PRV-RD P56PRV-RD/WH C46HN-WH P23PCON-BK C47OUT-WH/BK S132LDS-BL/WH
J149B-1 J149B-2 J150B-3 J150B-1 J150B-2 J150B-4
OPTIONAL SWING GATE WIRING
BL
RD
BK
LSJ1RO JIB NOT RETRACTED (RETRACTED POS)
WH
22
BR
BK
21 NC
RD
FOOTSWITCH GNDPCON-BR P52PCON-WH J148B-1 J147B-1 GNDPCON-BR P52PCON-WH
JIB BELLCRANK DOWN (J136)
JIB BELLCRANK UP (J135)
JIB RETRACT (J141)

D82CAN+ -YL D81CAN- -GR S56PRV-RD GNDDCON-BR P21DCON-WH C61AXR-GR C60AXE-GR/WHT P53LS-WH/BK
S21 JIB BELLCRANK SENSOR
14
13 NO
SWING GATE INTERLOCK
J151B-A J151B-B J151B-C
SLIP RING
J36-DRIVE CHASSIS HARNESS
A B C P16 A B C YEL GRN
88 88 88
J33-BOOM HARNESS
CAN HIGH CAN LOW YEL GRN A B C A B C D82CAN+ -YL D81CAN- -GR D82CAN+ -YL D81CAN- -GR
7
J34-LIMIT SWITCH HARNESS
88 88

1 2
P18 1 2 WH BK P7R DCON GND WH BK 1 2 1 2
S56PRV-RD GNDDCON-BR
S56PRV-RD GNDDCON-BR
SLIP RING
1 2 3 4 5 6 P17 1 2 3 4 5 6 RD OR BR BL YL GR
88 88 88 88 88 88
J35-LIMIT SWITCH HARNESS

DCON PWR P9A P12 P18 P11 P6R1 RD OR BR BL YL GR 1 2 3 4 5 6 1 2 3 4 5 6 P21DCON-WH P21DCON-WH
C61AXR-GR
C61AXRT-GR
C60AXE-GR/WH P53LS-WH/BK
C60AXEX-GR/WHT P53LS-WH/BK
Part No. 106783
Z-135/70
6 - 35
April 2008
6 - 35
6 - 36
April 2008
6 - 37
6 - 38
April 2008 REV B

A 1 B C D E F G H I J K L M
TCON
P11-10 P11-12 P11-13 P11-15 P11-17 P11-18 P11-02 P52PCON-WH P11-03 P11-05 P11-07 P11-08 P11-20 P11-22 P11-23 P11-11 P11-01 GNDPCON-BR P11-21 P11-16 P11-19 P11-14 P11-06 P11-09 P11-04 C47OUT-WH/BK
J11 BLACK 23 PIN BOOM HARNESS
R117FB-RD
C46HN-WH
P23PCON-BK
D81CAN- -GR
P56PRV-RD/WH
C145CAL-RD/WH
S56PRV-RD
D82CAN+ -YL
Continued on View 3
J147C-1
J148C-1
TO FLASHING BEACON P117FB-RD R117FB-RD R117FB-RD
87a 87 86 30 85 GND-BR
3
TO HYDRAULIC GENERATOR/WELDER OPTION
S56PRV-RD P56PRV-RD/WH C46HN-WH P23PCON-BK C47OUT-WH/BK C145CAL-RD/WH S132LDS-BL/WH S132LDS-BL/WH J129-02 J129-01 C145CAL-RD/WH S132LDS-BL/WH
Continued on View 8
GNDPCON-BR P52PCON-WH
BA BA BB
BB
BC
BA
D82CAN+ -YL
BA BB
AA AB
AA AB J152B AC
D81CAN- -GR
BC
AC
J152A
BB BC BA
7
S56PRV-RD GNDDCON-BR S56PRV-RD GNDDCON-BR
P21DCON-WH
P21DCON-WH
C61AXR-GR
C61AXR-GR
C60AXE-GR/WHT P53LS-WH/BK
C60AXE-GR/WHT P53LS-WH/BK
6 - 38
Z-135/70
Part No. 106783
Limit Switches
C64LS-OR/BK C143DEL-BL/RD BR WH
22 14
21
RD BK
ORN/YEL
NC
NO
BLU
C67SBD-BL C64LS-OR/BK C73SBR-BL/RD BR WH

14 24 2
BK
13
C64LS-OR/BK RD
23 1
LSS1RO SECONDARY BOOM RETRACT OPERATIONAL LEFT J49
LST20 DRIVE ENABLE LEFT OPERATIONAL J125
ENGINE HARNESS
LOWER LIMIT SWITCH HARNESS
J146 ENGINE HARNESS
NO
13
NO
C64LS-OR/BK C144DER-BL/WH
BR
22 14
BK WH
ORN
C64LS-OR/BK
21
RD
LST10 DRIVE ENABLE RIGHT OPERATIONAL J124
13
Continued on View 4
C65LOFL-BL/WH VLVRET BR
FST1S LOW FUEL FLOAT SWITCH
C124SBS-OR/BK YL BR OR BL S19 SECONDARY BOOM ANGLE OPERATIONAL SNSR GND-BR P109PSR-GR/WH C142SBS-OR
SNSR GND-BR P109PSR-GR/WH RD S20 SECONDARY BOOM ANGLE SAFETY
BK
J154
21
C64LS-OR/BK
13 1
RD BR WH
ORN/RED 22 14
NC
NO
S13DE-BL/RD
2
BK
LST1S DRIVE ENABLE SAFETY J126
21
13
C64LS-OR/BK RD
BLU/RED 14 1
NC
NO
S73SLE-BL/RD WH
4
April 2008
P12-35 C70PBR-BL/WH S140ENL-OR/RD C124SBS-OR/BK C123PBS-RD/BK P12-34 P12-33 P12-32 P12-31 P12-30 P12-29 P12-28 C143DEL-BL/RD P12-27 P12-26 P109PSR-GR/WH SNSR GND-BR C123PBS-RD/BK SNSR GND-BR P109PSR-GR/WH C141PBS-RD SNSR GND-BR C71PBE-BL/BK P109PSR-GR/WH C70PBR-BL/WH C64LS-OR/BK C67SBD-BL C73SBR-BL/RD C144DER-BL/WH C65LOF-BL/WH C64LS-OR/BK
J122 BLACK 12 PIN SCON MODULE
C64LS-OR/BK
C64LS-OR/BK C71PBE-BL/BK
P12-25 P12-24
P12-23 P12-22 P12-21 P12-20 P12-19 P12-18 P12-17 P12-16
P12-15 P12-14 P12-13 P12-12 P12-11 P12-10 C61AXR-GR C61AXRT-GR S56PRV-RD P58LS-RD/BK P54ENG-BK/WH S140ENL-OR/RD P53LS-WH/BK S13DE-BL/RD S12SB-BL/WH C60AXE-GR/WH C141PBS-RD C142SBS-OR P21DCON-WH S140ENL-OR/RD S59CNBK-GR/WH P58LS RD/BK P53LS-WH/BK S56PRV-RD P54ENG-BK/WH P53LS-WH/BK P21DCON-WH GNDDCON-BR P12-09 P12-08
P122-12 P122-11 P122-10 P122-09 P122-08 P122-07 P122-06 P122-05 P122-04 P122-03 P122-02 P122-01
P12 P7R P9B P6R2 P11+P30 P6R1 DRV. ENA. SEC. BOOM RET AXLE EXTENDED RSP1AS RSS1AS ECU PWR
P12-07 P12-06 P12-05 P12-04 P12-03 P12-02 P12-01

J12 BLACK 35 PIN LIMIT SWITCH HARNESS
GND-BR S139TRF-WH/RD S137PLL-RD/WH S56PRV-RD S59CNBK-GR/WH D81CAN- -GR D82CAN+ -YL
P121-12 P121-11 P121-10 P121-09 P121-08 P121-07 P121-06 P121-05 C145CAL-RD/WH P121-04 P121-03 S73SLE-BL/RD S132LDS-BL/WH P121-02 P121-01
J121 GRAY 12 PIN SCON MODULE
GND P39 P38 P7R P10 CANCAN+ RD 232 CALIBRATION IN
SEC. SW. CONNECTION LOAD SENSE
REV D
Continued on View 9
C145CAL-RD/WH
S132LDS-BL/WH
SCON MODULE
TD RS232
Continued on View 10A
22
BK
Part No. 106783
S12SB-BL/WH C64LS-OR/BK BR
3 2
LSS1RS 3' EXTENDED SAFETY J46
Z-135/70
NC
NO
6 - 39
April 2008

Limit Switches
6 - 39
6 - 40
April 2008 REV A
Electrical Schematic - View 10A

Limit Switches
M L K J I H G F E
J20
A 1
J20
11
12
10
9 4
11
12
10
9 4
8 3
BEFORE SERIAL NUMBER 130 WITH SOFTWARE VERSION S0675110
GR
OR/BK
BL
RD
WH/BK
OR
WH
GR/BK
RD/BK
BK BL/BK
BK/WH
BK
WH
RD
WH/BK BL/BK
1 J114
OR RD
J20
S18 PRIMARY BOOM ANGLE SAFETY
GR BK
RD/BK
6 10
GR/BK
BK/WH
BL
OR/BK
AFTER SERIAL NUMBER 129 WITH SOFTWARE VERSION S0675110
4 3 2
1
J114
4 3 2
RD
BR
BL
BK
BK WH
RD
BR
RD
BK
BR
WH
OR
YL
BR
11
12
BL RD
BK WH
RD
BR
RD
BK
BR
WH
S17 PRIMARY BOOOM ANGLE OPERATIONAL
OR
YL
22 14 YEL
21 NC 13 NO
22 14 WHT
21 NC 13 NO
22 14 YEL
21 NC 13 NO
22 14 WHT
21 NC 13 NO
LSP1E0 3'FROM FULLY EXTENDED J45
LSP1R0 3' EXTENDED OPERATIONAL J44
J20
5
11 12 2 10 7 6
5
9 4
8 3
9 4
8 3
GR
OR/BK
BL
RD
WH/BK
OR
WH
GR/BK
BK BL/BK
RD/BK
BK/WH
BK
WH
1 J114
OR RD
GR BK
RD/BK
6
GR/BK
BK/WH
WH/BK BL/BK
BL
OR/BK
BEFORE SERIAL NUMBER 130 WITH SOFTWARE VERSION S0675100

4 3 2 1
AFTER SERIAL NUMBER 129 WITH SOFTWARE VERSION S0675100

1 J114
4 3 2
RD
BR
BL
BK
BK WH
RD
BR
RD
BK
BR
WH
OR
YL
BR
BL
BK WH
RD
BR
RD
BK
BR
WH
OR
YL
22 14 YEL
21 NC 13 NO
22 14 WHT
21 NC 13 NO
22 14 YEL
21 NC 13 NO
22 14 WHT
21 NC 13 NO
Part No. 106783
Z-135/70
6 - 41
April 2008
Electrical Schematic - View 10A

Limit Switches
6 - 41
6 - 42
April 2008

Deutz BF4L 2011 Engine Deutz TD2011L04i Engine
6 - 43
6 - 44
April 2008 REV D

Deutz BF4L 2011 Engine and Deutz TD2011L04i Engine
A 1 B C
D
P1-01 B1BAT-RD P1-02 GND-BR P1-04 P1-03 GND-BR
E
P1-01
F
P1-08 P1-05 P1-02 C35RPM-BK/RD P1-03 C21IGN-WH P1-04 C34SA-BK/WH P1-06 P1-07 C46HRN-WH
G
P1-09 C33STR-BK P1-10 C30EDC-WH P1-11 C31EDC-WH/BK P1-12 C25PSR-WH/BK P1-13 C26TSR-WH/RD P1-14 P1-15 P1-16
H
P1-17 S137PLL-RD/WH P1-18 C41RPM-OR/BK P1-20 P1-21 P1-22 P1-23 P1-19 S139TRF-WH/RD
C45GEN-GR/WH
Continued on View 5
C45GEN-GR/WH TO BELT DRIVEN AC GENERATOR/WELDER
S137PLL-RD/WH
2
S139TRF-WH/RD S137PLL-RD/WH
S139TRF-WH/RD
C33STR-BK B1ENG-RD
AUX MAIN
J168 ENGINE HARNESS
B1ENG-RD
B1BAT-RD
J146 ENGINE HARNESS 1 INTEGRAL WITH BATTERY CABLE 2 J146 ENGINE HARNESS SEPARATE 4 GA WIRE ENGINE HARNESS B1ENG-RD B1ENG-RD B1ENG-RD
C26TSR-WH/RD C25PSR-WH/BK B1ENG-RD
C21IGN-WH
B1BAT-RD
B1BAT-RD
B1ENG-RD
F7 10A
F7 OIL COOLER F20 RPM F22 GLOW PLUG F23 ENG/ST/ALT

F7 20A F22 60A F20 20A F23 20A
C21IGN-WH
B1ENG-RD
C34SA-BK/WH
P35RPM-BK/RD
B3BAT/14-RD
B3BAT/14-RD
B1ENG-RD
B3BAT/14-RD
C35RPM-BK/RD
P34SA-BK/WH WH-PULL IN RD-HOLD
P34SA-BK/WH
B3BAT/14-RD
5
B2BAT-RD B1BAT-RD B1BAT-RD
CR1 STARTER RELAY
30
C21IGN-WH
TROMBETTA TIME DELAY MOM N.O.

B
86
BAT+ A
87
85
R21IGN-WH
INTEGRAL WITH BATTERY CABLE POWER HARNESS
AUX+ GNDC
30
86
87a
87
85
CR5 HORN RELAY
CR15 GLOW PLUG RELAY
86
30
85
CR17 OIL COOLER RELAY
86
30 87 87a
87
87a
85
CR28 ENGINE FUEL RELAY
30
86
87a
87
85
C107AF-RD
RD-HOLD
WH-PULL IN
07GND-BR
6
R33STR-BK
C25PSR-WT/BK
C26TSR-WT/RD
SUPPLIED BY DEUTZ B1BAT-RD
S-500
C31EDC-WH/BK
C116HYD-OR
R116HYD-OR
VLVRET2-BR
C41RPM-OR/BK
R46HRN WH
J57
GND04-BR
C30EDC-WH
SEPARATE 4 GA WIRE
D2
GND04-BR
ALTERNATOR
RD WH BK
VLVRET-BR
R34SA-BK/WH
EXCT.
C27AUX-RD
D5 OTS1P N.O.
D3
7
TWO 6V DC BATTERIES
B2
B1
8
AUXILIARY HYDRAULIC PUMPS ENGINE START AND ELECTRONICS BATTERY STARTER AUXILIARY POWER BATTERIES STARTER RELAY
6 - 44
Z-135/70
+ + ENGINE BLOCK GROUND
+
BAT GND-BR
PR1
PR1
BAT. +
BAT. D1
J120
BAT GND-BR
PULL IN HOLD
FAN
AUX. PUMP
AUX. PUMP
TO J4-32PWHITE 35 PIN
STA.
D
BAT GND-BR BAT GND-BR
BAT GND-BR
REGULATOR IND.
H1
HYDRAULIC COOLER RELAY
FUEL SOLENOID
GLOW PLUG RELAY
GLOW PLUG
HORNPRELAY
OIL PRESSURE SENDER
HYDRAULIC OIL COOLER FAN
HORN
DUAL COIL EDC
RPM SOLENOID
OIL TEMPERATURE SWITCH
OIL TEMPERATURE SENDER
ALTERNATOR
Part No. 106783
J153
J153
P14-35
V150HG GR/BK V150HG GR/BK V155PSE OR/RD V155PSE OR/RD FUNCTION ENABLE VALVE (Y74) V155PSE-OR/RD
WELDER GEN BYPASS VALVE (Y75)
P14-33 P14-32 C27AUX-RD C27AUX-RD
P14-31 P14-30 P14-29 P14-28 P14-27 P14-26 V05TRR-WH/BK V04TRL-WH C04TRL-WH TURNTABLE ROTATE CW VALVE (J70) C05TRR WH/BK TURNTABLE ROTATE CCW VALVE (J71) VLVRET7-BR VLVRTN7-BR VLVRET6-BR VLVRTN6-BR
P14-34
TO AUXILIARY HYDRAULIC PUMP RELAYS
MANIFOLD HARNESS
MANIFOLD HARNESS
ENGINE HARNESS
ENGINE HARNESS
P14-24 P14-23 P14-22 V73SBR-GR/BK P14-21 V72SBE-GR V10SBU-BL V10SBU-BL V73SBR-GR/BK V10SBU-BL VLVRET5-BR P14-20 P14-19 P14-18 V73SBR-GR/BK V72SBE-GR V72SBE-GR
P14-17 VLVRET5-BR
SEC EXT VLV (J65) SEC RET VLV (J66) SEC UP VLV (J67) SEC DWN VLV (J68)
P14-16
P14-15
P14-14 VLVRET5-BR C49LP - WH/BK V11SBD-BL/BK VLVRET5-BR V11SBD-BL/BK C49LP - WH/BK P14-13 P14-12 P14-11
P14-10
V08PBR-BK/WH V07PBE-BK V07PBE-BK PRI EXT VLV (J62) PRI DWN VLV (J60) PRI UP VLV (J59) SEC. BM ER F.C. (J64) SEC. BM UD F.C. (J64) TT ROT CW/CCW F.C. (J69)
V08PBR-BK/WH
PRI RET VLV (J63)
P14-08 P14-07 V01PBU-RD V01PBU-RD
V02PBD-RD/BK
V02PBD-RD/BK
P14-04 P14-03 V09PER-BK/RD

V09PER-BK/RD
V06TRF-WH/RD PRI BM EXT/RET F.C. (J61) PRI BM UP/DWN F.C. (J58)
V06TRF-WH/RD
P14-01
J14 WHITE 35 PIN MANIFOLD HARNESS
VLVRET4-BR
VLVRET4-BR
C49LP - WH/BK
Continued on View 6
CR23 DRIVE LIGHTS RELAY
REV B
87a
DRIVE LIGHTS
86
30
87
85
P14-02
V03PUD-RD/WH
V03PUD-RD/WH
P14-05
V12SUD-BL/WH V12SUD-BL/WH
P14-06
V09SER-BK/RD
V176SER-GR/WH
Part No. 106783
P14-09
April 2008
P 2
P14-25
Z-135/70
6 - 45
April 2008
6 - 45
6 - 46
April 2008

Perkins 1104C-44 Engine Perkins 804D-33T Engine
6 - 47
6 - 48
REV B
C26TSR-WT/RD
WATER TEMP SENDER
C25PSR-WT/BK
OIL PRESSURE SENDER
R21IGN-WH
FUEL SOLENOID
J56
HOLD
SW28 ENGINE CYLINDER HEAD TEMPERATURE
Continued on View 5
CR28 ENGINE FUEL RELAY
R21IGN-WH
BAT GND-BR
COLD START ADVANCE
PUMP
FUEL
87a
R21IGN-WH
FUEL LIFT PUMP
BAT GND-BR
86
30
85
87
BAT GND-BR
CR2 RELAY
R21IGN-WH
FAN
87a
R116HYD-OR BAT GND-BR
87
B3BAT/14-RD
COOLER RELAY
30
C21IGN-WH C116HYD-OR
86 85
BAT GND-BR
OTS1 N.O.
HYDRAULIC OIL TEMPERATURE SWITCH
GLOW PLUG
C45GEN-GR/WH
J32-ENG HARN
GLOW PLUG
B2BAT-RD
GND-BR
R34SA-BK/WH
GLOW PLUG
R21IGN-WH
C26TSR-WH/RD
C25PSR-WH/BK
B1ENG-RD
C21IGN-WH
87a
CR15 GLOW PLUG RELAY
30
GLOW PLUG GLOW PLUG RELAY
TO AUXILIARY HYDRAULIC POWER UNIT BATTERYPNEG TERM (B2)
C34SA-BK/WH VLVRET-BR
86 85
87
J120 C D
C31EDC-WH/BK
DUAL COIL EDC
GND04-BR C30EDC-WH
GND04-BR
B1ENG-RD
P1-23 P1-22 P1-21

P34SA/10-BK/WH
C45GEN-GR/WH
BATGND(A) BK
B3BAT/14-RD
P1-20 WH-PULL IN
WH RD
HOLD
P1-19 RD-HOLD
S139TRF-WH/RD
P1-17
CR5 HORN RELAY
S137PLL-RD/WH
P1-16 P1-15
86
J57
P1-18
C41RPM-OR/BK
P1-14 P1-13 P1-12

87a 87
85

WH-PULL IN BATGND(A) RD-HOLD
B1ENG-RD
VLVRET2-BR
30
R46HRN-WH
HORN RELAY
B3BAT/14-RD BAT GND-BR C41RPM-OR/BK C107AF-RD
P1-11 P1-10 P1-09 P1-08 P1-07 P1-06 P1-05 P1-04 P1-03 P1-02 P1-01
EXCT.
H1
C46HRN-WH
ALTERNATOR
STA.
BAT. -
REGULATOR
IND.
C34SA-BK/WH C21IGN-WH
B A P34SA/10-BK/WH ENGINE HARNESS
C35RPM-BK/RD
B3BAT/14-RD
C27AUX-RD
TO J4-32PWHITE 35 PIN
PR1
B1ENG-RD AUX+ GNDBAT+
AUX. PUMP
C35RPM-BK/RD PR1
S139TRF-WH/RD S137PLL-RD/WH F7 OIL COOLER F20 RPM F22 GLOW PLUG F23 ENG/ST/ALT
AUXILIARY HYDRAULIC PUMP
Perkins 1104C-44 Engine and Perkins 804D-33T Engine
BAT GND-BR
86 85
C33STR-BK
WORK LAMP TOGGLE SWITCH
87
AUX. PUMP
P1-04 P1-03 P1-02

WORK LAMPS
GND-BR GND-BR B2BAT-RD
F7 10A
B1ENG-RD
B1ENG-RD
STARTER
CR1 STARTER RELAY F23 20A
30
R33STR-BK
STARTER RELAY
P1-01
12-3 CABLE
P35RPM-BK/RD
F20 20A
ENGINE BLOCK GROUND
INTEGRAL WITH BATTERY CABLE
POWER HARNESS
B1
B1BAT-RD
B1BAT-RD B1BAT-RD
ENGINE START AND ELECTRONICS BATTERY

F22 60A
F7 20A
AUX
MAIN
B1BAT-RD B1BAT-RD
AUXILIARY POWER BATTERIES
B2BAT-RD
SEPARATE 4 GA WIRE TWO 6V DC BATTERIES
S139TRF-WH/RD
S137PLL-RD/WH
J146 ENGINE HARNESS
6 - 48 1 2 3 4 5 6 7 8
Z-135/70
-
B2
Part No. 106783

TROMBETTA TIME DELAY
C
April 2008
MOM N.O.
S-500
BAT. +
PULL IN
RPM SOLENOID
HORN
ALTERNATOR
+
+ +
April 2008 REV B

Cummins B4.5L Engine and Cummins B3.3T Engine
M L
K
P1-01 B2BAT-RD P1-02 GND-BR P1-03 GND-BR P1-04
J
P1-01 P1-02
I
P1-07 P1-08 P1-09 P1-10 P1-03 C21IGN-WH P1-06 P1-04 P1-05
H
P1-11 P1-12 P1-13 P1-15 P1-17 P1-16 P1-18 P1-14
G
P1-19 S139TRF-WH/RD P1-20 P1-21 P1-22 C45GEN-GR/WH P1-23
A 1
S137PLL-RD/WH
C35RPM-BK/RD
C34SA-BK/WH
C46HRN-WH
C33STR-BK
C30EDC-WH
C31EDC-WH/BK
C25PSR-WH/BK
C26TSR-WH/RD
C41RPM-OR/BK
Continued on View 5
2
C45GEN-GR/WH TO AUXILIARY POWER UNIT BATTERY NEG TERMINAL (B2) TO BELT DRIVEN AC GENERATOR WELD MASTER GND-BR B2BAT-RD J32-ENGINE HARNESS
S137PLL-RD/WH S139TRF-WH/RD
S139TRF-WH/RD
S137PLL-RD/WH
WORK LAMPS WORK LAMP TOGGLE SWITCH
TO AUXILIARY POWER UNIT BATTERY POS TERMINAL (B2)
3
AUX MAIN
C33STR-BK
J146 ENGINE HARNESS 1
12-3 CABLE 2
INTEGRAL WITH BATTERY CABLE
C26TSR-WH/RD C25PSR-WH/BK
F7 10A
B1BAT-RD
B2BAT-RD
B1BAT-RD
B1BAT-RD
B1ENG-RD
B1ENG-RD
B1ENG-RD
B1ENG-RD
4
86 85 30 87a 87
SEPARATE 4 GA WIRE
F7 20A SPARE F20 20A F23 20A
B1ENG-RD
F7 OIL COOLER F20 RPM F23 ENG/ST/ALT
C21IGN-WH CR28 ENGINE FUEL RELAY
C34SA-BK/WH
P35RPM-BK/RD
POWER HARNESS
R21IGN-WH
B1ENG-RD
B3BAT/14-RD
B3BAT/14-RD
P34SA/4-RD WH-PULL IN RD-HOLD BATGND(A) B BAT+
P34SA/4-RD
5
R21IGN-WH B3BAT/14-RD C21IGN-WH
C35RPM-BK/RD
B3BAT/14-RD
TROMBETTA TIME DELAY MOM N.O.
B1BAT-RD
F22 275A
WH
RD
EXCT.
C27AUX-RD
BK
PR1
PR1
AUX. PUMP
AUX. PUMP
TO J4-32 WHITE 35 PIN
HOLD
PULL IN
B2
B1
ENGINESTARTING AND ELECTRONICS BATTERY
TWO 6V DC BATTERIES
B1BAT-RD
B2BAT-RD
AUXILIARY POWER BATTERIES
CR1 STARTER RELAY

87a
30
86
87
85
R21IGN-WH A
30
C25PSR-WT/BK
C26TSR-WT/RD
86
AUX+ GNDC
87a 87 85
CR5 HORN RELAY
ENGINE HARNESS
86
30 87 87a
85
S-500
CR15 GRID HEATER RELAY
C107AF-RD VLVRET2-BR C41RPM-OR/BK R46HRN-WH
RD-HOLD
WH-PULL IN
BATGND(A)
C31EDC-WH/BK
C116HYD-OR
R116HYD-OR
J57
GND04-BR
C30EDC-WH
R33STR-BK
GND04-BR
J56
OTS1 N.O.
ALTERNATOR
VLVRET-BR
R34SA/4-RD
BAT. +
BAT. HOLD
J120
FAN
BAT GND-BR
BAT GND-BR
STA.
BAT GND-BR
BAT GND-BR
BAT GND-BR
REGULATOR IND.
H1
8
WATER TEMPERATURE SENDER
RPM SOLENOID
STARTER
AUXILIARY POWER UNITS
ALTERNATOR
HORN RELAY
HORN
DUAL COIL EDC
PRE-HEATER RELAY
PRE-HEATER
HYDRAULIC OIL TEMPERATURE SWITCH
OIL COOLER RELAY
CR2 RELAY
FUEL SOLENOID
OIL PRESSURE SENDER
STARTER RELAY
ENGINE BLOCK GROUND
Part No. 106783
Z-135/70
6 - 49
April 2008

Cummins B4.5L Engine Cummins B3.3T Engine
6 - 49
6 - 50
April 2008 REV B
Generator Wiring
120V AC W/O REGULATOR
CB
87a
120V AC W/REGULATOR
CB RD
87a
3 4
30A
30 87
110V AC REGULATOR
RD/12VDC WH
RED WH BRN
RD
30A
30 87
WT
2
86
85
5
BRN GND
WT
2
BRN BRN GR
86
2
85
BRN
BK BK/WH
BK/WH
GR
BK
3
WHT-NEUTRAL WHT-NEUTRAL 120V AC AUTO RESET CB BLK-120VAC 15A BLK-120VAC 15A
120V AC AUTO RESET CB
220V AC W/REGULATOR
87a
3
RED/12V WH
RD 30A WT
6
220V AC REGULATOR
RED WH BRN BK BK/WH
30 87 86
85
5
BRN BK BK/WH
BRN
WHT-NEUTRAL 220V AC
8
AUTO RESET CB BLK-220VAC 12.5A
Part No. 106783
Z-135/70
6 - 51
April 2008
Generator Wiring
6 - 51
6 - 52
April 2008
Hydraulic Schematic
(before serial number 180, except for serial number 102)
6 - 53
6 - 54
April 2008 REV D
Hydraulic Schematic
(before serial number 180, except for serial number 102)
A 1 B C D E F G H I J K L M
CHARGE FILTER
FUNCTION ENABLE VALVE
TURNTABLE ROTATE 6.5 GPM

CB CA CB CA
PRIMARY LIFT 9.0/7.2 GPM
PRIMARY EXT/RET 8.5/5.0GPM 13.3(REGEN)
SECONDARY LIFT 10.5/5.0 GPM
SECONDARY EXTENSION CYLINDERS 17.0/5.6GPM 22.6(REGEN)

CL CM CO CP CQ
51 PSI
CE
CF
CG
CH
CI
CJ
HIGH PRESSURE FILTER
2
CD CD CN CK
2
M1 E D
250 PSI
M2
X B
102 PSI
.030
CC
.030
CC
JIB MANIFOLD
PMP TEST
DD E DB B C
JIB UP/DWN 3.3/1.2 GPM

CR Z
TRL
TRR
PU
PD
PETST
2600 PSI
PE
PR
SU
H G
SD
SE
J
SR
X
JU
M5 A
315 PSI
2900 PSI
AX1 AX2
DC
JD
Y CS
M4
3625 PSI
3625 PSI
9
DRIVE PUMP
FUNCTION PUMP
AUXILIARY PUMP 1
D M L O
F U S AC AD
M
AUXILIARY PUMP 2
JIB EXT/RET 2.0 GPM 3.8 (REGEN)

.040
CT
L1
3100 PSI
N
JE
2.0 GPM 25 PSI
AB
B L1
L2
M2
TANK
P2 T1
P T
JR
CU
25 PSI
25 PSI
T2
OIL COOLER
STR
FUNCTION MANIFOLD
TANK
FRONT AXLE EXTENSION LEFT REAR STEERING RIGHT REAR STEERING
REAR AXLE EXTENSION
AA
AE
BELLCRANK LEVEL 3.6/1.6 GPM

AF CV
4 2A 4
3 3
1 1
5 5 T P
LEFT FRONT STEERING
RIGHT FRONT STEERING
DB
DC
DD
DE
JLU
2B
JLD LFE
BB
LFR
BC
RFE
RFR
BD
LRE
LRR
BE
RRE
RRR
TEST
FAE
FAR
RAE
RAR P2 P T2 T
0.2 GPM
CW
T RIGHT REAR RRA A

AJ AK
TEST
B RFA A RIGHT FRONT
PLATFORM ROTATE 0.30 GPM

CX
2.1 GPM
BF
1.5 GPM
BG
2.1 GPM
BH
1.5 GPM
BI
2.1 GPM
BJ
1.5 GPM
BK
2.1 GPM
BL
1.5 GPM
BM
BT
PRL
6
B RRB 50%
AM AN
BU AO BS AG
RFB
BN
BO
BP
BQ
2400 PSI
7.0 GPM
PRR
AH CY
STEER/AXLE MANIFOLD
50%
250 PSI
AR
BR
.063
AL AP
.063
PLATFORM LEVEL 0.9/0.7 GPM

AI CZ
50%
50% 50%
AS
7
LRB B
50%
AT AU
.052
AQ
G1 LFB A B PMP A
WELDER MANIFOLD
BV
WELDER OPTION
MTR A 4
AV
.031
AW
A LEFT REAR LRA LRBK LR2SP RR2SP RRBK

AZ BA AX AY
A LFA LFBK LF2SP RF2SP RFBK
DRIVE PUMP
BW
.030
LEFT FRONT B PMP B

BY
HYDRAULIC ROTARY COUPLER
BX
COUNTERBALANCE VALVES RATIO PRESS CT 3:1 1000 PSI CA CB 3:1 1250 PSI CG 1500 PSI 3:1 CU 4.5:1 2000 PSI CM CP 2500 PSI 1:1 CL CO CQ 3:1 2500 PSI CE CF DB DC 3000 PSI 3:1
DD CH DE CN CY CS CZ DA CV CW
PLU P1 PLD
PLATFORM MANIFOLD
DA
MTR B
3 1
OIL COOLER
CX CR CI CJ
21
GENERATOR TO APU SUCTION
270 PSI
G2
BZ
CLR
CK
4.5:1 3:1 1.5:1 2:1 4.5:1
3000 PSI 3300 PSI 3500 PSI 4000 PSI 4000 PSI
TRACTION MANIFOLD
6 - 54
Z-135/70
Part No. 106783
April 2008 REV B
Hydraulic Schematic
(serial number 102 and from serial number 180 to 534)
M L K J I H G
F
E
A 1
CQ
CHARGE FILTER

CB CA CB CA

CL CM CO CP
51 PSI
CE
CF
CG
CH
CI
CJ

CD CD
CN CK CC
2
JIB MANIFOLD
Z X
M1
D
250 PSI
M2
X B
102 PSI
.030
CC
.030
M5 A M4
PMP
315 PSI 2900 PSI
TEST
DD
TRL
TRR
C
PU
PD
E
PETST
2600 PSI
PE
PR
SU
H G
SD
SE
J
SR
JU
CR
AX1 AX2
DB
3625 PSI
AFTER SERIAL NUMBER 439

100 PSI
M L DF O D
JD
Y CS
3
3625 PSI
9
DRIVE PUMP
FUNCTION PUMP
AUXILIARY PUMP 1
DC
F U S AC
M
AUXILIARY PUMP 2
L1
3100 PSI
N
.040
AB W
AD
JE
2.0 GPM 25 PSI
AA AE
CT
B L1
L2
M2
TANK
P2 T1
P T
JR
CU
4
25 PSI
25 PSI
T2
OIL COOLER
STR
FUNCTION MANIFOLD
TANK
REAR AXLE EXTENSION
2 2B 2A
4 4
3 3
1 1 T
5 5 P
LEFT FRONT STEERING
AF DB DC DD DE
JLU
CV
JLD LFE
BB
5
CW
LFR
BC
RFE
RFR
BD
LRE
LRR
BE
RRE
RRR
TEST
FAE
FAR
RAE
RAR P2 P T2 T
0.2 GPM
T RIGHT REAR RRA A

AJ AK
TEST
B RFA A RIGHT FRONT

PRL
CX
2.1 GPM
BF
1.5 GPM
BG
2.1 GPM
BH
1.5 GPM
BI
2.1 GPM
BJ
1.5 GPM
BK
2.1 GPM
BL
1.5 GPM
BM
BT BU
AO
B RRB 50%
AM
AN
RFB
BS BN BO BP BQ
6
AG
2400 PSI
7.0 GPM
STEER/AXLE MANIFOLD
PRR
AH CY
50%
250 PSI
AR
BR
.039
AL AP
.063

AI
29%
71% 50%
AQ
AS
50% LRB B
AT AU AV
.052
G1 LFB B A PMP A
WELDER MANIFOLD
BV
WELDER OPTION
MTR A 4
.031
AW

AZ BA AX AY
DRIVE PUMP
BW
.030
LEFT FRONT B PMP B

BY
BX
COUNTERBALANCE VALVES RATIO PRESS CT 3:1 1000 PSI CA CB 3:1 1250 PSI CG 1500 PSI 3:1 CU 4.5:1 2000 PSI CM CP 2500 PSI 1:1 CL CO CQ 3:1 2500 PSI CE CF DB DC 3000 PSI 3:1
DD CH CX CR DE CN CY CS CZ DA CV CW
PLU P1 PLD
CZ
7
PLATFORM MANIFOLD
DA
MTR B
3 1
OIL COOLER
21
270 PSI
G2
BZ
CI CJ CK
CLR
TRACTION MANIFOLD
4.5:1 3:1 1.5:1 2:1 4.5:1
3000 PSI 3300 PSI 3500 PSI 4000 PSI 4000 PSI
HS0080F
Part No. 106783
Z-135/70
6 - 55
April 2008
Hydraulic Schematic
(serial number 102 and from serial number 180 to 534)
6 - 55
6 - 56
April 2008 REV A
Hydraulic Schematic
(from serial number 535)
M L
CHARGE FILTER
K
J
G
F
E
A 1
CQ

CL CM CO CP
51 PSI
CB A
CA
CB
CA
CE
CF
CG
CH
CI
CJ

CD CD
CN CC CK
M1
D
250 PSI
M2
X B
102 PSI
.030
CC
.030
2
JIB MANIFOLD
Z X
M5 A M4
PMP
315 PSI 2900 PSI
TEST
DD
TRL
TRR
C
PU
PD
E
PETST
2600 PSI
PE
PR
SU
H G
SD
SE
J
SR
JU
CR
AX1 AX2
DB
3625 PSI
AFTER SERIAL NUMBER 439

100 PSI
M L DF O D
JD
Y CS
3625 PSI
9
DRIVE PUMP
FUNCTION PUMP
AUXILIARY PUMP 1
DC
F U S AC
M
AUXILIARY PUMP 2

.040
AD
L1
3100 PSI
N
JE
2.0 GPM 25 PSI
AA AE
CT
B L1
L2
M2
AB W
TANK
P2 T1
P T
JR
CU
25 PSI
25 PSI
T2
OIL COOLER
STR
FUNCTION MANIFOLD
TANK
REAR AXLE EXTENSION

AF
2 2B 2A
4 4
3 3
1 1 T
5 5 P
LEFT FRONT STEERING
DB
DC
DD
DE
JLU
CV
JLD LFE
BB
5
CW
LFR
BC
RFE
RFR
BD
LRE
LRR
BE
RRE
RRR
TEST
FAE
FAR
RAE
RAR P2 P T2 T
0.2 GPM
T RIGHT REAR RRA A

AJ AK
TEST
B RFA A RIGHT FRONT

PRL
CX
2.1 GPM
BF
1.5 GPM
BG
2.1 GPM
BH
1.5 GPM
BI
2.1 GPM
BJ
1.5 GPM
BK
2.1 GPM
BL
1.5 GPM
BM
BT BU
AO
B RRB 50%
AM
AN
RFB
BS BN BO BP BQ
2400 PSI
7.0 GPM
AG
STEER/AXLE MANIFOLD
PRR
AH CY
6
50%
250 PSI
AR
BR
.039
AL AP
.063
29%
71% 50%
AQ
AS
50% LRB B
AT AU AV
.052
G1 LFB B A PMP A
WELDER MANIFOLD
BV
WELDER OPTION
MTR A 4
.031
AW

AZ BA AX AY
DRIVE PUMP
BW
.030
LEFT FRONT B PMP B

BY
COUNTERBALANCE VALVES RATIO PRESS CT 3:1 1000 PSI CA CB 3:1 1250 PSI CG 3:1 1500 PSI CU (before serial number 558) 4.5:1 2000 PSI CM CP 1:1 2500 PSI CL CO CQ 3:1 2500 PSI
CE CF DE DB CV DC CW DD
AI
PLU P1 PLD
CZ
7
DA
PLATFORM MANIFOLD
BX
MTR B
3 1
OIL COOLER
(from serial number CU 558 to 658)

CH CX CR CI CJ CK CN CY CS CZ DA
3:1
3000 PSI 3000 PSI 3300 PSI 3500 PSI 4000 PSI 4000 PSI 3000 PSI
21
270 PSI
G2
BZ
CLR
TRACTION MANIFOLD
CU (after serial number 657)
4.5:1 3:1 1.5:1 2:1 4.5:1 2:1
HS0080J
Part No. 106783
Z-135/70
6 - 57
April 2008
Hydraulic Schematic
(from serial number 535)
6 - 57
6 - 58
California Proposition 65
Warning
The 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 Scandinavia

Phone +46 31 575100 Fax +46 31 579020 Phone +61 7 3375 1660 Fax +61 7 3375 1002
Genie China
Phone +86 21 53852570 Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99 Fax +33 (0)2 37 26 09 98
Genie Malaysia
Phone +65 98 480 775 Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042 Fax +34 93 579 5059
Genie Japan
Phone +81 3 3453 6082 Fax +81 3 3453 6083
Genie Germany
Phone Phone Fax 0800 180 9017 +49 422 149 1818 +49 422 149 1820
Genie Korea
Phone +82 25 587 267 Fax +82 25 583 910
Genie U.K.
Phone +44 (0)1476 584333 Fax +44 (0)1476 584334
Genie Brasil
Phone +55 11 41 665 755 Fax +55 11 41 665 754
Genie Mexico City

Phone +52 55 5666 5242 Fax +52 55 5666 3241
Genie Holland
Phone +31 183 581 102 Fax +31 183 581 566
Distributed By:
Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475

Service Genie Z135

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Service Manual

Serial Number Range

Part No. 106783 Rev D1 July 2009

Part No. 106783

Serial Number Legend

Genie Industries 18340 NE 76th Street Redmond, WA 98052 USA

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Section 1 Safety Rules

Do Not Perform Maintenance Unless:

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Section 1 - Safety Rules

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Repair Procedures Introduction ............................................................................................................ 4 - 1

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Engines 5-1 5-2 RPM Adjustment ........................................................................................ 4 - 66 Flex Plate ................................................................................................... 4 - 66

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Fault Codes Introduction ............................................................................................................ 5 - 1

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For operational specifications, refer to the Operator's Manual.

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Cleanliness level, minimum Water content, maximum

Fire resistant Mineral based

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Manifold Component Specifications

5.5 to 7.5 8 to 10 3.5 to 5.5 7.5 to 9.5

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Deutz BF4L 2011 Engine

Motorpal 15,000 psi 1034 bar 3046 psi 210 bar

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Deutz TD2011L04i Engine

Oil pressure switch point

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Cummins B4.5L Engine

12V DC, Group 31 1 1000A 200 minutes

125A 0.72 in 18.3 mm

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Cummins B3.3T Engine

550A 130 rpm

9.1 quarts 8.6 liters 120A, 12V DC

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Perkins 1104C-44 Engine

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140-200A 200-250 rpm

14 quarts 13.2 liters

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Perkins 804D-33T Engine

Type Quantity AH rating Reserve capacity @ 25A rate

6V DC 2 285AH 745 minutes

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Machine Torque Specifications