You are on page 1of 295

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.

ii

Z-135/70

Part No. 106783

April 2008

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

Part No. 106783

Z-135/70

iii

April 2008

This page intentionally left blank.

iv

Z-135/70

Part No. 106783

April 2008

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

Z-135/70

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.

vi

Z-135/70

Part No. 106783

Juyl 2009

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

Part No. 106783

Z-135/70

vii

July 2009

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

viii

Z-135/70

Part No. 106783

Juyl 2009

TABLE OF CONTENTS

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

Part No. 106783

Z-135/70

ix

July 2009

TABLE OF CONTENTS

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

Z-135/70

Part No. 106783

Juyl 2009

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

Part No. 106783

Z-135/70

xi

July 2009

TABLE OF CONTENTS

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

xii

Z-135/70

Part No. 106783

Juyl 2009

TABLE OF CONTENTS

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

Part No. 106783

Z-135/70

xiii

July 2009

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

xiv

Z-135/70

Part No. 106783

Juyl 2009

TABLE OF CONTENTS

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

Part No. 106783

Z-135/70

xv

July 2009

This page intentionally left blank.

xvi

Z-135/70

Part No. 106783

July 2009

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.

Part No. 106783

Z-135/70

2-1

Section 2 Specifications

July 2009

SPECIFICATIONS

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

2-2

Z-135/70

Part No. 106783

July 2009

Section 2 Specifications

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

Part No. 106783

Z-135/70

2-3

Section 2 Specifications

July 2009

SPECIFICATIONS

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

2-4

Z-135/70

Part No. 106783

July 2009

Section 2 Specifications

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

Part No. 106783

Z-135/70

2-5

Section 2 Specifications

July 2009

SPECIFICATIONS

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

2-6

Z-135/70

Part No. 106783

July 2009

Section 2 Specifications

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

Part No. 106783

Z-135/70

2-7

Section 2 Specifications

July 2009

SPECIFICATIONS

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

2-8

Z-135/70

Part No. 106783

July 2009

Section 2 Specifications

REV G

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.

Part No. 106783

Z-135/70

2-9

Section 2 Specifications

July 2009

SPECIFICATIONS

REV G

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.

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

2 - 10

Z-135/70

Part No. 106783

July 2009

Section 2 Specifications

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

Part No. 106783

Z-135/70

2 - 11

Section 2 Specifications

July 2009

SPECIFICATIONS

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

2 - 12

Z-135/70

Part No. 106783

July 2009

Section 2 Specifications

REV G

SPECIFICATIONS

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

Part No. 106783

Z-135/70

2 - 13

Section 2 Specifications

July 2009

SPECIFICATIONS

REV G

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

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

2 - 14

Z-135/70

Part No. 106783

July 2009

Section 2 Specifications

REV G

SPECIFICATIONS

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

Part No. 106783

Z-135/70

2 - 15

Section 2 Specifications

July 2009

SPECIFICATIONS

REV G

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

2 - 16

Z-135/70

Part No. 106783

April 2008

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.

Part No. 106783

Z-135/70

3-1

Section 3 Scheduled Maintenance Procedures

April 2008

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.

3-2

Z-135/70

Part No. 106783

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

Part No. 106783

Z-135/70

3-3

Section 3 Scheduled Maintenance Procedures

April 2008

This page intentionally left blank.

3-4

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

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

Part No. 106783

Z-135/70

3-5

Section 3 Scheduled Maintenance Procedures

April 2008

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

3-6

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV G

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.

Part No. 106783

Z-135/70

3-7

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST A

PROCEDURES

REV G

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.

3-8

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV G

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.

Part No. 106783

Z-135/70

3-9

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST A

PROCEDURES

REV G

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.

3 - 10

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV G

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.

Part No. 106783

Z-135/70

3 - 11

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST A

PROCEDURES

REV G

3 Loosen the vent plug located on the fuel filter/ water separator head.

a d

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.

a b c d

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.

3 - 12

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV G

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

Part No. 106783

Z-135/70

3 - 13

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST A

PROCEDURES

REV G

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.

3 - 14

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

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.

Part No. 106783

Z-135/70

3 - 15

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

a b

engine pivot plate anchor hole engine pivot plate retaining fastener

3 - 16

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 17

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

3 - 18

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 19

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

a b

engine pivot plate anchor hole engine pivot plate retaining fastener

3 - 20

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 21

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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

3 - 22

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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

b a c d

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.

Part No. 106783

Z-135/70

3 - 23

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

3 - 24

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 25

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.
a b c

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.

3 - 26

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 27

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

3 - 28

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 29

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

3 - 30

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 31

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

a b

engine pivot plate anchor hole engine pivot plate retaining fastener

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.

3 - 32

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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

Part No. 106783

Z-135/70

3 - 33

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

3 - 34

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 35

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

3 - 36

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 37

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST B PROCEDURES

REV D

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.

3 - 38

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST B PROCEDURES

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).
Cummins B4.5 Operation and Maintenance Manual Genie part number Cummins B3.3 Operation and Maintenance Manual Genie part number

107527

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.

Part No. 106783

Z-135/70

3 - 39

Section 3 Scheduled Maintenance Procedures

April 2008

Checklist C Procedures
C-1 Perform Engine Maintenance Deutz Models

REV D

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).
Deutz BF4L2011 Operation Manual Genie part number Deutz TD2011 Operation Manual Genie part number

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).
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.

3 - 40

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

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).
Perkins 1100 Series User's Handbook Genie part number Perkins 800 Series Operation and Maintenance Manual Genie part number

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

107526

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

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.

Part No. 106783

Z-135/70

3 - 41

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST C PROCEDURES

REV D

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.

3 - 42

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST C PROCEDURES

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).

Part No. 106783

Z-135/70

3 - 43

Section 3 Scheduled Maintenance Procedures

April 2008

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

3 - 44

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

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

Part No. 106783

Z-135/70

3 - 45

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST D PROCEDURES

REV D

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.

3 - 46

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST D PROCEDURES

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

Part No. 106783

Z-135/70

3 - 47

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST D PROCEDURES

REV D

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).

3 - 48

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST D PROCEDURES

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.

Part No. 106783

Z-135/70

3 - 49

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST D PROCEDURES

REV D

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.

3 - 50

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST D PROCEDURES

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).
Deutz BF4L2011 Operation Manual Genie part number Deutz TD2011 Operation Manual Genie part number

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).
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.

Part No. 106783

Z-135/70

3 - 51

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST D PROCEDURES

REV D

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).
Perkins 1100 Series User's Handbook Genie part number Perkins 800 Series Operation and Maintenance Manual Genie part number

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

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.

a b

engine pivot plate anchor hole engine pivot plate retaining fastener

3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate.

3 - 52

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST D PROCEDURES

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)

Part No. 106783

Z-135/70

3 - 53

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST D PROCEDURES

REV D

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.

3 - 54

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

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.

Part No. 106783

Z-135/70

3 - 55

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST E PROCEDURES

REV D

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.

3 - 56

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST E PROCEDURES

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).
Cummins B4.5 Operation and Maintenance Manual Genie part number Cummins B3.3 Operation and Maintenance Manual Genie part number

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

111332

107527

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.

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.

Part No. 106783

Z-135/70

3 - 57

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST E PROCEDURES

REV D

E-4 Perform Engine Maintenance Perkins 804D-33T Models

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).
Perkins 800 Series Operation and Maintenance Manual Genie part number

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

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.

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.

3 - 58

Z-135/70

Part No. 106783

April 2008

Section 3 Scheduled Maintenance Procedures

REV D

CHECKLIST E PROCEDURES

E-6 Perform Engine Maintenance Deutz TD2011L04i Models

E-7 Perform Engine Maintenance Perkins 804D-33T 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).
Perkins 800 Series Operation and Maintenance Manual Genie part number

139320

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. 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.

Part No. 106783

Z-135/70

3 - 59

Section 3 Scheduled Maintenance Procedures

April 2008

CHECKLIST E PROCEDURES

REV D

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

E-9 Perform Engine Maintenance Perkins 804D-33T 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).
Perkins 800 Series Operation and Maintenance Manual Genie part number

107526

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. 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.

3 - 60

Z-135/70

Part No. 106783

April 2008

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

4-1

Section 4 Repair Procedures

April 2008

Display Module
The key switch must be in the off position before entering the programming mode. Activation of the setting, use the or

REV C

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

4-2

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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)

Part No. 106783

Z-135/70

4-3

Section 4 Repair Procedures

April 2008

DISPLAY MODULE

REV C

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

4-4

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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

Part No. 106783

Z-135/70

4-5

Section 4 Repair Procedures

April 2008

DISPLAY MODULE

REV C

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

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

U se +/- buttons to adjust

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

4-6

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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)

Part No. 106783

Z-135/70

4-7

Section 4 Repair Procedures

April 2008

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

REV C

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

4-8

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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.

Part No. 106783

Z-135/70

4-9

Section 4 Repair Procedures

April 2008

PLATFORM CONTROLS

REV C

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.

4 - 10

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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.

Part No. 106783

Z-135/70

4 - 11

Section 4 Repair Procedures

April 2008

PLATFORM CONTROLS

REV C

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.

4 - 12

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

PLATFORM CONTROLS

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.

Part No. 106783

Z-135/70

4 - 13

Section 4 Repair Procedures

April 2008

PLATFORM CONTROLS

REV C

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.

4 - 14

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

PLATFORM CONTROLS

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 .

Part No. 106783

Z-135/70

4 - 15

Section 4 Repair Procedures

April 2008

PLATFORM CONTROLS

REV C

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.

4 - 16

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

PLATFORM CONTROLS

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.

Part No. 106783

Z-135/70

4 - 17

Section 4 Repair Procedures

April 2008

PLATFORM CONTROLS

REV C

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 .

4 - 18

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV D

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.

Part No. 106783

Z-135/70

4 - 19

Section 4 Repair Procedures

April 2008

PLATFORM COMPONENTS

REV D

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.

4 - 20

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV D

PLATFORM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 21

Section 4 Repair Procedures

April 2008

PLATFORM COMPONENTS

REV D

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.

4 - 22

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV D

PLATFORM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 23

Section 4 Repair Procedures

April 2008

PLATFORM COMPONENTS

REV D

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.

4 - 24

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

This page intentionally left blank.

Part No. 106783

Z-135/70

4 - 25

Section 4 Repair Procedures

April 2008

Jib Boom Components


a b c d

REV E

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

4 - 26

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

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.

Part No. 106783

Z-135/70

4 - 27

Section 4 Repair Procedures

April 2008

JIB BOOM COMPONENTS

REV E

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.

4 - 28

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

JIB BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 29

Section 4 Repair Procedures

April 2008

JIB BOOM COMPONENTS

REV E

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.

4 - 30

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

JIB BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 31

Section 4 Repair Procedures

April 2008

JIB BOOM COMPONENTS

REV E

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.

4 - 32

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

JIB BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 33

Section 4 Repair Procedures

April 2008

JIB BOOM COMPONENTS

REV E

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.

4 - 34

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

JIB BOOM COMPONENTS

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

Part No. 106783

Z-135/70

4 - 35

Section 4 Repair Procedures

April 2008

JIB BOOM COMPONENTS

REV E

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: .

4 - 36

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

JIB BOOM COMPONENTS

10 Remove the key from the main key switch. 11 Insert the key into the service/bypass 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

Run Service Bypass Recovery

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.

Part No. 106783

Z-135/70

4 - 37

Section 4 Repair Procedures

April 2008

JIB BOOM COMPONENTS

REV E

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

4 - 38

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

JIB BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 39

Section 4 Repair Procedures

April 2008

Boom Components
a

REV F

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

4 - 40

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 41

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 42

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 43

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 44

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 45

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 46

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 47

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 48

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 49

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

a b

engine pivot plate anchor hole engine pivot plate retaining fastener

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.

4 - 50

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 51

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 52

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 53

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 54

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.
a b c

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.

a b c d e

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.

Part No. 106783

Z-135/70

4 - 55

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

a b c

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.

4 - 56

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.
STOP

00000

Run Service Bypass Recovery

Part No. 106783

Z-135/70

4 - 57

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 58

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 59

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.
STOP

00000

Run Service Bypass Recovery

4 - 60

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.

a b c

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.

Part No. 106783

Z-135/70

4 - 61

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 62

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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

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.

00000

Run Service Bypass Recovery

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.

Part No. 106783

Z-135/70

4 - 63

Section 4 Repair Procedures

April 2008

BOOM COMPONENTS

REV F

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.

4 - 64

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

BOOM COMPONENTS

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.
STOP

00000

Run Service Bypass Recovery

Part No. 106783

Z-135/70

4 - 65

Section 4 Repair Procedures

April 2008

Engines
5-1 RPM Adjustment
Refer to Maintenance Procedure B-18, Check and Adjust the Engine RPM.

REV C

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)

4 - 66

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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.
a b c d e

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

Part No. 106783

Z-135/70

4 - 67

Section 4 Repair Procedures

April 2008

ENGINES

REV C

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

4 - 68

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV D

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.
Run Service Bypass Recovery

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

Part No. 106783

Z-135/70

4 - 69

Section 4 Repair Procedures

April 2008

GROUND CONTROLS

REV D

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.

4 - 70

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV D

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.

Part No. 106783

Z-135/70

4 - 71

Section 4 Repair Procedures

April 2008

GROUND CONTROLS

REV D

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.

4 - 72

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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.

Part No. 106783

Z-135/70

4 - 73

Section 4 Repair Procedures

April 2008

HYDRAULIC PUMPS

REV C

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.

4 - 74

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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.

Part No. 106783

Z-135/70

4 - 75

Section 4 Repair Procedures

April 2008

HYDRAULIC PUMPS

REV C

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.

4 - 76

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV C

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.

Part No. 106783

Z-135/70

4 - 77

Section 4 Repair Procedures

April 2008

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

4 - 78

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

1 W

12

D C

11

10

G 9 K J

L 7 6

H 5

Part No. 106783

Z-135/70

4 - 79

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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


Index No. 1 Description Schematic Item Function Torque

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

4 - 80

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

1
DB

2
DC M

3
O

14

N E

13 12 11 10

P Q R U V DD S

6 7

Part No. 106783

Z-135/70

4 - 81

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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

4 - 82

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

1 D

G F K J I H DF

3 4 5

14

6 7 8 9

13

B L

10

11

12

Part No. 106783

Z-135/70

4 - 83

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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


Index No. 1 Description Schematic Item Function Torque

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

4 - 84

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

1 DB W

P 12 DC

V DD T

11

10

Part No. 106783

Z-135/70

4 - 85

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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.

4 - 86

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

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.

Part No. 106783

Z-135/70

4 - 87

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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

4 - 88

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

1 AH AI

AG

Part No. 106783

Z-135/70

4 - 89

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

8-7 Jib Boom Manifold


The jib boom manifold is mounted inside the primary extension boom at the platform end.
Index No. 1 Description Schematic Item Function Torque

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

2 3 4 5 6 7 8 9

4 - 90

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

1 X

2 AE

3 AD

4 AC

AB

AF

AA

Part No. 106783

Z-135/70

4 - 91

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

8-8 Function Enable Valve


The function enable valve is mounted behind the medium pressure filter.
Index No. 1 Description Schematic Item Function Torque

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

4 - 92

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

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

Part No. 106783

Z-135/70

4 - 93

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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.
Index No. 1 Description Schematic Item Function Torque

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.

4 - 94

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

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

Part No. 106783

Z-135/70

4 - 95

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

Steer and Axle Manifold, continued


Index No. 14 Description Schematic Item Function Torque

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

4 - 96

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

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

Part No. 106783

Z-135/70

4 - 97

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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.

4 - 98

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

This page intentionally left blank.

Part No. 106783

Z-135/70

4 - 99

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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

4 - 100

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

1 BA AZ

12 11

AP AM

AJ

10

AR

AT 9 AX

AY

AW AN 7 AO 6

Part No. 106783

Z-135/70

4 - 101

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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

4 - 102

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

AK

AL AU

AQ

AS

AV 4

Part No. 106783

Z-135/70

4 - 103

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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.

4 - 104

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

MANIFOLDS

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

Part No. 106783

Z-135/70

4 - 105

Section 4 Repair Procedures

April 2008

MANIFOLDS

REV E

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

4 - 106

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

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.

Part No. 106783

Z-135/70

4 - 107

Section 4 Repair Procedures

April 2008

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.

REV E

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.

4 - 108

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

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.
Run Service Bypass Recovery

Part No. 106783

Z-135/70

4 - 109

Section 4 Repair Procedures

April 2008

TURNTABLE ROTATION COMPONENTS

REV E

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.

4 - 110

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV E

TURNTABLE ROTATION COMPONENTS

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.

Part No. 106783

Z-135/70

4 - 111

Section 4 Repair Procedures

April 2008

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.

REV F

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)

4 - 112

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

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.

Part No. 106783

Z-135/70

4 - 113

Section 4 Repair Procedures

April 2008

AXLE COMPONENTS

REV F

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.

4 - 114

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

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.

Part No. 106783

Z-135/70

4 - 115

Section 4 Repair Procedures

April 2008

AXLE COMPONENTS

REV F

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.

9 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

Run Service Bypass Recovery

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.

4 - 116

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

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.

Part No. 106783

Z-135/70

4 - 117

Section 4 Repair Procedures

April 2008

AXLE COMPONENTS

REV F

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.

4 - 118

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

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

Part No. 106783

Z-135/70

4 - 119

Section 4 Repair Procedures

April 2008

AXLE COMPONENTS

REV F

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.

4 - 120

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

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: .

Part No. 106783

Z-135/70

4 - 121

Section 4 Repair Procedures

April 2008

AXLE COMPONENTS

REV F

11 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

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.
Run Service Bypass Recovery

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.

4 - 122

Z-135/70

Part No. 106783

April 2008

Section 4 Repair Procedures

REV F

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.

Part No. 106783

Z-135/70

4 - 123

Section 4 Repair Procedures

April 2008

This page intentionally left blank.

4 - 124

Z-135/70

Part No. 106783

April 2008

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

Section 5 Fault Codes

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.

5-2

Z-135/70

Part No. 106783

April 2008

Section 5 Fault Codes

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.

Part No. 106783

Z-135/70

5-3

Section 5 Fault Codes

April 2008

CONTROL SYSTEM FAULT CODES

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

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

Value at 0,

Out of Tolerance Not calibrated Just calibrated

5-4

Z-135/70

Part No. 106783

April 2008

Section 5 Fault Codes

REV B

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 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)

Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.

Sec Boom 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

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

5-5

Section 5 Fault Codes

April 2008

CONTROL SYSTEM FAULT CODES

REV B

Error Source

Error Type Value at 5.0 V

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

5-6

Z-135/70

Part No. 106783

April 2008

Section 5 Fault Codes

REV B

CONTROL SYSTEM FAULT CODES

Error Source

Error Type Value at 5.0 V

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

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

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

Section 5 Fault Codes

April 2008

CONTROL SYSTEM FAULT CODES

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

5-8

Z-135/70

Part No. 106783

April 2008

Section 5 Fault Codes

REV B

CONTROL SYSTEM FAULT CODES

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

5-9

Section 5 Fault Codes

April 2008

CONTROL SYSTEM FAULT CODES

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)

5 - 10

Z-135/70

Part No. 106783

April 2008

Section 5 Fault Codes

REV B

CONTROL SYSTEM FAULT CODES

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

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.

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

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 - 11

Section 5 Fault Codes

April 2008

CONTROL SYSTEM FAULT CODES

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.

5 - 12

Z-135/70

Part No. 106783

April 2008

Section 5 Fault Codes

REV B

CONTROL SYSTEM FAULT CODES

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.

Part No. 106783

Z-135/70

5 - 13

Section 5 Fault Codes

April 2008

CONTROL SYSTEM FAULT CODES

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.

Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.

5 - 14

Z-135/70

Part No. 106783

April 2008

Section 5 Fault Codes

REV B

CONTROL SYSTEM FAULT CODES

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

Part No. 106783

Z-135/70

5 - 15

Section 5 Fault Codes

April 2008

CONTROL SYSTEM FAULT CODES

REV B

Error Source

Error Type Value at 5.0 V

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.

5 - 16

Z-135/70

Part No. 106783

April 2008

Section 5 Fault Codes

REV B

CONTROL SYSTEM FAULT CODES

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

Section 5 Fault Codes

April 2008

CONTROL SYSTEM FAULT CODES

REV B

Error Source

Error Type Value at 5.0 V

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

Section 5 Fault Codes

REV B

CONTROL SYSTEM FAULT CODES

Error Source

Error Type Value at 5.0 V

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

Section 5 Fault Codes

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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)

BLACK 23 PIN CONNECTOR

WHITE 23 PIN CONNECTOR

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

Section 6 Schematics

April 2008

Safety Controller Pin Legend


REV B

GRAY 12 PIN CONNECTOR

J121

J122

BLACK 12 PIN CONNECTOR

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

PIN NUMBERING FOR 12 PIN CONNECTORS

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

Section 6 Schematics

Turntable Controller Pin Legend


REV B

STOP

24

1 16

4 19

8 23

WHITE 35 PIN CONNECTOR

J14

29 35

6 12
00000

PIN NUMBERING FOR 23 PIN CONNECTORS

WHITE 23 PIN CONNECTOR

J13

16 19 23

1 4 8

4 PIN CONNECTOR
24

J15

4 1 1

3 2

1 24

6 29

12 35

BLACK 35 PIN CONNECTOR

J12

29 35

6 12

PIN NUMBERING FOR 35 PIN CONNECTORS

BLACK 23 PIN CONNECTOR

J11

16 19 23

1 4 8

4 3

1 2

TURNTABLE CONTROLLER

TCON
J11

TURNTABLE CONTROLLER

TCON
J12

TURNTABLE CONTROLLER

TCON
J13

TURNTABLE CONTROLLER

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)

TURNTABLE CONTROLLER

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

Section 6 Schematics

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

CR17POILPCOOLERPRELAY

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. -

SERVICE HRN P1-07 C46HRN-WH

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

TO J4-32PWHITE 35 PIN C27AUX-RD


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

TWO 6 VOLTPBATTERIES

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

CR17POILPCOOLERPRELAY

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

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


WH-PULL IN

MULTI FUNCTION VLV RECOVERY SIGNAL

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

AUXILIARY HYD RECOVERY SIGNAL

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

SERVICE HRN P1-07 C46HRN-WH

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

TO J4-32PWHITE 35 PIN C27AUX-RD

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

TWO 6 VOLTPBATTERIES

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
MULTI FUNCTION VLV RECOVERY SIGNAL

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

AUXILIARY HYD RECOVERY SIGNAL

PRI BOOM LENGTH 100' STATUS

PRI BOOM LENGTH 3' STATUS

PRI BOOM RETRACTED STATUS

BOOM RET RECOVERY SIGNAL

BOOM DWN RECOVERY SIGNAL

(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

ALTERNATOR RPM P1-18 C41RPM-OR/BK

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


D82CAN+ -YL D81CAN- -GR

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

Section 6 Schematics

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)

J36-DRIVE CHASSIS HARN

J38-DRIVE CHASSIS HARN

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

ALTERNATOR RPM P1-18 C41RPM-OR/BK

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

Section 6 Schematics

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

Section 6 Schematics

Electrical Connector and Circuit Legend

6 - 19

6 - 20

Section 6 Schematics

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

Electrical Schematic - View 1

Drive Chassis Controller (DCON)

V36RRS-BL

V29MS-RD/WH V60AXEX-GR/WH V61AXRT - GR VLVRET1-BR

Section 6 Schematics

6 - 22 1 2 3 4 5 6 7 8

Z-135/70

V37RRS-BL/BK

Part No. 106783

April 2008

Electrical Schematic - View 2


Platform Controls (PCON)

Section 6 Schematics

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

Section 6 Schematics

Electrical Schematic - View 2


Platform Controls (PCON)

6 - 23

6 - 24

Section 6 Schematics

April 2008

Electrical Schematic - View 3


Ground Controls (TCON)

6 - 25

6 - 26

Section 6 Schematics

April 2008 REV C

Electrical Schematic - View 3


Ground Controls (TCON)
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

Section 6 Schematics

Electrical Schematic - View 4


Ground Controls (TCON)
M L K J I H G F E D C B A 1

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

Section 6 Schematics

Electrical Schematic - View 4


Ground Controls (TCON)

6 - 27

6 - 28

Section 6 Schematics

April 2008

Electrical Schematic - View 5


Ground Controls (TCON)

6 - 29

6 - 30

Section 6 Schematics

April 2008 REV A

Electrical Schematic - View 5


Ground Controls (TCON)
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

Continued on View 11

6 - 30

Z-135/70

Part No. 106783

Electrical Schematic - View 6

Section 6 Schematics

Ground Controls (TCON)

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

BOOM DWN RECOVERY SIGNAL

BOOM RET RECOVERY SIGNAL

15
P10

AUXILIARY HYD RECOVERY SIGNAL

STRT ASST

J10

START

REV C

Continued on View 5

Continued on View 12

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

Section 6 Schematics

Electrical Schematic - View 6


Ground Controls (TCON)

6 - 31

6 - 32

Section 6 Schematics

April 2008

Electrical Schematic - View 7

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

Electrical Schematic - View 7

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

Section 6 Schematics

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

Section 6 Schematics

Electrical Schematic - View 8


M L K J I H G F E D C B A 1
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

D82CAN+ -YL D81CAN- -GR

J151B-A J151B-B J151B-C

D82CAN+ -YL D81CAN- -GR

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

J37-DRIVE CHASSIS HARNESS


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
J38-DRIVE CHASSIS HARNESS
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

Section 6 Schematics

Electrical Schematic - View 8

6 - 35

6 - 36

Section 6 Schematics

April 2008

Electrical Schematic - View 9

6 - 37

6 - 38

Section 6 Schematics

April 2008 REV B

Electrical Schematic - View 9


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

Continued on View 10

GNDPCON-BR P52PCON-WH
BA BA BB

BB

BC

BA

D82CAN+ -YL

D82CAN+ -YL D81CAN- -GR

BA BB

AA AB

D82CAN+ -YL D81CAN- -GR

AA AB J152B AC

D81CAN- -GR

BC

AC

J152A
BB BC BA

D82CAN+ -YL D81CAN- -GR

D82CAN+ -YL D81CAN- -GR

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

Section 6 Schematics

Electrical Schematic - View 10

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

Continued on View 11

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

Section 6 Schematics

Electrical Schematic - View 10


Limit Switches

6 - 39

6 - 40

April 2008 REV A

Section 6 Schematics

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

Continued on View 10

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

S18 PRIMARY BOOM ANGLE SAFETY

S17 PRIMARY BOOOM ANGLE OPERATIONAL

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

S18 PRIMARY BOOM ANGLE SAFETY

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

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

S18 PRIMARY BOOM ANGLE SAFETY

S17 PRIMARY BOOOM ANGLE OPERATIONAL

LSP1E0 3'FROM FULLY EXTENDED J45

LSP1R0 3' EXTENDED OPERATIONAL J44

Part No. 106783

Z-135/70

6 - 41

April 2008

Section 6 Schematics

Electrical Schematic - View 10A


Limit Switches

6 - 41

6 - 42

Section 6 Schematics

April 2008

Electrical Schematic - View 11


Deutz BF4L 2011 Engine Deutz TD2011L04i Engine

6 - 43

6 - 44

Section 6 Schematics

April 2008 REV D

Electrical Schematic - View 11


Deutz BF4L 2011 Engine and Deutz TD2011L04i Engine
A 1 B C
J15 BLACK 4 PIN POWER HARNESS

D
P1-01 B1BAT-RD P1-02 GND-BR P1-04 P1-03 GND-BR

E
J13 WHITE 23 PIN ENGINE HARNESS
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

Continued on View 12

AUX MAIN

J168 ENGINE HARNESS

B1ENG-RD

B1BAT-RD

LOWER LIMIT SWITCH HARNESS

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

Continued on View 10

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

Section 6 Schematics

Electrical Schematic - View 12

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

Continued on View 11

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

Section 6 Schematics

Electrical Schematic - View 12

6 - 45

6 - 46

Section 6 Schematics

April 2008

Electrical Schematic - View 13


Perkins 1104C-44 Engine Perkins 804D-33T Engine

6 - 47

6 - 48

REV B

Continued on View 12

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

HYDRAULIC OIL COOLER FAN

87

B3BAT/14-RD
COOLER RELAY

30

C21IGN-WH C116HYD-OR
86 85

BAT GND-BR
OTS1 N.O.

HYDRAULIC OIL TEMPERATURE SWITCH

CR17 OIL COOLER RELAY

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

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


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
J13 WHITE 23 PIN ENGINE HARNESS

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
J15 BLACK 4 PIN POWER HARNESS

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

Electrical Schematic - View 13

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

Section 6 Schematics

Continued on View 10

J146 ENGINE HARNESS

LOWER LIMIT SWITCH 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

Section 6 Schematics

Electrical Schematic - View 14


Cummins B4.5L Engine and Cummins B3.3T Engine
M L
J15 BLACK 4 PIN POWER HARNESS

K
P1-01 B2BAT-RD P1-02 GND-BR P1-03 GND-BR P1-04

J
P1-01 P1-02
J13 WHITE 23 PIN ENGINE HARNESS

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)

Continued on View 12
3

AUX MAIN

C33STR-BK

LOWER LIMIT SWITCH HARNESS

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

Continued on View 10

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

CR17 OIL COOLER RELAY

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

HYDRAULIC OIL COOLER FAN

CR2 RELAY

FUEL SOLENOID

OIL PRESSURE SENDER

STARTER RELAY

ENGINE BLOCK GROUND

Part No. 106783

Z-135/70

6 - 49

April 2008

Section 6 Schematics

Electrical Schematic - View 14


Cummins B4.5L Engine Cummins B3.3T Engine

6 - 49

6 - 50

April 2008 REV B

Section 6 Schematics

Generator Wiring
M L K J I H G F E D C B A 1
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

Section 6 Schematics

Generator Wiring

6 - 51

6 - 52

Section 6 Schematics

April 2008

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

6 - 53

6 - 54

Section 6 Schematics

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

Section 6 Schematics

Hydraulic Schematic
(serial number 102 and from serial number 180 to 534)
M L K J I H G
PRIMARY LIFT 9.0/7.2 GPM

F
PRIMARY EXT/RET 8.5/5.0GPM 13.3(REGEN)

E
SECONDARY LIFT 10.5/5.0 GPM

A 1
CQ

CHARGE FILTER

FUNCTION ENABLE VALVE

TURNTABLE ROTATE 6.5 GPM


CB CA CB CA

SECONDARY EXTENSION CYLINDERS 17.0/5.6GPM 22.6(REGEN)


CL CM CO CP

51 PSI

CE

CF

CG

CH

CI

CJ

HIGH PRESSURE FILTER


CD CD

CN CK CC

2
JIB MANIFOLD
JIB UP/DWN 3.3/1.2 GPM
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
JIB EXT/RET 2.0 GPM 3.8 (REGEN)

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
BELLCRANK LEVEL 3.6/1.6 GPM

25 PSI

25 PSI

T2
OIL COOLER

STR

FUNCTION MANIFOLD

TANK

FRONT AXLE EXTENSION LEFT REAR STEERING RIGHT REAR STEERING

REAR AXLE EXTENSION

2 2B 2A

4 4

3 3

1 1 T

5 5 P

LEFT FRONT STEERING

RIGHT 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

PLATFORM ROTATE 0.30 GPM


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

PLATFORM LEVEL 0.9/0.7 GPM


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

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 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

GENERATOR TO APU SUCTION

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

Section 6 Schematics

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

6 - 55

6 - 56

April 2008 REV A

Section 6 Schematics

Hydraulic Schematic
(from serial number 535)
M L
CHARGE FILTER

K
FUNCTION ENABLE VALVE

J
TURNTABLE ROTATE 6.5 GPM

G
PRIMARY LIFT 9.0/7.2 GPM

F
PRIMARY EXT/RET 8.5/5.0GPM 13.3(REGEN)

E
SECONDARY LIFT 10.5/5.0 GPM

A 1
CQ

SECONDARY EXTENSION CYLINDERS 17.0/5.6GPM 22.6(REGEN)


CL CM CO CP

51 PSI

CB A

CA

CB

CA

CE

CF

CG

CH

CI

CJ

HIGH PRESSURE FILTER


CD CD

CN CC CK

M1

D
250 PSI

M2

X B

102 PSI

.030

CC

.030

2
JIB MANIFOLD
JIB UP/DWN 3.3/1.2 GPM
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

JIB EXT/RET 2.0 GPM 3.8 (REGEN)


.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

FRONT AXLE EXTENSION LEFT REAR STEERING RIGHT REAR STEERING

REAR AXLE EXTENSION

BELLCRANK LEVEL 3.6/1.6 GPM


AF

2 2B 2A

4 4

3 3

1 1 T

5 5 P

LEFT FRONT STEERING

RIGHT 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

PLATFORM ROTATE 0.30 GPM


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
PLATFORM LEVEL 0.9/0.7 GPM

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

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

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

GENERATOR TO APU SUCTION

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

Section 6 Schematics

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