106783

Introduction July 2011
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 dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie 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 Copyright © 2011 by Terex Corporation
and send in suggestions for improvement. All
106783 Rev E July 2011
communications will be carefully considered for First Edition, Fifth Printing
future printings of this and all other manuals.
Genie and Z are registered trademarks of Terex
South Dakota, Inc. in the USA and many other
Contact Us: countries.
Printed on recycled paper

http://www.genielift.com
e-mail: techsup@genieind.com Printed in U.S.A.
ii Z-135/70 Part No. 106783

July 2011
INTRODUCTION
Serial Number Legend
Model: Z-135/70
Serial number: Z13505-12345
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 Z135 05 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 135 ft/ 41.15 m
Model Sequence
Maximum platform reach : 69 ft 9 in/ 21.26 m
number
Gradeability: 45%
Country of manufacture: USA Year of
manufacture
This machine complies with:
ANSI A92.5
CAN B.354.4
Terex South Dakota, Inc.

500 Oakwood Road
PO Box 1150
Watertown, SD 57201 Serial label
Serial number
(located under cover)
USA tam ed on c a i
PN - 77055
Part No. 106783 Z-135/70 iii

July 2011
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iv Z-135/70 Part No. 106783

July 2011 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:
- manufacturer’s instructions and safety rules
- employer’s 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 v

Section 1 - Safety Rules July 2011
SAFETY RULES
Personal Safety Workplace Safety

Any person working on or around a machine must Be sure to keep sparks, flames and
be aware of all known safety hazards. Personal lighted tobacco away from flammable and
safety and the continued safe operation of the combustible materials like battery gases
machine should be your top priority. and engine fuels. Always have an approved fire
extinguisher within easy reach.
Read each procedure thoroughly. This
manual and the decals on the machine, Be sure that all tools and working areas
use signal words to identify the following: are properly maintained and ready for use.
Keep work surfaces clean and free of
Safety alert symbol—used to alert debris that could get into machine components and
personnel to potential personal cause damage.
injury hazards. Obey all safety
messages that follow this symbol Be sure any forklift, overhead crane or
to avoid possible injury or death. other lifting or supporting device is fully
capable of supporting and stabilizing the
Used to indicate the presence of
weight to be lifted. Use only chains or straps that
an imminently hazardous situation
are in good condition and of ample capacity.
which, if not avoided, will result in
death or serious injury. Be sure that fasteners intended for one
Used to indicate the presence of a time use (i.e., cotter pins and self-locking
potentially hazardous situation nuts) are not reused. These components
which, if not avoided, could result may fail if they are used a second time.
in death or serious injury. Be sure to properly dispose of old oil or
Used to indicate the presence of a other fluids. Use an approved container.
potentially hazardous situation Please be environmentally safe.
which, if not avoided, may cause Be sure that your workshop or work area is
minor or moderate injury. properly ventilated and well lit.
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.
vi Z-135/70 Part No. 106783

July 2011
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules

General Safety Rules .................................................................................................. v
Section 2 Rev Specifications

H 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 2011
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-delivery Preparation ......................................................................................... 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
G Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
A-4 Perform Engine Maintenance - Deutz Models ............................................... 3 - 9
A-5 Perform Engine Maintenance - Cummins Models ......................................... 3 - 9
A-6 Perform Engine Maintenance - Perkins Models .......................................... 3 - 10
A-7 Check the Hydraulic Return Filter Condition Indicator ................................. 3 - 10
A-8 Inspect the Fuel Filter/Water Separator Element - Perkins Models ............. 3 - 11
A-9 Drain the Fuel Filter/Water Separator Element -
Deutz and Cummins Models ...................................................................... 3 - 12
A-10 Perform 30 Day Service ............................................................................. 3 - 13
A-11 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-12 Replace the Drive Hub Oil .......................................................................... 3 - 14
D Checklist B Procedures
B-1 Inspect the Batteries .................................................................................. 3 - 15
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 16
B-3 Test the Key Switches ............................................................................... 3 - 18
B-4 Check the Exhaust System ....................................................................... 3 - 20
B-5 Check the Engine Oil Cooler and Cooling Fins - Deutz Models ................... 3 - 21
B-6 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22
viii Z-135/70 Part No. 106783

July 2011
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

B-7 Confirm the Proper Brake Configuration ...................................................... 3 - 22
B-8 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23
B-9 Test the Ground Control Override ............................................................... 3 - 24
B-10 Test the Platform Self-leveling ................................................................... 3 - 25
B-11 Test the Engine Idle Select Operation ........................................................ 3 - 26
B-12 Test the Drive Brakes ................................................................................ 3 - 27
B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 27
B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 28
B-15 Test the Alarm and Optional Flashing Beacon ............................................ 3 - 29
B-16 Perform Hydraulic Oil Analysis ................................................................... 3 - 29
B-17 Replace the Inline Fuel Filter/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 Perform Engine Maintenance - Deutz Models ............................................. 3 - 40
C-2 Perform Engine Maintenance - Cummins Models ....................................... 3 - 40
C-3 Perform Engine Maintenance - Perkins Models .......................................... 3 - 41
C-4 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 41
C-5 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 42
Part No. 106783 Z-135/70 ix

July 2011
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

D Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 44
D-2 Check the Free-wheel Configuration ........................................................... 3 - 45
D-3 Replace the Drive Hub Oil .......................................................................... 3 - 46
D-4 Adjust the Turntable Rotation Backlash ...................................................... 3 - 48
D-5 Replace the Hydraulic Filter Elements ........................................................ 3 - 49
D-6 Perform Engine Maintenance - Deutz Models ............................................. 3 - 51
D-7 Perform Engine Maintenance - Cummins Models ....................................... 3 - 51
D-8 Perform Engine Maintenance - Perkins Models .......................................... 3 - 52
D-9 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 52
D-10 Inspect for Turntable Bearing Wear ............................................................ 3 - 54
D Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 55
E-2 Perform Engine Maintenance - Cummins Models ....................................... 3 - 57
E-3 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 57
E-5 Perform Engine Maintenance -
Deutz TD2011L04i and Perkins 804D-33T Models ...................................... 3 - 58
E-6 Perform Engine Maintenance - Deutz TD2011L04i Models ......................... 3 - 59
E-8 Perform Engine Maintenance - Perkins 1104C-44 Models .......................... 3 - 60
x Z-135/70 Part No. 106783

July 2011
TABLE OF CONTENTS
Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
D Display Module ...................................................................................................... 4 - 2
C Platform Controls
1-1 ALC-1000 Circuit Board ................................................................................ 4 - 9
1-2 Membrane Decal ........................................................................................ 4 - 10
1-3 Joysticks ................................................................................................... 4 - 11
E Platform Components
2-1 Platform Leveling Cylinder .......................................................................... 4 - 19
2-2 Platform Rotator ......................................................................................... 4 - 20
2-3 Platform Level Sensor ................................................................................ 4 - 21
2-4 Platform Overload System (if equipped) ..................................................... 4 - 23
F Jib Boom Components
3-1 Jib Boom Cable Track ................................................................................ 4 - 27
3-2 Jib Boom .................................................................................................... 4 - 29
3-3 Jib Boom Lift Cylinder ................................................................................ 4 - 31
3-4 Jib Boom Level Cylinder ............................................................................. 4 - 32
3-5 Jib Boom Extension Cylinder ..................................................................... 4 - 33
3-6 Jib Boom Bellcrank Angle Sensor .............................................................. 4 - 34
Part No. 106783 Z-135/70 xi

July 2011
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

G Boom Components
4-1 Primary Boom Cable Track ........................................................................ 4 - 41
4-2 Secondary Boom Cable Track .................................................................... 4 - 44
4-3 Primary Boom ............................................................................................ 4 - 47
4-4 Primary Boom Lift Cylinder ......................................................................... 4 - 49
4-5 Secondary Boom Lift Cylinder .................................................................... 4 - 50
4-6 Primary Boom Extension Cylinder .............................................................. 4 - 53
4-7 Secondary Boom Extension Cylinders ....................................................... 4 - 54
4-8 Primary Boom Angle Sensor ...................................................................... 4 - 55
4-9 Secondary Boom Angle Sensor .................................................................. 4 - 61
C Engines
5-1 RPM Adjustment ........................................................................................ 4 - 66
5-2 Flex Plate ................................................................................................... 4 - 66
E Ground Controls
6-1 Service Bypass / Recovery Keyswitch ....................................................... 4 - 69
6-2 Circuit Boards ............................................................................................ 4 - 71
6-3 Membrane Decal ........................................................................................ 4 - 72
C Hydraulic Pumps
7-1 Function Pump .......................................................................................... 4 - 73
7-2 Drive Pump ................................................................................................ 4 - 76
xii Z-135/70 Part No. 106783

July 2011
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued

E Manifolds
8-1 Function Manifold - View 1 (before serial number 440) ................................ 4 - 78
8-2 Function Manifold - View 2 (before serial number 440) ................................ 4 - 80
8-3 Function Manifold - View 1 (after serial number 439) .................................. 4 - 82
8-4 Function Manifold - View 2 (after serial number 439) .................................. 4 - 84
8-5 Valve Adjustments - Function Manifold ...................................................... 4 - 86
8-6 Platform Manifold ....................................................................................... 4 - 88
8-7 Jib Boom Manifold ..................................................................................... 4 - 90
8-8 Function Enable Valve ............................................................................... 4 - 92
8-9 Turntable Rotation Manifolds ...................................................................... 4 - 93
8-10 Steer and Axle Manifold ............................................................................. 4 - 94
8-11 Valve Adjustments - Steer and Axle Manifold ............................................ 4 - 98
8-12 Traction Manifold - View 1 ......................................................................... 4 - 100
8-13 Traction Manifold - View 2 ......................................................................... 4 - 102
8-14 Valve Adjustments, Traction Manifold ....................................................... 4 - 104
8-15 Drive Oil Diverter Manifold (welder option) ................................................. 4 - 105
8-16 Valve Coils ................................................................................................ 4 - 106
E Turntable Rotation Components
9-1 Turntable Rotation Assembly .................................................................... 4 - 108
9-2 Turntable Level Sensor ............................................................................. 4 - 109
G 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 2011
TABLE OF CONTENTS
Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
B Control System Fault Codes .................................................................................. 5 - 2
A SCON Fault Matrix ............................................................................................... 5 - 14
Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
C Wire Circuit Legend ................................................................................................ 6 - 2
C Limit Switches and Angle Sensors ......................................................................... 6 - 9
B Drive Chassis and Platform Controller Pin Legend ............................................... 6 - 11
B Safety Controller Pin Legend ................................................................................ 6 - 12
B Turntable Controller Pin Legend ........................................................................... 6 - 13
B Engine Relay and Fuse Panel Legend .................................................................. 6 - 14
A Electrical Symbols Legend .................................................................................. 6 - 15
A Hydraulic Symbols Legend .................................................................................. 6 - 16
B Electrical Connector and Circuit Legend ............................................................... 6 - 18
A Electrical Schematic (ES0366) .............................................. Located at end of Manual
B Electrical Schematic - View 13,
Perkins 1104C-44 Engine and Perkins 804D-33T ....................................... 6 - 21
B Electrical Schematic - View 14,
Cummins B4.5L Engine and Cummins B3.3T Engine ................................. 6 - 22
B Generator Wiring .................................................................................................. 6 - 24
A Hydraulic Generator (Welder Option) .................................................................... 6 - 25
D Hydraulic Schematic (before serial number 180, except for serial number 102) .... 6 - 28
B Hydraulic Schematic (serial number 102 and from serial number 180 to 534) ....... 6 - 29
A Hydraulic Schematic (from serial number 535) ..................................................... 6 - 31
xiv Z-135/70 Part No. 106783

July 2011 Section 2 • Specifications
REV G
Specifications
Machine Specifications Performance Specifications
Tires and wheels Drive speeds, maximum
Tire size 445/65D22.5, FF Stowed position, high speed 2.8 mph

4.5 km/h
Tire ply rating 18
40 ft / 9.7 sec
Tire weight, new foam-filled (minimum) 815 lbs 12.2 m / 9.7 sec
370 kg
Raised or extended 0.7 mph
Overall tire diameter 46.5 in 1.1 km/h
118.1 cm 40 ft / 40 sec
12.2 m / 40 sec
Wheel diameter 22.5 in
Raised and extended 0.4 mph
57.2 cm
0.64 km/h
Wheel width 13 in 40 ft / 68.5 sec
33 cm 12.2 m / 68.5 sec
Wheel lugs 10 @ 3/4 -16 Braking distance, maximum
Lug nut torque, dry 420 ft-lbs High range on paved surface 3 to 6 ft
569.4 Nm 1 to 2 m
Lug nut torque, lubricated 320 ft-lbs Gradeability See Operator's Manual
433.9 Nm
Fluid capacities
Boom function speeds, maximum
Fuel tank 40 gallons from platform controls
151.4 liters
Jib boom up/down 38 to 43 seconds
Hydraulic tank 65 gallons
Jib boom extend/retract 38 to 42 seconds
246 liters
Primary boom up/down
Hydraulic system 123 gallons
-60° to +70° 88 to 105 seconds
(including tank) 466 liters
Primary boom extend/retract 35 to 48 seconds
Drive hubs 47 fl oz
1.4 liters Secondary boom up/down 80 to 95 seconds
Turntable rotation drive hub 40 fl oz Secondary boom extend/retract 88 to 98 seconds
1.18 liters
Turntable rotate, 360° 88 to 92 seconds
Drive hub oil type: fully stowed
SAE 90 multipurpose hypoid gear oil API service
classification GL5 Turntable rotate, 360° 160 to 180 seconds
jib or primary booms extended
Turntable rotate, 360° 280 to 350 seconds

For operational specifications, refer to the
jib and primary booms extended
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 2011
SPECIFICATIONS REV G
Hydraulic Specifications Component damage hazard.

Continued use of Chevron Aviation
Hydraulic Oil Specifications A hydraulic fluid when ambient
temperatures are consistently
Hydraulic oil type Chevron Rykon MV equivalent above 32°F / 0°C may result in
Viscosity grade Multi-viscosity component damage.
Viscosity index 200
Note: Use Chevron Aviation A hydraulic oil when in
Cleanliness level, minimum 15/13 ambient temperatures consistently below 0°F / -
Water content, maximum 200 ppm
18°C.
Chevron Rykon MV oil is fully compatible and Note: Use Shell Tellus T46 hydraulic oil when oil
mixable with Shell Donax TG (Dexron III) oils. temperatures consistently exceed 205°F / 96°C.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
Note: Genie specifications require additional
systems, have the ability to perform over a wide equipment and special installation instructions for
temperature range, and the viscosity index should the approved optional fluids. Consult the Genie
exceed 140. They should provide excellent antiwear, Industries Service Department before use.
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
Fire resistant UCON Hydrolube HP-5046

Quintolubric 822
Mineral based Shell Tellus T32

Shell Tellus T46
Chevron Aviation A

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

REV G SPECIFICATIONS
Drive pump Function manifold
Type: bi-directional variable displacement piston pump Function relief pressure 3100 psi
(measured at TEST port) 213.7 bar
Displacement 2.8 cu in
46 cc Primary boom extend relief pressure 2600 psi
(measured at PTEST port) 179 bar
Flow rate @ 2350 rpm 28.5 gpm
108 L/min Jib and platform manifolds
Drive pressure, maximum 3625 psi Platform rotate and platform level 0.2 gpm
250 bar flow regulator 0.76 L/min
Charge pump Jib manifold flow regulator 2 gpm

7.6 L/min
Type: gerotor
Steer/Axle manifold
13.9 cc Axle extend relief pressure 2400 psi
165 bar
Flow rate @ 2350 rpm 9 gpm
34 L/min Drive manifold
Charge pressure @ 2350 rpm 315 psi Hot oil relief pressure 250 psi
Neutral position 21.7 bar 17.2 bar
Function pumps Hydraulic filters
Type: variable displacement piston pump High pressure filter Beta 3  200
Displacement 0 to 2.75 cu in High pressure filter 102 psi

0 to 45 cc bypass pressure 7 bar
Flow rate @ 2350 rpm 0 to 28 gpm Medium pressure filter Beta 3  200
0 to 106 L/min
Medium pressure filter 51 psi
Pressure, maximum 2900 psi bypass pressure 3.5 bar
200 bar
Hydraulic tank 10 micron with
Pressure compensator 2900 psi return filter 25 psi / 1.7 bar bypass
200 bar
Drive motor case drain Beta 10  2
Standby pressure 250 psi return filter
17 bar
Auxiliary pumps
Type: fixed displacement gear pump
2.47 cc

Part No. 106783 Z-135/70 2-3

Brakes Manifold Component

Brake release pressure 190 psi Specifications
13 bar
Plug torque
Drive motors
(before serial number 180) (see note below) SAE No. 2 36 in-lbs / 4 Nm
Displacement per revolution, 0.8 cu in SAE No. 4 10 ft-lbs / 13 Nm

high speed 13.3 cc
SAE No. 6 14 ft-lbs / 19 Nm
Displacement per revolution, 2.7 cu in
low speed 45 cc SAE No. 8 38 ft-lbs / 51 Nm
Drive motors SAE No. 10 41 ft-lbs / 55 Nm

(after serial number 179) SAE No. 12 56 ft-lbs / 76 Nm
high speed 13.3 cc
Valve coil resistance specifications
low speed (square end) 45 cc Proportional solenoid valve 3.5 to 5.5
(schematic items N, P, R, T, V)
low speed (circle end) 25 cc 3 position 4 way solenoid valve 4 to 6
(schematic item B)
Note: Serial number 102 is equipped with drive 3 position 4 way solenoid valve 7 to 9
motors equal to those used on machines after (schematic items BN, BO, BP and BQ)
serial number 179. 3 position 4 way solenoid valve 8 to 10
(schematic item AH)
3 position 4 way proportional 8 to 10

solenoid valve
(schematic items Y and AI)
2 position 3 way solenoid valve 5.5 to 7.5

(schematic items F and AD)
2 position 3 way solenoid valve 8 to 10

(schematic items AE and AF)

(schematic items H and J)

(schematic items C, D, G, I, K,
AX, AY, BU and BT)

(schematic item A)
2-4 Z-135/70 Part No. 106783

Deutz BF4L 2011 Engine Oil viscosity requirements
Displacement 189.6 cu in -22°F to 86°F / -30°C to 30°C 5W-30

3.1 liters (synthetic)
Number of cylinders 4 -4°F to 90°F / -20°C to 32°C 10W-40
Bore and stroke 3.7 x 4.409 inches Above 23°F / -5°C 20W-50
94 x 112 mm Units ship with 15W-40.
Horsepower Extreme operating temperatures may require the use of
Continuous @ 2500 rpm 69 / 51 kW alternative engine oils. For oil requirements, refer to the
Net intermittent @ 2500 rpm 73 / 54 kW Engine Operator Handbook on your machine.
Firing order 1-3-4-2 Oil temperature switch
Low idle 1500 rpm Installation torque 8-18 ft-lbs

383 Hz 11-24 Nm
High idle 2350 rpm Oil temperature switch point 275°F

599 Hz 135°C
Compression ratio 17.5:1 Oil pressure switch
Compression pressure Installation torque 8-18 ft-lbs

Pressure (psi or bar) of the lowest cylinder must be at 11-24 Nm
least 75% of the highest cylinder. Oil pressure switch point 7 psi
Governor centrifugal mechanical 0.48 bar
Valve clearance, cold Fuel injection system
Intake 0.012 in Injection pump make Motorpal

0.3 mm Injection pump pressure, maximum 15,000 psi
Exhaust 0.020 in 1034 bar
0.5 mm Injector opening pressure 3046 psi
Lubrication system 210 bar
Oil pressure, hot 40 to 60 psi Fuel requirement

(at 2000 rpm) 2.8 to 4.1 bar For fuel requirements, refer to the engine Operator's
Oil capacity 11 quarts Manual on your machine.
(including filter) 10.4 liters Starter motor
Current draw, normal load 140-200A
Cranking speed 200-250 rpm

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

Battery - Auxiliary power units
Type 6V DC
Quantity 2
AH rating 285AH
Reserve capacity @ 25A rate 745 minutes
Battery - Engine starting and control system
Type 12V DC, Group 31

Quantity 1
Cold cranking ampere 1000A
Alternator output 80A @ 14V DC
Fan belt deflection 3 /8to 1/2 inch

9 to 12 mm

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

Deutz TD2011L04i Engine Lubrication system
Displacement 220.9 cu in Oil pressure, hot 40 to 60 psi

3.62 liters (at 2000 rpm) 2.8 to 4.1 bar
Number of cylinders 4 Oil capacity 12.8 quarts

(including filter) 12.1 liters
Bore and stroke 3.78 x 4.92 inches
96 x 125 mm Oil viscosity requirements
Horsepower -22°F to 86°F / -30°C to 30°C 5W-30

Net intermittent @ 2400 rpm 74 / 55 kW (synthetic)
Induction system turbocharged -4°F to 104°F / -20°C to 40°C 10W-40
Firing order 1-3-4-2 Above 5°F / -15°C 15W-40
Low idle 1500 rpm Units ship with 15W-40.

383 Hz Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
High idle 2350 rpm Engine Operator Handbook on your machine.
599 Hz
Oil temperature switch
Compression ratio 17.5:1
Installation torque 8-18 ft-lbs
Compression pressure 11-24 Nm
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder. Oil temperature switch point 275°F
135°C
Governor centrifugal mechanical
Oil pressure switch
Valve clearance, cold
Intake 0.012 in 11-24 Nm
0.3 mm
Oil pressure switch point 22 psi
Exhaust 0.020 in 1.5 bar
0.5 mm

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

Fuel injection system
Injection pump make Motorpal
Injection pump pressure, maximum 15,000 psi

1034 bar
Injector opening pressure 3046 psi

210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator's

Manual on your machine.
Starter motor
Type 6V DC
Quantity 2
AH rating 285AH
Type 12V DC, Group 31

Quantity 1
Alternator output 80A @ 14V DC
Fan belt deflection 3 /8to 1/2 inch

9 to 12 mm

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

Cummins B4.5L Engine

Displacement 275 cu in Fuel injection system
4.5 liters Injection pump make Delphi
Number of cylinders 4 Injection pump pressure 3480 to 3680 psi
Bore and stroke 4.02 x 5.42 inches 240 to 254 bar
102 x 138 mm Injector opening pressure 3480 psi
Horsepower 80 @ 2200 rpm 240 bar
60 kW @ 2200 rpm Fuel requirement
Firing order 1-3-4-2 For fuel requirements, refer to the engine Operator's
Low idle 1300 rpm Manual on your machine.
368 Hz Battery - Auxiliary power units
High idle 2350 rpm Type 6V DC
666 Hz Quantity 2
Compression ratio 18:1 AH rating 285AH
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at Battery - Engine starting and control system
least 75% of the highest cylinder. Type 12V DC, Group 31
Valve clearance, cold Quantity 1
Intake 0.010 in Reserve capacity @ 25A rate 200 minutes
0.254 mm
Starter motor
Exhaust 0.020 in
0.508 mm Current draw, no load 125A
Lubrication system Brush length, minimum 0.72 in

18.3 mm
Oil pressure, hot 50 psi
(at 2000 rpm) 3.45 bar Engine coolant
Oil capacity 9.5 quarts Capacity 17 quarts

(including filter) 9 liters 16 liters
Oil viscosity requirements Coolant temperature sending unit
Below 68°F / 20°C 5W-30 Installation torque 8-18 ft-lbs

11-24 Nm
-10° to 68°F / -23° to 20°C 10W-30
Temperature switch point 230°F
Above 15°F / -9°C 15W-40 110°C
Units ship with 15W-40. Alternator output 95A, 12V DC

Extreme operating temperatures may require the use of
Fan belt deflection 3/8 to 1/2 inch
Engine Operator Handbook on your machine. 10 to 12.5 mm
Part No. 106783 Z-135/70 2-9

Cummins B3.3T Engine

Displacement 199 cu in Fuel injection system
3.26 liters Injection pump make Zexel
Number of cylinders 4 Injection pressure 12,000 psi
Bore and stroke 3.74 x 4.53 inches 827 bar
95 x 115 mm Fuel requirement
Horsepower 80 @ 2200 rpm For fuel requirements, refer to the engine Operator's
60 kW @ 2200 rpm Manual on your machine.
Firing order 1-2-4-3 Battery - Auxiliary power units
Low idle 1300 rpm Type 6V DC
368 Hz Quantity 2
High idle 2350 rpm AH rating 285AH
666 Hz Reserve capacity @ 25A rate 745 minutes
Compression ratio 17:1 Battery - Engine starting and control system
Compression pressure Type 12V DC, Group 31

Pressure (psi or bar) of the lowest cylinder must be at Quantity 1
least 75% of the highest cylinder. Cold cranking ampere 1000A
Starter motor
Intake 0.014 in
0.35 mm Current draw, maximum 550A
Exhaust 0.020 in Engine cranking speed, minimum 130 rpm

0.5 mm Engine coolant
Lubrication system Capacity 9.1 quarts
Oil pressure, hot 31 to 72 psi 8.6 liters
(at 2000 rpm) 2 to 5 bar Alternator output 120A, 12V DC
Oil capacity 9 quarts Fan belt deflection 3/8 to 1/2 inch
(including filter) 8.5 liters 10 to 12.5 mm
Oil viscosity requirements
Below 68°F / 20°C 5W-30
-10° to 68°F / -23° to 20°C 10W-30
Above 14°F / -10°C 15W-40
Units ship with 15W-40.

Extreme operating temperatures may require the use of
Engine Operator Handbook on your machine. Genie policy. Product specifications are subject
2 - 10 Z-135/70 Part No. 106783

Perkins 1104C-44 Engine Oil viscosity requirements
Displacement 268.5 cu in Below 68°F / 20°C 5W-20

4.4 liters 10°F to 104°F / -12°C to 40°C 10W-30
Number of cylinders 4 Above 14°F / -10°C 15W-40
Bore and stroke 4.13 x 5 inches Units ship with 15W-40.
105 x 127 mm Extreme operating temperatures may require the use of
Horsepower alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Gross intermittent @ 2400 rpm 86 / 64 kW
Net intermittent @ 2400 rpm 83 / 62 kW Oil pressure sending unit
Firing order 1-3-4-2 Installation torque 8-18 ft-lbs

11-24 Nm
Low idle 1300 rpm
316 Hz Oil pressure switch point 8 psi
0.55 bar
High idle 2350 rpm
572 Hz Fuel injection system
Compression ratio 18.2:1 Injection pump make Bosch
Compression pressure Injector opening pressure 2200 psi

Pressure (psi or bar) of the lowest cylinder must be at 152 bar
least 75% of the highest cylinder. Fuel requirement
Governor centrifugal mechanical For fuel requirements, refer to the engine Operator's
Valve clearance, cold Manual on your machine.
Intake 0.008 in Battery - Auxiliary power units

0.2 mm Type 6V DC
Exhaust 0.018 in Quantity 2
0.45 mm AH rating 285AH
Lubrication system
Oil pressure, hot 40 to 60 psi
(at 2000 rpm) 2.8 to 4.1 bar Type 12V DC, Group 31
Quantity 1
Oil capacity 7.3 quarts Cold cranking ampere 1000A
(including filter) 6.9 liters Reserve capacity @ 25A rate 200 minutes

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

Starter motor
Engine coolant
Capacity 14 quarts
13.2 liters
Coolant temperature sending unit

11-24 Nm
Temperature switch point 230°F

110°C
Alternator output 85A @ 13.8V DC
Fan belt deflection 3/8 in

10 mm

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

Perkins 804D-33T Engine Oil viscosity requirements
Displacement 203 cu in Below 86°F / 30°C 5W-30

3.33 liters -4°F to 104°F / -20°C to 40°C 10W-30
Number of cylinders 4 Above 14°F / -10°C 15W-40
Bore and stroke 3.7 x 4.72 inches Units ship with 15W-40.
94 x 120 mm Extreme operating temperatures may require the use of
Horsepower alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Gross intermittent @ 2500 rpm 83 / 62 kW
Oil pressure sending unit
Induction system turbocharged
Firing order 1-3-4-2 11-24 Nm
Low idle 1300 rpm Oil pressure switch point 8 psi

316 Hz 0.55 bar
High idle 2350 rpm Fuel injection system

572 Hz
Injection pump make Bosch
Compression ratio 19.5:1
Injector opening pressure 2200 psi
Compression pressure 152 bar
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder. Fuel requirement
Governor centrifugal mechanical For fuel requirements, refer to the engine Operator's
Manual on your machine.
Intake 0.0098 in
0.25 mm Type 6V DC
Quantity 2
Exhaust 0.0098 in AH rating 285AH
0.25 mm Reserve capacity @ 25A rate 745 minutes
Lubrication system Battery - Engine starting and control system
Oil pressure, hot 40 to 60 psi Type 12V DC, Group 31

(at 2000 rpm) 2.8 to 4.1 bar Quantity 1
Oil capacity 10.6 quarts Reserve capacity @ 25A rate 200 minutes
(including filter) 10 liters

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

Starter motor Machine Torque Specifications

Current draw, normal load 200A Platform rotator
Cranking speed 250 rpm 1-8 center bolt, GR 5 480 ft-lbs
Engine coolant 651 Nm
3 /8 -16 bolts, GR 8 44 ft-lbs
Capacity 12.5 quarts
11.8 liters 60 Nm
Coolant temperature sending unit Turntable rotate assembly
Installation torque 8-18 ft-lbs Rotate bearing mounting bolts, lubricated 320 ft-lbs
11-24 Nm (3/4 -10 SHC) 434 Nm
Temperature switch point 230°F Rotate bearing mounting bolts, lubricated 180 ft-lbs
110°C (5/8 -11 SHC) 244 Nm
Alternator output 90A @ 12V DC Rotate drive hub mounting bolts, lubricated 80 ft-lbs
108 Nm
Fan belt deflection 3/8 to 1/2 in
9 to 12 mm Drive motor mounting bolts, dry 75 ft-lbs
102 Nm
Drive motor mounting bolts, lubricated 56 ft-lbs

76 Nm
Backlash plate mounting bolts, lubricated 320 ft-lbs

434 Nm
Drive motors and hubs
Drive hub mounting bolts, lubricated 180 ft-lbs

217 Nm
Drive motor mounting bolts, dry 75 ft-lbs

102 Nm
Drive motor mounting bolts, lubricated 56 ft-lbs

76 Nm
Engine vibration isolators
Mounting bolts, dry 60 ft-lbs

81 Nm
Mounting bolts, lubricated 45 ft-lbs

61 Nm

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

Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be replaced
anytime the seal has been broken. The O-ring
Your machine is equipped with Parker Seal-Lok® cannot be re-used if the fitting or hose end has
fittings and hose ends. Genie specifications require been tightened beyond finger tight.
that fittings and hose ends be torqued to
specification when they are removed and installed Note: The O-rings used in the Parker Seal Lok®
or when new hoses or fittings are installed. 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
SAE O-ring Boss Port number 49612).
(tube fitting - installed into Aluminum)
2 Lubricate the O-ring before installation.
SAE Dash size Torque
3 Be sure that the face seal O-ring is seated and
-4 11 ft-lbs / 14.9 Nm retained properly.
-6 23 ft-lbs / 31.2 Nm 4 Position the tube and nut squarely on the face
seal end of the fitting and tighten the nut finger
-8 40 ft-lbs / 54.2 Nm tight.
-10 69 ft-lbs / 93.6 Nm 5 Tighten the nut or fitting to the appropriate
-12 93 ft-lbs / 126.1 Nm torque per given size as shown in the table.
-16 139 ft-lbs / 188.5 Nm

6 Operate all machine functions and inspect the
hoses and fittings and related components to
-20 172 ft-lbs / 233.2 Nm confirm that there are no leaks.
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port Seal-Lok® Fittings

(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm -4 18 ft-lbs / 25 Nm
-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm
-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm
-10 105 ft-lbs / 142.4 Nm -10 60 ft-lbs / 80 Nm
-12 140 ft-lbs / 190 Nm -12 85 ft-lbs / 115 Nm
-16 210 ft-lbs / 284.7 Nm -16 110 ft-lbs / 150 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 180 ft-lbs / 245 Nm
Part No. 106783 Z-135/70 2 - 15

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8 Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
1/4 20 80 9 100 11.3 110 12.4 140 15.8 130 14.7

28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.4
5/16
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 75 101.6 80 108.4 110 149 93 126
1/2
20 64 86.7 85 115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
9/16
18 90 122 120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
5/8
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8 480 650 640 867 680 922 910 1233 770 1044
1
12 530 718 710 962 750 1016 990 1342 840 1139
1 7 590 800 790 1071 970 1315 1290 1749 1090 1477
1 /8 12 670 908 890 1206 1080 1464 1440 1952 1220 1654
1 7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
1 /4
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1 1 /2
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(mm) LUBED DRY LUBED DRY LUBED DRY LUBED DRY

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED DRY LUBED DRY LUBED DRY LUBED DRY
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
2 - 16 Z-135/70 Part No. 106783

July 2011 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: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly, six months, annually
Used to indicate the presence of
and every two years as specified on the
Maintenance Inspection Report.
Failure to perform each procedure death or serious injury.
as presented and scheduled could
result in death, serious injury or
substantial machine damage.
which, if not avoided, could result
Immediately tag and remove from service a in death or serious injury.
damaged or malfunctioning machine.
Repair any machine damage or malfunction potentially hazardous situation
before operating machine. which, if not avoided, may cause
minor or moderate injury.
Use only Genie approved replacement parts.
Unless otherwise specified, perform each potentially hazardous situation
maintenance procedure with the machine in the which, if not avoided, may result in
following configuration: property damage.
• Machine parked on a firm, level surface Indicates that a specific result is expected after
• Boom in the stowed position performing a series of steps.
• Turntable rotated with the boom between Indicates that an incorrect result has occurred
the circle-end (yellow arrow) wheels after performing a series of steps.
• 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 3-1

Section 3 • Scheduled Maintenance Procedures July 2011
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

Note: The following symbols have been used in this The pre-delivery preparation report contains
manual to help communicate the intent of the checklists for each type of scheduled inspection.
instructions. When one or more of the symbols
appear at the beginning of a maintenance Make copies of the Pre-delivery Preparation report
procedure, it conveys the meaning below. to use for each inspection. Store completed forms
as required.
Maintenance Schedule
Indicates that tools 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
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
have been divided into five subsections—A, B, C,
D and E. Use the following chart to determine which
group(s) of procedures are required to perform a
Indicates that a cold engine will be scheduled inspection.
required to perform this procedure.
Inspection Checklist
Indicates that a warm engine will be Daily or every 8 hours A

required to perform this procedure.
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C

Indicates that dealer service is required
to perform this procedure. Annual or every 1000 hours A+B+C+D
Two years or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report 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
Pre-Deliveryy Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and reinspect it. After repair, place
a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Terex South Dakota, Inc USA Genie UK

500 Oak Wood Road The Maltings, Wharf Road
PO Box 1150 Grantham, Lincolnshire
Watertown, SD 57201-6150 NG31- 6BH England
(605) 882-4000 (44) 1476-584333
Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South
Dakota, Inc. 133192 Rev D
3-4 Z-135/70 Part No. 106783

Maintenance Inspection Report

Model Checklist A - Rev G Y N R Checklist B - Rev D Y N R
A-1 Manuals and decals B-1 Batteries
Serial number
A-2 Pre-operation B-2 Electrical wiring
Date inspection B-3 Key switches
A-3 Function tests B-4 Exhaust system
Hour meter A-4 Engine maintenance - B-5 Engine oil cooler and
Deutz models cooling fins -
Machine owner A-5 Engine maintenance - Deutz models
Cummins models B-6 Tires and wheels
Inspected by (print)
A-6 Engine maintenance - B-7 Brake configuration
Inspector signature Perkins models
B-8 Drive hub oil level
A-7 Hydraulic return filter
B-9 Ground control override
Inspector title condition indicator
B-10 Platform self leveling
A-8 Inspect filter/separator -
Inspector company Perkins models B-11 Engine idle select
A-9 Drain fuel filter/ B-12 Drive brakes
Instructions separator - Deutz and B-13 Drive speed - stowed
· Make copies of this report to use for Cummins models
each inspection. B-14 Drive speed - raised
Perform after 40 hours: or extended
· Select the appropriate checklist(s) for
A-10 30 Day Service B-15 Alarm and beacon
the type of inspection to be performed.
Perform every 100 hours: B-16 Hydraulic oil analysis
Daily or 8 hour A-11 Grease rotation B-17 Replace fuel filter/
Inspection: A bearing separator -
Quarterly or 250 hour Perform after 150 hours: Perkins models
Inspection: A+B A-12 Drive hub oil B-18 Engine RPM
Semi-annual or 500 hour B-19 Safety envelope
Inspection: A+B+C limit switches
Annual or 1000 hours B-20 Primary boom
Inspection: A+B+C+D angle sensor
2 Year or 2000 hour B-21 Fuel and hydraulic
Inspection: A+B+C+D+E tank cap venting
B-22 Engine maintenance -
· Place a check in the appropriate box Cummins models
after each inspection procedure is
completed.
Comments
· 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

MAINTENANCE INSPECTION REPORT
Model Checklist C - Rev D Y N R Checklist E - Rev D Y N R

C-1 Engine maintenance - E-1 Replace hydraulic oil
Serial number Deutz models E-2 Engine maintenance -
Date C-2 Engine maintenance - Cummins models
Cummins models E-3 Engine maintenance -
Hour meter C-3 Engine maintenance - Perkins 804D-33T
Perkins models models
Machine owner C-4 Grease platform Perform every 2 years:
overload (if equipped) E-4 Engine maintenance -
Inspected by (print) C-5 Test the platform Perkins 804D-33T
overload (if equipped) models
Inspector signature
Perform every 3,000 hours:
Inspector title Checklist D - Rev D Y N R E-5 Engine maintenance -
D-1 Boom wear pads Deutz models
Inspector company D-2 Free-wheel Perform every 5,000 hours:
configuration E-6 Engine maintenance -
Instructions Deutz TD2011L04i
D-3 Drive hub oil
· Make copies of this report to use for models
each inspection. D-4 Rotation gear backlash
Perform every 6,000 hours:
· Select the appropriate checklist(s) for D-5 Replace hydraulic filters
E-7 Engine maintenance -
the type of inspection to be performed. D-6 Engine maintenance -
Perkins 804D-33T
Deutz models
Daily or 8 hour models
D-7 Engine maintenance -
Inspection: A Perform every 8,000 hours:
Cummins models
Quarterly or 250 hour E-8 Engine maintenance -
D-8 Engine maintenance -
Inspection: A+B Perkins 1104C-44
Perkins models
models
Semi-annual or 500 hour D-9 Turntable rotation bolts
Inspection: A+B+C Perform every 12,000 hours:
D-10 Turntable bearing
Annual or 1000 hours E-9 Engine maintenance -
wear
Inspection: A+B+C+D Perkins 804D-33T
models
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

REV G
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Note: Genie specifications require that this and damage.
procedure be performed daily or every 8 hours, Result: The machine is equipped with all
whichever comes first. required decals, and all decals are legible and in
Maintaining the operator’s and safety manuals in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each machine required decals, or one or more decals are
and should be stored in the container provided in illegible or in poor condition. Remove the
the platform. An illegible or missing manual will not machine from service until the decals are
provide safety and operational information replaced.
necessary for a safe operating condition.
4 Always return the manuals to the storage
In addition, maintaining all of the safety and container after use.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators Note: Contact your authorized Genie distributor or
and personnel to the many possible hazards Genie Industries if replacement manuals or decals
associated with using this machine. They also are needed.
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

CHECKLIST A PROCEDURES REV G
A-2 A-3
Perform Pre-operation Perform Function Tests
Inspection Completing the function tests is essential to safe
Completing a pre-operation inspection is essential machine operation. Function tests are designed to
to safe machine operation. The pre-operation discover any malfunctions before the machine is
inspection is a visual inspection performed by the put into service. A malfunctioning machine must
operator prior to each work shift. The inspection is never be used. If malfunctions are discovered, the
designed to discover if anything is apparently wrong machine must be tagged and removed from
with a machine before the operator performs the service.
function tests. The pre-operation inspection also Complete information to perform this procedure is
serves to determine if routine maintenance available in the appropriate operator's manual. Refer
procedures are required. to the Operator's Manual on your machine.
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

REV G CHECKLIST A PROCEDURES
A-4 A-5
Perform Engine Maintenance - Perform Engine Maintenance -
Deutz Models Cummins Models
Note: Engine specifications require that this Note: Engine specifications require that this
procedure be performed daily or every 8 hours, procedure be performed daily or every 8 hours,
whichever comes first. whichever comes first.
Proper engine maintenance, following the engine Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential manufacturer's maintenance schedule, is essential
to good engine performance and service life. to good engine performance and service life.
Failure to perform the maintenance procedures Failure to perform the maintenance procedures
can lead to poor engine performance and can lead to poor engine performance and
component damage. component damage.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
Deutz BF4L2011 Operation Manual Cummins B4.5 Operation and Maintenance Manual
(Deutz part number 0297 9929) OR the (Cummins part number 4021389-01) OR the
Deutz TD2011 Operation Manual Cummins B3.3 Operation and Maintenance Manual
(Deutz part number 0312 3547). (Cummins part number 3666417-00).
Deutz BF4L2011 Operation Manual Cummins B4.5 Operation and

Genie part number 84794 Maintenance Manual
Genie part number 107527
Deutz TD2011 Operation Manual
Genie part number 139320 Cummins B3.3 Operation and
Maintenance Manual
To access the engine:
1 Remove the engine tray retaining fastener To access the engine:
located under the engine tray. Swing the engine
tray out and away from the machine. 1 Remove the engine tray retaining fastener
2 Install the fastener that was just removed tray out and away from the machine.
through the engine tray and into the engine tray
anchor hole in the turntable. 2 Install the fastener that was just removed
Crushing hazard. Failure to install anchor hole in the turntable.
the fastener into the engine tray
anchor hole to secure the engine Crushing hazard. Failure to install
tray from moving could result in the fastener into the engine tray
death or serious injury. anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Part No. 106783 Z-135/70 3-9

A-6 A-7
Perform Engine Maintenance - Check the Hydraulic Return
Perkins Models Filter Condition Indicator
procedure be performed daily or every 8 hours, procedure be performed daily or every 8 hours,
whichever comes first. whichever comes first.
Proper engine maintenance, following the engine Maintaining the hydraulic filters in good condition is
manufacturer's maintenance schedule, is essential essential to good system performance and safe
to good engine performance and service life. machine operation. The filter condition indicator will
Failure to perform the maintenance procedures show when the hydraulic flow is bypassing a
can lead to poor engine performance and clogged filter. If the filter is not frequently checked
component damage. and replaced, impurities will remain in the hydraulic
system and cause component damage.
Required maintenance procedures and additional
engine information are available in the Note: There are four hydraulic filters on the
Perkins 1100 Series User's Handbook machine: one tank return filter, one medium
(Perkins part number TPD 1477) OR the pressure filter, one high pressure filter and one
Perkins 800 Series Operation and Maintenance drive motor case drain filter. Only the tank return
Manual (Perkins part number SEBU7853-00). filter has a condition indicator.
1 Start the engine from the ground controls.
Perkins 1100 Series User's Handbook
Genie part number 107526 2 Press and release the engine idle select button
to change the engine rpm to high idle.
Perkins 800 Series Operation and
Maintenance Manual
1 Remove the engine tray retaining fastener

tray out and away from the machine.
2 Install the fastener that was just removed
anchor hole in the turntable.
Crushing hazard. Failure to install
anchor hole to secure the engine
3 - 10 Z-135/70 Part No. 106783

3 Open the ground control side turntable cover and A-8

inspect the filter condition indicator gauge.
Inspect the Fuel Filter/ Water
a 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, well-
ventilated area away from heaters,
a filter condition indicator gauge
sparks, flames and lighted
Result: The needle on the gauge should be tobacco. Always have an
operating in the green area. approved fire extinguisher within
easy reach.
Result: If the needle is in the red area, this
indicates that the hydraulic filter is being Note: Perform this procedure with the engine off.
bypassed and the filter needs to be replaced.
1 Open the engine side turntable cover and locate
See D-5, Replace the Hydraulic Filter Elements.
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.
Part No. 106783 Z-135/70 3 - 11

3 Loosen the vent plug located on the fuel filter/ A-9

water separator head.
Drain the Fuel Filter/ Water
Separator - Deutz and Cummins
a
Models
d
c
procedure be performed daily or every 8 hours,
b 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.
a vent plug
b drain plug
Explosion and fire hazard. Engine
c filter bowl
d separator head fuels are combustible. Perform this
4 Loosen the drain plug located at the bottom of ventilated area away from heaters,
the bowl. Allow the water to drain into a suitable sparks, flames and lighted
container until fuel starts to come out. tobacco. Always have an
Immediately tighten the drain plug. approved fire extinguisher within
5 Tighten the vent plug. easy reach.
Note: If the fuel filter/water separator is completely Note: Perform this procedure with the engine off.
drained, you must prime the fuel filter/water 1 Open the engine side turntable cover and locate
separator before starting the engine. See B-17, the fuel filter/water separator.
Replace The Fuel Filter/Water Separator Element -
Perkins Models, for instructions on how to prime 2 Loosen the drain plug at the bottom of the filter.
the fuel filter/water separator. Allow the water to drain into a suitable container
until fuel starts to come out. Immediately tighten
6 Clean up any fuel that may have spilled. the drain plug. Do not completely drain the filter.
7 Start the engine from the ground controls and 3 Clean up any fuel that may have spilled.
check the fuel filter/water separator and vent
plug for leaks. 4 Start the engine from the ground controls and
check the fuel filter/water separator and vent
Explosion and fire hazard. If a fuel plug for leaks.
leak is discovered, keep any
additional personnel from entering Explosion and fire hazard. If a fuel
the area and do not operate the leak is discovered, keep any
machine. Repair the leak additional personnel from entering
immediately. the area and do not operate the
machine. Repair the leak
immediately.
3 - 12 Z-135/70 Part No. 106783

A-10 A-11
Perform 30 Day Service 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 Note: Genie specifications require that this
comes first. After this interval, refer to the procedure be performed every 100 hours of
maintenance checklists for continued scheduled operation. Perform this procedure more often if
maintenance. dusty conditions exist.
1 Perform the following maintenance procedures: Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
• A-11 Grease the Turntable Rotation machine performance and service life. Continued
Bearing and Rotate Gear use of an improperly greased bearing and gear will
result in component damage.
• B-6 Inspect the Tires, Wheels and
Lug Nut Torque 1 Locate the grease fitting below the ground
• B-8 Check the Drive Hub Oil Level and control box.
Fastener Torque 2 Pump grease into the turntable rotation bearing.
• C-2 Perform Engine Maintenance - Rotate the turntable in increments of 4 to 5
Cummins Models inches / 10 to 13 cm at a time and repeat this
step until the entire bearing has been greased.
• C-3 Perform Engine Maintenance -
Perkins Models 3 Apply grease to each tooth of the drive gear,
located under the turntable.
• D-5 Replace the Hydraulic Filter
Elements Grease Specification
• D-6 Perform Engine Maintenance -
Deutz Models Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
• D-9 Check the Turntable Rotation
Bearing Bolts
Part No. 106783 Z-135/70 3 - 13

A-12
Replace the Drive Hub Oil
Note: Drive hub specifications require that this one-

time 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

REV D
Checklist B Procedures
B-1 1 Put on protective clothing and eye wear.
Inspect the Batteries 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
Note: Genie requires that this procedure be power unit batteries and the engine starting battery.
performed every 250 hours or quarterly, whichever
comes first. 3 Be sure that the battery cable connections are
free of corrosion.
Proper battery condition is essential to good engine
Note: Adding terminal protectors and a corrosion
performance and operational safety. Improper fluid
preventative sealant will help eliminate corrosion on
levels or damaged cables and connections can
the battery terminals and cables.
result in engine component damage and hazardous
conditions. There are 3 batteries on the machine. 4 Be sure that the battery retainers and cable
One is used for starting the engine and powering connections are tight.
the control system. The other two batteries are 6V
DC deep cycle batteries which are wired in series to 5 Be sure that the battery separator wire
provide power for the auxiliary power units. The connections are tight.
batteries are charged by the alternator through a 6 Fully charge the battery(s) and allow the
battery separator. battery(s) to rest at least 6 hours.
Electrocution/burn hazard. Contact 7 Remove the battery vent caps and check the
with hot or live circuits could result specific gravity of each battery cell with a
in death or serious injury. Remove hydrometer. Note the results.
all rings, watches and other
jewelry. 8 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
Bodily injury hazard. Batteries follows:
contain acid. Avoid spilling or
contacting battery acid. Neutralize • Add 0.004 to the reading of each cell for
battery acid spills with baking soda every 10° / 5.5° C above 80° F / 26.7° C.
and water. • Subtract 0.004 from the reading of each cell for
Note: Perform this test after fully charging the every 10° / 5.5° C below 80° F / 26.7° C.
batteries. Result: All battery cells display an adjusted
Note: For a more accurate determination of the specific gravity of 1.277 or higher. The battery
battery condition, fully charge the batteries and is fully charged. Proceed to step 12.
allow the batteries to rest 24 hours before Result: One or more battery cells display a
performing this procedure to allow the battery cells specific gravity of 1.217 or below. Proceed to
to equalize. step 9.
Part No. 106783 Z-135/70 3 - 15

CHECKLIST B PROCEDURES REV D
9 Perform an equalizing charge OR fully charge B-2

the battery(s) and allow the battery(s) to rest at
least 6 hours. Inspect the Electrical Wiring
10 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Note: Genie requires that this procedure be
11 Check the ambient air temperature and adjust performed every 250 hours or quarterly, whichever
the specific gravity reading for each cell as comes first.
follows:
Maintaining electrical wiring in good condition is
• Add 0.004 to the reading of each cell for essential to safe operation and good machine
every 10° / 5.5° C above 80° F / 26.7° C. performance. Failure to find and replace burnt,
• Subtract 0.004 from the reading of each cell for chafed, corroded or pinched wires could result in
every 10° / 5.5° C below 80° F / 26.7° C. unsafe operating conditions and may cause
component damage.
Result: All battery cells display a specific gravity
of 1.277 or greater. The battery is fully charged. Electrocution/burn hazard. Contact
Proceed to step 12. with hot or live circuits could result
in death or serious injury. Remove
Result: The difference in specific gravity all rings, watches and other
readings between cells is greater than 0.1 OR jewelry.
the specific gravity of one or more cells is less
than 1.177. Replace the battery. 1 Open the engine side turntable cover.
12 Check the battery acid level. If needed, 2 Remove the engine pivot plate retaining
replenish with distilled water to 1/8 inch / 3 mm fastener. Swing the engine pivot plate out away
below the bottom of the battery fill tube. Do not from the machine.
overfill.
13 Install the vent caps and neutralize any
electrolyte that may have spilled.
14 Install the cover for the auxiliary power unit
batteries.
a engine pivot plate anchor hole

b engine pivot plate retaining fastener
3 - 16 Z-135/70 Part No. 106783

REV D CHECKLIST B PROCEDURES
3 Locate the engine pivot plate anchor hole at the 11 Inspect for a liberal coating of dielectric grease
pivot end of the engine pivot plate. in the following location:
4 Install the bolt that was just removed into the • Wire harness connectors to DCON module
anchor hole to secure the engine pivot plate 12 Start the engine from the ground controls and
from moving. raise the secondary boom above the turntable
Crushing hazard. Failure to install covers.
the bolt into the engine pivot plate Component damage hazard. Be
to secure it from moving could sure the hydraulic supply hoses to
result in death or serious injury. the function and drive pumps are
5 Inspect the following areas for burnt, chafed, not kinked before starting the
corroded, pinched and loose wires: engine.
• Engine wiring harness 13 Inspect the turntable area for burnt, chafed and
pinched cables.
• Battery area wiring
6 Open the ground controls side turntable cover. 14 Lower the secondary boom to the stowed
position and turn the engine off.
7 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires: 15 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
• Inside of the ground control box
• Cable track on the boom
• Hydraulic manifold wiring
• Cables on the boom, jib boom and jib boom
• Battery area wiring pivot area
• Hydraulic oil cooler wiring • Jib boom/platform rotate manifold
8 Inspect for a liberal coating of dielectric grease • Platform control box
in the following locations:
• Inside of the platform control box
• All wire harness connectors to
16 Inspect for a liberal coating of dielectric grease
ground control box
in the following location:
• Wire harness connectors to SCON module
• All wire harness connectors to
9 Open the hydraulic manifold box covers at both platform control box
sides of the drive chassis.
17 Remove the engine pivot plate retaining
10 Inspect the following areas for burnt, chafed, fastener from the engine pivot plate anchor hole
corroded, pinched and loose wires: at the pivot end of the engine pivot plate.
• Hydraulic manifold wiring 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.
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

B-3
STOP
Test the Key Switches 00000

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 Run
hazardous operating situation.
Service
There are two key switches on the machine - the Bypass
Main key switch and the Service Bypass/Recovery Recovery

key switch.
The Main key switch controls machine operation 1 Open the ground controls side turntable side
from the ground or platform controls. cover.
When the Service Bypass/Recovery key switch is 2 Pull out the red Emergency Stop button to the
turned to the service bypass position, the primary on position at both the ground and platform
boom can be raised while the axles are retracted. controls.
This feature of the machine is especially helpful for
3 At the ground controls, turn the service
storage purposes or when loading the machine for
bypass/recovery key switch to the run position.
transport.
4 Turn the main key switch to ground control, start
Note: When the boom is raised with the axles the engine and then turn the key switch to
retracted, the boom cannot be rotated past either platform control.
circle-end wheel.
5 Check any machine function from the ground
When the Service Bypass/Recovery key switch is controls.
turned and held to the recovery position, the
auxiliary power units will turn on and fully retract the Result: The machine functions should not
boom and then lower the boom. This feature of the operate.
machine is especially helpful if the operator in the 6 Turn the main key switch to ground control.
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.
3 - 18 Z-135/70 Part No. 106783

7 Check any machine function from the platform 16 Remove the key from the main key switch and
controls. insert the key into the service bypass/recovery
key switch.
Result: The machine functions should not
operate. 17 Turn and hold the service bypass/recovery key
switch to the recovery position.
8 Turn the main key switch to the off position.
Result: The boom should return to the stowed
Result: The engine should stop and no
position.
functions should operate.
18 Turn the service bypass/recovery key switch to
9 Turn the main key switch to ground control and
the run position.
start the engine.
19 Remove the key from the service
10 Attempt to raise the primary boom.
bypass/recovery key switch and insert the key
Result: The boom should not raise. into the main key switch.
Note: The primary boom will not raise until the 20 Turn the main key switch to the off position.
axles are fully extended.
21 Close the turntable side cover.
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.
Part No. 106783 Z-135/70 3 - 19

B-4 2 Locate the engine pivot plate anchor hole at the

pivot end of the engine pivot plate.
Check the Exhaust System
anchor hole to secure the engine pivot plate
from moving.
Note: Engine specifications require that this Crushing hazard. Failure to install
procedure be performed every 250 hours or the bolt into the engine pivot plate
quarterly, whichever comes first. to secure it from moving could
Maintaining the exhaust system is essential to
good engine performance and service life. 4 Be sure that all nuts and bolts are tight.
Operating the engine with a damaged or leaking 5 Inspect all welds for cracks.
exhaust system can cause component damage
and unsafe operating conditions. 6 Inspect for exhaust leaks (i.e., carbon buildup)
around seams and joints.
Bodily injury hazard. Do not
inspect while the engine 7 Remove the engine pivot plate retaining
is running. Remove the key to fastener from the engine pivot plate anchor hole
secure from operation. at the pivot end of the engine pivot plate.
Bodily injury hazard. Beware of 8 Swing the engine pivot plate in towards the
hot engine components. Contact machine.
with hot engine components may 9 Install the bolt that was just removed into the
cause severe burns. original hole to secure the engine pivot plate.
1 Remove the engine pivot plate retaining Crushing hazard. Failure to install
fastener. Swing the engine pivot plate out away the bolt into the engine pivot plate
from the machine. to secure it from moving could

3 - 20 Z-135/70 Part No. 106783

B-5 Cooling and blower fins:

Check the Engine Oil Cooler and 5 Inspect the fan blower fins for physical damage.
Cooling Fins - Deutz Models 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
Note: Engine specifications require that this foreign material.
procedure be performed every 250 hours or
quarterly, whichever comes first. 8 If needed, clean the cylinder head cooling
passages and fins of debris and foreign
Maintaining the oil cooler in good condition is material.
essential for good engine performance. Operating
a machine with a damaged oil cooler may result in 9 Install the engine side cover and tighten the
engine damage. Also, restricting air flow through retaining fasteners.
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

B-6 B-7
Inspect the Tires, Wheels and Confirm the Proper
Lug Nut Torque Brake Configuration
Note: Genie specifications require that this Note: Engine specifications require that this
procedure be performed every 250 hours or procedure be performed every 250 hours or
quarterly, whichever comes first. quarterly, whichever comes first.
Maintaining the tires and wheels, including proper Proper brake configuration is essential to safe
wheel fastener torque, is essential to safe operation and good machine performance.
operation and good performance. Tire and/or Hydrostatic brakes and hydraulically-released,
wheel failure could result in a machine tip-over. spring-applied individual wheel brakes can appear
Component damage may also result if problems to operate normally when they are actually not fully
are not discovered and repaired in a timely fashion. operational.
Note: The tires on this machine are foam filled and 1 Check each drive hub disconnect cap to be
do not need air added to them. sure it is in the engaged position.
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear. disengaged position
2 Check each wheel for damage, bends and

cracked welds.
3 Check each lug nut for proper torque. Refer to engaged position
Section 2, Specifications.
3 - 22 Z-135/70 Part No. 106783

2 Be sure the free-wheel valve on the drive pump B-8

is closed (clockwise).
Check the Drive Hub Oil Level
Note: The free-wheel valve is located on the drive
pump.
and Fastener Torque
b Note: Genie specifications require that this

a c quarterly, whichever comes first.
d
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and
continued use may cause component damage.
a drive pump Drive hubs:
b screwdriver
c lift pump
1 Drive the machine to rotate the hub until the
d free-wheel valve
plugs are located one at the side and the other
Note: The free-wheel valve should always remain at the other side.
closed.
a
a 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
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

Turntable rotate drive hubs: B-9

1 Remove the fixed turntable cover at the ground Test the Ground Control
controls side of the machine. Override
2 Remove the plug located on the side of the hub
Note: Genie specifications require that this
and check the oil level.
Result: The oil level should be even with the quarterly, whichever comes first.
bottom of the plug hole.
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.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
a drive hub plugs
3 If necessary, add oil until the oil level is even

with the bottom of the plug hole. Refer to
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

B-10 4 Press and hold a function enable/speed select

button and adjust the platform to zero degrees
Test the Platform Self-leveling 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.
quarterly, whichever comes first. Result: The platform should remain level at
all times to within ±2 degrees.
Automatic platform self-leveling throughout
the full cycle of primary boom raising and lowering Note: If the platform becomes out of level, the tilt
is essential for safe machine operation. The alarm will sound and the Platform Not Level
platform is maintained level by the communication Indicator will flash at the ground controls. The
between the platform level sensor and the turntable platform level up/down buttons will only work in the
level sensor. If the platform becomes out of level, direction that will level the platform. Level the
the computer at the ground controls will open the platform until the indicator light turns off.
appropriate solenoid valve(s) at the platform
6 Push and hold a function enable/speed select
manifold to maintain a level platform.
button and fully lower the primary boom.
A platform self-leveling failure creates an unsafe
working condition for platform and ground Result: The platform should remain level at
personnel. all times to within ±2 degrees.
1 Start the engine from the ground controls. Note: If the platform becomes out of level, the tilt
alarm will sound and the Platform Not Level
2 Press and hold a function enable/speed select
Indicator will flash at the ground controls. The
button and fully retract the primary boom.
platform level up/down buttons will only work in the
3 Push one of the LCD direction that will level the platform. Level the
screen buttons shown until platform until the indicator light turns off.
platform angle is
Note: If the platform does not level properly, see
displayed.
Repair Procedure 2-3, How to Calibrate the Platform
Level Sensor.
Part No. 106783 Z-135/70 3 - 25

B-11 5 Push and release the rpm select button until low
rpm is selected (turtle symbol).
Test the Engine Idle Select
Result: The engine should return to low idle.
Operation
6 Turn the key switch to platform controls.
procedure be performed every 250 hours or 7 At the platform controls, press the engine idle
quarterly, whichever comes first. select button until high idle (rabbit symbol) is
selected.
A properly operating engine idle select function
is essential to good engine performance and safe Result: The engine should change to high idle.
machine operation. There are three settings.
a b c
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. d
Foot switch activated high idle (rabbit and foot a foot switch activated high idle
switch symbols) should be used for normal indicator light
b low idle indicator light
machine operation. This selection activates high c high idle indicator light
idle only when the foot switch is pressed down. d engine rpm select button
1 Turn the key switch to ground controls. 8 Press the engine idle select button until low idle
(turtle symbol) is selected.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform Result: The engine should change to low idle.
controls.
9 Press the engine idle select button until the foot
3 Start the engine from the ground controls. switch activated high idle (rabbit and foot switch
symbol) is selected.
4 Push and release the rpm select button until
high rpm is selected (rabbit symbol). Result: The engine should not change to
high idle.
Result: The engine should 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

B-12 B-13
Test the Drive Brakes Test the Drive Speed -
Stowed Position

procedure be performed every 250 hours or Note: Genie specifications require that this
quarterly, whichever comes first. procedure be performed every 250 hours or
Proper brake action is essential to safe machine quarterly, whichever comes first.
operation. The drive brake function should operate Proper drive function movement is essential to safe
smoothly, free of hesitation, jerking and unusual machine operation. The drive function should
noise. Hydraulically-released individual wheel respond quickly and smoothly to operator control.
brakes can appear to operate normally when they Drive performance should also be free of
are actually not fully operational. hesitation, jerking and unusual noise over the
Collision hazard. Be sure that the entire proportionally controlled speed range.
machine is not in free-wheel or Note: Select a test area that is firm, level and free
partial free-wheel configuration. of obstructions.
Refer to B-7, Confirm the Proper
Brake Configuration. Note: Perform this procedure with the boom in the
stowed position.
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.
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
4 Choose a point on the machine (i.e., contact
when crossing the start and finish lines.
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 start line. Begin timing when your
5 Bring the machine to top drive speed before
reference point on the machine crosses the
reaching the test line. Release the drive
start line.
controller when your reference point on the
machine crosses the test line. 6 Continue at full speed and note the time when
the machine reference point crosses the finish
6 Measure the distance between the test line and
line. Refer to Section 2, Specifications.
your machine reference point. Refer to
Part No. 106783 Z-135/70 3 - 27

B-14 7 Continue at full speed and note the time when

Test the Drive Speed - line. Refer to Section 2, Specifications.
Raised or Extended Position 8 Lower the boom to the stowed position.
9 Extend the primary boom 12 inches / 0.3 m.
10 Choose a point on the machine; i.e., contact
Note: Genie specifications require that this patch of a tire, as a visual reference for use
procedure be performed every 250 hours or when crossing the start and finish lines.
quarterly, whichever comes first.
Proper drive function movement is essential to safe reaching the start line. Begin timing when your
machine operation. The drive function should reference point on the machine crosses the
respond quickly and smoothly to operator control. start line.
Drive performance should also be free of
12 Continue at top speed and note the time when
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
line. Refer to Section 2, Specifications.
of obstructions.
1 Create start and finish lines by marking two lines
on the ground 40 feet / 12.2 m apart.
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.
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
3 - 28 Z-135/70 Part No. 106783

B-15 B-16
Test the Alarm and Optional Perform Hydraulic Oil Analysis
Flashing Beacon
procedure be performed every 250 hours or Note: Genie specifications require that this
quarterly, whichever comes first. procedure be performed every 250 hours or
An alarm and optional flashing beacon are installed
to alert operators and ground personnel of Replacement or testing of the hydraulic oil is
machine proximity and motion. There are four essential for good machine performance and
alarm option modes that can be activated based on service life. Dirty oil and a clogged suction strainer
user preference or requirement. Refer to Display or hydraulic filters may cause the machine to
Module in the Repair Section for information. perform poorly and continued use may cause
component damage. Extremely dirty conditions
1 Turn the key switch to ground control and pull
may require oil changes to be performed more
out the red Emergency Stop button to the on
often.
position at both the ground and platform
controls. Note: Before replacing the hydraulic oil, the oil may
Result: The alarm should sound twice. The be tested by an oil distributor for specific levels of
flashing beacon (if equipped) should be on and contamination to verify that changing the oil is
flashing. 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

B-17 3 Loosen the vent plug located on the inline fuel

filter/water separator head.
Replace the Inline Fuel Filter/
4 Place a suitable container under the filter bowl.
Water Separator Element -
Perkins Models 5 Loosen the drain plug located at the bottom of
the bowl. Completely drain the fuel from the
bowl.
e a
Replacing the inline fuel filter/water separator

element is essential for good engine performance b
and service life. A dirty or clogged filter may cause
the engine to perform poorly and continued use
may cause component damage. Extremely dirty
c
conditions may require that the filter be replaced
more often.
Explosion and fire hazard. Engine d
fuels are combustible. Perform this
procedure in an open, well- a vent plug
ventilated area away from heaters, b filter element
sparks, flames and lighted c filter bowl
d drain plug
tobacco. Always have an e fuel filter/water separator head
approved fire extinguisher within
easy reach. 6 Remove the filter element from the filter head.
Note: Perform this procedure with the engine off. 7 Remove the filter bowl from the old filter
element and install the bowl onto the new filter
1 Open the engine side turntable cover and locate element. Tighten the drain plug.
the fuel filter/water separator next to the
medium pressure filter. 8 Fill the element and bowl with clean diesel fuel.
2 Tag, disconnect and plug the fuel line from the 9 Apply a thin layer of oil onto the element gasket.
fuel tank at the inline fuel filter/water separator
head.
3 - 30 Z-135/70 Part No. 106783

10 Install the filter/bowl assembly onto the filter B-18

head and tighten it securely by hand.
Check and Adjust the
Note: The filter/bowl assembly must be full of fuel
when it is installed onto the filter head or the fuel
Engine RPM
system will have to be bled.
11 Tighten the vent plug.

12 Clean up any diesel fuel that may have spilled Note: Genie specifications require that this
during the procedure. procedure be performed every 250 hours or
13 Use a permanent ink marker to write the date
and number of hours from the hour meter on Maintaining the engine rpm at the proper setting for
the filter. both low and high idle is essential to good engine
performance and service life. The machine will not
14 Install the fuel tank line onto the fuel filter/water
operate properly if the rpm is incorrect and
separator head. Tighten the hose clamp.
Deutz models:

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

3 Loosen the locknut on the low idle adjustment Cummins and Perkins models:
screw.
1 Remove the engine pivot plate retaining
fastener. Swing the engine pivot plate out away
from the machine.

2 Locate the engine pivot plate anchor hole at the

a 3 Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
a low idle adjustment screw
from moving.
4 Adjust the low idle adjustment screw until low Crushing hazard. Failure to install
idle is 1500 rpm. Tighten the locknut. the bolt into the engine pivot plate
5 Push and hold the function enable/high speed to secure it from moving could
button. Note the engine rpm on the display. result in death or serious injury.
Result: High idle should be 2350 rpm. 4 Start the engine from the ground controls.
If the high idle is correct, disregard adjustment Component damage hazard. Be

step 6. sure the hydraulic supply hoses to
the function and drive pumps are
6 Loosen the yoke lock nut. Turn the high idle not kinked before starting the
adjustment nut and solenoid boot engine.
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the 5 Push one of the LCD
yoke lock nut and recheck the rpm. screen buttons shown until
engine rpm is displayed.
Note: Be sure the solenoid fully retracts when
activating high idle. Result: Low idle should be 1300 rpm.
Skip to step 7 if the low idle rpm is correct.
3 - 32 Z-135/70 Part No. 106783

6 Loosen the low idle lock nut. Turn the low idle 7 Push and hold the function enable/high speed
adjustment screw clockwise to increase the rpm button. Note the engine rpm on the display.
or counterclockwise to decrease the rpm.
Result: High idle should be 2350 rpm.
Tighten the low idle lock nut and confirm the
rpm. If the high idle is correct, disregard adjustment
step 8.
a
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.
c b
9 Remove the engine pivot plate retaining fastener
Perkins models from the engine pivot plate anchor hole at the
b solenoid boot
c yoke lock nut 10 Swing the engine pivot plate in towards the
machine.
the bolt into the engine pivot plate
a b c
Cummins models
b solenoid cable
c rpm solenoid
Part No. 106783 Z-135/70 3 - 33

B-19 4 Remove the upper cover retaining fasteners and

remove the upper cover from turntable.
Test the Safety Envelope Limit
Crushing hazard. The turntable
Switches riser lower cover could become
Note: Genie specifications require that this unbalanced and fall when
procedure be performed every 250 hours or removed from the turntable if not
quarterly, whichever comes first. properly supported and secured to
the lifting device.
Testing the machine envelope safety limit switches
is critical to safe machine operation. If the boom is 5 Locate the secondary boom #1 retracted safety
allowed to operate when a safety switch is not limit switch (LSS1RS) inside the secondary
functioning correctly, the machine stability could be boom tube.
compromised and may tip over. 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
extended and the boom in the stowed position.
and red tie wraps attached to the limit switch cable.
Note: This procedure may require two people.
Secondary Boom #1 Retracted Safety Limit
7 Fully raise the secondary boom. Do not extend
Switch, LSS1RS
the boom. Turn the machine off.
1 Working at the platform end of the turntable, 8 Locate and disconnect the deutsch connector to
support and secure the lower turntable riser LSS1RS.
end cover to a suitable lifting device.
9 Connect the leads from a multimeter with
2 Remove the lower cover retaining fasteners and continuity checking capability to pins 1 and 2 at
remove the lower cover from turntable. the deutsch connector of the limit switch cable.
Crushing hazard. The turntable Result: The limit switch should not have
riser lower cover could become continuity.
unbalanced and fall when
removed from the turntable if not Result: The limit switch does have continuity.
properly supported and secured to The limit switch is faulty and needs to be
the lifting device. replaced.
3 Support and secure the upper turntable riser end 10 Remove the multimeter leads and connect the
cover to a suitable lifting device. deutsch connector to LSS1RS.
3 - 34 Z-135/70 Part No. 106783

12 Extend the secondary boom while visually 15 Turn the machine off.
inspecting the roller arm of the limit switch.
Continue to extend the boom until the limit 16 With the key switch off, press and hold the
switch arm is released by the limit switch ramp button and turn the key switch to the on
bracket. position. Release the button after five
Result: The roller arm of the limit switch remains seconds and press the buttons.
centered with the limit switch ramp bracket
through the entire length of travel. 17 Press the button until CLEAR ALL SAFETY SWITCH
FAULTS appears.
Result: The roller arm of the limit switch does
not remain centered with the limit switch ramp 18 Select YES, then press the button.
bracket through the entire length of travel.
Adjust or replace the limit switch ramp bracket 19 Press the button until EXIT appears.
to ensure the limit switch roller arm remains
20 Select YES, then press the button.
centered with the limit switch ramp bracket
through the entire length of travel. 21 Install the secondary boom end covers.
Note: The limit switch ramp bracket is attached to Turntable Rotate Safety Limit Switch, LST1S
the number 4 boom tube.
22 Locate the turntable rotate safety limit switch
13 Locate and disconnect the deutsch connector to (LST1S) at the center of the turntable.
LSS1RS.
Note: The turntable rotate safety limit switch
Result: The alarm should sound. (LST1S) is located between the two operational
turntable rotate limit switches. It can easily be
Result: The LCD screen should display the
identified by the orange and red tie wraps attached
message "Sec Boom Retracted Safety Switch
to the limit switch cable.
Disconnected Fault".
Result: The alarm doesn't sound and the LCD 23 Locate and disconnect the deutsch connector to
screen doesn't display a Fault message. The LST1S.
limit switch is faulty and needs to be replaced. 24 Connect the leads from a multimeter with
Note: A P30 Power Fault and a P11 Power Fault continuity checking capability to pins 1 and 2 at
will also display as a result of this test. the deutsch connector of the limit switch cable.
Result: The limit switch should have continuity.
14 Re-connect the deutsch connector to LSS1RS.
Result: The limit switch does not have
Result: The LCD screen displays "Sec LSS1RS
continuity. The limit switch is faulty and needs
Fault".
to be replaced.
Result: The LCD screen doesn't display the
Fault message. The limit switch is faulty and
needs to be replaced.
Part No. 106783 Z-135/70 3 - 35

25 Remove the multimeter leads and connect the 35 Connect the leads from a multimeter with
deutsch connector to LST1S. continuity checking capability to pins 1 and 2 at
the deutsch connector of the limit switch cable.
26 Start the engine and rotate the turntable more
than 15°. Turn the engine off Result: The limit switch should not have
continuity.
27 Locate and disconnect the deutsch connector to
LST1S. Result: The limit switch does have continuity.
The limit switch is faulty and needs to be
replaced.
continuity checking capability to pins 1 and 2 at
the deutsch connector of the limit switch cable. 36 Remove the multimeter leads and connect the
deutsch connector to the limit switch.
Result: The limit switch should not have
continuity. 37 Repeat steps 34 through 36 for the other axle
extend safety limit switch.
Result: The limit switch does have continuity.
The limit switch is faulty and needs to be 38 Start the engine from the platform controls and
replaced OR the mounting position of the limit fully extend the axles. Turn the machine off.
switch needs to be adjusted until it activates
39 Choose an axle extend safety limit switch to
when the turntable is rotated more than 15°.
test.
29 Remove the multimeter leads and connect the
40 Locate and disconnect the deutsch connector to
deutsch connector to LST1S.
the axle extend limit switch.
Axle Extended Safety Limit Switches, LSFA1ES
and LSRA1ES
continuity checking capability to pins 1 and 2 at
30 Start the engine from the ground controls and the deutsch connector of the limit switch cable.
lower the boom to the stowed postion.
Result: The limit switch should have continuity.
31 Turn the key switch to platform controls.
Result: The limit switch does not have
32 From the platform controls, drive the machine in continuity. The limit switch is faulty and needs
either direction and fully retract the axles. to be replaced.
Turn the machine off.
42 Remove the multimeter leads and connect the
33 Choose an axle extend safety limit switch to deutsch connector to the limit switch.
test.
43 Repeat steps 40 through 42 for the other axle
34 Locate and disconnect the deutsch connector to extend safety limit switch.
the axle extend limit switch.
3 - 36 Z-135/70 Part No. 106783

B-20 5 Continue to raise the primary boom until it stops

at 58°.
Test the Primary Boom Angle
Tip-over hazard. If the boom does
Sensor not stop at 58°, release the
Note: Genie specifications require that this function enable button immediately
procedure be performed every 250 hours or and lower the primary boom.
quarterly, whichever comes first. Contact Genie Industries Service
Department. Failure to lower the
A properly functioning primary boom angle sensor boom could cause the machine to
is essential to safe machine operation. The ECM at tip over resulting in death or
the ground controls (TCON) monitors the position serious injury.
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.
screen buttons shown
until PRIMARY BOOM ANGLE
TO GRAVITY DEGREES is
displayed.
4 Raise the primary boom while watching the
display screen.
Part No. 106783 Z-135/70 3 - 37

B-21 3 Using a mild solvent, carefully wash the cap

venting system. Dry using low pressure
Inspect the Fuel and Hydraulic compressed air. Repeat this procedure
Tank Cap Venting Systems beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
Note: Genie requires that this procedure be tank.
performed every 250 hours or quarterly, whichever 6 Check for proper venting.
comes first. Perform this procedure more often if
dusty conditions exist. Result: Air passes through the fuel tank cap.
Proceed to step 8.
Free-breathing fuel and hydraulic tank caps are
essential for good machine performance and Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 7.
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use Note: When checking for positive tank cap venting,
may cause component damage. Extremely dirty air should pass freely through the cap.
conditions may require that the caps be inspected
more often. 7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
Explosion and fire hazard. Engine compressed air. Repeat this procedure
fuels are combustible. Perform this beginning with step 6.
ventilated area away from heaters, 8 Install the breather cap onto the hydraulic tank.
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

B-22
Perform Engine Maintenance -
Cummins Models

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.
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

Maintenance Manual

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

Checklist C Procedures REV D
C-1 C-2
procedure be performed every 500 hours or 6 procedure be performed every 500 hours or 6
months, whichever comes first. months, whichever comes first.

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

REV D CHECKLIST C PROCEDURES
C-3 C-4
Perform Engine Maintenance - Grease the Platform Overload
Perkins Models Mechanism (if equipped)
Note: Engine specifications require that this Note: Genie specifications require
procedure be performed every 500 hours or 6 that this procedure be performed every 500 hours or
months, whichever comes first. 6 months, whichever comes first. Perform this
procedure more often if dusty conditions exist.
manufacturer's maintenance schedule, is essential Application of lubrication to the platform overload
to good engine performance and service life. mechanism is essential to safe machine operation.
Failure to perform the maintenance procedures Continued use of an improperly greased platform
can lead to poor engine performance and overload mechanism could result in the system not
component damage. sensing an overloaded platform condition and will
result in component damage.
engine information are available in the 1 Locate the grease fittings on each pivot pin of
Perkins 1100 Series User's Handbook the platform overload assembly.
(Perkins part number TPD 1477) OR the
Perkins 800 Series Operation and Maintenance 2 Thoroughly pump grease into each grease
Manual (Perkins part number SEBU7853-00). fitting.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
Maintenance Manual

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

CHECKLIST C PROCEDURES REV D
C-5 As weight is added to the platform, the spring will

compress until, when the platform is overloaded,
Test the Platform Overload the lower arm contacts a limit switch and thereby
System (if equipped) activating the overload signal. When adjusted
correctly, the platform overload system will
deactivate normal boom operation at platform
capacity.
Note: Genie specifications require that this Note: Perform this procedure with the machine on a
procedure be performed every 500 hours or six firm, level surface.
months.
1 Turn the key switch to platform control. Start the
Genie specifications require that this procedure be engine from the platform controls.
performed every 500 hours or six months,
whichever comes first. 2 Level the platform.
3 Determine the maximum platform capacity.
Testing the platform overload system regularly is
Refer to the machine serial plate.
essential to safe machine operation. Continued
use of an improperly operating platform overload 4 Using a suitable lifting device, place an
system could result in the system not sensing an appropriate test weight equal to that of the
overloaded platform condition. Machine stablity maximum platform capacity in one of the
could be compromised resulting in the machine locations shown.
tipping over.
Result: The platform overload indicator light
The platform overload system is designed to detect should be off at both the ground and platform
an overloaded platform and prevent machine controls.
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.
5 Carefully move the test weight to each
The platform support subassembly utilizes two remaining location.
load support arms that are opposed in a full
Result: The platform overload indicator light
parallelogram link. This isolates platform loads into
should be off at both the ground and platform
a shear or vertical state, which translates into a
controls.
compressive load. A spring in the parallelogram
link supports this purely compressive load
regardless of where the load is placed in the
platform.
3 - 42 Z-135/70 Part No. 106783

REV D CHECKLIST C PROCEDURES
6 Add an additional 12 lbs / 5.4 kg test weight to 8 Test all machine functions from the platform
the original test weight to overload the platform. controls.
Result: The alarm should be sounding. Result: All platform control functions should not
The platform overload indicator light should be operate.
flashing at the platform controls and
9 Turn the key switch to ground control.
PLATFORM OVERLOAD should be displayed on the
LCD screen at the ground controls. 10 Test all machine functions from the ground
controls.
Result: If the alarm does not sound and the
platform overload indicator light does not come Before serial number 471:
on with the test weights in any of the platform
locations, the platform overload system needs Result: All ground control functions should not
to be calibrated. Refer to repair procedure 2-4, operate.
How to Calibrate the Platform Overload System After serial number 470:
(if equipped).
Result: All ground control functions should
Note: There may be an approximate 2 second delay operate using the auxiliary pump.
before the overload indicator light turns on and the
alarm sounds. 11 Lift the test weights off the platform floor using a
suitable lifting device.
7 Carefully move the test weights to each
remaining location in the platform. Result: The platform overload indicator light and
alarm should turn off at both the ground and
Result: The alarm should be sounding. platform controls.
The platform overload indicator light should be
flashing at the platform controls and Note: There may be an approximate 2 second delay
before the overload indicator light and alarm turn
LCD screen at the ground controls. off.
Result: If the alarm does not sound and the 12 Test all machine functions from the ground
platform overload indicator light does not come controls.
on with the test weights in any of the platform Result: All ground control functions should
locations, the platform overload system needs operate normally.
to be calibrated. Refer to repair procedure 2-4,
How to Calibrate the Platform Overload System 13 Turn the key switch to platform control.
(if equipped). 14 Test all machine functions from the platform
Note: There may be an approximate 2 second delay controls.
before the overload indicator light turns on and the Result: All platform control functions should
alarm sounds. 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

Checklist D Procedures REV D
D-1 Secondary boom wear

pad specifications Minimum
Check the Boom Wear Pads
Top wear pads 3 /8
inch
(extension end of boom) 9.5 mm
Side wear pads 1/2 inch

Note: Genie requires that this procedure be (extension end of boom) 12.7 mm
performed every 1000 hours or annually, whichever
comes first. Bottom wear pads 7 /8
inch
(extension end of boom) 22 mm
Maintaining the boom wear pads in good condition
Top and bottom wear pads 5/8 inch
is essential to safe machine operation. Wear pads
are placed on boom tube surfaces to provide a low (pivot end of boom) 15.9 mm
friction, replaceable wear pad between moving
Side wear pads 1/2 inch
parts. Improperly shimmed wear pads or continued
(pivot end of boom) 12.7 mm
use of extremely worn wear pads may result in
component damage and unsafe operating Jib boom wear
conditions. pad specifications Minimum
1 Measure each wear pad. Replace the wear pad Bottom and side wear pads 5/8 inch
once it reaches the minimum allowable (platform end of boom) 15.9 mm
thickness. If the wear pad is still within
specification, shim as necessary to obtain Top wear pads 1/2 inch
minimum clearance with zero binding. (platform end of boom) 12.7 mm
Note: The minimum shim clearance for the 3 /8
Top and side wear pads inch
secondary boom wear pads is 0.070 inch / 1.8 mm (pivot end of boom) 9.5 mm
and the maximum allowable shim clearance is 0.25
inch / 6.4 mm. Bottom wear pads 5/8 inch
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. 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.
Primary boom wear
pad specifications Minimum Note: Always maintain squareness between the
outer and inner boom tubes.
Top, bottom and side wear pads 5/8 inch
(platform end of boom) 15.9 mm
Top and bottom wear pads 1/2 inch

Side wear pads 3 /8

inch
3 - 44 Z-135/70 Part No. 106783

REV D CHECKLIST D PROCEDURES
D-2 5 Manually rotate each wheel at the square-end of

the machine.
Check the Free-wheel
Result: Each wheel at the square-end of the
Configuration 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.
comes first.
Collision hazard. Failure to
Proper use of the free-wheel configuration is re-engage the drive hubs could
essential to safe machine operation. The result in death or serious injury
free-wheel configuration is used primarily for and property damage.
towing. A machine configured to free-wheel without
operator knowledge may cause death or serious 7 Chock both of the wheels at the square-end of
injury and property damage. the machine to prevent the machine from
rolling.
Collision hazard. Select a work
site that is firm and level. 8 Place a lifting jack of ample capacity
(35,000 lbs / 16000 kg) under each of the steer
Component damage hazard. If the yokes at the circle-end of the machine.
machine must be towed, do not
exceed 2 mph / 3.2 km/h. 9 Lift the wheels off the ground and place blocks
under the drive chassis for support.
1 Chock both of the wheels at the circle-end of the
machine to prevent the machine from rolling. 10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each wheel hub
2 Place a lifting jack of ample capacity at the circle-end of the machine.
(35,000 lbs / 16000 kg) under each of the steer
disengaged position
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 engaged position
drive hub disconnect caps on each wheel hub at
the square-end of the machine. 11 Manually rotate each wheel at the circle-end of
the machine.
disengaged position
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

CHECKLIST D PROCEDURES REV D
12 Re-engage the drive hubs by turning over D-3

the drive hub disconnect caps. Rotate each
wheel to check for engagement. Lift the Replace the Drive Hub Oil
machine and remove the blocks. Lower the
machine.
Collision hazard. Failure to
re-engage the drive hubs could Note: Genie requires that this procedure be
result in death or serious injury performed every 1000 hours or annually, whichever
and property damage. comes first.
All models: Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
13 Be sure the free-wheel valve on the drive pump replace the drive hub oil at yearly intervals may
is closed (clockwise). cause the machine to perform poorly and
Note: The free-wheel valve is located on the drive
pump, and should always remain closed. 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
2 Remove both plugs and drain the oil into a
a c
suitable container.
d
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 drive pump
a
b screwdriver
c lift pump
d free-wheel valve
a 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

Turntable Rotate Drive Hub: 4 Remove the drive hub mounting bolts from one
drive hub assembly. Carefully remove the
1 Secure the turntable from rotating with the turntable rotate drive hub assembly from the
turntable rotation lock pin. machine. Do not remove both turntable rotate
2 Tag, disconnect and plug the hydraulic hoses to drive hub assemblies at the same time.
the drive hub drive motor and brake for each Crushing hazard. The turntable
drive hub assembly. rotate drive hub assembly could
Bodily injury hazard. Spraying become unbalanced and fall when
hydraulic oil can penetrate and removed from the machine if not
burn skin. Loosen hydraulic properly supported by the lifting
connections very slowly to allow device.
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.
a b
a drive hub mounting bolts

b drive hub plugs
Part No. 106783 Z-135/70 3 - 47

5 Remove the plug from the side of the drive hub. D-4
Drain the oil from the hub into a suitable
container. Adjust the Turntable Rotatation
6 Install the drive hub assembly onto the
Gear Backlash
machine. Lubricate and torque the drive hub Note: Genie requires that this procedure be
mounting bolts to specification. Refer to Section performed every 1000 hours or annually, whichever
2, Specifications. comes first.
7 Fill the drive hub with oil from the side hole until Properly adjusted turntable rotation gear backlash
the oil level is even with the bottom of the hole. is essential for good machine performance and
Apply pipe thread sealant to the plug. Install the service life. Improperly adjusted turntable rotation
plug. Refer to Section 2, Specifications. gear backlash will cause the machine to perform
8 Repeat steps 3 through 7 for the other turntable poorly and continued use will cause component
rotate drive hub assembly. damage. The turntable rotation drive hubs are
mounted on an adjustable plate on the swing
9 Adjust turntable rotation gear backlash. See chassis behind the fixed side cover at the ground
D-4, Adjust the Turntable Rotation Gear controls side of the machine.
Backlash.
Note: Perform this procedure with the machine fully
stowed and the counterweight at the square end of
the machine.

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

5 Loosen the lock nut on the adjustment bolt. D-5

6 Turn the adjustment bolt clockwise until it Replace the Hydraulic Filter
contacts the backlash pivot plate.
Elements

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:
1 Open the ground controls side turntable cover

a b c
and locate the hydraulic return filter mounted on
the hydraulic tank.
a backlash pivot plate
b adjustment bolt with lock nut 2 Place a suitable container under the hydraulic
c backlash pivot plate mounting bolts
tank return filter.
7 Turn the adjustment bolt 1/4 turn 3 Remove the filter with an oil filter wrench.
counterclockwise. Tighten the lock nut on the
adjustment bolt. 4 Apply a thin layer of fresh oil to the gasket of
the new oil filter.
8 Pull the backlash pivot plate away from the
turntable until it contacts the adjustment bolt. 5 Install the new hydraulic return filter element
Then lubricate the mounting fasteners on the and tighten it securely by hand. Clean up any
backlash pivot plate and torque to specification. oil that may have spilled during the installation
Refer to Section 2, Specifications. procedure.
9 Rotate the turntable through an entire rotation. 6 Use a permanent ink marker to write the date
Check for tight spots that could cause binding. and number of hours from the hour meter on
Readjust if necessary. the oil filter.
Part No. 106783 Z-135/70 3 - 49

High pressure filter and drive motor case 12 Remove the filter element from the housing.
drain filter:
13 Inspect the housing seal and replace it if
Note: The high pressure filter is for all machine necessary.
functions except the drive functions. The drive
14 Install the new high pressure filter element into
motor case drain filter is used to filter oil returning
the housing. Install the filter housing onto the
to the hydraulic tank from the drive motors.
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.
a b 18 Place a suitable container under the filter.
a drive motor case drain filter

19 Remove the medium pressure filter housing by
b high pressure filter using a wrench on the nut provided on the
bottom of the housing.
7 Locate the high pressure filter and the drive
motor case drain filter near the auxillary power 20 Remove the filter element from the housing.
units. 21 Inspect the housing seal and replace it if
8 Place a suitable container under the filters. necessary.
9 Use a filter wrench to remove the drive motor 22 Install the new medium pressure filter element
case drain filter element. into the housing. Install the filter housing onto
the filter head and tighten it securely.
10 Install the new drive motor case drain filter
element onto the filter head and tighten it 23 Clean up any oil that may have spilled during
securely. the installation procedure.
11 Remove the high pressure filter housing by 24 Use a permanent ink marker to write the date
using a wrench on the nut provided on the and number of hours from the hour meter on
bottom of the housing. the oil filter housing.
26 Inspect the all of the filter housings and related
components to be sure that there are no leaks.
3 - 50 Z-135/70 Part No. 106783

D-6 D-7
procedure be performed every 1000 hours. procedure be performed every 1000 hours.

Maintenance Manual
Part No. 106783 Z-135/70 3 - 51

D-8 D-9
Perform Engine Maintenance - Check the Turntable Rotation
Perkins Models Bearing Bolts
Note: Engine specifications require that this Note: Genie requires that this procedure be
procedure be performed every 1000 hours. performed every 1000 hours or annually, whichever
comes first.
manufacturer's maintenance schedule, is essential Maintaining proper torque on the turntable bearing
to good engine performance and service life. bolts is essential to safe machine operation.
Failure to perform the maintenance procedures Improper bolt torque could result in an unsafe
can lead to poor engine performance and operating condition and component damage.
component damage.
1 Raise the secondary boom to the point where it
Required maintenance procedures and additional begins to extend. Turn the machine off.
engine information are available in the
Perkins 1100 Series User's Handbook 2 Remove the engine pivot plate retaining
(Perkins part number TPD 1477) OR the fastener. Swing the engine pivot plate out away
Perkins 800 Series Operation and Maintenance from the machine.
Manual (Perkins part number SEBU7853-00).


Maintenance Manual
To access the engine: a engine pivot plate anchor hole

located under the engine tray. Swing the engine 3 Locate the engine pivot plate anchor hole at the
tray out and away from the machine. pivot end of the engine pivot plate.
3 - 52 Z-135/70 Part No. 106783

4 Install the bolt that was just removed into the 6 Lower the secondary boom to the stowed
anchor hole to secure the engine pivot plate position.
from moving.
7 Remove the engine pivot plate retaining fastener
Crushing hazard. Failure to install from the engine pivot plate anchor hole at the
the bolt into the engine pivot plate pivot end of the engine pivot plate.
8 Swing the engine pivot plate in towards the
machine.
5 Confirm that each turntable mounting bolt is
torqued in sequence to specification. Refer to
10 1 28 the bolt into the engine pivot plate
8
18 20
22 16
13 12 result in death or serious injury.
26 24 10 Confirm that each bearing mounting bolt under
3 6 the drive chassis is torqued in sequence to
specification. Refer to Section 2, Specifications.
1 9
36 23 25
13 15
29 5
7 33
18 28
5 4
31 20
23 27
27 11
15 14
19 21 12 3
11 17
7 25 2 9 4 26
21 34
Bolt torque sequence
(from above turntable) 35 17
16 8
6 22
32 14
24 10 30
2 19
Bolt torque sequence

(from above turntable)
Part No. 106783 Z-135/70 3 - 53

D-10
a
Inspect for Turntable Bearing
Wear
b

performed every 1000 hours or annually, whichever c
comes first.
Periodic inspection of turntable bearing wear is
d
essential to safe machine operation, good machine
performance and service life. Continued use of a
a turntable
worn turntable bearing could create an unsafe b dial indicator
operating condition, resulting in death or serious c drive chassis
injury and component damage. d turntable rotation bearing
Note: Perform this procedure with the machine on a 5 At the dial indicator, adjust it to "zero" the
firm, level surface and the boom in the stowed indicator.
position. 6 Fully extend the boom and lower to a horizontal
1 Grease the turntable bearing. See A-10, Grease position.
the Turntable Bearing and Rotate Gear. 7 Note the reading on the dial indicator.
2 Torque the turntable bearing bolts to Result: The measurement is less than
specification. See D-9, Check the Turntable 0.063 inch / 1.6 mm. The bearing is good.
Rotation Bearing Bolts.
Result: The measurement is more than
3 Start the machine from the ground controls and 0.063 inch / 1.6 mm. The bearing is worn and
raise the boom to full height. Do not extend the needs to be replaced.
boom.
8 Fully retract the boom and raise the boom to full
4 Place a dial indicator between the drive chassis height. Visually inspect the the dial indicator to
and the turntable at a point that is directly be sure the needle returns to the "zero"
under, or inline with, the boom and no more position.
than 1 inch / 2.5 cm from the bearing.
9 Remove the dial indicator and rotate the
Note: To obtain an accurate measurement, place turntable 90°.
the dial indicator no more than 1 inch /
2.5 cm from the turntable rotation bearing. 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

REV D
Checklist E Procedures
E-1 1 Close the two hydraulic tank shut-off valves at
the hydraulic tank.
Test or Replace the Hydraulic Oil
Component damage hazard. The
engine must not be started with the
hydraulic tank shut-off valves in
the closed position or component
Note: Genie specifications require that this damage will occur. If the tank
procedure be performed every 2000 hours or every valves are closed, remove the key
two years, whichever comes first. Perform this from the key switch and tag the
procedure more often if dusty conditions exist. machine to inform personnel of the
Replacement or testing of the hydraulic oil is condition.
essential for good machine performance and 2 Remove the drain plug from the hydraulic tank
service life. Dirty oil and a clogged suction strainer and completely drain the tank into a container
or hydraulic filters may cause the machine to of suitable capacity. Refer to Section 2,
perform poorly and continued use may cause Specifications.
component damage. Extremely dirty conditions
may require oil changes to be performed more 3 Tag, disconnect and plug the two suction hoses
frequently. from the hydraulic tank.
Note: Before replacing the hydraulic oil, the oil may 4 Tag, disconnect and plug the two supply hoses
be tested by an oil distributor for specific levels of for the auxiliary power units. Cap the fittings on
contamination to verify that changing the oil is the hydraulic tank.
necessary. If the hydraulic oil is not replaced at 5 Tag, disconnect and plug the hydraulic hose
the two year inspection, test the oil quarterly. from the drive motor case drain filter at the
Replace the oil when it fails the test. hydraulic tank. Cap the fitting on the hydraulic
tank.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be 6 Disconnect and plug the hydraulic hose at the
replaced and then torqued to specification during return filter. Cap the fitting on the return filter
installation. housing.
Refer to Section Two, Hydraulic Hose and Fitting
Torque Specifications. 7 Remove the turntable cover using a suitable
lifting device.
Note: Perform this procedure with the boom in the
stowed position.
cover may become unbalanced
and fall if not properly supported
and secured to a suitable lifting
device.
Part No. 106783 Z-135/70 3 - 55

CHECKLIST E PROCEDURES REV D
8 Remove the ground control box mounting 14 Remove the hydraulic tank retaining fasteners.
fasteners. Move the ground control box out of
15 Support the hydraulic tank with 2 lifting straps.
the way.
Place one lifting strap at each end of the tank
9 Remove the cover from the auxiliary power unit and attach the lifting straps to an appropriate
batteries. lifting device.
10 Tag and disconnect the cables from the 16 Remove the hydraulic tank from the machine.
auxiliary power unit batteries.
Crushing hazard. The hydraulic
Electrocution/burn hazard. Contact tank could become unbalanced
with electrically charged circuits and fall when removed from the
could result in death or serious machine if not properly supported.
injury. Remove all rings, watches
17 Remove the suction strainers from the tank and
and other jewelry.
clean them using a mild solvent.
11 Tag and disconnect the cables from the engine
18 Rinse out the inside of the tank using a mild
starting battery located on the engine side of
solvent.
the machine.
19 Install the suction strainers using pipe thread
Electrocution/burn hazard. Contact
sealant on the threads.
with electrically charged circuits
could result in death or serious 20 Install the drain plug using pipe thread sealant
injury. Remove all rings, watches on the threads.
and other jewelry.
21 Install the hydraulic tank onto the machine.
12 Attach an overhead crane or similar lifting
device to the battery box for the auxiliary power 22 Install the ground control box and mounting
unit batteries. fasteners.
13 Remove the battery box retaining fasteners and 23 Install the two suction hoses, return filter hose,
carefully remove the battery box from the drive motor case drain filter hose and the
machine. supply hoses for the auxiliary power units.
Crushing hazard. The battery box 24 Install the turntable cover.

could become unbalanced and fall 25 Fill the tank with hydraulic oil until the level is
when removed from the machine if within the top 2 inches / 5 cm of the sight
not properly supported. gauge. Do not overfill.
Bodily injury hazard. Batteries 26 Open the two hydraulic tank shut-off valves at
contain acid. Avoid spilling or the hydraulic tank.
contacting battery acid. Neutralize
battery acid spills with baking soda 27 Clean up any oil that may have spilled.
and water. 28 Start the engine and check for leaks.
3 - 56 Z-135/70 Part No. 106783

REV D CHECKLIST E PROCEDURES
E-2 E-3
Cummins Models Perkins 804D-33T Models
procedure be performed every 2000 hours. procedure be performed every 2000 hours.
to good engine performance and service life. to good engine performance and service life. Failure
Failure to perform the maintenance procedures to perform the maintenance procedures can lead to
can lead to poor engine performance and poor engine performance and component damage.
component damage.
Required maintenance procedures and additional engine information are available in the
engine information are available in the Perkins 800 Series Operation and Maintenance
Cummins B4.5 Operation and Maintenance Manual Manual (Perkins part number SEBU7853-00).
(Cummins part number 4021389-01) OR the
Cummins B3.3 Operation and Maintenance Manual Perkins 800 Series Operation and
(Cummins part number 3666417-00). Maintenance Manual
Maintenance Manual
Genie part number 107527 To access the engine:
Cummins B3.3 Operation and 1 Remove the engine tray retaining fastener
Maintenance Manual located under the engine tray. Swing the engine
Genie part number 139324 tray out and away from the machine.
1 Remove the engine tray retaining fastener Crushing hazard. Failure to install
located under the engine tray. Swing the engine the fastener into the engine tray
tray out and away from the machine. anchor hole to secure the engine
2 Install the fastener that was just removed tray from moving could result in
through the engine tray and into the engine tray death or serious injury.
Part No. 106783 Z-135/70 3 - 57

E-4 E-5
Perkins 804D-33T Models Deutz TD2011L04i and
Perkins 804D-33T Models

procedure be performed every 2 years. Note: Engine specifications require that this
Proper engine maintenance, following the engine procedure be performed every 3000 hours.
manufacturer's maintenance schedule, is essential Proper engine maintenance, following the engine
to good engine performance and service life. Failure manufacturer's maintenance schedule, is essential
to perform the maintenance procedures can lead to to good engine performance and service life. Failure
poor engine performance and component damage. to perform the maintenance procedures can lead to
Required maintenance procedures and additional poor engine performance and component damage.
engine information are available in the Required maintenance procedures and additional
Perkins 800 Series Operation and Maintenance engine information are available in the
Manual (Perkins part number SEBU7853-00). Deutz TD2011 Operation Manual
(Deutz part number 0312 3547) OR the
Perkins 800 Series Operation and Perkins 800 Series Operation and Maintenance
Maintenance Manual Manual (Perkins part number SEBU7853-00).

Maintenance Manual
located under the engine tray. Swing the engine Genie part number 111332
through the engine tray and into the engine tray To access the engine:
Crushing hazard. Failure to install located under the engine tray. Swing the engine
the fastener into the engine tray tray out and away from the machine.
tray from moving could result in 2 Install the fastener that was just removed
death or serious injury. through the engine tray and into the engine tray
3 - 58 Z-135/70 Part No. 106783

REV D CHECKLIST E PROCEDURES
E-6 E-7
Deutz TD2011L04i Models Perkins 804D-33T Models
procedure be performed every 5000 hours. procedure be performed every 6000 hours or
3 years, whichever comes first.
poor engine performance and component damage.
Deutz TD2011 Operation Manual engine information are available in the
(Deutz part number 0312 3547). Perkins 800 Series Operation and Maintenance
Genie part number 139320 Perkins 800 Series Operation and
Maintenance Manual

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

E-8 E-9
Perkins 1104C-44 Models Perkins 804D-33T Models
procedure be performed every 8000 hours. procedure be performed every 12,000 hours or
6 years, whichever comes first.
poor engine performance and component damage.
Perkins 1100 Series User's Handbook engine information are available in the
(Perkins part number TPD 1477). Perkins 800 Series Operation and Maintenance
Genie part number 107526 Perkins 800 Series Operation and
Maintenance Manual

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

July 2011 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: Perform disassembly procedures to the point where
repairs can be completed. To re-assemble, perform
Repair procedures shall be completed by a
the disassembly steps in reverse order.
person trained and qualified on the repair of this
machine. Symbols Legend
Immediately tag and remove from service a Safety alert symbol—used to alert
damaged or malfunctioning machine. personnel to potential personal
injury hazards. Obey all safety
Repair any machine damage or malfunction
messages that follow this symbol
before operating the machine.
to avoid possible injury or death.
Before Repairs Start: Used to indicate the presence of
operating instructions in the appropriate death or serious injury.
Operator's Manual on your machine.
Be sure that all necessary tools and parts are potentially hazardous situation
available and ready for use. which, if not avoided, could result
Use only Genie approved replacement parts. in death or serious injury.
With safety alert symbol—used to
Read each procedure completely and adhere
indicate the presence of a
to the instructions. Attempting shortcuts may
produce hazardous conditions.
which, if not avoided, may cause
Unless otherwise specified, perform each minor or moderate injury.
repair procedure with the machine in the Used to indicate the presence of a
following configuration: potentially hazardous situation
· Machine parked on a firm, level surface which, if not avoided, may result in
· Boom in the stowed position property damage.
· Turntable rotated with the boom between Indicates that a specific result is expected after
the circle-end (yellow arrow) wheels performing a series of steps.
· Turntable secured with the turntable Indicates that an incorrect result has occurred
rotation lock pin after performing a series of steps.
· 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 July 2011
Display Module REV D
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.
The key switch must be in the off position before entering the programming mode.
Activation of the or buttons scrolls through the screens. To change parameter values or select a
setting, use the button (to increase or scroll forward) and the button (to decrease or scroll
backwards). Then press the button to save new value to memory. An audible beep will indicate a save
to memory. Use the and buttons to scroll to the EXIT menu. Use the button to change to YES
and use the button to exit.
Screen or Procedure Description Range or Selection

Menu
Default Hourmeter (on power up)
Operator
Engine speed
Engine oil pressure PSI (English)
Engine oil pressure kPa (metric)
Engine temperature °F (Engilsh)
Engine temperature °C (metric)
Primary boom angle to gravity
Turntable level sensor X° direction
Turntable level sensor Y° direction
Platform level sensor degree
Battery volts
With key switch Hydraulic pressure PSI (English) 0-4500 PSI

Machine Hydraulic pressure kPa (metric) 0-31000 kPa
ON, press the
Status Primary boom to secondary boom angle* +22° to +136°
and Primary boom length =0', >0', >22'
buttons at the Secondary boom angle* -3.5° to 75°
same time. Secondary boom length =0FT, >0 FT
Jib bellcrank angle* -10° to +10°
*(referenced to chassis tilt angle)
With key switch Metric/English (measurement units) English, German, French,

Unit of Spanish, Portuguese,
OFF, press the
Measure Italian, Dutch, and
button and turn Swedish.
and
key switch to on Set engine Cummins B3_3T (CB33T)
Language position. Cummins B4_5L (CUMMN)
Release the Deutz TD2011 L04i (DL041)
and press Perkins 804D (P804T)
Deutz BFL2011 (DEUTZ)
Perkins 1104C-44 (PERKN)
Note: Actual TCON display
charcters in ( )
4-2 Z-135/70 Part No. 106783

REV D DISPLAY MODULE

Menu
Drive Forward extended drive speed % 120% (max) 100% (default) 50% (min)
With key switch
Forward not slowed drive speed % 120% (max) 100% (default) 50% (min)
Functions OFF, press and
Forward low drive speed % 120% (max) 100% (default) 50% (min)
hold the Forward high drive speed % 120% (max) 100% (default) 50% (min)
button and turn Reverse extend drive speed % 120% (max) 100% (default) 50% (min)
key switch to on Reverse not stowed drive speed % 120% (max) 100% (default) 50% (min)
position. Reverse low drive speed % 120% (max) 100% (default) 50% (min)
Reverse high drive speed % 120% (max) 100% (default) 50% (min)
Release the Drive acceleration % 125% (max) 100% (default) 25% (min)
button and press Drive decceleration % 125% (max) 100% (default) 25% (min)
Speed limit on steer angle 100% (max) 50% (default) 0% (min)
Boom With key switch Primary boom up speed stowed

OFF, press and Primary boom up speed not stowed
Function Primnary boom down speed stowed
Speeds hold the Primary boom down speed
button and turn not stowed
key switch to on Primary boom extend speed
position. Primary boom retract speed
Secondary boom up speed stowed
Release the Secondary boom up speed
button and press not stowed
Secondary boom down speed
stowed 120% max, 50% min,
Secondary boom down speed 100% (default)
not stowed
Secondary boom extend speed
Secondary boom retract speed
Turntable rotate speed retracted
Turntable rotate speed not retracted
Turntable rotate speed extended
Jib up speed retracted
Jib up speed not retracted
Jib down speed retracted
Jib down speed not retracted
Part No. 106783 Z-135/70 4-3

DISPLAY MODULE REV D

Menu
Primary boom up/down ramp acceleration %
Lift With key switch Primary boom up/down ramp deceleration %
Functions OFF, press and Primnary boom extend/retract
Ramps ramp acceleraton %
hold the
Primary boom extend/retract
button and turn ramp deceleration %
key switch to on Secondary boom up/down ramp acceleration % 150% max and 50% min,
position. Secondary boom up/down ramp deceleration % 100% (default),
Release the Secondary boom extend/retract 5% imcrement
ramp acceleration %
button and press Secondary boom extend/retract
ramp deceleration %
Turntable rotate ramp acceleration %
Turntable rotate ramp deceleration %
Jib boom up/down ramp acceleration % 120% max and 50% min,
Jib boom up/down ramp deceleration % 100% (default), 5% incr
Reset drive valve defaults

Valve With key switch
Reset primary boom up/down valve defaults
OFF, press and
Calibration Reset primary boom extend/retract
hold the valve defaults
button and turn Reset secondary boom valve defaults
key switch to on Reset turntable rotate valve defaults
Allow primary boom up/down speed calibration
position.
Allow primary boom extend/retract
Release the speed calibration
button and press 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
4-4 Z-135/70 Part No. 106783

REV D DISPLAY MODULE

Menu
Sensor Set unit X-axis to gravity

With key switch
Set unit Y-axis to gravity
Calibration OFF, press and
Set platform level to gravity (YES/NO)
hold the YES: Set platform level to gravity (YES/NO)
button and turn Platform level sensor millivolts/degree
Reset axle angle sensors (YES/NO)
key switch to on
YES: Axle angle fully retracted (YES/NO)
position.
YES: Axle angle fully extended (YES/NO)
Release the Reset all steer sensors (YES/NO)
button and press Reset blue end blue side steer sensor (FL)
(YES/NO)
Reset yellow end blue side steer sensor (RL)
(YES/NO)
Reset yellow end blue side steer sensor (FR)
(YES/NO)
Reset yellow end yellow side steer sensor (RR)
(YES/NO)
Calibrate secondary boom angle sensor
(YES/NO) Use +/- buttons to adjust
secondary boom angle to gravity -3.5°
secondary boom angle to gravity 20°
Calibrate primary boom angle sensor (YES/NO)
primary boom angle to gravity 0°
primary boom angle to gravity -50°
primary boom angle to gravity -20°
Reset level angle sensor (YES/NO)
jib level calibration deg to gravity 60°
jib level calibration deg to gravity -18°
With key switch

Default Reset drive functions
OFF, press and
Reset hold the Reset boom functions Reset faults will reset
button and turn active latching faults, will
key switch to on Reset lift function ramps not clear fault history
position.
Reset all
Release the
button and press Reset faults
Part No. 106783 Z-135/70 4-5

DISPLAY MODULE REV D

Menu
Options With key switch Boom Function Limit No LT= No limit; EXT LT= secondary
OFF, press and (NO LT/EXT LT) boom extend inhibited
AC Generator
hold the (NONE/BELT/HILO/HYDRL/GHG10)
button and turn Alarm
key switch to on No (NO AL)/Motion (MO AL)/
position. Travel (TR AL)/ Descent (DE AL)/
Travel and Descent (TD AL)
Release the
Lift/Drive
button and press No (NO CO)/ Drive cut out while
not stored (DCONS)/ Lifting or
driving (LORDR)
Proximity Kill Switch
(NONE/PROX)
Platform Overload
(NONE/PLFTS)
Work Li ghts
(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
(0-30 minutes) 30.0 max and 0.0 min, 10.0 (default)
Platform Always Level to Gravity
(NO/YES)
Axle Motion Only While Driving
(NO/YES)
Holding +/- button will cause display to

scroll through options or increment
number settings automatically at
0.2 min increase/decrease
4-6 Z-135/70 Part No. 106783

1234567890123456
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REV C DISPLAY MODULE
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1234567890123456
1234567890123456
1234567890123456
Part No. 106783 Z-135/70 4-7

Platform Controls REV C
The platform controls contains two printed a

circuit boards:
The LED circuit board is mounted to the underside b
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 c
circuit board (PCON) sends the data to the
turntable control box (TCON) for processing. f d
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)
e
and require no adjustment. The operating
parameters of the joysticks are stored in memory at
a platform controls ALC-1000
the turntable controls. If a joystick controller error circuit board
occurs or if a joystick is replaced, it will need to be b jib boom up/down, jib boom extend/
calibrated before that particular machine function retract and platform rotate left right
will operate. See 1-3, How to Calibrate a Joystick. joystick
c secondary boom up/extend and
down/retract joystick
Each joystick controller should operate smoothly
d drive/steer joystick controller
and provide proportional speed control over its e LED circuit board
entire range of motion. f primary boom up/down, primary
boom extend/retract and
For further information or assistance, consult the turntable rotate left/right joystick
Genie Industries Service Department.
4-8 Z-135/70 Part No. 106783

REV C PLATFORM CONTROLS
1-1 7 Attach a grounded wrist strap to the ground

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

PLATFORM CONTROLS REV C
How to Remove the LED 1-2

Circuit Board Membrane Decal
1 Push in the red Emergency Stop button to the
off position at both the ground and platform How to Replace the Membrane
controls. Decal
2 Remove the platform control box lid retaining The membrane decal is a special decal that
fasteners. Open the control box lid. incorporates an electronic membrane on the
3 Locate the LED circuit board mounted to the backside. The membrane contains touch sensitive
inside of the platform control box lid. areas that, when pushed, activates the machine
functions. The membrane buttons function similar
Electrocution/burn hazard. Contact to toggle switches, but do not have any moving
with electrically charged circuits parts.
could result in death or serious
injury. Remove all rings, watches 1 Push in the red Emergency Stop button to the
and other jewelry. off position at both the ground and platform
controls.
Component damage hazard.
Electrostatic discharge (ESD) can 2 Remove the platform control box lid retaining
damage printed circuit board fasteners. Open the control box lid.
components. Maintain firm contact 3 Tag and carefully disconnect the two ribon
with a metal part of the machine cables from the membrane circuit board.
that is grounded at all times when
handling printed circuit boards OR Electrocution/burn hazard. Contact
use a grounded wrist strap. with electrically charged circuits
4 Tag and carefully disconnect the ribbon cables injury. Remove all rings, watches
from the membrane circuit board. and other jewelry.
5 Remove the LED circuit board retaining Component damage hazard.
fasteners. Electrostatic discharge (ESD) can
6 Carefully remove the LED circuit board from the damage printed circuit board
platform control box lid. Do not lose the plastic components. Maintain firm contact
spacers. with a metal part of the machine
Note: When installing the LED circuit board, be sure handling printed circuit boards OR
the plastic spacers are installed between the circuit use a grounded wrist strap.
board and the control box lid.
4 - 10 Z-135/70 Part No. 106783

4 Close the control box lid. 1-3

5 Remove the platform controls decal from the Joysticks
platform control box.
6 Carefully remove the membrane decal from the How to Calibrate a Joystick
platform control box while guiding the ribbon
cables out of the control box lid. The joystick controllers on this machine utilize
digital Hall Effect technology for proportional
7 Remove any decal adhesive from the control control. If a joystick controller is disconnected or
box lid with a mild solvent. replaced, it must be calibrated before that particular
machine function will operate.
Note: Do not allow any solvent to come in contact
with the membrane circuit board. Note: The joystick must be calibrated before the
threshold, max-out or ramping can be set.
8 Install the new membrane decal while guiding
the ribbon cables through the control box lid. Note: After each joystick is calibrated, check the
Note: Be sure that all LED locations on the display at the ground control box. There should be
membrane decal align with the LEDs on the no calibration faults shown on the display. If
membrane circuit board. calibration faults exist, repeat steps 1 through 8 for
that joystick controlled function.
9 Install a new platform controls decal over the
membrane decal. Note: Perform this procedure with the engine off.
10 Open the control box lid and carefuly connect Drive functions:
the ribbon cables from the membrane decal to
1 Turn the key switch to the off position.
the membrane circuit board.
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 twice, then press the

enter button twice.
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

5 Do not start the engine. Primary boom extend/retract functions:

6 Locate the drive/steer joystick. 1 Turn the key switch to the off position.
7 Move the drive/steer joystick full stroke in the 2 Press and hold the enter button on the
forward direction and hold for 5 seconds, then ground control panel while turning the key
return to the center or neutral position. switch to platform controls. Hold the enter
8 Move the drive/steer joystick full stroke in the button for approximately 5 seconds.
reverse direction and hold for 5 seconds, then
return to the center or neutral position.
enter button twice.
Result: The alarm at the ground controls should
sound for a successful calibration. 4 Use the scroll button to scroll through the
Steer functions: menu until RESET PRIMARY BOOM EXTEND/RETRACT
JOYSTICK DEFAULTS is displayed. Press the
1 Turn the key switch to the off position. button to select YES, then press the button.
2 Press and hold the enter button on the 5 Do not start the engine.
switch to platform controls. Hold the enter 6 Locate the thumb rocker switch on top of the
button for approximately 5 seconds. primary boom/turntable rotate joystick.
3 Press the minus button twice, then press the 7 Move the primary boom extend/retract thumb
rocker switch full stroke in the extend direction
enter button twice. and hold for 5 seconds, then return to the center
or neutral position.
menu until RESET STEER JOYSTICK DEFAULTS is 8 Move the primary boom extend/retract thumb
displayed. Press the button to select YES, rocker switch full stroke in the retract direction
and hold for 5 seconds, then return to the center
or neutral position.
5 Do not start the engine.
6 Locate the drive/steer joystick. sound for a successful calibration.
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
sound for a successful calibration.
4 - 12 Z-135/70 Part No. 106783

Secondary boom up/down and Primary boom up/down functions:

extend/retract functions:
2 Press and hold the enter button on the ground control panel while turning the key
ground control panel while turning the key switch to platform controls. Hold the enter
switch to platform controls. Hold the enter button for approximately 5 seconds.
3 Press the minus button twice, then press the enter button twice.
enter button twice.
4 Use the scroll button to scroll through the menu until RESET PRIMARY BOOM UP/DOWN JOYSTICK
menu until RESET SECONDARY BOOM JOYSTICK DEFAULTS DEFAULTS is displayed. Press the button to
is displayed. Press the button to select YES, select YES, then press the button.
6 Locate the primary boom/turntable rotate
6 Locate the secondary boom up/down and joystick.
extend/retract joystick.
7 Move the boom/turntable rotate joystick full
7 Move the secondary boom up/down and extend/ stroke in the up direction and hold for 5
retract joystick full stroke in the up/extend seconds, then return to the center or neutral
direction and hold for 5 seconds, then return to position.
8 Move the boom/turntable rotate joystick full
8 Move the secondary boom up/down and extend/ stroke in the down direction and hold for 5
retract joystick full stroke in the down/retract seconds, then return to the center or neutral
direction and hold for 5 seconds, then return to position.
Result: The alarm at the ground controls should sound for a successful calibration.
Part No. 106783 Z-135/70 4 - 13

Jib boom up/down functions: Turntable rotate functions:

1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the 2 Press and hold the enter button on the
ground control panel while turning the key ground control panel while turning the key
switch to platform controls. Hold the enter switch to platform controls. Hold the enter
button for approximately 5 seconds. button for approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until RESET JIB BOOM UP/DOWN JOYSTICK menu until RESET TURNTABLE ROTATE JOYSTICK
DEFAULTS is displayed. Press the button to DEFAULTS is displayed. Press the button to
select YES, then press the button. select YES, then press the button.
5 Do not start the engine. 5 Do not start the engine.
6 Locate the jib boom joystick. 6 Locate the primary boom/turntable rotate
joystick.
7 Move the jib boom joystick full stroke in the up
direction and hold for 5 seconds, then return to 7 Move the boom/turntable joystick full stroke in
the center or neutral position. the left direction and hold for 5 seconds, then
8 Move the jib boom joystick full stroke in the
down direction and hold for 5 seconds, then 8 Move the boom/turntable joystick full stroke in
return to the center or neutral position. the right direction and hold for 5 seconds, then
sound for a successful calibration. Result: The alarm at the ground controls should
4 - 14 Z-135/70 Part No. 106783

How to Reset a Proportional How to Set the Function

Valve Coil Default Thresholds and Default
Note: This procedure only needs to be performed if Functions Speeds
a proportional valve has been replaced. Note: Before the threshold and default function
Note: After the valve coil defaults have been set, speeds can be set, the boom function proportional
each machine function threshold and default valve coil defaults must be set first.
function speed must be set. See How to Set the See How to Reset a Proportional Valve Coil
Function Thresholds and Default Function Speeds. Default.
1 Turn the key switch to the off position. Note: If a boom function proportional valve coil has
not been replaced and just want to reset the
2 Press and hold the enter button on the function speed to original factory settings, begin
ground control panel while turning the key with step 12.
switch to platform controls. Hold the enter
button for approximately 5 seconds. 1 Start the engine from the platform controls.
2 Press down the foot switch.
enter button twice. Note: Be sure the engine rpm is set to foot switch
activated high idle.
Function threshold:
menu until the function valve that needs to be
reset is displayed. Press the button to 3 Select a joystick controlled function that needs
select YES, then press the button to save the to have the threshold set.
setting. 4 Slowly move the joystick off center in either
5 Push one of the LCD direction just until the machine function starts to
screen buttons shown move, then move the joystick very slowly
until EXIT is displayed. towards the neutral or center position just before
the machine function stops.
6 Press the plus button or minus button to Do not let go of the joystick.
select YES and then press the enter button . 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.
Part No. 106783 Z-135/70 4 - 15

7 While holding the joystick in position, press the Function speeds:

engine start button at the platform controls Note: Be sure the machine is in the stowed position
to set the joystick controller threshold. and the boom is rotated between the circle end
8 Repeat steps 3 through 7 for each joystick tires.
controlled machine function (primary boom up/ Note: Perform this procedure with the machine
down and turntable rotate left/right, primary parked on a firm, level surface which is free of
boom extend/retract, secondary up/down and obstructions.
extend/retract, drive forward/reverse).
9 Once the threshold has been set, press and hold
the engine start button until the engine 13 Select a boom function that needs the function
speed set.
shuts off. Do not press the red Emergency Stop
button. 14 Primary boom up/down and extend/retract
functions: Move the joystick full stroke in the
Note: Approximately 3 seconds after the engine
up or extend direction. When the alarm sounds,
shuts off, the alarm at the ground controls will
move the joystick in the opposite direction full
sound to indicate the threshold settings are being
stroke until the alarm sounds again. Return the
saved in memory.
joystick to center.
10 At the ground controls, turn the key switch to Secondary boom up/extend and down/retract
the off position, wait a moment and then turn functions: Move the joystick full stroke in the
the key switch to platform controls. up or extend direction. When the alarm sounds,
11 Check the display at the ground controls to be move the joystick in the opposite direction full
sure there are no calibration faults. stroke until the alarm sounds again. Return the
joystick to center.
Note: There should be no calibration faults shown
on the display. If calibration faults exist, repeat Turntable rotate functions: Move the joystick
this procedure. 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

15 Once the function speeds have been set, press How to Adjust the Function
and hold the engine start button until the Speeds
engine shuts off. Do not press the red
Emergency Stop button. Note: Perform this procedure with the boom in the
stowed position.
Note: Approximately 3 seconds after the engine
shuts off, the alarm at the ground controls will 1 Pull out the red Emergency Stop button to the
sound to indicate the speed settings are being on position at both the ground and platform
saved in memory. controls.
16 At the ground controls, turn the key switch to 2 Press and hold the enter button on the
the off position, wait a moment and then turn ground control panel while turning the key
the key switch to platform controls. switch to ground controls. Hold the enter
17 Check the display at the ground controls to be
sure there are no calibration faults. 3 Press the plus button twice, then press the
Note: There should be no calibration faults shown minus button twice.
on the display. If calibration faults exist, repeat
this procedure. 4 Press the scroll button until the function to
be adjusted is displayed.
5 Press the plus button to increase the speed

or press the minus button to decrease the
speed.
6 Press the enter button to save the setting in

memory.
until EXIT is displayed.
8 Press the plus button or minus button to

select YES and then press the enter button .
9 Continue to perform this procedure until the
machine function speed meets specification.
Refer to Section 2, Specifications for function
speeds.
Part No. 106783 Z-135/70 4 - 17

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.

stowed position.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.

switch to ground controls. Hold the enter
3 Press the plus button twice, then press the

scroll button twice.
4 Press the scroll button until the function to

be adjusted is displayed.
5 Press the plus button to increase the ramp

rate or press the minus button to decrease
the ramp rate.
6 Press the enter button to save the setting in

memory.

select YES and then press the enter button .
4 - 18 Z-135/70 Part No. 106783

REV E
Platform Components
2-1 4 Place a block under the platform leveling
cylinder for support.
Platform Leveling Cylinder
5 Remove the external snap rings from the barrel-
The platform leveling cylinder keeps the platform end pivot pin. Use a soft metal drift to remove
level through the entire range of boom motion. the barrel-end pivot pin.
The platform is maintained level to the turntable. To 6 Support the rod end of the platform level
accomplish this, the ECM at the ground controls cylinder.
compares the difference in readings between the
platform angle sensor and the turntable level 7 Remove the pin retaining fasteners from
sensor, which then sends a signal to the platform the platform leveling cylinder rod-end pivot pin.
controls to open or close the appropriate platform Use a soft metal drift to remove the barrel-end
level proportional valve on the platform manifold to pivot pin.
maintain a level platform. The platform leveling 8 Carefully pull the platform leveling cylinder out of
cylinder is equipped with counterbalance valves to the boom to access the hydraulic hoses.
prevent movement in the event of a hydraulic line
failure. 9 Tag, disconnect and plug the hydraulic hoses
from the platform leveling cylinder. Cap the
How to Remove the Platform fittings on the cylinder.
Leveling Cylinder Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
the O-ring on the fitting and/or hose end must be
connections very slowly to allow
replaced and then torqued to specification during
installation. Refer to Section Two, Hydraulic Hose
gradually. Do not allow oil to
and Fitting Torque Specifications.
squirt or spray.
1 Extend the jib boom until the platform leveling 10 Remove the platform leveling cylinder from the
cylinder barrel-end pivot pin is accessible. machine.
2 Raise the jib boom slightly and place blocks Crushing hazard. The platform
under the platform. leveling cylinder may fall if not
3 Lower the jib boom until the platform is resting properly supported when removed
on the blocks just enough to support the from the machine.
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
Part No. 106783 Z-135/70 4 - 19

PLATFORM COMPONENTS REV E
2-2 3 Remove the platform angle sensor retaining

fasteners. Remove the platform angle sensor
Platform Rotator from the platform rotator.
The platform rotator is a hydraulically activated Component damage hazard. The

helical gear assembly used to rotate the platform platform angle sensor is a very
160 degrees. sensitive instrument. It can be
damaged internally if is dropped or
How to Remove the sustains any physical shock, even
if the damage is not visible.
Platform Rotator
4 Tag, disconnect and plug the hydraulic hoses
Component damage hazard. Mark from the platform rotator manifold. Cap the
the platform mounting weldment fittings on the manifold.
and the rotator flange before
removing the platform mounting Bodily injury hazard. Spraying
weldment. The platform mounting hydraulic oil can penetrate and
weldment must be replaced in the burn skin. Loosen hydraulic
exact same position on the rotator connections very slowly to allow
flange as it was before removal. If the oil pressure to dissipate
a new rotator is installed or the gradually. Do not allow oil to squirt
rotator is disassembled, proper or spray.
alignment can be achieved by 5 Tag, disconnect and plug the hydraulic hoses
rotating the rotator all the way to from the platform manifold. Cap the fittings on
the left and then installing the the manifold.
platform mounting weldment all the
way in the left position. Bodily injury hazard. Spraying
Note: When removing a hose assembly or fitting, burn skin. Loosen hydraulic
the O-ring on the fitting and/or hose end must be connections very slowly to allow
replaced and then torqued to specification during the oil pressure to dissipate
installation. Refer to Section Two, Hydraulic Hose gradually. Do not allow oil to squirt
and Fitting Torque Specifications. or spray.
1 Remove the platform. 6 Remove the power to platform electrical outlet
2 Tag and disconnect the electrical connector box bracket mounting fasteners. Do not
from the platform angle sensor. disconnect the wiring.
7 Remove the hose and cable guide retaining
fasteners and remove the guide from the
platform support.
4 - 20 Z-135/70 Part No. 106783

REV E PLATFORM COMPONENTS
8 Remove the weld cable from the platform 2-3

(if equipped).
Platform Level Sensor
with electrically charged circuits The platform level sensor is mounted to the side of
could result in death or serious the platform rotator. The platform level sensor is
injury. Remove all rings, watches monitored by the control system to maintain a level
and other jewelry. platform throught boom range of motion. If a
9 Support the platform mounting weldment, but do platform level sensor is replaced, it must be
not apply any lifting pressure. calibrated prior to machine operation.
10 Remove the eight mounting bolts from the How to Calibrate the Platform
platform mounting weldment.
Level Sensor
11 Remove the center bolt and slide the platform
mounting weldment off of the platform rotator. Note: Perform this procedure with the machine on a
firm, level surface and in the stowed position.
Crushing hazard. The platform
mounting weldment could become 1 Secure a digital level to one of the side railings
unbalanced and fall if not properly of the platform.
supported. 2 Start the machine and level the platform to
12 Support the platform rotator with a suitable lifting gravity. Turn the machine off.
device. Do not apply any lifting pressure. 3 Open the ground control box.
13 Place a block under the platform leveling Before serial number 321:
cylinder rod for support.
4 Locate the 2 pin connector in the lower left hand
14 Remove the pin retaining fasteners from area of the ground control box.
the platform leveling cylinder rod-end pivot pin.
Do not remove the pin. 5 Remove the connector plug and insert a jumper
wire between the two pins of the connector.
15 Remove the pin retaining fasteners from the jib
boom to platform rotator pivot pin. Do not After serial number 320:
remove the pin.
4 Locate the calibration toggle switch at the top of
16 Use a soft metal drift to remove both pins and the ground control box. Activate calibration
remove the platform rotator from the machine. mode by moving the toggle switch in the left
direction.
Crushing hazard. The platform
rotator could fall when removed 5 Temporarily install a control box door retaining
from the machine if not properly fastener between the door and the box to
supported. prevent the control box door from moving the
toggle switch while calibrating the machine.
Part No. 106783 Z-135/70 4 - 21

All models: 13 Press the plus button or minus button to

6 Insert the key into the service/bypass key correct the display to match the data sheet.
switch and turn it to the service/bypass Then press the enter button to save the
position. setting in memory.
Note: The angle sensor calibration values will not 14 Push one of the LCD
be saved correctly unless the key switch is in the screen buttons shown
service/bypass position. until EXIT is displayed.
7 Press and hold the enter button on the 15 Press the plus button or minus button to
ground control panel while turning the key select YES and then press the enter button .
switch to ground controls. Hold the enter
Before serial number 321:
8 Enter sensor calibration mode by pressing the 16 Remove the wire jumper from the 2 pin
buttons at the ground controls in the following connector in the lower left hand area of the
ground control box that was installed in step 5.
sequence: .
Install the connector plug.
9 Push one of the LCD Tip-over hazard. Failure to remove
screen buttons shown the jumper wire will result in an
until RESET PLATFORM LEVEL unsafe configuration which will
SENSOR TO GRAVITY is
compromise machine stability.
displayed. Operating the machine in this
10 Press the plus button to select YES, then configuration will result in the
press the enter button. machine tipping over causing
death or serious injury. The jumper
11 Push one of the LCD wire must be removed before
screen buttons shown operating the machine.
until PLATFORM LEVEL SENSOR
MV PER DEGREE is displayed.
17 Close the ground control box and install the door
retaining fasteners.
12 Confirm that the number shown on the display is
the same as that shown on the data sheet After serial number 320:
supplied with the new platform level sensor. 17 Remove the fastener that was temporarily
Result: If the number shown on the display is installed in step 5. Close the control box door
the same as that shown on the data sheet and install the door retaining fasteners.
supplied with the new platform level sensor, Note: When the control box door is closed, the
continue to step 13. calibration toggle switch is automatically activated
Result: If the number shown on the display is to exit out of calibration mode.
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

REV E PLATFORM COMPONENTS
2-4 Determine the limit switch trigger point:

Platform Overload System 4 Gently move the platform up and down by hand,
(if equipped) so it bounces approximately 1 to 2 inches /
2.5 to 5 cm. Allow the platform to settle.
Proper calibration of the platform overload system Result: The overload indicator light and the
is essential to safe machine operation. Continued alarm is on. Slowly tighten the load spring
use of an improperly calibrated platform overload adjustment nut by turning it clockwise just until
system could result in the system failing to sense the overload indicator light and alarm turns off.
an overloaded platform. The stability of the
machine is compromised and it could tip over. Note: The platform will need to be moved up and
down and allowed to settle in between adjustments.
How to Calibrate the Platform Note: There may be an approximate 2 second delay
Overload System (if equipped) before the overload indicator light turns on and the
alarm sounds.
Note: Perform this procedure with the machine on a
firm, level surface. Result: The overload indicator light and
alarm is off. Slowly loosen the load spring
1 Level the platform. adjustment nut by turning it counterclockwise
2 Determine the maximum platform capacity. just until the overload indicator light and alarm
Refer to the machine serial plate. turn on.
3 Using a suitable lifting device, place an Note: There may be an approximate 2 second delay
appropriate test weight equal to that of the before the overload indicator light turns on and the
maximum platform capacity at the center of the alarm sounds.
platform floor. 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.
Part No. 106783 Z-135/70 4 - 23

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
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

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

Jib Boom Components REV F
a b c d e
l k j i h g f
Jib boom components
a primary extension boom

b jib boom manifold
c bellcrank
d cable track tube
e platform rotator
f platform leveling cylinder
g jib boom
h jib extension boom
i hose and cable junction box
j jib boom lift cylinder
k jib boom cable track
l jib boom leveling cylinder
4 - 26 Z-135/70 Part No. 106783

REV F JIB BOOM COMPONENTS
3-1 5 Pull the hoses out of the plastic hose guide

located on the primary extension boom near the
Jib Boom Cable Track jib boom manifold.
The jib boom cable track guides the cables and 6 Tag, disconnect and plug the jib boom lift
hoses running up the jib boom. It can be repaired cylinder hydraulic hoses. Cap the fittings on the
link by link without removing the cables and hoses cylinder.
that run through it. Removing the entire jib boom Bodily injury hazard. Spraying
cable track is only necessary when performing hydraulic oil can penetrate and
major repairs that involve removing the jib boom. burn skin. Loosen hydraulic
How to Remove the Jib Boom the oil pressure to dissipate
Cable Track gradually. Do not allow oil to squirt
or spray.
the O-ring on the fitting and/or hose end must be 7 Remove the hose and cable clamp retaining
replaced and then torqued to specification during fasteners from the jib boom cable track junction
installation.Refer to Section Two, Hydraulic Hose box. Remove the clamps.
and Fitting Torque Specifications. 8 Pull the jib boom lift cylinder hydraulic hoses out
1 Raise the jib boom to a horizontal position. of the jib boom cable track junction box.
Turn the machine off. 9 Remove the hose and cable clamp retaining
2 Remove the cover from the hose and cable fasteners at the platform end of the jib boom
junction box under the jib boom cable track. cable track tube. Remove the clamps.
3 Tag and disconnect the electrical connectors 10 Tag and disconnect the electrical connectors
inside the cable track junction box. from the platform manifold.
4 Tag, disconnect and plug the two hydraulic 11 Tag and disconnect the electrical connectors
hoses from the jib boom manifold that lead to from the platform box.
the platform manifold. Cap the fittings on the 12 Tag and disconnect the electrical connector
manifold. from the foot switch.
Bodily injury hazard. Spraying 13 Tag and disconnect the electrical connector
hydraulic oil can penetrate and from the platform angle sensor.
connections very slowly to allow 14 Tag, disconnect and plug the hydraulic hoses
the oil pressure to dissipate from the "P" and "T" ports on the platform
gradually. Do not allow oil to squirt manifold.
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

JIB BOOM COMPONENTS REV F
15 Pull the two hydraulic hoses just removed and How to Repair the Cable Track
all of the cables through the hose and cable
guide at the platform support. Component damage hazard.
The boom cable track can be
Component damage hazard. damaged if it is twisted.
Cables and hoses can be damaged
if they are kinked or pinched. Note: A cable track repair kit is available through
the Genie Industries Service Parts Department,
16 Remove the cotter pin from the upper cable part no. 77896. The kit includes a 4-link section of
track tube at the platform end of the jib boom. cable track.
Do not discard the washer.
1 Visually inspect the cable track and determine
Note: Always replace the cotter pin with a new one.
which 4-link section needs to be replaced.
17 Remove the fasteners from the cable track tube 2 Carefully remove the snap rings and pins from
guide at the platform end of the jib boom. each end of the damaged section of cable track.
Remove the cable track tube guide from the jib
boom. 3 Remove the retaining fasteners from the upper
black rollers from the 4-link section of cable
18 Place blocks between the upper and lower cable track to be replaced. Remove the rollers.
tracks and secure the upper and lower tracks
together. 4 Lift up the hoses and cables and carefully
remove the damaged 4-link section of cable
Crushing hazard. If the upper and track.
lower cable tracks are not properly
secured together, the cable track Component damage hazard. Hoses
could become unbalanced and fall and cables can be damaged if
when removed from the machine. they are kinked or pinched.
19 Attach a lifting strap from an overhead crane to 5 Remove the upper rollers from the replacement
the cable track. section of cable track.
20 Remove the mounting fasteners that attach the 6 Lift up the hoses and cables and carefully insert
lower cable track to the jib boom. the new 4-link section of cable track.
21 Remove the cable track from the machine and Component damage hazard.
place it on a structure capable of supporting it. Hoses and cables can be damaged
if they are kinked or pinched.
Crushing hazard. The cable track
could become unbalanced and fall 7 Connect the ends of the replacement cable track
if not properly attached to the section to the existing cable track using the
overhead crane. pins and snap rings.
Component damage hazard. 8 Install the rollers onto the new section of cable
Cables and hoses can be track.
damaged if they are kinked or
9 Operate the jib boom extend/retract function
pinched.
through a full cycle to ensure smooth operation
of the new section of cable track.
4 - 28 Z-135/70 Part No. 106783

3-2 3 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses from the jib boom
Jib Boom manifold. Cap the fittings on the manifold.
Bodily injury hazard. Spraying
How to Remove the Jib Boom hydraulic oil can penetrate and
Bodily injury hazard. This burn skin. Loosen hydraulic
procedure requires specific repair connections very slowly to allow
skills, lifting equipment and a the oil pressure to dissipate
suitable workshop. Attempting this gradually. Do not allow oil to
procedure without these skills and squirt or spray.
tools could result in death or 4 Remove the cotter pin from the upper cable
serious injury and significant track tube at the platform end of the jib boom.
component damage. Dealer
service is strongly recommended. Note: Always replace the cotter pin with a new one.
Note: Perform this procedure with the boom in the 5 Remove the cable track guide fasteners from
stowed position. the cable track guide at the platform end of the
jib boom and remove the cable track guide from
Note: When removing a hose assembly or fitting, the jib boom.
replaced and then torqued to specification during 6 Place blocks between the upper and lower cable
installation. Refer to Section Two, Hydraulic Hose tracks and secure the upper and lower tracks
and Fitting Torque Specifications. together.
1 Remove the platform mounting weldment Crushing hazard. If the upper and
and the platform rotator. See 2-2, How to lower cable tracks are not properly
Remove the Platform Rotator. secured together, the cable track
could become unbalanced and fall
2 Tag, disconnect and plug the the two hydraulic when removed from the machine.
hoses from the jib boom manifold that lead to
the platform manifold. Cap the fittings on the 7 Attach a lifting strap from an overhead crane to
manifold. the cable track.
Bodily injury hazard. Spraying 8 Remove the mounting fasteners that attach the
hydraulic oil can penetrate and lower cable track to the jib boom.
burn skin. Loosen hydraulic 9 Remove the cable track from the machine and
connections very slowly to allow lay to the side.
gradually. Do not allow oil to Crushing hazard. The cable track
squirt or spray. could become unbalanced and fall
if not properly attached to the
overhead crane.
Cables and hoses can be
damaged if they are kinked or
pinched.
Part No. 106783 Z-135/70 4 - 29

10 Disconnect the electrical connector from the jib 18 Secure the jib boom lift cylinder to the jib boom
boom angle sensor located at the jib boom pivot with a strap or other suitable device.
pin on the engine side of the machine.
19 Raise the jib boom to a horizontal position using
11 Remove the cover retaining fasteners from the the overhead crane.
jib boom angle sensor. Remove the cover.
20 Attach a second lifting strap from the overhead
12 Remove the jib boom angle sensor mounting crane to the pivot end of the jib boom.
bracket fasteners from the side of the primary
21 Remove the pin retaining fastener from the jib
extension boom.
boom pivot pin. Do not remove the pin.
13 Carefully remove the bracket and sensor
22 Place a block under the jib boom level cylinder
assembly. Note the location of the springs.
for support. Protect the cylinder rod from
Do not lose the springs.
damage.
Note: There is one spring inside the jib boom pivot
23 Use a soft metal drift to tap the pin halfway out
pin and one inside the angle sensor.
in one direction and lower one side of the jib
Note: When the jib boom is installed, the jib boom boom bellcrank. Tap the pin in the other
angle sensor will need to be calibrated. See 3-6, Jib direction and lower the other side of the jib
Boom Bellcrank Angle Sensor for the calibration boom bellcrank.
procedure.
24 Use a soft metal drift to remove the jib boom
14 Attach a lifting strap from an overhead crane to pivot pin. Remove the jib boom from the
the platform end of the jib boom. machine and place it on a structure capable of
supporting it.
15 Support the barrel end of the jib boom lift
cylinder with another suitable lifting device. Crushing hazard. The jib boom
assembly could become
16 Remove the pin retaining fasteners from the jib unbalanced and fall when removed
boom lift cylinder barrel-end pivot pin. from the machine if not properly
17 Use a soft metal drift to remove the jib boom lift supported by the overhead crane.
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.
4 - 30 Z-135/70 Part No. 106783

3-3 3 Support the rod end of the jib boom lift cylinder
with a suitable lifting device.
Jib Boom Lift Cylinder
boom lift cylinder rod-end pivot pin. Use a soft
How to Remove the Jib Boom metal drift to remove the pin and let the cylinder
Lift Cylinder hang down.
Note: Perform this procedure with the boom in the 5 Attach a lifting strap from an overhead crane to
stowed position. the barrel end of jib boom lift cylinder.
Note: When removing a hose assembly or fitting, 6 Remove the pin retaining fasteners from the jib
the O-ring on the fitting and/or hose end must be boom lift cylinder barrel-end pivot pin. Use a
replaced and then torqued to specification during soft metal drift to remove the pin.
installation. Refer to Section Two, Hydraulic Hose 7 Remove the jib boom lift cylinder from the
and Fitting Torque Specifications. machine.
1 Raise the jib boom slightly and place blocks Crushing hazard. The jib boom lift
under the platform mounting weldment. Lower cylinder could become unbalanced
the jib boom until the platform is resting on the and fall when removed from the
blocks just enough to support the platform. machine if not properly supported
Note: Do not rest the entire weight of the boom on by the overhead crane.
the blocks.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.
Part No. 106783 Z-135/70 4 - 31

3-4 7 Tag, disconnect and plug the jib boom level

cylinder hydraulic hoses from the jib boom
Jib Boom Level Cylinder manifold. Cap the fittings on the manifold.
How to Remove the Jib Boom hydraulic oil can penetrate and
Level Cylinder burn skin. Loosen hydraulic
stowed position.
Note: When removing a hose assembly or fitting, squirt or spray.
the O-ring on the fitting and/or hose end must be 8 Attach an overhead crane or other suitable
replaced and then torqued to specification during device to the jib boom level cylinder for support.
and Fitting Torque Specifications. 9 Carefully remove the jib boom level cylinder
from the machine.
1 Extend the primary boom until the jib boom level
cylinder barrel-end pivot pin is accessible. Crushing hazard. The jib boom
level cylinder could become
2 Raise the jib boom above horizontal. unbalanced and fall when removed
3 Attach an overhead crane to the jib boom from the machine if not properly
assembly for support. supported.
4 Place a block under the jib boom level cylinder

damage.
boom level cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
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.
4 - 32 Z-135/70 Part No. 106783

REV E JIB BOOM COMPONENTS
3-5 4 Tag, disconnect and plug the the two hydraulic

hoses from the jib boom manifold that lead to
Jib Boom Extension Cylinder the platform manifold. Cap the fittings on the
manifold.
How to Remove the Jib Boom Bodily injury hazard. Spraying
Extension Cylinder hydraulic oil can penetrate and
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
squirt or spray.
procedure without these skills and
tools could result in death or 5 Tag, disconnect and plug the jib boom lift
serious injury and significant cylinder and jib boom extension cylinder
component damage. Dealer hydraulic hoses from the jib boom manifold. Cap
service is strongly recommended. the fittings on the manifold.
Note: Perform this procedure with the boom in the Bodily injury hazard. Spraying
stowed position. hydraulic oil can penetrate and
Note: When removing a hose assembly or fitting, connections very slowly to allow
the O-ring on the fitting and/or hose end must be the oil pressure to dissipate
replaced and then torqued to specification during gradually. Do not allow oil to
installation. Refer to Section Two, Hydraulic Hose squirt or spray.
6 Remove the cover from the lower jib boom cable
1 Remove the jib boom lift cylinder. See 3-3, How track.
to Remove the Jib Boom Lift Cylinder.
7 Tag and disconnect the electrical connectors
2 Attach a lifting strap from an overhead crane to inside the lower cable track.
the platform end of the jib boom for support.
Raise the jib boom to a horizontal position using 8 Remove the hose and cable clamp retaining
the overhead crane. fasteners from lower cable track at the pivot end
of the jib boom. Remove the clamps.
3 Extend the jib boom until the jib boom extension
cylinder rod-end pivot pin is accessible. 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

11 Place a block under the jib boom level cylinder 3-6

damage. Jib Boom Bellcrank Angle
12 Remove the pin retaining fastener from the jib
Sensor
boom pivot pin. Do not remove the pin.
The jib boom bellcrank angle sensor is monitored
13 Use a soft metal drift to tap the jib boom pivot by the control system to keep the jib boom
pin halfway out in one direction and lower one bellcrank vertical and to help maintain a level
side of the jib boom bellcrank. Tap the pin in the platform through boom range of motion. If a jib
other direction and lower the other side of the jib boom bellcrank angle sensor is replaced, it must be
boom bellcrank. calibrated prior to machine operation. The jib boom
bellcrank angle sensor is mounted to the bellcrank
14 Use a soft metal drift to remove the jib boom
pivot pin on the engine side of the machine.
pivot pin. Remove the jib boom and platform
assembly from the machine and place it on a
structure capable of supporting it.
How to Replace the Jib Boom
Bellcrank Angle Sensor
Crushing hazard. The jib boom and
platform assembly could become Note: Perform this procedure on a firm, level
unbalanced and fall when removed surface with the boom in the stowed position.
from the machine if not properly
supported by the overhead crane. 1 Locate the jib boom bellcrank angle sensor
where the jib boom bellcrank connects to the
15 Remove the pin retaining fasteners from the jib primary boom.
boom extension cylinder rod-end pivot pin. Use
a soft metal drift to remove the pin. 2 Disconnect the electrical connector from the
sensor. Remove any tie wraps securing the
16 Attach a lifting strap from an overhead crane to wiring.
the barrel end of the jib boom extension
cylinder. 3 Remove the retaining fasteners from the angle
sensor guard. Remove the guard from the
17 Remove the pin retaining fasteners from the jib machine.
boom extension cylinder barrel-end pivot pin.
Use a soft metal drift to remove the pin. 4 Remove the angle sensor cover retaining
fastener. Remove the cover.
18 Carefully slide the jib boom extension cylinder
out of the jib boom and place it on a structure 5 Remove the angle sensor mounting bracket
capable of supporting it. retaining fasteners.

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.
4 - 34 Z-135/70 Part No. 106783

6 Remove the angle sensor and bracket 12 Insert the hex-shaped key into the bellcrank
assembly. Do not lose the two springs or the pivot pin allowing free clockwise rotation of the
hex-shaped key. angle sensor mounting bracket.
7 Remove the sensor retaining fasteners from the Note: Be sure the hex-shaped key remains
mounting bracket. Remove the angle sensor. engaged in the sensor.
Note: Note the sensor orientation on the bracket 13 Rotate the angle sensor mounting bracket, while
during removal so the new sensor will be installed holding the key in the sensor, clockwise until
in the same position. the mounting bracket fits into the machined
pocket.
8 Install the new angle sensor onto the mounting
bracket. 14 Install the angle sensor bracket retaining
fasteners.
9 Install one spring, removed in step 6, into the
hex-shaped hole in the angle sensor. Install the 15 Install the angle sensor cover and install the
other spring into the hex-shaped hole in the cover retaining fasteners.
center of the boom pivot pin.
16 Connect the electrical connector to the new
10 Insert the hex-shaped key into the angle sensor. sensor.
11 Align the side of the sensor with flat area of the 17 Install the angle sensor guard over the angle
boom pivot pin as shown below. sensor.
18 Calibrate the jib boom bellcrank angle sensor.
See How to Calibrate the Jib Boom Bellcrank
Angle Sensor.
a b c
a flat area
b angle sensor
c hex-shaped hole
Part No. 106783 Z-135/70 4 - 35

How to Calibrate the Jib Boom 3 Push in the ground controls red Emergency Stop
button to the off position. Do not turn the key
Bellcrank Angle Sensor switch to the off position.
Note: If the secondary boom and/or primary boom 4 Open the ground control box
angle sensors have been removed or replaced, they
will need to be calibrated before the jib boom Before serial number 321:
bellcrank angle sensor. See 4-9, Secondary Boom 5 Locate the 2 pin connector in the lower left hand
Angle Sensor and/or 4-8, Primary Boom Angle area of the ground control box.
Sensor for the calibration procedures.
6 Remove the connector plug and insert a jumper
Note: Perform this procedure with the machine on a wire between the two pins of the connector.
firm, level surface and in the stowed position with
the axles extended. After serial number 320:
Note: A digital level will be required to perform this 5 Locate the calibration toggle switch at the top of
procedure. the ground control box. Activate calibration
mode by moving the toggle switch in the left
Note: A kit is available through the Genie Industries direction.
Service Department (Genie part number 58351).
This kit includes a digital level with a magnetic 6 Temporarily install a control box door retaining
base and cable harnesses. fastener between the door and the box to
prevent the control box door from moving the
Digital levels with alternate zero function: toggle switch while calibrating the machine.
1 Prepare the digital level by placing it vertically
on a known surface that is perpendicular to STOP
gravity. Zero out the level with the alternate zero

function.
00000
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.
Run
During calibration, the measured value will need to
be subtracted from 90 degrees to get the correct Service
Bypass
number to enter into the system.
Recovery
2 Raise the jib boom to a slightly less than
horizontal position.
Service Bypass /
Recovery Key Switch
4 - 36 Z-135/70 Part No. 106783

All models: 13 Press and hold a function enable/speed select

button and the platform level up button. Fully
7 Insert the key into the service/bypass key extend the jib boom level cylinder.
switch and turn it to the service/bypass
position. Note: When in service/bypass mode, the platform
level buttons are used to adjust the jib boom level
Note: The angle sensor calibration values will not cylinder.
be saved correctly unless the key switch is in the
service/bypass position. Note: With the jib boom level cylinder is fully
extended, the jib boom bellcrank angle should be at
8 Press and hold the enter button on the approximately 60 ± 5 degrees.
ground control panel while pulling out the ground
controls red Emergency Stop button to the on 14 Attach the digital level to the surface of the jib
position. Hold the enter button for approximately boom bellcrank as shown.
5 seconds and then release it.
9 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: .
until RESET JIB LEVEL ANGLE
SENSOR is displayed. c b a
11 Press the plus button to select YES, then a jib boom angle sensor
press the enter button to accept. b jib boom bellcrank
c place level on this surface
12 At the JIB LEVEL CALIBRATION DEG 60.0DEG screen,
start the engine. 15 At the ground controls, press the plus button
or minus button to adjust the display to
Note: If the system exits out of calibration mode
to the exact value shown on the digital level and
when the engine is started, repeat step 7 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.
Part No. 106783 Z-135/70 4 - 37

16 Press and hold a function enable/speed select 20 Press and hold a function enable/speed select
button and the platform level down button until button and raise the jib boom above horizontal
the digital level displays approximately to provide additional ground clearance for the
34 ± 5 degrees. remaining calibration points.
17 At the ground controls, press the plus button 21 Press and hold a function enable/speed select
button and the platform level down button until
or minus button to adjust the display to
the digital level displays approximately
18 ± 5 degrees.
22 At the ground controls, press the plus button
angle shown on the display at the ground controls, or minus button to adjust the display to
change the angle and then change back to the press the enter button .
measured value. The system must detect a change Note: Be sure the number entered at the ground
in displayed value to record the calibrated value. controls is a negative number.
18 Press and hold a function enable/speed select Note: If the measured angle already matches the
button and the platform level down button until angle shown on the display at the ground controls,
8 ± 5 degrees.
19 At the ground controls, press the plus button measured value. The system must detect a change
or minus button to to adjust the display to
to the exact value shown on the digital level and 23 Press and hold a function enable/speed select
press the enter button . button and the platform level down button until
Note: If the measured angle already matches the 44 ± 5 degrees.
press the plus button or minus button to 24 At the ground controls, press the plus button
change the angle and then change back to the or minus button to adjust the display to
measured value. The system must detect a change to the exact value shown on the digital level and
in displayed value to record the calibrated value. press the enter button .
Note: Be sure the number entered at the ground
controls is a negative number.
-70° Note: If the measured angle already matches the

60° press the plus button or minus button to
-44°
34° measured value. The system must detect a change
8° 0° -18°
Calibration angles
4 - 38 Z-135/70 Part No. 106783

25 Press and hold a function enable/speed select 31 Wait approximately 20 seconds and turn the
button and the platform level down button until machine off by pressing the red Emergency
the digital level displays approximately Stop button in.
70 ± 5 degrees. The jib boom level cylinder
should be fully retracted at this point.
32 Remove the wire jumper from the 2 pin
connector in the lower left hand area of the
or minus button to adjust the display to ground control box that was installed in step 6.
to the exact value shown on the digital level and Install the connector plug.
Tip-over hazard. Failure to remove
Note: Be sure the number entered at the ground the jumper wire will result in an
controls is a negative number. unsafe configuration which will
Note: If the measured angle already matches the Operating the machine in this
angle shown on the display at the ground controls, configuration will result in the
press the plus button or minus button to machine tipping over causing
change the angle and then change back to the death or serious injury. The jumper
measured value. The system must detect a change wire must be removed before
in displayed value to record the calibrated value. operating the machine.
Note: With the jib boom level cylinder fully 33 Close the ground control box and install the door
retracted, the jib boom bellcrank angle should be at retaining fasteners.
approximately 70 degrees. After serial number 320:
27 Press and hold the engine start button for 34 Remove the fastener that was temporarily
approximately 5 seconds to shut off the engine installed in step 6.
and to save the calibration settings.
35 Close the control box door and install the door
Note: Do not turn the engine off with the key switch retaining fasteners.
or red Emergency Stop button or all calibration
points or values will not be saved. Note: When the control box door is closed, the
calibration toggle switch is automatically activated
28 Push one of the LCD to exit out of calibration mode.
until EXIT is displayed. All models:
29 Press the plus button to select YES, then 36 Use the key to turn the service/bypass key
switch to the run postion.
press the enter button to accept.
Note: Be sure that the service/bypass key switch is
30 Turn the key back to the run position and
in the run position before attempting to operate the
remove the key from the service/bypass key
machine.
switch. Insert the key into the main key switch
and turn it to ground controls. 37 Pull out the red Emergency Stop button. Start
the engine and lower the boom to the stowed
position. Be sure there are no calibration faults
shown on the display.
Part No. 106783 Z-135/70 4 - 39

Boom Components REV G
a b c d e
m l k j i h g f
Boom components
a upper primary boom lift cylinder linkage arm

b primary boom
c cable track
d primary extension boom
e jib boom manifold
f secondary boom lift cylinder
g secondary boom cable track
(inside of secondary boom)
h primary boom lift cylinder
i number 1 secondary boom tube
j number 2 secondary boom tube
k number 3 secondary boom tube
l lower primary boom lift cylinder linkage arm
m number 4 secondary boom tube
4 - 40 Z-135/70 Part No. 106783

REV G BOOM COMPONENTS
4-1 5 Tag and disconnect the electrical connectors

from the jib boom manifold located at the
Primary Boom Cable Track platform end of the primary extension boom.
The primary boom cable track guides the cables 6 Tag, disconnect and plug the two hydraulic
and hoses running up the boom. It can be repaired hoses from the side of the jib boom manifold
link by link without removing the cables and hoses that lead to the primary boom cable track.
that run through it. Removing the entire primary Cap the fittings on the manifold.
boom cable track is only necessary when Bodily injury hazard. Spraying
performing major repairs that involve removing the hydraulic oil can penetrate and
primary boom. burn skin. Loosen hydraulic
How to Remove the Cable Track the oil pressure to dissipate
Note: When removing a hose assembly or fitting, gradually. Do not allow oil to
the O-ring on the fitting and/or hose end must be squirt or spray.
replaced and then torqued to specification during 7 Remove the retaining fasteners from the hose
installation. Refer to Section 2, Hydraulic Hose and and cable guide at the platform end of the
Fitting Torque Specifications. primary boom. Remove the hose and cable
guide.
firm, level surface and the boom in the stowed 8 Tag and disconnect the electrical connector
position. from the limit switch on the side of the primary
boom. Do not remove the limit switch.
1 Remove the cover from the lower jib boom cable
track. 9 Remove the cotter pin from the upper cable
track tube at the platform end of the primary
2 Tag and disconnect the electrical connectors
extension boom.
inside the lower cable track.
Note: Always replace the cotter pin with a new one.
3 Remove the hose and cable clamp retaining
fasteners from lower cable track at the pivot end 10 Remove the retaining fasteners from the cable
of the jib boom. Remove the clamps. track guide at the platform end of the boom.
Remove the cable track guide from the
4 Pull the electrical cables out of the lower cable
machine.
track that lead to the primary boom.
11 Place blocks between the upper and lower cable
tracks and secure the upper and lower tracks
Cables can be damaged if they are
together.
kinked or pinched.
Crushing hazard. If the upper and
lower cable tracks are not properly
secured together, the cable track
when removed from the machine.
Part No. 106783 Z-135/70 4 - 41

BOOM COMPONENTS REV G
12 Remove the hose and cable clamps from the 18 Pull all hydraulic hoses and electrical cables
primary boom lift cylinder. that lead to the cable track out of the secondary
boom riser.
13 At the counterweight end of the secondary
boom, support and secure the secondary boom Component damage hazard.
lower end cover to a suitable lifting device. Cables and hoses can be damaged
14 Remove the cover retaining fasteners and
remove the cover from the end of the secondary 19 Attach a lifting strap to each end of the cable
boom. track from an overhead crane for support. Do
not apply any lifting pressure.
Crushing hazard. The secondary
boom lower end cover could 20 Remove the mounting fasteners that attach the
become unbalanced and fall when lower cable track to the primary boom lift
removed from the secondary boom cylinder.
if not properly supported and
21 Remove the mounting fasteners that attach the
secured to the lifting device.
cable track to the primary boom.
15 Locate the two hydraulic hoses inside the end of
22 Carefully remove the cable track from the
the secondary boom that lead to the primary
machine and lay it on a structure capable of
boom cable track.
supporting it.
16 Tag, disconnect and plug the hydraulic hoses
Crushing hazard. The primary
from the unions. Cap the fittings on the unions.
boom cable track could become
Bodily injury hazard. Spraying unbalanced and fall when removed
hydraulic oil can penetrate and from the primary boom if not
burn skin. Loosen hydraulic properly supported by the overhead
connections very slowly to allow crane.
squirt or spray.
damaged if it is twisted.
17 Disconnect the electrical connectors for the
electrical cables that lead to the cable track at
Cables and hoses can be damaged
the end of the secondary boom.
4 - 42 Z-135/70 Part No. 106783

How to Repair the Primary Boom 7 Connect the ends of the replacement cable track
section to the existing cable track using the
Cable Track pins and snap rings.
Component damage hazard. 8 Install the rollers onto the new section of cable
The boom cable track can be track.
damaged if it is twisted.
9 Operate the primary boom extend/retract
Note: A cable track repair kit is available through function through a full cycle to ensure smooth
the Genie Industries Service Parts Department, operation of the new section of cable track.
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
track to be replaced. Remove the rollers.
4 Lift up the hoses and cables and carefully
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.
Hoses and cables can be damaged
Part No. 106783 Z-135/70 4 - 43

4-2 4 Remove the cover retaining fasteners and

remove the cover from the secondary boom.
Secondary Boom Cable Track
The secondary boom cable track guides the cables boom end cover could become
and hoses running up through the inside of the unbalanced and fall when removed
secondary boom. It can be repaired link by link from the secondary boom if not
without removing the cables and hoses that run properly supported and secured to
through it. Removal of the secondary boom cable the lifting device.
track is required to repair it. 5 Working at the platform end of the secondary
boom, remove the hose and cable U-bolt
How to Remove the Secondary fasteners near the upper cable track tube.
Boom Cable Track 6 Working at the platform end of the secondary
Note: When removing a hose assembly or fitting, boom, remove the upper cable track tube
the O-ring on the fitting and/or hose end must be retaining fasteners. Remove the curved hose
replaced and then torqued to specification during guide.
installation. Refer to Section 2, Hydraulic Hose and 7 Working at the platform end of the secondary
Fitting Torque Specifications. boom, remove the lower cable track retaining
1 Working at the counterweight end of the fasteners.
secondary boom, support and secure the 8 Working at the counterweight end of the
secondary boom end cover to a suitable lifting secondary boom, remove the lower cable track
device. retaining fasteners.
2 Remove the cover retaining fasteners and 9 Tag, disconnect and plug the hydraulic hoses
remove the cover from the secondary boom. from the following ports of the function manifold:
Crushing hazard. The secondary PE, PR, P2, T1, PU and PD. Cap the fittings on
boom end cover could become the manifold.
unbalanced and fall when removed Bodily injury hazard. Spraying
from the secondary boom if not hydraulic oil can penetrate and
properly supported and secured to burn skin. Loosen hydraulic
the lifting device. connections very slowly to allow
3 Working at the platform end of the secondary the oil pressure to dissipate
boom, support and secure the secondary boom gradually. Do not allow oil to
end cover to a suitable lifting device. squirt or spray.
4 - 44 Z-135/70 Part No. 106783

10 Pull the hydraulic hoses just removed through 17 Working at the counterweight end of the
the turntable bulkhead. secondary boom, attach a lifting strap from an
overhead crane to the secondary boom cable
track.
Hoses can be damaged if they are
kinked or pinched. 18 Carefully pull the secondary boom cable track
out of the counterweight end of the boom.
11 Working at the counterweight end of the
secondary boom, tag, disconnect and plug the 19 Remove the secondary boom cable track from
hydraulic hoses from the unions that lead to the the machine and place it on a structure capable
cable track. of supporting it.
12 Working at the counterweight end of the Crushing hazard. The secondary
secondary boom, tag and disconnect the boom cable track could become
electrical connectors to all of the cables that unbalanced and fall if not properly
lead to the secondary boom cable track. supported when removed from the
machine.
13 Tag, disconnect and plug the primary boom lift
cylinder hydraulic hoses. Cap the fittings on the Component damage hazard.
cylinder. Cables and hoses can be damaged
14 Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses at the unions Component damage hazard.
located above the primary boom lift cylinder. The secondary boom cable track
Cap the fittings on the unions. can be damaged if it is twisted.
15 Pull the hydraulic hoses for the primary boom lift Note: The lifting strap from the overhead crane will
cylinder and extension cylinder out through the need to be adjusted during removal for proper
hole in the number 4 secondary boom tube. balancing of the cable track.
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.
Part No. 106783 Z-135/70 4 - 45

How to Repair the Secondary 6 Remove the upper rollers from the replacement
section of cable track.
Boom Cable Track
7 Lift up the hoses and cables and carefully insert
Component damage hazard. the new 4-link section of cable track.
damaged if it is twisted. Component damage hazard.
Hoses and cables can be damaged
Note: A cable track repair kit is available through if they are kinked or pinched.
the Genie Industries Service Parts Department,
part no.107717. The kit includes a 4-link section of 8 Connect the ends of the replacement cable track
cable track. section to the existing cable track using the
pins and snap rings.
1 Remove the secondary boom cable track.
See How to Remove the Secondary Boom 9 Install the rollers onto the new section of cable
Cable Track. track.
2 Visually inspect the cable track and determine 10 Install the secondary boom cable track into the
which 4-link section needs to be replaced. secondary boom.
3 Carefully remove the snap rings and pins from 11 Operate the secondary boom up/extend and
each end of the damaged section of cable track. down/retract functions through a full cycle to
ensure smooth operation of the new section of
4 Remove the retaining fasteners from the upper cable track.
track to be replaced. Remove the rollers.
5 Lift up the hoses and cables and carefully
track.
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.
4 - 46 Z-135/70 Part No. 106783

4-3 4 Remove the primary boom cable track.

See 4-1, How to Remove the Cable Track.
Primary Boom
5 Remove the end cover from the pivot end of the
primary boom.
How to Remove the Primary
Boom 6 Remove the limit switch mounting fasteners
from the limit switch on the ground controls side
Bodily injury hazard. This of the primary boom. Do not disconnect the
procedure requires specific repair wiring. Remove the limit switch.
7 Disconnect the electrical connector from the
primary boom angle sensor.
tools could result in death or Note: The primary boom angle sensor is located
serious injury and significant inside the primary boom at the pivot end.
service is strongly recommended. 8 Remove the primary boom angle sensor bracket
mounting fasteners and remove the primary
Note: When removing a hose assembly or fitting, boom angle sensor from the primary boom. Do
the O-ring on the fitting and/or hose end must be not remove the angle sensor from the bracket.
replaced and then torqued to specification during Note the location of the springs.
installation. Refer to Section 2, Hydraulic Hose and Do not lose the springs.
Fitting Torque Specifications.
Note: There is one spring inside the primary boom
Note: Perform this procedure with the boom in the pivot pin and one inside the angle sensor.
stowed position.
Note: When the primary boom is installed, the
1 Remove the platform. primary boom angle sensor will need to be
calibrated. See 4-8, Primary Boom Angle Sensor
2 Remove the platform mounting weldment
for the calibration procedure.
and the platform rotator. See 2-2, How to
Remove the Platform Rotator. 9 Remove the hose and cable guide fasteners at
3 Remove the jib boom. the primary boom pivot pin. Remove the hose
See 3-2, How to Remove the Jib Boom. and cable guide.
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.
Part No. 106783 Z-135/70 4 - 47

10 Tag, disconnect and plug the primary boom 18 Attach a 5 ton / 5000 kg overhead crane to both
extension cylinder hydraulic hoses. Cap the ends of the primary boom. Do not apply any
fittings on the cylinder. lifting pressure.
Bodily injury hazard. Spraying 19 Remove the pin retaining fasteners from the
hydraulic oil can penetrate and primary boom pivot pins.
20 Use a soft metal drift to remove the primary
boom pivot pins.
gradually. Do not allow oil to 21 Carefully remove the primary boom from the
squirt or spray. machine and place it on a structure capable of
supporting it.
11 Place blocks under both ends of the primary
boom lift cylinder for support. Crushing hazard. The primary
boom could become unbalanced
12 Attach a lifting strap from an overhead crane to
and fall when removed from the
the rod end of the primary boom lift cylinder.
machine if not properly attached to
13 Remove the pin retaining fasteners from the the overhead crane.
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.
4 - 48 Z-135/70 Part No. 106783

4-4 4 Tag, disconnect and plug the primary boom lift

cylinder hydraulic hoses. Cap the fittings on the
Primary Boom Lift Cylinder cylinder.
The primary boom lift cylinder raises and lowers the Bodily injury hazard. Spraying
primary boom. The primary boom lift cylinder is hydraulic oil can penetrate and
equipped with a counterbalance valve to prevent burn skin. Loosen hydraulic
movement in the event of a hydraulic line failure. connections very slowly to allow
How to Remove the Primary gradually. Do not allow oil to
squirt or spray.
Boom Lift Cylinder
Bodily injury hazard. This the rod end of the primary boom lift cylinder. Do
procedure requires specific repair not apply any lifting pressure.
suitable workshop. Attempting this 6 Remove the pin retaining fasteners from the
procedure without these skills and primary boom lift cylinder rod-end pivot pin. Use
tools could result in death or a soft metal drift to remove the pin and rest the
serious injury and significant cylinder on the block.
component damage. Dealer 7 Attach a lifting strap from a second overhead
service is strongly recommended. crane to the barrel end of the primary boom lift
Note: When removing a hose assembly or fitting, cylinder. Do not apply any lifting pressure.
the O-ring on the fitting and/or hose end must be 8 Remove the primary boom lift cylinder
replaced and then torqued to specification during barrel-end pivot pin retaining fasteners.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. 9 Use a soft metal drift to remove the barrel-end
pivot pin. Carefully remove the primary boom lift
Note: Perform this procedure with the boom in the cylinder from the machine.
stowed position.
Crushing hazard. The lift cylinder
1 Remove the hose and cable clamps from the could become unbalanced and fall
primary boom lift cylinder. when removed from the machine if
2 Remove the cable track retaining fasteners at not properly supported by the
the primary boom lift cylinder. overhead crane.
3 Place blocks under both ends of the primary Crushing hazard. The primary
boom lift cylinder. Place another block under the boom lift cylinder linkage arms
cylinder linkage arms under the primary boom may fall if not properly supported
lift cylinder barrel-end pivot pin. when the barrel-end pivot pin is
removed.
Part No. 106783 Z-135/70 4 - 49

4-5 2 Remove the engine pivot plate retaining

fastener. Swing the engine pivot plate out away
Secondary Boom Lift Cylinder from the machine.
How to Remove the Secondary

Boom Lift Cylinder
tools could result in death or
serious injury and significant
component damage. Dealer b engine pivot plate retaining fastener
service is strongly recommended.
3 Locate the engine pivot plate anchor hole at the
replaced and then torqued to specification during 4 Install the bolt that was just removed into the
installation. Refer to Section 2, Hydraulic Hose and anchor hole to secure the engine pivot plate
Fitting Torque Specifications. from moving.
Note: Perform this procedure with the boom in the Crushing hazard. Failure to install
stowed position and the axles extended. the bolt into the engine pivot plate
1 Tag, disconnect and plug the hydraulic hoses result in death or serious injury.
from the secondary boom lift cylinder. The
hoses can be accessed from under the 5 Remove the retaining fasteners from the fixed
turntable. turntable cover at the ground controls side of
the machine. Remove the fixed turntable cover
Bodily injury hazard. Spraying from the machine.
burn skin. Loosen hydraulic 6 Tag, disconnect and plug the fuel hoses from
connections very slowly to allow the fuel tank. Clean up any fuel that may have
the oil pressure to dissipate spilled.
or spray.
4 - 50 Z-135/70 Part No. 106783

7 Close the two hydraulic tank shut-off valves at 14 Remove the ground control box mounting
the hydraulic tank. fasteners. Move the ground control box out of
the way.
engine must not be started with the 15 Remove the hydraulic tank retaining fasteners.
16 Remove the cover from the auxiliary power unit
batteries.
damage will occur. If the tank
valves are closed, remove the key 17 Tag and disconnect the cables from the auxiliary
from the key switch and tag the power unit batteries.
machine to inform personnel of the
condition. Electrocution/burn hazard. Contact
8 Remove the drain plug from the hydraulic tank could result in death or serious
and completely drain the tank into a container of injury. Remove all rings, watches
suitable capacity. Refer to Section 2, and other jewelry.
Specifications.
18 Tag and disconnect the cables from the engine
9 Tag, disconnect and plug the two suction hoses starting/controls battery located on the engine
from the hydraulic tank. side of the machine.
10 Tag, disconnect and plug the two supply hoses Electrocution/burn hazard. Contact
for the auxiliary power units. Cap the fittings on with electrically charged circuits
the hydraulic tank. could result in death or serious
11 Tag, disconnect and plug the hydraulic hose
and other jewelry.
from the drive motor case drain filter at the
hydraulic tank. Cap the fitting on the hydraulic 19 Attach an overhead crane or similar lifting
tank. device to the battery box for the auxiliary power
unit batteries.
12 Tag, disconnect and plug the hydraulic hose at
the return filter. Cap the fitting on the return filter 20 Remove the battery box retaining fasteners and
housing. carefully remove the battery box from the
machine.
13 Remove the turntable cover using a suitable
lifting device. Crushing hazard. The battery box
when removed from the machine if
cover may become unbalanced
not properly supported.
and fall if not properly supported
and secured to a suitable lifting Bodily injury hazard. Batteries
device. 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

21 Support the hydraulic tank with 2 lifting straps. 29 Use a slide hammer to remove the barrel-end
Place one lifting strap at each end of the tank pivot pin.
and attach the lifting straps to an appropriate
lifting device.
and cables can become damaged
22 Remove the hydraulic tank from the machine. if the barrel end of the secondary
boom lift cylinder is allowed to fall
Crushing hazard. The hydraulic
when the barrel-end pivot pin is
tank could become unbalanced
removed.
and fall when removed from the
machine if not properly supported. 30 Carefully remove the secondary boom lift
cylinder from the machine.
23 Place a block under the secondary boom lift
cylinder for support. Crushing hazard. The secondary
boom lift cylinder could become
24 Remove the secondary boom lift cylinder
rod-end pivot pin retaining fasteners. Use a soft
from the machine if not properly
metal drift to remove the pin through the access
supported by the overhead crane.
holes in the turntable bulkheads.
25 Attach an overhead crane with a minimum
and cables can be damaged if the
capacity of 7 tons / 7000 kg to the
secondary boom lift cylinder is
counterweight end of the secondary boom.
pulled across them.
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.
4 - 52 Z-135/70 Part No. 106783

4-6 3 Tag, disconnect and plug the primary boom

extension cylinder hydraulic hoses. Cap the
Primary Boom Extension fittings on the cylinder.
Cylinder Bodily injury hazard. Spraying
The primary boom extension cylinder extends and burn skin. Loosen hydraulic
retracts the primary boom extension tube.The connections very slowly to allow
primary boom extension cylinder is equipped with the oil pressure to dissipate
counterbalance valves to prevent movement in the gradually. Do not allow oil to
event of a hydraulic line failure. squirt or spray.
How to Remove the Primary 4 At the platform end, remove the external snap
rings from the extension cylinder rod-end pivot
Boom Extension Cylinder pin. Use a soft metal drift to remove the pin.
5 Remove the extension cylinder retainers from
the saddle blocks.
suitable workshop. Attempting this 6 Attach a lifting strap from an overhead crane to
procedure without these skills and the barrel end of the primary boom extension
tools could result in death or cylinder.
serious injury and significant
7 Using the overhead crane, lift the extension
cylinder to clear the saddle blocks.
service is strongly recommended.
8 Support and slide the primary boom extension
cylinder out of the primary boom and place it on
a structure capable of supporting it.
installation. Refer to Section 2, Hydraulic Hose and Crushing hazard. The extension
Fitting Torque Specifications. cylinder could fall when removed
from the primary boom if not
Note: Perform this procedure with the axles properly supported.
Note: The lifting strap from the overhead crane will
1 Extend the primary boom until the primary boom need to be adjusted during removal for proper
extension cylinder rod-end pivot pin is balancing of the extension cylinder.
accessible in the primary boom extension tube.
Note: Note the length of the cylinder after removal.
2 Remove the access cover from the pivot end of The cylinder must be at the same length for
the primary boom. installation.
Part No. 106783 Z-135/70 4 - 53

4-7 3 Remove the cover retaining fasteners and

remove the cover from the secondary boom.
Secondary Boom Extension
Cylinders boom end cover could become
The secondary boom extension cylinders extend from the secondary boom if not
and retract the secondary boom. The secondary properly supported and secured to
boom extension system consists of 3 hydraulic the lifting device.
cylinders and each are equipped with
counterbalance valves to prevent movement in the 4 Remove the retaining fasteners from both
event of a hydraulic line failure. secondary boom extend limit switches and
remove the limit switches. Do not disconnect
How to Remove the Secondary the wiring.
Boom Extension Cylinders Note: Label the location of each limit switch as they
are not the same and their mounting locations
cannot be exchanged.
skills, lifting equipment and a 5 Tag, disconnect and plug all hydraulic hoses for
suitable workshop. Attempting this the 3 secondary boom extension cylinders.
procedure without these skills and Cap the fittings on the cylinder.
tools could result in death or
serious injury and significant Bodily injury hazard. Spraying
component damage. Dealer hydraulic oil can penetrate and
service is strongly recommended. burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting, the oil pressure to dissipate
the O-ring on the fitting and/or hose end must be gradually. Do not allow oil to
replaced and then torqued to specification during squirt or spray.
Fitting Torque Specifications. 6 Remove the upper extension cylinder retainers
from the saddle blocks.
the rod end of the upper extension cylinder.
1 Raise the primary boom approximately 8 Using the overhead crane, lift the extension
10 feet / 3 m. Turn the machine off. cylinder to clear the saddle blocks.
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

9 Support and slide the upper extension cylinder 4-8

out of the secondary boom and place it on a
structure capable of supporting it. Primary Boom Angle Sensor
Crushing hazard. The extension The primary boom angle sensor is used to limit the
cylinder could fall when removed angle of the primary boom relative to the angle of
from the secondary boom if not the secondary boom and gravity.
properly supported.
Note: The lifting strap from the overhead crane will How to Replace the Primary
need to be adjusted during removal for proper Boom Angle Sensor
balancing of the extension cylinder.
Note: Perform this procedure on a firm, level
10 Repeat steps 6 through 9 for the remaining surface with the boom in the stowed position.
secondary boom extension cylinders.
1 Remove the retaining fasteners from the boom
Note: The secondary boom extension cylinders end cover at the pivot end of the primary boom.
must be installed in the same order they were Remove the cover from the machine.
removed.
2 Locate the primary boom angle sensor inside the
Note: When installing the middle and upper primary boom at the boom pivot pin.
secondary boom extension cylinders, be sure the
grooved wear pads are correctly aligned with the
sensor.
channels on the top of the cylinders.
4 Remove the angle sensor mounting bracket
a b c
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.
e d
7 Install the new angle sensor onto the mounting
a upper extension cylinder (#1) bracket.
b middle extension cylinder (#2)
c bottom extension cylinder (#3)
d cylinder grooved wear pads
e channels
Part No. 106783 Z-135/70 4 - 55

8 Install one spring, removed in step 5, into the 12 Insert the hex-shaped key into the boom pivot
hex-shaped hole in the angle sensor. Install the pin and the bracket into the machined pocket.
other spring into the hex-shaped hole in the
Note: Be sure the hex-shaped key remains
engaged in the sensor.
9 Insert the hex-shaped key into the angle sensor.
13 Install the angle sensor bracket retaining
10 Align the side of the sensor with flat area of the fasteners.
boom pivot pin shown as shown below while
holding the bracket away from key insertion. 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
a flat area
b angle sensor
c 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

How to Calibrate the Primary All models:

Boom Angle Sensor 6 Remove the key from the main key switch.
Insert the key into the service/bypass key
Note: If the secondary boom angle sensor has been switch and turn it to the service/bypass
removed or replaced, it will need to be calibrated position.
first. See 4-9, Secondary Boom Angle Sensor for
the calibration procedure. Note: The angle sensor calibration values will not
Note: Perform this procedure with the machine on a service/bypass position.
firm, level surface with the axles extended and in
the stowed position. 7 Press and hold the enter button on the
Note: A digital level will be required to perform this
controls red Emergency Stop button to the on
procedure.
position. Hold the enter button for approximately
Note: A kit is available through the Genie Industries 5 seconds and then release it.
Service Department (Genie part number 58351). 8 Enter sensor calibration mode by pressing the
This kit includes a digital level with a magnetic buttons at the ground controls in the following
base and cable harnesses.
sequence: .
1 Push in the ground controls red Emergency Stop
button to the off position. STOP
2 Turn the key switch to ground controls. 00000
3 Open the ground control box.


area of the ground control box.
Run
After serial number 320:
Service
4 Locate the calibration toggle switch at the top of Bypass
the ground control box. Activate calibration
mode by moving the toggle switch in the left Recovery
direction.
Service Bypass /
5 Temporarily install a control box door retaining Recovery Key Switch
fastener between the door and the box to
Part No. 106783 Z-135/70 4 - 57

9 Push one of the LCD 14 Fully raise the secondary boom. Stop before the
screen buttons shown secondary boom begins to extend.
until RESET PRIMARY BOOM
ANGLE SENSOR is displayed.
button and the primary boom down button and
10 Press the plus button to select YES, then lower the primary boom down as far as it will go.
press the enter button to accept. 16 Measure the angle of the primary boom with the
digital level.
11 Place the digital level on top of the primary
boom and note the angle displayed on the digital Note: The angle of the primary boom must be
level. between -45 and -55 degrees. If the primary boom
angle is not within this range, adjust the primary
13 At the PRIMARY BOOM ANGLE TO GRAVITY 0.0 DEG
boom until the digital level displays approximately
screen, press the plus button or minus -50 ± 5 degrees.
button to adjust the display to the exact
value shown on the digital level, then press the 17 At the ground controls, press the plus button
enter button . or minus button to adjust the display to the
exact value shown on the digital level and press
the enter button .
press the plus button or minus button to Note: Be sure the number entered at the ground
change the angle and then change back to the controls is a negative number.
Note: If the system exits out of calibration mode press the plus button or minus button to
when the engine is started, repeat step 7 and change the angle and then change back to the
continue to step 14. measured value. The system must detect a change
13 At the PRIMARY BOOM ANGLE TO GRAVITY -50 DEG
button and the primary boom up button until the
screen, press the plus button or minus digital level displays approximately
button to adjust the display to the exact -20 ± 5 degrees.
value shown on the digital level, then press the
enter button .
4 - 58 Z-135/70 Part No. 106783

19 At the ground controls, press the plus button 23 At the ground controls, press the plus button
or minus button to adjust the display to the or minus button to to adjust the display to
exact value shown on the digital level and press the exact value shown on the digital level and
the enter button . press the enter button .
Note: Be sure the number entered at the ground Note: If the measured angle already matches the
controls is a negative number. angle shown on the display at the ground controls,
angle shown on the display at the ground controls, change the angle and then change back to the
press the plus button or minus button to in displayed value to record the calibrated value.
measured value. The system must detect a change 24 Press and hold a function enable/speed select
in displayed value to record the calibrated value. button and the primary boom up button until the
primary boom is fully raised. The angle will be
20 Press and hold a function enable/speed select approximately 70 ± 5 degrees.
button and the primary boom up button until the
digital level displays approximately Note: If the measured angle already matches the
10 ± 5 degrees. angle shown on the display at the ground controls,
21 At the ground controls, press the plus button change the angle and then change back to the
or minus button to adjust the display to the measured value. The system must detect a change
exact value shown on the digital level and press in displayed value to record the calibrated value.
the enter button .
25 Press and hold the engine start button for
Note: If the measured angle already matches the approximately 5 seconds to shut off the engine
angle shown on the display at the ground controls, and to save the calibration settings.
press the plus button or minus button to Note: Do not turn the engine off with the key switch
change the angle and then change back to the or red Emergency Stop button or all calibration
measured value. The system must detect a change points or values will not be saved.
22 Press and hold a function enable/speed select screen buttons shown
button and the primary boom up button until the until EXIT is displayed.
digital level displays approximately
40 ± 5 degrees. 27 Press the plus button to select YES, then
Part No. 106783 Z-135/70 4 - 59

28 Turn the key back to the run position and All models:.
remove the key from the service/bypass key
switch. Insert the key into the main key switch 34 Pull out the red Emergency Stop button. Start
and turn it to ground controls. the engine and lower the boom to the stowed
position. Be sure there are no calibration faults
29 Wait approximately 20 seconds and turn the shown on the display.
machine off by pressing the red Emergency
Stop button in.
STOP
30 Remove the wire jumper from the 2 pin 00000
connector in the lower left hand area of the

the jumper wire will result in an
unsafe configuration which will
Operating the machine in this Run
configuration will result in the
machine tipping over causing Service
Bypass
wire must be removed before Recovery
operating the machine.
31 Close the ground control box and install the door Service Bypass /
retaining fasteners. Recovery Key Switch
32 Remove the fastener that was temporarily

installed in step 5.
Note: When the control box door is closed, the
to exit out of calibration mode.
4 - 60 Z-135/70 Part No. 106783

4-9 8 Install one spring, removed in step 5, into the

hex-shaped hole in the angle sensor. Install the
Secondary Boom Angle Sensor other spring into the hex-shaped hole in the
The secondary boom angle sensor is used to limit
the angle of the primary boom relative to the angle 9 Insert the hex-shaped key into the angle sensor.
of the secondary boom and gravity. 10 Align the side of the sensor with flat area of the
boom pivot pin as shown below. Hold the
How to Replace the Secondary bracket out to clear the side of the turntable
Boom Angle Sensor side plate.
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.
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
5 Remove the angle sensor and bracket
assembly. Do not lose the two springs or the
hex-shaped key.
a b c
6 Remove the sensor retaining fasteners from the
bracket. Remove the angle sensor. a flat area
b angle sensor
Note: Note the sensor orientation on the bracket
c hex-shaped hole
during removal so the new sensor will be installed
in the same position. 11 While holding the hex-shaped key in position,
rotate the angle sensor mounting bracket
7 Install the new angle sensor onto the mounting clockwise until it aligns with the machined
bracket. 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

12 Insert the hex-shaped key into the boom pivot Before serial number 321:
pin and the bracket into the machined pocket.
13 Install the angle sensor bracket retaining area of the ground control box.
fasters.
14 Install the angle sensor cover and install the wire between the two pins of the connector.
cover retaining fastener.
15 Connect the electrical connector to the new
sensor. 4 Locate the calibration toggle switch at the top of
16 Calibrate the secondary boom angle sensor. See mode by moving the toggle switch in the left
How to Calibrate the Secondary Boom Angle direction.
Sensor.
5 Temporarily install a control box door retaining
How to Calibrate the Secondary fastener between the door and the box to
Boom Angle Sensor prevent the control box door from moving the
Note: If the primary boom angle sensor and/or jib
All models:
boom angle sensor has been removed or replaced,
the secondary boom angle sensor will need to be 6 Remove the key from the main key switch.
calibrated first. Insert the key into the service/bypass key
position.
firm, level surface with the axles extended and in
the stowed position. Note: The angle sensor calibration values will not
Note: A digital level will be required to perform this service/bypass position.
procedure.
STOP
Note: A kit is available through the Genie Industries

Service Department (Genie part number 58351). 00000
This kit includes a digital level with a magnetic

2 Turn the key switch to ground controls.
Run
Service
Bypass
Recovery
Service Bypass /
Recovery Key Switch
4 - 62 Z-135/70 Part No. 106783

7 Press and hold the enter button on the 14 Press and hold a function enable/speed select
ground control panel while pulling out the ground button and the secondary boom up button until
controls red Emergency Stop button to the on the digital level displays approximately
position. Hold the enter button for approximately 20 ± 5 degrees.
8 Enter sensor calibration mode by pressing the or minus button to adjust the display to the
buttons at the ground controls in the following exact value shown on the digital level and press
sequence: . the enter button .
9 Push one of the LCD Note: If the measured angle already matches the
screen buttons shown angle shown on the display at the ground controls,
until RESET SECONDARY BOOM
ANGLE SENSOR is displayed.
10 Press the plus button to select YES, then measured value. The system must detect a change
11 Place the digital level on top of the secondary 16 Press and hold a function enable/speed select
boom. button and the secondary boom up button until
12 At the SECONDARY BOOM ANGLE TO GRAVITY -3.5DEG 35 ± 5 degrees.
screen, press the plus button or minus
button to adjust the display to the exact
or minus button to adjust the display to the
value shown on the digital level and press the
exact value shown on the digital level and press
enter button .
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
Note: If the measured angle already matches the press the plus button or minus button to
angle shown on the display at the ground controls, change the angle and then change back to the
press the plus button or minus button to measured value. The system must detect a change
change the angle and then change back to the in displayed value to record the calibrated value.
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
13 Start the engine from the ground controls. the digital level displays approximately
50 ± 5 degrees.
Note: If the system exits out of calibration mode
when the engine is started, repeat step 7 and
Part No. 106783 Z-135/70 4 - 63

19 At the ground controls, press the plus button 23 At the ground controls, press the plus button
or minus button to to adjust the display to or minus button to adjust the display to the
the exact value shown on the digital level and exact value shown on the digital level and press
press the enter button . the enter button .
Note: If the measured angle already matches the Note: If the measured angle already matches the
angle shown on the display at the ground controls, angle shown on the display at the ground controls,
press the plus button or minus button to press the plus button or minus button to
change the angle and then change back to the change the angle and then change back to the
measured value. The system must detect a change measured value. The system must detect a change
in displayed value to record the calibrated value. in displayed value to record the calibrated value.
20 Press and hold a function enable/speed select 24 Press and hold the engine start button for
button and the secondary boom up button until approximately 5 seconds to shut off the engine
the digital level displays approximately and to save the calibration settings.
65 ± 5 degrees.
Note: Do not turn the engine off with the key switch
21 At the ground controls, press the plus button or red Emergency Stop button or all calibration
points or values will not be saved.
or minus button to adjust the display to the
exact value shown on the digital level and press 25 Push one of the LCD screen buttons shown
the enter button . until EXIT is displayed.
Note: If the measured angle already matches the 26 Press the plus button to select YES, then
angle shown on the display at the ground controls, press the enter button to accept.
change the angle and then change back to the 27 Turn the key back to the run position and
measured value. The system must detect a change remove the key from the service/bypass key
in displayed value to record the calibrated value. switch. Insert the key into the main key switch
and turn it to ground controls.
28 Wait approximately 20 seconds and turn the
button and the secondary boom up button. Fully
raise the secondary boom. Stop before the
Stop button in.
secondary boom begins to extend. The angle
will be approximately 76 ± 5 degrees.
4 - 64 Z-135/70 Part No. 106783

Before serial number 321: All models:

29 Remove the wire jumper 33 Use the key to turn the service/bypass key
from the 2 pin connector in switch to the run postion.
the lower left hand area of the ground control
box that was installed in step 5. Install the
connector plug.
machine.
the jumper wire will result in an 34 Pull out the red Emergency Stop button. Start
unsafe configuration which will the engine and lower the boom to the stowed
compromise machine stability. position. Be sure there are no calibration faults
Operating the machine in this shown on the display.
machine tipping over causing STOP

wire must be removed before 00000

Run
retaining fasteners. Service
Bypass
calibration toggle switch is automatically activated Recovery
Service Bypass /
Recovery Key Switch
Part No. 106783 Z-135/70 4 - 65

Engines REV C
5-1 How to Remove the Flex Plate

RPM Adjustment 1 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on
Refer to Maintenance Procedure B-18, Check and the drive pump.
Adjust the Engine RPM.
2 Support the drive pump with an appropriate
lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.
5-2 3 Carefully pull the pump away from the engine
Flex Plate and secure it from moving.
4 Remove the flex plate mounting fasteners,
The flex plate acts as a coupler between the engine then remove the flex plate from the engine
and the pump. It is bolted to the engine flywheel 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" Type "B"

(flexplate with (flexplate with
separate coupler) coupler combined)
4 - 66 Z-135/70 Part No. 106783

REV C ENGINES
How to Install a Type "A" 3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
Flex Plate appropriate gap between coupler and pump end
1 Install the flex plate onto the engine flywheel plate for your engine.
with the raised spline towards the pump.
a b c d e
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 f
a pump
Perkins models: Torque the flex plate mounting b pump shaft
bolts in sequence to 49 ft-lbs / 66 Nm. c pump coupler
Then torque the flex plate mounting bolts in d flex plate with raised spline
e engine flywheel
f 0.188 inch / 4.8 mm gap -
1 Deutz models
0.25 inch / 6.4 mm gap -
Cummins and Perkins models
6 3
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.
5
Deutz models: Apply Loctite® removable thread
4
sealant to the pump coupler set screw. Torque
the set screw to 61 ft-lbs / 83 Nm.
2 Component damage hazard. Do
Ford and Deutz models not force the drive pump during
installation or the flex plate teeth
may become damaged.
1
2 3
Perkins models
Part No. 106783 Z-135/70 4 - 67

ENGINES REV C
How to Install a Type "B" 6 1
Flex Plate
1 Deutz and Perkins models: Install the flex
plate onto the engine flywheel with the rubber
vibration isolators towards the pump. 4 3
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 2 5
flex plate fasteners and loosely install the
Deutz and Perkins models
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 1
mounting bolts in sequence to 40 ft-lbs / 54 Nm.
Cummins models: Torque the flex plate 6 3
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
4 5
pump shaft and flex plate.
Grease Specification 2
Shell Alvania® Grease CG, NLGI 0/1 or equivalent. Cummins models
4 - 68 Z-135/70 Part No. 106783

REV E
Ground Controls
6-1 How to Use the Service Bypass
Service Bypass/Recovery Mode
Key Switch Tip-over hazard. Operating the
machine outside of the operating
The ground control box contains two key switches. envelope while in Service Bypass
The main key switch towards the top of the control mode will result in death or serious
box is for selection of ground or platform controls. injury if proper operating
The key switch at the bottom of the control box is procedures and safety precautions
the Service Bypass/Recovery key switch. Service are not followed. Do not use this
Bypass and Recovery modes are only intended for mode if you are not trained and
certain circumstances and are not part of normal familiar with the operating envelope
machine operation. If either the Service Bypass or of the machine.
the Recovery function is required, this indicates
there may be faults with the machine. Contact Note: Before using the Service Bypass mode,
trained personnel immediately. make sure you understand the fault code or issue
affecting the operation of the machine to be sure
Service Bypass is used for a platform out-of- the use of service bypass is required.
envelope condition and certain service situations.
The Service Bypass mode will allow the platform to
Recovery is only to be used as a last attempt to be manually leveled when an out-of-envelope
lower the platform when the operator in the platform condition exists. In the event that the platform
is unable to do so, system failure or in emergency angle is greater than 10° from level, the boom angle
situations. 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
STOP
to correct an out of level platform fault.

00000
1 Turn the engine off.

2 Turn the main key switch to ground controls.
Remove the key from the main key switch and
key switch.
Note: The main key switch must remain in the
ground control position.
Run
Service
Bypass
Recovery
Service Bypass /
Recovery Key Switch
Part No. 106783 Z-135/70 4 - 69

GROUND CONTROLS REV E
3 Turn the service bypass/recovery key switch to The Recovery mode allows the platform to be
the service bypass position. lowered in the event the operator in the platform is
unable to lower the platform using the platform
4 Using auxiliary power, operate the platform level
controls, system failure or emergency situations.
toggle switch to level the platform.
The recovery sequence will automatically retract
Note: Only the auxiliary power unit can be used to the primary and secondary booms and then lower
correct an out of level platform fault. the primary boom using the auxiliary power unit to
allow the operator at the platform controls to exit
5 Turn the service bypass/recovery key switch to the platform.
the run position.
Note: This procedure is for machines using
6 Remove the key from the service bypass/ software version 1.11 and later. For machines using
recovery key switch and insert the key into the software version 1.01, contact the Service
main key switch. Department.
Note: If the Service Bypass function has been
used, there may be faults with the machine. Check
Remove the key from the main key switch and
the LCD screen on the ground control box for
machine faults, then contact trained service
key switch.
personnel.
2 Turn and hold the service bypass/recovery key
How to Use the Recovery Mode switch to the recovery position. The switch
must be held in the recovery position.
Recovery is only to be used as a last attempt to
lower the platform when the operator in the platform Result: The auxiliary power unit will turn on and
is unable to do so, system failure or in emergency the boom will begin the following recovery
situations. sequence.
· The secondary boom will retract
Bodily injury hazard. When using · The primary boom will retract
recovery mode, the platform may
· The primary boom will lower
not fully lower to the ground when
the recovery mode is completed. Note: The key switch must be held in the recovery
Failure to use only suitable position until the recovery sequence is complete or
equipment and/or practices to until the operator in the platform can safely exit the
allow the operator to safely exit the platform.
platform could result in death or
serious injury. Note: If any boom safety limit switches are faulty,
the boom will only retract and not lower and the
Bodily injury hazard. Platform operator will need to be recovered from that point.
leveling is not active when using
recovery mode. The platform could Note: If the Recovery function has been used, this
reach high out-of-level conditions may indicate there may be faults with the machine.
when using this mode. The Tag and remove the machine from service until the
operator will need to secure fault has been corrected by trained personnel.
themself to the platform to prevent
falling injury.
4 - 70 Z-135/70 Part No. 106783

REV E GROUND CONTROLS
The ground control box (TCON) is the 6-2

communication and operations center for the
machine. The ground control box contains two key Circuit Boards
switches. The key switch towards the top of the
control box is for selection of ground or platform How to Remove the LCD Display
controls. The key switch at the bottom of the
control box is the Service Bypass key switch. It is
Screen Circuit Board
used when calibrating certain machine parameters 1 Push in the red Emergency Stop button to the
and also to correct an out-of-level platform. If the off position at both the ground and platform
machine trips an envelope safety switch, an controls.
operator at the ground controls can turn and hold
the Service Bypass key switch in the recover 2 Remove the ground control box lid fasteners.
position, which will automatically retract the boom Open the control box lid.
and lower the platform close to the ground. Electrocution/burn hazard. Contact
The ground control box contains a replaceable
membrane decal with touch sensitive buttons for
various machine functions. The ground control box
and other jewelry.
also contains two printed circuit boards:
The LCD (Liquid Crystal Display) circuit board is Electrostatic discharge (ESD) can
mounted to the inside of the control box lid which damage printed circuit board
controls the LCD display screen. components. Maintain firm contact
The ECM circuit board is the main circuit board for with a metal part of the machine
the machine. All operating parameters and that is grounded at all times when
configuration of options for the machine are stored handling printed circuit boards OR
in the ECM memory. use a grounded wrist strap.
Note: When the ECM circuit board is replaced, the 3 Carefully disconnect the LCD circuit board
joysticks will need to be calibrated. See 1-3, How to ribbon cable from the ECM circuit board.
Calibrate a Joystick. 4 Remove the LCD display circuit board retaining
fasteners.
Note: When the ECM circuit board is replaced, all
the boom, platform and axle angle sensors will 5 Carefully remove the LCD display circuit board
need to be calibrated and in a specific order. from the ground control box lid.
Contact the Genie Industries Service Department.
Part No. 106783 Z-135/70 4 - 71

GROUND CONTROLS REV E
6-3 5 Remove the membrane decal from the control

box lid while guiding the ribbon cables out of the
Membrane Decal control box lid.
The membrane decal is a special decal that 6 Remove any decal adhesive from the control
consists of a decal with an electronic membrane on box lid with a mild solvent.
the backside. The membrane contains touch Note: Do not allow any solvent to come in contact
sensitive areas that, when pushed, activates the with the LCD display screen.
machine functions. The membrane buttons activate
machine functions similar to toggle switches, but 7 Install the new membrane decal while guiding
do not have any moving parts. the ribbon cables through the control box lid.
8 Connect the ribbon cables to the ECM circuit
How to Replace the Membrane board.
Decal
9 Close the control box lid and install the retaining
1 Turn the key switch at the ground controls to the fasteners.
off position.
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.
and other jewelry.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
handling printed circuit boards OR
use a grounded wrist strap.
4 - 72 Z-135/70 Part No. 106783

REV C
Hydraulic Pumps
7-1 2 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
Function Pump
The function pump is a pressure compensated, hydraulic oil can penetrate and
variable displacement piston pump. Any internal burn skin. Loosen hydraulic
service to the pump should be performed at an connections very slowly to allow
authorized Sauer-Danfoss service center. Contact the oil pressure to dissipate
the Genie Industries Service Department to locate gradually. Do not allow oil to
your local authorized service center. squirt or spray.
3 Support the pump with a suitable lifting device.
How to Remove the
4 Remove the two pump mounting fasteners.
Function Pump Carefully remove the pump.
Note: When removing a hose assembly or fitting, Component damage hazard. Be
the O-ring on the fitting and/or hose end must be sure to open the two hydraulic tank
replaced and then torqued to specification during valves and prime the pump after
installation. Refer to Section 2, Hydraulic Hose and installing the pump.
1 Locate the two hydraulic tank valves at the
hydraulic tank. Close the valves.
open closed

engine must not be started with the
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

HYDRAULIC PUMPS REV C
How to Prime the Function How to Adjust the Function

Pump Pump Standby Pressure
Note: When removing a hose assembly or fitting, 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
the O-ring on the fitting and/or hose end must be 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
1 Remove the case drain hydraulic hose from the gauge.
top of the function pump.
Result: The gauge should show
Note: The case drain hose is the smaller of the two
250 psi / 17 bar.
hoses on top of the function pump and closest to
the drive pump. Result: If the gauge does not show
250 psi / 17 bar, proceed with step 4 to adjust
2 Locate and open the hydraulic tank shut-off the function pump standby pressure.
valve at the hydraulic tank that supplies
hydraulic oil to the function pump. Do not open 4 Loosen the set screw for the standby pressure
the valve for the drive pump. adjustment screw.
3 When hydraulic fluid begins to come out of the a

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 b
check for hydraulic leaks.
a standby pressure set screw

b 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

REV C HYDRAULIC PUMPS
How to Adjust the Function 6 Loosen the set screw for the pressure
compensator adjustment screw.
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 a
gauge to the TEST port on the function manifold.
change the rpm to high idle.
b
4 Push and hold the high speed function enable
button (rabbit symbol). Do not activate any
a pressure compensator set screw
boom functions.
b pressure compensator
5 Observe the pressure reading on the pressure adjustment screw
gauge. 7 Adjust the pressure compensator pressure. Turn
Result: The gauge should show the adjustment screw clockwise to increase the
2900 psi / 200 bar. pressure or counterclockwise to decrease the
pressure. Tighten the set screw.
Result: If the gauge does not show
2900 psi / 200 bar, proceed with step 6 to adjust Component damage hazard. Do
the function pump pressure compensator. 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

HYDRAULIC PUMPS REV C
7-2 2 Locate the two hydraulic tank valves at the

hydraulic tank. Close the valves.
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 Sauer- open closed
Danfoss service center. Contact the Genie
Industries Service Department to locate your local Component damage hazard. The
authorized service center. engine must not be started with the
How to Remove the Drive Pump the closed position or component
Component damage hazard. The valves are closed, remove the key
work area and surfaces where this from the key switch and tag the
procedure will be performed must machine to inform personnel of the
be clean and free of debris that condition.
could get into the hydraulic system
and cause severe component 3 Tag, disconnect and plug the hydraulic hoses
damage. Dealer service is from the drive and function pumps. Cap the
recommended. fittings on the pumps.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring on the fitting and/or hose end must be hydraulic oil can penetrate and
replaced and then torqued to specification during burn skin. Loosen hydraulic
installation. Refer to Section 2, Hydraulic Hose and connections very slowly to allow
Fitting Torque Specifications. the oil pressure to dissipate
1 Disconnect the electrical connection at the squirt or spray.
electronic displacement controller (EDC) located
on the drive pump. 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

REV C HYDRAULIC PUMPS
5 Carefully pull the drive pump out until the pump How to Prime the Drive Pump
coupler separates from the flex plate.
Component damage hazard. Be
6 Remove the drive pump from the machine. sure to open the two hydraulic tank
Component damage hazard. The valves before performing this
pumps may become unbalanced procedure.
and fall if not properly supported. 1 Connect a 0 to 600 psi / 0 to 50 bar pressure
Component damage hazard. Be gauge to either the "A" or "B" test port on the
sure to open the two hydraulic tank drive pump.
valves and prime the pump after 2 Perkins and Cummins models: Disconnect
installing the pump. 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.
check for hydraulic leaks.
Part No. 106783 Z-135/70 4 - 77

Manifolds REV E
8-1
Function Manifold - View 1 (before serial number 440)
The function manifold is located next to the ground control box.
Index Schematic
No. Description Item Function Torque
1 Check valve ....................................... W .......... Prevents the draining of

hydraulic oil from the
jib manifold and platform
manifold ............................................ 30-35 ft-lbs / 41-47 Nm
2 Solenoid valve, 2 position 3 way ...... C ........... Primary boom up .............................. 30-35 ft-lbs / 41-47 Nm
3 Solenoid valve, 2 position 3 way ...... G ........... Primary boom retract ........................ 30-35 ft-lbs / 41-47 Nm
4 Solenoid valve, 2 position 3 way ...... J ............ Secondary boom extend .................. 50-55 ft-lbs / 68-75 Nm
5 Solenoid valve, 2 position 3 way ...... H ........... Secondary boom up ......................... 50-55 ft-lbs / 68-75 Nm
6 Plug, 16 SAE .................................................... Port plug ................................... 130-140 ft-lbs / 176-190 Nm
7 Relief valve, 3100 psi / 214 bar ........ L ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid valve, 2 position 3 way ...... I ............ Secondary boom down .................... 30-35 ft-lbs / 41-47 Nm
9 Solenoid valve, 2 position 3 way ...... K ........... Secondary boom retract ................... 30-35 ft-lbs / 41-47 Nm
10 Solenoid valve, 2 position 3 way ...... F ........... Primary boom extend ....................... 30-35 ft-lbs / 41-47 Nm
11 Solenoid valve, 3 position 4 way ...... B ........... Turntable rotate left/right .................. 30-35 ft-lbs / 41-47 Nm
12 Solenoid valve, 2 position 3 way ...... D ........... Primary boom down ......................... 30-35 ft-lbs / 41-47 Nm
4 - 78 Z-135/70 Part No. 106783

REV E MANIFOLDS
D
12
C
2
B
11
F
10
G
3
K
9
J
4
I
8
L H
7 6 5
Part No. 106783 Z-135/70 4 - 79

MANIFOLDS REV E
8-2
Function Manifold - View 2 (before serial number 440)
Index Schematic
1 Check valve ....................................... DB ........ Prevents hydraulic pressure

from flowing back into auxiliary
pump #1
2 Check valve ....................................... DC ........ Prevents hydraulic pressure
pump #2
3 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
150 psi / 10.3 bar .............................. O ........... Primary boom up/down circuit,
primary boom up/down
proportional valve ............................. 30-35 ft-lbs / 41-47 Nm
5 Relief valve, 2600 psi / 179 bar ........ E ........... Primary boom extend ....................... 20-25 ft-lbs / 27-34 Nm
150 psi / 10.3 bar .............................. Q ........... Primary boom extend/retract circuit,
primary boom extend/retract
150 psi / 10.3 bar .............................. U ........... Secondary boom extend/retract circuit,
secondary boom extend/retract
150 psi / 10.3 bar .............................. S ........... Secondary boom up/down circuit,
secondary boom up/down
9 Proportional solenoid valve .............. T ........... Secondary boom up/down circuit ..... 50-55 ft-lbs / 68-75 Nm
10 Check valve ....................................... DD ........ Prevents hydraulic pressure
from flowing back into the
function pump ........................... 130-140 ft-lbs / 176-190 Nm
11 Proportional solenoid valve .............. V ........... Secondary boom extend/
retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm
12 Proportional solenoid valve .............. R ........... Primary boom extend/
13 Proportional solenoid valve .............. P ........... Primary boom up/down circuit .......... 50-55 ft-lbs / 68-75 Nm
14 Proportional solenoid valve .............. N ........... Turntable rotate left/right circuit ........ 50-55 ft-lbs / 68-75 Nm
4 - 80 Z-135/70 Part No. 106783

REV E MANIFOLDS
1 2 3 4
DB DC M O
N
14
E
5
P
13
Q
6
R
12
U
7
V
11
DD S
10
8
T
9
Part No. 106783 Z-135/70 4 - 81

MANIFOLDS REV E
8-3
Function Manifold - View 1 (after serial number 439)
Index Schematic
1 Solenoid Valve, 2 position 3 way ...... D ........... Primary boom down ......................... 30-35 ft-lbs / 41-47 Nm
2 Solenoid Valve, 2 position 3 way ...... C ........... Primary boom up .............................. 30-35 ft-lbs / 41-47 Nm
3 Solenoid Valve, 2 position 3 way ...... G ........... Primary boom retract ........................ 30-35 ft-lbs / 41-47 Nm
4 Solenoid Valve, 2 position 3 way ...... F ........... Primary boom extend ....................... 30-35 ft-lbs / 41-47 Nm
5 Solenoid Valve, 2 position 3 way ...... K ........... Secondary boom retract ................... 30-35 ft-lbs / 41-47 Nm
6 Solenoid Valve, 2 position 3 way ...... J ............ Secondary boom extend .................. 30-35 ft-lbs / 41-47 Nm
7 Solenoid Valve, 2 position 3 way ...... I ............ Secondary boom down .................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid Valve, 2 position 3 way ...... H ........... Secondary boom up ......................... 30-35 ft-lbs / 41-47 Nm
9 Check valve ....................................... DF ......... Tank return circuit ..................... 130-140 ft-lbs / 176-190 Nm
10 Solenoid valve, 3 position 4 way ...... B ........... Turntable rotate left/right .................. 30-35 ft-lbs / 41-47 Nm
11 Relief valve, 3100 psi / 214 bar ........ L ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar .............................. S ........... Secondary boom up/down circuit,
secondary boom up/down
150 psi / 10.3 bar .............................. U ........... Secondary boom extend/retract circuit,
secondary boom extend/retract
150 psi / 10.3 bar .............................. Q ........... Primary boom extend/retract circuit,
primary boom extend/retract
4 - 82 Z-135/70 Part No. 106783

REV E MANIFOLDS
C
2
G
3
F
4
Q
14
K
5
J
6
I
7
H
8
DF
9
U
13 B 10
L
11
S
12
Part No. 106783 Z-135/70 4 - 83

MANIFOLDS REV E
8-4
Function Manifold - View 2 (after serial number 439)
Index Schematic
1 Check valve ....................................... DB ........ Prevents hydraulic pressure

pump #1
2 Check valve ....................................... W .......... Prevents the draining of
hydraulic oil from the
jib manifold and platform
manifold ............................................ 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar .............................. O ........... Primary boom up/down circuit,
primary boom up/down
4 Relief valve, 2600 psi / 179 bar ........ E ........... Primary boom extend ....................... 20-25 ft-lbs / 27-34 Nm
5 Proportional solenoid valve .............. P ........... Primary boom up/down circuit .......... 50-55 ft-lbs / 68-75 Nm
6 Proportional solenoid valve .............. R ........... Primary boom extend/
7 Proportional solenoid valve .............. V ........... Secondary boom extend/
8 Proportional solenoid valve .............. T ........... Secondary boom up/down circuit ..... 50-55 ft-lbs / 68-75 Nm
9 Proportional solenoid valve .............. N ........... Turntable rotate left/right circuit ........ 50-55 ft-lbs / 68-75 Nm
150 psi / 10.3 bar .............................. M .......... Turntable rotate circuit,
turntable rotate proportional valve ... 30-35 ft-lbs / 41-47 Nm
11 Check valve ....................................... DD ........ Prevents hydraulic pressure
from flowing back into the
function pump ........................... 130-140 ft-lbs / 176-190 Nm
12 Check valve ....................................... DC ........ Prevents hydraulic pressure
pump #2
4 - 84 Z-135/70 Part No. 106783

REV E MANIFOLDS
1 2
DB W
O
3
E
4
P
5
DC
12
R
3
V
7
DD
11
T
8
N
9
M
10
Part No. 106783 Z-135/70 4 - 85

MANIFOLDS REV E
8-5 How to Adjust the System

Valve Adjustments - Relief Valve
Function Manifold (after serial number 439)
How to Adjust the System stowed position.
Relief Valve Note: Auxiliary power will be used to perform this
(before serial number 440) procedure. Do not start the engine.
Note: Perform this procedure with the boom in the 1 Locate the system relief valve on the function
stowed position. manifold (item L). Hold the relief valve stem with
a hex wrench and loosen the lock nut.
Note: Auxiliary power will be used to perform this
procedure. Do not start the engine. 2 Turn the valve stem counterclockwise several
turns. Do not allow the relief valve to come
1 Locate the system relief valve on the function apart. Tighten the lock nut.
manifold (item L). Hold the relief valve and
remove the cap. 3 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the TEST port on the function manifold.
2 Turn the internal hex socket counterclockwise
several turns. Do not allow the relief valve to 4 Simultaneously push and hold the auxiliary
come apart. Install the relief valve cap. power button and the primary boom retract
button with the primary boom fully retracted.
3 Connect a 0 to 5000 psi / 0 to 350 bar pressure Observe the pressure reading on the pressure
gauge to the TEST port on the function manifold. gauge. Refer to Section 2, Specifications.
4 Simultaneously push and hold the auxiliary 5 Hold the relief valve stem with a hex wrench and
power button and the primary boom retract loosen the lock nut.
button with the primary boom fully retracted.
Observe the pressure reading on the pressure 6 Adjust the valve stem. Turn it clockwise to
gauge. Refer to Section 2, Specifications. increase the pressure. Tighten the lock nut.
5 Use a wrench to hold the relief valve and Component damage hazard. Do
remove the cap (item L). not adjust the relief valve higher
than specified.
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure. Install the relief valve 7 Repeat step 4 to confirm relief valve pressure.
cap.
8 Remove the pressure gauge.
Component damage hazard. Do
not adjust the relief valve higher
than specified.
7 Repeat step 4 to confirm relief valve pressure.
4 - 86 Z-135/70 Part No. 106783

REV E MANIFOLDS
How to Adjust the Primary Boom 9 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
Extend Relief Valve decrease the pressure. Install the relief valve
Note: Perform this procedure with the axles cap.
extended. Component damage hazard. Do
1 Remove the primary boom end cover from the
than specified.
pivot end of the boom.
10 Repeat step 7 to confirm relief valve pressure.
2 Locate the primary boom extend limit switch on
the side of the primary boom. 11 At the pivot end of the primary boom, connect
the primary boom extend limit switch connector,
3 Follow the wiring from the switch to the pivot
that was disconnected in step 3.
end of the primary boom. Locate and disconnect
the wire connector for the primary boom extend 12 Install the primary boom end cover and remove
limit switch. the pressure gauge.
Note: The correct wire connector will be a 2 pin 13 Start the engine and fully retract the primary
connector with a yellow marker on the cable. boom. Turn the engine off.
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.
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).
Part No. 106783 Z-135/70 4 - 87

MANIFOLDS REV E
8-6
Platform Manifold
The platform manifold is mounted to the platform mounting weldment.
Index Schematic
1 Solenoid valve, 3 position 4 way ......... AH ......... Platform rotate left/right ................. 20-25 ft-lbs / 27-34 Nm
2 Proportional solenoid valve,
3 position 4 way .................................... AI .......... Platform level up/down ................. 20-25 ft-lbs / 27-34 Nm
3 Flow control valve,
0.2 gpm / 0.76 L/min ............................. AG ......... Platform rotate left/right circuit ...... 20-25 ft-lbs / 27-34 Nm
4 - 88 Z-135/70 Part No. 106783

REV E MANIFOLDS
1 2
AH AI
AG
3
Part No. 106783 Z-135/70 4 - 89

MANIFOLDS REV E
8-7
Jib Boom Manifold
The jib boom manifold is mounted inside the primary extension boom at the platform end.
Index Schematic
1 Pressure compensator valve,

150 psi / 10.3 bar .................................. X ........... Jib boom up/down circuit,
jib boom up/down
proportional valve ......................... 30-35 ft-lbs / 41-47 Nm
2 Solenoid valve, 2 position 3 way ......... AE .......... Jib boom retract ............................ 20-25 ft-lbs / 27-34 Nm
3 Solenoid valve, 2 position 3 way ......... AD ......... Jib boom extend ........................... 20-25 ft-lbs / 27-34 Nm
4 Flow regulator valve,
2 gpm / 7.6 L/min .................................. AC ......... Jib boom extend/retract circuit ...... 20-25 ft-lbs / 27-34 Nm
5 Orifice, 0.040 inch / 1 mm ..................... AB .......... Jib boom extend/retract circuit
6 Check valve, 25 psi / 1.7 bar ................ AA .......... Holds oil in jib boom manifold ...... 20-25 ft-lbs / 27-34 Nm
7 Shuttle valve .......................................... Z ........... Jib boom up/down circuit .............. 10-12 ft-lbs / 14-16 Nm
3 position 4 way .................................... Y ........... Jib boom up/down ........................ 20-25 ft-lbs / 27-34 Nm
3 position 4 way ................................... AF .......... Jib boom bellcrank
level up/down ................................ 20-25 ft-lbs / 27-34 Nm
4 - 90 Z-135/70 Part No. 106783

REV E MANIFOLDS
1 2 3 4
X AE AD AC
AB
5
AF
9
Y
8
Z
7
AA
6
Part No. 106783 Z-135/70 4 - 91

MANIFOLDS REV E
8-8
Function Enable Valve
The function enable valve is mounted behind the medium pressure filter.
Index Schematic
1 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
4 - 92 Z-135/70 Part No. 106783

REV E MANIFOLDS
8-9
Turntable Rotation Manifold
The turntable rotation manifolds are mounted to the turntable rotation drive hub motors.
Index Schematic
1 Counterbalance valve .................... CA ........... Turntable rotate right ....................... 25-30 ft-lbs / 34-41 Nm
2 Counterbalance valve .................... CB ........... Turntable rotate left .......................... 25-30 ft-lbs / 34-41 Nm
3 Shuttle valve, 2 position 3 way ...... CC ........... Turntable rotation brake release ....... 8-10 ft-lbs / 11-14 Nm
4 Orifice plug, 0.030 inch / 0.76 mm . CD ........... Turntable rotation brake release
1 2
CA CB
CD
4
CC
3
Part No. 106783 Z-135/70 4 - 93

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 Schematic

1.5 gpm / 5.7 L/min ............................ BI .......... Right front steer cylinder
2 Check valve ....................................... BC ........ Prevents right front steer cylinder
from moving when not steering ........ 20-25 ft-lbs / 27-34 Nm
3 Check valve ....................................... BB ......... Prevents left front steer cylinder
2.1 gpm / 8 L/min ............................... BL ......... Right rear steer cylinder
extend circuit .................................... 20-25 ft-lbs / 27-34 Nm
5 Solenoid valve, 3 position 4 way ...... BQ ........ Steer left/right,
right rear steer cylinder ..................... 20-25 ft-lbs / 27-34 Nm
6 Check valve ....................................... BE ......... Prevents right rear steer cylinder
7 Check valve ....................................... BD ........ Prevents left rear steer cylinder
8 Solenoid valve, 3 position 4 way ...... BP ......... Steer left/right,
left rear steer cylinder ....................... 20-25 ft-lbs / 27-34 Nm
2.1 gpm / 8 L/min ............................... BJ ......... Left rear steer cylinder
7 gpm / 26.5 L/min ............................. BS ......... Axle extend/retract circuit ................. 20-25 ft-lbs / 27-34 Nm
11 Solenoid valve, 2 position 3 way ...... BU ........ Axle retract ........................................ 30-35 ft-lbs / 41-47 Nm
12 Solenoid valve, 2 position 3 way ...... BT ......... Axle extend ....................................... 30-35 ft-lbs / 41-47 Nm
13 Pressure reducing valve,
2400 psi / 165 bar ............................. BR ........ Axle extend/retract circuit ................. 30-35 ft-lbs / 41-47 Nm
This list continues. Please turn the page.
4 - 94 Z-135/70 Part No. 106783

REV E MANIFOLDS
1 2 3 2 3
BI BC BB BC BB
BO
20
BN
19
BL
4
BQ
5
BH
18
BF
17
BE
6
16 BG
BM
15
BE
6
BD
BK 7
14
BD
7
BR
13
BP
8
BT BU BS BJ
12 11 10 9
Part No. 106783 Z-135/70 4 - 95

MANIFOLDS REV E
Steer and Axle Manifold, continued

Index Schematic

1.5 gpm / 5.7 L/min ............................ BK ......... Left rear steer cylinder
1.5 gpm / 5.7 L/min ............................ BM ........ Right rear steer cylinder
1.5 gpm / 5.7 L/min ............................ BG ........ Left front steer cylinder
2.1 gpm / 8 L/min ............................... BF ......... Left front steer cylinder
2.1 gpm / 8 L/min ............................... BH ........ Right front steer cylinder
19 Solenoid valve, 3 position 4 way ...... BN ........ Steer left/right,
left front steer cylinder ...................... 20-25 ft-lbs / 27-34 Nm
20 Solenoid valve, 3 position 4 way ...... BO ........ Steer left/right,
right front steer cylinder .................... 20-25 ft-lbs / 27-34 Nm
4 - 96 Z-135/70 Part No. 106783

REV E MANIFOLDS
1 2 3 2 3
BI BC BB BC BB
BO
20
BN
19
BL
4
BQ
5
BH
18
BF
17
BE
6
16 BG
BM
15
BE
6
BD
BK 7
14
BD
7
BR
13
BP
8
BT BU BS BJ
12 11 10 9
Part No. 106783 Z-135/70 4 - 97

MANIFOLDS REV E
8-11
Valve Adjustments -
Steer and Axle Manifold
How to Adjust the Axle

Relief Valve
stowed position and the axles fully extended.
Note: This procedure will require 2 people.

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.
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
than specified.
6 Repeat steps 3 through 5 to confirm relief valve
pressure.
4 - 98 Z-135/70 Part No. 106783

REV E MANIFOLDS
Part No. 106783 Z-135/70 4 - 99

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 Schematic
1 Check valve, 5 psi / 0.3 bar ............... BA ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
2 Check valve, 5 psi / 0.3 bar ............... AZ ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
3 Check valve, 5 psi / 0.3 bar ............... AJ ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
4 Check valve, 5 psi / 0.3 bar ............... AT ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
5 Check valve, 5 psi / 0.3 bar ............... AW ........ Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
6 Shuttle valve, 3 position 3 way ......... AO ........ Charge pressure circuit that
directs hot oil out of low pressure
side of drive pump ............................ 50-55 ft-lbs / 68-75 Nm
7 Relief valve, 250 psi / 17.2 bar ......... AN ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid valve, 2 position 3 way ...... AY ......... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
9 Solenoid valve, 2 position 3 way ...... AX ......... 2-speed drive motor shift .................. 20-25 ft-lbs / 27-34 Nm
10 Flow divider/combiner valve ............. AR ........ Controls flow to square end
drive motors in forward
and reverse ................................. 90-100 ft-lbs / 122-136 Nm
11 Flow divider/combiner valve ............. AM ........ Controls flow to circle end
drive motors in forward
and reverse ................................. 90-100 ft-lbs / 122-136 Nm
12 Flow divider/combiner valve ............. AP ......... Controls flow to flow divider/
combiner valves AR and AM
in forward and reverse .............. 90-100 ft-lbs / 122-136 Nm
4 - 100 Z-135/70 Part No. 106783

REV E MANIFOLDS
1 2
BA AZ
AP
12
AM
11
AJ
3
AR
10
AT
4
AX
9
AY
8
AW
5
AN AO
7 6
Part No. 106783 Z-135/70 4 - 101

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 Schematic
1 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
2 Orifice, 0.052 in / 1.3 mm .................. AQ ........ Equalizes pressure on both sides
of flow divider/combiner AP
3 Orifice, 0.063 in / 1.6 mm .................. AS ......... Equalizes pressure on both sides
of flow divider/combiner AR
4 Orifice, 0.030 in / 0.76 mm ................ AV ......... Brake release and 2-speed
motor shift circuit
5 Check valve, 5 psi / 0.3 bar ............... AU ........ Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
6 Check valve, 5 psi / 0.3 bar ............... AK ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
4 - 102 Z-135/70 Part No. 106783

REV E MANIFOLDS
AK
6
AL
1
AU
5
AQ
2
AS
3
AV
4
Part No. 106783 Z-135/70 4 - 103

MANIFOLDS REV E
8-14 8 Start the engine from the ground controls.

Valve Adjustments, 9 Press and hold the function enable/high rpm
select button (rabbit symbol) position.
Traction Manifold
10 Adjust the internal hex socket until the pressure
How to Adjust the Hot Oil reading on the gauge is 40 psi / 2.8 bar less
than the pressure reading on the pump. Turn it
Relief Valve clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Note: The hydraulic oil temperature must be
Install the relief valve cap.
100°F to 150°F / 38°C to 65.5°C before performing
this procedure. 11 Turn the engine off and remove the pressure
gauge.
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.
5 Press and hold the function enable/high rpm
select button (rabbit symbol) position. Note the
reading on the pressure gauge.
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).
4 - 104 Z-135/70 Part No. 106783

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 Schematic
1 Directional valve ............................ BV ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
2 Orifice disc,
0.030 inch / 0.080 cm ..................... BW ........... Delays shift to drive
3 Solenoid valve ............................... BX ........... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve, 270 psi / 18.6 bar ....... BZ ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
5 Check valve .................................... BY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
CY
5
CU
1
CV
2
CW
3
CX
4
Part No. 106783 Z-135/70 4 - 105

MANIFOLDS REV E
8-16 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromotive force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 10°C
within the coil that provides this force field. that your air temperature increases or decreases
from 68°F / 20°C.
Since coil resistance is sensitive to temperature,
resistance values outside specification can produce Valve coil resistance specifications
erratic operation. When coil resistance decreases
below specification, amperage increases. As Proportional solenoid valve 3.5 to 5.5
resistance rises above specification, voltage (schematic items N, P, R, T, V)
increases. 3 position 4 way solenoid valve 4 to 6
While valves may operate when coil resistance is (schematic item B)
outside specification, maintaining coils within 3 position 4 way solenoid valve 7 to 9
specification will help ensure proper valve function (schematic items BN, BO, BP and BQ)
over a wide range of operating temperatures.
Electrocution/burn hazard. Contact (schematic item AH)
3 position 4 way proportional 8 to 10
solenoid valve
(schematic items Y and AI)
and other jewelry.
1 Tag and disconnect the wiring from the coil to be
(schematic items F and AD)
tested.
2 Test the coil resistance. (schematic items AE and AF)
Result: The resistance should be within 2 position 3 way solenoid valve 3.5 to 5.5
specification, plus or minus 30%. (schematic items H and J)
Result: If the resistance is not within 2 position 3 way solenoid valve 7.5 to 9.5
specification, plus or minus 30%, replace the (schematic items C, D, G, I, K,
coil.Valve Coil Resistance Specification AX, AY, BU and BT)

(schematic item A)
4 - 106 Z-135/70 Part No. 106783

REV E MANIFOLDS
How to Test a Coil Diode COIL

a
Properly functioning coil diodes protect the d
MULTI
METER
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current c -
to a coil. Faulty diodes can fail to protect the
+
b
electrical system, resulting in a tripped circuit
10 W 9V
breaker or component damage. RESISTOR BATTERY
+
with electrically charged circuits c - b
injury. Remove all rings, watches a multimeter
and other jewelry. b 9V DC battery
c 10 resistor
1 Test the coil for resistance. See, How to Test a d coil
Coil. Note: Dotted lines in illustration indicate a
reversed connection as specified in
2 Connect a 10 resistor to the negative terminal
step 6
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the 3 Set a multimeter to read DC current.
coil.
Note: The multimeter, when set to read DC current,
should be capable of reading up to 800 mA.

Resistor, 10
Genie part number 27287 4 Connect the negative lead to the other terminal
on the coil.
Note: The battery should read 9V DC or more when 5 Momentarily connect the positive lead from the
measured across the terminals. 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.
Part No. 106783 Z-135/70 4 - 107

Turntable Rotation Components REV E
9-1 6 Repeat steps 3 through 5 for the other turntable

rotation assembly.
Turntable Rotation Assembly
Tip-over hazard. If the turntable
rotation lock pin is not properly
How to Remove a Turntable installed, machine stability is
Rotation Assembly compromised and the machine
could tip over when the drive hub
is removed from the machine,
which could result in death or
serious injury.
Fitting Torque Specifications. Crushing hazard. The drive hub
Note: Perform this procedure with the primary boom if not properly supported by the
between the circle-end tires and with the machine overhead crane or lifting device
on a firm, level surface. when removed from the machine.
1 Secure the turntable from rotating with the Note: When installing a turntable rotation assembly,
turntable rotation lock pin. the rotation gear backlash must be adjusted. See
2 Remove the ground controls side fixed turntable Maintenance Procedure D-4, Adjust the Turntable
cover. Rotation Gear Backlash.
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.
4 - 108 Z-135/70 Part No. 106783

REV E TURNTABLE ROTATION COMPONENTS
9-2 All models:

Turntable Level Sensor 5 Turn the key switch to ground controls.
6 Remove the key from the main key switch.
How to Calibrate the Turntable Insert the key into the service/bypass key
Level Sensor switch and turn it to the service/bypass
position.
Note: If the Safety Controller (SCON) has been
replaced, the entire machine needs to be calibrated Note: The angle sensor calibration values will not
in a specific order. Consult the Genie Industries be saved correctly unless the key switch is in the
Service Department. service/bypass position.
Note: Perform this procedure with the machine on a 7 Press and hold the enter button on the
firm, level surface and in the stowed position. ground control panel while pulling out the ground
Note: A digital level will be required to perform this position. Hold the enter button for approximately
procedure. 5 seconds and then release it.
Note: A kit is available through the Genie Industries 8 Enter sensor calibration mode by pressing the
Service Department (Genie part number 58351). buttons at the ground controls in the following
This kit includes a digital level with a magnetic sequence: .

STOP

00000


Run
Service
3 Locate the calibration toggle switch at the top of Bypass
mode by moving the toggle switch in the left Recovery
direction.
Part No. 106783 Z-135/70 4 - 109

TURNTABLE ROTATION COMPONENTS REV E
9 Push one of the LCD 13 Place the digital level along the Y axis of the
screen buttons shown turntable.
until SET UNIT X AXIS LEVEL TO
GRAVITY is displayed. +Y axis -Y axis
10 Place the digital level along the X axis of the
turntable. 14 Press the plus button or minus button to
adjust the display to the exact value shown on
-X axis
the digital level and press the enter button .
Platform

+X axis
16 Press the plus button to select YES, then
adjust the display to the exact value shown on
the digital level and press the enter button . 17 Wait approximately 20 seconds and turn the
Note: If the measured angle already matches the Stop button in to the off position or by turning
angle shown on the display at the ground controls, the main key switch to the off position.

until SET UNIT Y AXIS LEVEL TO
GRAVITY is displayed.
4 - 110 Z-135/70 Part No. 106783

REV E TURNTABLE ROTATION COMPONENTS
Before serial number 321: All models:

18 Remove the wire jumper from the 2 pin 20 Use the key to turn the service/bypass key
connector in the lower left hand area of the switch to the run postion.
Tip-over hazard. Failure to remove machine.
unsafe configuration which will 21 Start the engine. Be sure there are no calibration
compromise machine stability. faults shown on the display.
Operating the machine in this
machine tipping over causing
wire must be removed before
Part No. 106783 Z-135/70 4 - 111

Axle Components REV G
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 circle-
end 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.
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.
Illustration 1
Note: Inspect the sensor activator pin to make sure (square end, yellow side and
it is not broken or twisted. circle end, blue side shown)
Note: If the sensor activator pin needs to be

replaced, install the new activator pin per
Illustration 1
4 - 112 Z-135/70 Part No. 106783

REV G AXLE COMPONENTS
Left front (square-end, blue side) and right rear 6 Rotate the sensor housing in a clockwise
(circle-end, yellow side) angle sensors: direction until the sensor cable is pointing away
from the machine. Refer to Illustration 2.
a 7 Install the steer sensor cover retaining
fasteners. Do not tighten the cover retaining
b fasteners.
c
8 Connect the steer sensor assembly cable to the
main harness.
d 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.
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

AXLE COMPONENTS REV G
Right front (square-end, yellow side) and left 12 Rotate the sensor housing in a clockwise
rear (circle-end, blue side) angle sensors: direction until the sensor cable is pointing away
from the machine. Refer to Illustration 2.
a 13 Install the steer sensor cover retaining
fasteners. Do not tighten the cover retaining
b fasteners.
14 Connect the steer sensor assembly cable to the
c
main harness.
d 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
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.
into the sensor.
4 - 114 Z-135/70 Part No. 106783

How to Calibrate a Replacement How to Calibrate All

Steer Sensor Steer Sensors
Note: If a steer angle sensor has been removed or Note: This procedure will only need to be performed
replaced, the steer angle sensors will need to be if the ground controls circuit board (TCON) has
calibrated first. been replaced.
Note: Perform this procedure with the axles Note: Perform this procedure with the axles
retracted and the tires straightened. retracted and the tires straightened.
Note: This procedure will require two people. Before serial number 321:
Note: Be sure the yoke pivot pin retaining plate is 1 Locate the 2 pin connector in the lower left hand
fully engaged into the pivot pin and that the area of the ground control box.
1 Start the engine from the platform controls. wire between the two pins of the connector.
2 Select the proper steer mode. If a front (square- After serial number 320:
end) steer angle sensor has been replaced,
1 Locate the calibration toggle switch at the top of
select rear steer mode. If a rear (circle-end)
steer angle sensor has been replaced, select
front steer mode.
direction.
3 Have another person press down the foot
switch.
4 At the new steer angle sensor, loosen the steer prevent the control box door from moving the
angle sensor cover retaining fasteners. Do not toggle switch while calibrating the machine.
remove the fasteners or the sensor cover.
All models:
5 Rotate the sensor cover clockwise or
counterclockwise until the tire is straight in 3 Turn the key switch to ground controls and pull
relation with the other tires. Tighten the sensor out the ground controls red Emergency Stop
cover fasteners. button to the on position.
Note: If available, WebGPI can also be used for 4 Loosen the steer angle sensor cover retaining
this procedure. fasteners. Do not remove the fasteners or the
sensor cover.
off position.
Part No. 106783 Z-135/70 4 - 115

5 Using a voltmeter set to DC voltage, probe the

back of the electrical connector at pins B STOP
and C.
00000
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:
Run
Rotate the sensor cover clockwise or
counterclockwise until the voltage reading is Service
between 3.4 to 3.6V DC. Tighten the sensor Bypass
cover fasteners.
Recovery
Note: If available, WebGPI can also be used for
this procedure.
10 Enter sensor calibration mode by pressing the
7 Remove the key from the main key switch. buttons at the ground controls in the following
sequence: .
position. 11 Push one of the LCD screen buttons shown
Note: The angle sensor calibration values will not until RESET ALL STEER SENSORS is displayed.
be saved correctly unless the key switch is in the 12 Press the plus button to select YES, then
service/bypass position.
off position.
9 Press and hold the enter button on the until EXIT is displayed.
position. Hold the enter button for approximately press the enter button to accept.
4 - 116 Z-135/70 Part No. 106783

15 Turn the machine off by pushing in the red 10-2

Emergency Stop button to the off position.
Steer Cylinders
16 Remove the wire jumper How to Remove a Steer Cylinder

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 and Fitting Torque Specifications.
unsafe configuration which will Note: Perform this procedure with the axles
compromise machine stability. extended.
Operating the machine in this 1 Tag, disconnect and plug the hydraulic hoses
configuration will result in the from the steer cylinder. Cap the fittings on the
machine tipping over causing cylinder.
wire must be removed before Bodily injury hazard. Spraying
operating the machine. hydraulic oil can penetrate and
17 Close the ground control box and install the door connections very slowly to allow
retaining fasteners. the oil pressure to dissipate
After serial number 320: gradually. Do not allow oil to squirt
or spray.
installed in step 2. 2 Support the steer cylinder with a suitable lifting
device. Protect the cylinder rod from damage.
retaining fasteners. 3 Remove the pin retaining fasteners from both
steer cylinder pivot pins.
calibration toggle switch is automatically activated 4 Use a soft metal drift to remove the pins.
to exit out of calibration mode. 5 Remove the steering cylinder from the machine.
All models: Crushing hazard. The steer
cylinder may become unbalanced
18 Use the key to turn the service/bypass key and fall if not properly supported by
switch to the run postion. the lifting device when removed
Note: Be sure that the service/bypass key switch is from the machine.
in the RUN position before attempting to operate the
machine.
Part No. 106783 Z-135/70 4 - 117

10-3 4 Connect the hydraulic hoses from a portable

hydraulic power unit to the axle extension
Axle Extension Cylinders cylinder.
Note: Connect the pressure hose from the power
How to Remove an Axle unit to the "R" port of the cylinder and the return
Extension Cylinder hose from the power unit to the "E" port on the
cylinder.
the O-ring on the fitting and/or hose end must be 5 Support the axle extension cylinder with a
replaced and then torqued to specification during suitable lifting device. Protect the cylinder rod
installation. Refer to Section Two, Hydraulic Hose from damage.
6 Remove the pin retaining fasteners from both
Note: Perform this procedure with the machine on a axle extension cylinder pivot pins.
firm, level surface and the axles extended.
7 Use a soft metal drift to remove the pins.
Note: This procedure will require the use of a 8 Using the portable hydraulic power unit, retract
portable hydraulic power unit. the axle extension cylinder until the ends of the
1 Tag, disconnect and plug the hydraulic hoses cylinder clears the axles.
from the axle extension cylinder. Cap the 9 Remove the axle extension cylinder from the
fittings on the cylinder. machine.
Bodily injury hazard. Spraying Crushing hazard. The axle
hydraulic oil can penetrate and extension cylinder may become
burn skin. Loosen hydraulic unbalanced and fall if not properly
connections very slowly to allow supported by the lifting device.
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 - 118 Z-135/70 Part No. 106783

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

a
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.

b
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

3 Position the new axle angle sensor assembly 5 Rotate the sensor housing in a clockwise
over the sensor activator pin as shown. Refer to direction until the sensor cable is parallel with
Illustration 2. the drive chassis side plate. Refer to
Illustration 2.
6 Install the axle sensor cover retaing fasteners.
a
Do not tighten the cover retaining fasteners.
7 Connect the axle sensor assembly cable to the
b main harness.
c 8 Calibrate the axle angle sensor. See How to

Calibrate the Axle Angle Sensors.
Illustration 2
a starting position
b installed position
c sensor cover
d rotation arrow
e drive chassis side plate

into the sensor.
4 - 120 Z-135/70 Part No. 106783

How to Calibrate the Axle Before serial number 321:

Angle Sensors 7 Locate the 2 pin connector in the lower left hand
Note: If an axle angle sensor has been removed or
replaced, the axle angle sensors will need to be 8 Remove the connector plug and insert a jumper
calibrated first. wire between the two pins of the connector.
Note: Perform this procedure with the machine in After serial number 320:
the stowed position and the axles fully retracted. 7 Locate the calibration toggle switch at the top of
Note: This procedure will require two people. the ground control box. Activate calibration
1 Turn the key switch to ground controls and pull direction.
out the ground controls red Emergency Stop
button to the on position. 8 Temporarily install a control box door retaining
2 Loosen an axle angle sensor cover retaining prevent the control box door from moving the
fasteners. Do not remove the fasteners or the toggle switch while calibrating the machine.
sensor cover.
All models:
3 Using a voltmeter set to DC voltage, probe the
back of the electrical connector at pins 2 and 3. 9 Remove the key from the main key switch.
Note: If available, WebGPI can also be used for switch and turn it to the service/bypass
this procedure. position.
4 Rotate the sensor cover clockwise or Note: The angle sensor calibration values will not
counterclockwise until the voltage reading is be saved correctly unless the key switch is in the
between 4.2 to 4.4V DC. Tighten the sensor service/bypass position.
cover fasteners.
STOP
5 Repeat steps 2 through 4 for each remaining

axle angle sensor. 00000
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.
Run
Service
Bypass
Recovery
Part No. 106783 Z-135/70 4 - 121

10 Press and hold the enter button on the 19 Press and hold the engine start button for
ground control panel while pulling out the ground approximately 5 seconds to shut off the engine
controls red Emergency Stop button to the on and to save the calibration settings.
position. Hold the enter button for approximately Note: Do not turn the engine off with the key switch
5 seconds and then release it. or red Emergency Stop button or all calibration
11 Enter sensor calibration mode by pressing the points or values will not be saved.
buttons at the ground controls in the following 20 Wait approximately 20 seconds and turn the
sequence: . machine off by pressing the red Emergency
12 Push one of the LCD Stop button in to the off position or by turning
screen buttons shown the main key switch to the off position.
until RESET AXLE ANGLE Before serial number 321:
SENSORS is displayed.
21 Remove the wire jumper from the 2 pin
13 Press the plus button to select YES, then connector in the lower left hand area of the
press the enter button to accept. ground control box that was installed in step 8.
14 At the AXLE ANGLES FULLY RETRACTED screen, press
the plus button to select YES, then press the
enter button to accept. unsafe configuration which will
15 When the AXLE ANGLES FULLY EXTENDED screen is compromise machine stability.
displayed, start the engine and fully extend the Operating the machine in this
axles. configuration will result in the
machine tipping over causing
Note: If the system exits out of calibration mode death or serious injury. The jumper
when the engine is started, repeat step 10. wire must be removed before

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


All models:
23 Use the key to turn the service/bypass key

switch to the run postion.
machine.
Part No. 106783 Z-135/70 4 - 123

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

July 2011 Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
operating instructions printed in the
Genie Z-135/70 Operator's Manual on your
Observe and Obey: machine.
Troubleshooting and repair procedures shall be Be sure that all necessary tools and test
completed by a person trained and qualified on equipment are available and ready for use.
the repair of this machine.
Read each appropiate fault code thoroughly.
Immediately tag and remove from service a Attempting shortcuts may produce hazardous
damaged or malfunctioning machine. conditions.
Repair any machine damage or malfunction Be aware of the following hazards and follow
before operating the machine. generally accepted safe workshop practices.
Unless otherwise specified, perform each Crushing hazard. When testing
repair procedure with the machine in the or replacing any hydraulic
following configuration: component, always support
· Machine parked on a firm, level surface the structure and secure it
from movement.
· Boom in the stowed position
· Turntable rotated with the boom between Electrocution/burn hazard. Contact
the circle-end wheels (yellow arrow) with electrically charged circuits
· Turntable secured with the turntable
rotation lock pin
and other jewelry.
· Key switch in the off position with the
key removed Bodily injury hazard. Spraying
· Welder disconnected from the machine burn skin. Loosen hydraulic
(if equipped with the weld cable to connections very slowly to allow
platform option) the oil pressure to dissipate
· Wheels chocked gradually. Do not allow oil to
squirt or spray.
· All external AC power supply disconnected
from the machine Perform all troubleshooting on a
firm, level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Part No. 106783 Z-135/70 5-1

Section 5 • Fault Codes July 2011
Control System Fault Codes REV B
Error Source Error Type Effects Recovery Actions

Value at 5.0 V Check for damaged wiring to the
joystick. Check the connections to
Limited Speed and Direction frozen ensure the connector terminals
Value Too High
at zero and neutral, Alarm sounds have not backed out. Substitute a
Value Too Low known good joystick. If necessary
replace and recalibrate joystick.
Primary Ext/Ret Joystick Value at 0 V
Joystick Speed and Direction

Not calibrated frozen at zero and neutral Calibrate Joystick
Initiate one second beep of audible Self-clearing

Just calibrated warning device (transient)
Value Too High Limited Speed and Direction frozen ensure the connector terminals
Value at 0 V replace and recalibrate joystick.
Primary Up/Down Joystick
Not calibrated Calibrate Joystick
frozen at zero and neutral

Just calibrated
warning device (transient)

Value Too High Limited Speed and Direction joystick. Check the connections to
frozen at zero and neutral, ensure the connector terminals
Value Too Low have not backed out. Substitute a
Alarm sounds
Value at 0 V known good joystick. If necessary
Steer Joystick
Not calibrated Joystick Speed and Direction frozen
at zero and neutral Calibrate Joystick

Just calibrated (transient)
warning device
Primary Boom Up/Down disabled, Check ribbon and connector from

Primary Boom Up/Down Fault Check (both
display message on LCD membrane switch. If necessary,
switches on TCON buttons pressed)
replace membrane switch.
Check ribbon and connector from
Primary Boom Ext/Ret switches Fault Check (both Primary Boom Ext/Retract disabled, membrane switch. If necessary,
on TCON buttons pressed) display message on LCD replace membrane switch.
Stop all boom functions, allow only Check primary boom retracted and
Fault Check
Primary Boom Length boom retract, once fully retracted extended switches for proper
(unknown length)
allow boom down. Display message contact with the boom. Readjust or
on LCD shim switch as necessary.
Display message on LCD and allow Perform auto calibrate procedure.

Primary Up/Down Speed Not calibrated operation at default speed
Display message on LCD and allow Perform auto calibrate procedure.

Primary Extend/Retract Speed Not calibrated operation at default speed
5-2 Z-135/70 Part No. 106783

REV B CONTROL SYSTEM FAULT CODES

Display message on LCD Internal fault not on Z135
Safety Switch P3 P3 SAFETY SWITCH FAULT
Display message on LCD Check wiring for circuit P53LS (white/black

Safety Switch P6R1 wire) for damage resulting in shorts or opens.
P6R1 SAFETY SWITCH FAULT
Repair wiring or replace TCON.
Check wiring for circuit P54ENG (black/white
Display message on LCD wire) for damage resulting in shorts or opens.
Safety Switch P6R2 P6R2 SAFETY SWITCH FAULT Repair wiring or replace TCON.
Display message on LCD Check wiring for circuit S56PRV (red wire) for
Safety Switch P7 P7 SAFETY SWITCH FAULT damage resulting in shorts or opens. Repair
wiring or replace TCON.
Display message on LCD Function enable button was held down during
Safety Switch P7R P7R SAFETY SWITCH FAULT startup. Recycle power with the function
button released.
Safety Switch Display message on LCD DCON Check wiring for circuit S56PRV (red wire) for
DECON P7R P7R SAFETY SWITCH FAULT damage resulting in shorts or opens. Repair
wiring or replace DCON.
Display message on LCD Check wiring for circuit P53LS (white/black
Safety Switch P9A P9A SAFETY SWITCH FAULT wire) for damage resulting in shorts or opens.
Repair wiring or replace TCON.
Fault Check Boom has violated the safety limits resulting in
the engine being shut off as a safety feature.
Display message on LCD Use aux to get the boom back into operational
Safety Switch P9B
P9B SAFETY SWITCH FAULT limits. Check P54ENG and P58LS between
SCON and TCON for damage. Check SCON
chart for possible fault conditions.
Safety Switch P10 Display message on LCD
Recycle power
P10 SAFETY SWITCH FAULT
Recycle power and check wiring on circuit
Display message on LCD
Safety Switch P11 S140ENL (orange/black) between SCON and
TCON. Check SCON chart for possible faults.
Safety Switch P12 Recycle power
Display message on LCD Recycle power
Safety Switch P14
Display message on LCD Recycle power

Safety Switch P18
Display message on LCD Re-level platform. Check for wiring damage on

Safety Switch P22 circuite P56PRV (red/white).

Safety Switch P22R Re-level platform. Repair or replace PCON.
P22R SAFETY SWITCH FAULT
Display message on LCD Recycle power and check wiring on circuit

Safety Switch P30 P30 SAFETY SWITCH FAULT S140ENL (orange/black) between SCON and
Part No. 106783 Z-135/70 5-3

CONTROL SYSTEM FAULT CODES REV B

Display message on LCD Recycle power and check wiring on circuit
Safety Switch P38 P38 SAFETY SWITCH FAULT S137PLL (red/white) between SCON and
Fault Check Recycle power and check wiring on circuit
Safety Switch P39 S139TRF (white/red) between SCON and
Fault Check Check for an overload in the platform. Check
Display message on LCD the overload switch mounted on the platform
Platform Overload (if active)
support.
Check footswitch wiring for damage or
Footswitch Timeout Display message on LCD remove blocking item on footswitch.
Range Check Engine is running below 50 RPM.

Engine Speed Display message on LCD
(underspeed) Check fuel system.
Range Check Oil pressure is low.

Oil Pressure (low oil Check sender and oil level.
pressure)
Range Check Engine is overheating. Check sender, water or

Water/Oil Temperature Display message on LCD oil level or radiator/heat exchanger.
(high temp)
Oil Pressure Sender

Display message on LCD Check wiring to senders for opens or shorts.
Fault Check
Oil Temp Sender Repair or replace senders.
Fault Check Axle extend/retract disabled. Check ribbon and connector from membrane
Axle Extend/Retract switch. If necessary replace membrane
(both buttons Display message on LCD
Buttons switch.
pressed)
Limited speed and direction Check for defective or damaged wiring.

Axle Valve Fault Check frozen at zero and neutral, alarm Check for an open or shorted valve coil.
sounds Repair or replace as necessary.
Check CAN bus wiring from TCON to DCON
Display message on LCD through rotator. Repair or replace wiring or
DCON CAN Bus Fault Check
Disable propel DCON.
Check CAN bus wiring from TCON to

CAN Bus Display message on LCD SCON/PCON. Repair or replace wiring or
Fault Check SCON/PCON.
Primary Boom
Extend Valve
Primary Boom
Retract Valve Limited speed and direction Check for defective or damaged wiring.
Fault Check frozen at zero and neutral, alarm Check for an open or shorted valve coil.
sounds Repair or replace as necessary.
Primary Boom
Up Valve
Primary Boom
Down Valve
5-4 Z-135/70 Part No. 106783


Normal function except threshold
Perform calibration
Not calibrated for one or the other direction is
procedure
zero. Display message on LCD
Just calibrated
Primary Boom
Limited Speed and Direction frozen Check for opens in the wiring or a
Up/Down Flow Valve Value Too High
at zero and neutral, Alarm sounds bad ground. Replace coil if
necessary
Check for opens in the wiring or a
Limited Speed and Direction frozen
Value Too Low bad ground. Replace coil if
at zero and neutral, Alarm sounds
necessary
Perform calibration
Not calibrated for one or the other direction is
procedure
Just calibrated
Primary Boom
Extend/Retract Flow Valve Limited Speed and Direction frozen Check for opens in the wiring or a
Value Too High bad ground. Replace coil if
necessary
Value Too Low Limited Speed and Direction frozen
bad ground. Replace coil if
necessary
Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit
Extend disabled, Alarm sounds going to the sensor
Value Too High Sensor is out of range. Check

Primary up, Secondary up/down and sensor and actuating pin for proper
Extend disabled, Alarm sounds installation. Repair or replace
Value Too Low
sensor and recalibrate.
Check for 5.0 VDC at the sensor.
Operational Primary Boom Primary up, Secondary up/down and Check for damaged wiring going to
Angle Sensor Value at 0 V Extend disabled, Alarm sounds the sensor. Check that the % .0
VDC LED is lit on the TCON board.
Repair or replace as necessary
Primary up, Secondary up/down and
Out of Tolerance Recalibrate sensor
Extend disabled, Alarm sounds
Not calibrated Primary up only active from TCON, Perform calibration procedure per
activate alarm service manual or Z135 training CD

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



Value Too Low
SafetyPrimary Boom Primary up, Secondary up/down and Check for damaged wiring going to

Value at 5.0 V Primary up, Secondary up/down and

Check for damaged wring to the
Value Too High joystick. Check the connections to
Secondary Boom Value Too Low ensure the connector terminals
Joystick have not backed out. Substitute a
Value at 0 V known good joystick. If necessary
Not calibrated Joystick speed and direction frozen
at zero and neutral
Just calibrated Initiate one second beep of audible Self-clearing

Secondary Boom Fault Check Secondary boom Check ribbon and connector from
Up/Extend/Down/Retract (both buttons Up/Ext/Down/Retract disabled membrane switch. If necessary
Switches on TCON pressed) Display message on LCD replace membrane switch.
Secondary Boom Not calibrated Display message on LCD See service manual on how to
Up/Down Speed and allow operation at default speed perform this procedure.
Normal function except threshold Perform calibration
Not calibrated for one or the other direction is procedure
Secondary Boom Initiate one second beep of audible Self-clearing

Just calibrated
Up/Down/Extend/Retract warning device (transient)
Flow Valve Check for opens in the wiring or a
Value Too High Limited Speed and Direction frozen
necessary
Value Too Low bad ground. Replace coil if
necessary
5-6 Z-135/70 Part No. 106783


Secondary Boom
Extend Valve
Secondary Boom
Retract Valve
Secondary Boom Limited Speed and Direction frozen Check for defective or damaged
Up Valve Fault check wiring. Check for an open or
Secondary Boom shorted valve coil. Repair or
Down Valve replace as necessary.
Secondary Boom
Extend Sequence Valve
Secondary Boom
Down Sequence Valve

Value Too Low
Operational Secondary Boom Primary up, Secondary up/down and Check for damaged wiring going to
Not calibrated Secondary up only active from Perform calibration procedure per
TCON, activate alarm service manual or Z135 training CD


Value Too Low
Safety Secondary Boom Primary up, Secondary up/down and Check for damaged wiring going to
Not calibrated Secondary up only active from Perform calibration procedure per
TCON, activate alarm service manual or Z135 training CD

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


Limited Speed and Direction frozen ensure the connector terminals
Value Too High
Turntable Rotate Joystick Value at 0 V


Fault check Check ribbon and connector from
Turntable rotate disabled
Turntable Rotate Buttons (both buttons membrane switch. If necessary
pressed) replace membrane switch
Display message on LCD and allow Calibrate turntable rotate speed in
Turntable Rotate Speed Not calibrated
operation at default speed accordance with service manual
Normal function except threshold for
Not calibrated one or the other direction is zero. Perform calibration procedure
Just calibrated
Turntable Rotate warning device (transient)
Flow Valve Check for opens in the wiring or a
Value Too High Limited Speed and Direction frozen
bad ground. Replace coil if
necessary
Check for shorts to ground in the
Value Too Low
wiring. Replace coil if necessary
Turntable Rotate
Clockwise Valve
Check for defective or damaged
Turntable Rotate Fault Check Limited speed and direction frozen wiring. Check for an open or
Counterclockwise Valve at zero and neutral, alarm sounds shorted valve coil. Repair or
replace as necessary.
Multifunction Valve
Value at 5.0 V Check that SCON is grounded
Value Too High
Flash unit out of level icon and LED
Operational Turntable Value Too Low and activate alarm Replace SCON
Level Sensor X Direction Value at 0 V
Out of Tolerance

Value Too High
Flash unit out of level icon and LED
Safety Turntable Value Too Low
and activate alarm Replace SCON
Level Sensor X Direction Value at 0 V
Out of Tolerance

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


Value Too High
Primary and secondary up disabled,
Operational Turntable Value Too Low Alarm sounds Replace SCON
Level Sensor Y Direction Value at 0 V
Out of Tolerance

Value Too High
Safety Turntable Value Too Low
Alarm sounds Replace SCON
Level Sensor Y Direction Value at 0 V
Out of Tolerance

warning device
Value Too High
Platform Level Value Too Low
Alarm sounds Replace SCON
Sensor Y Direction Value at 0 V

warning device
Platform Rotate
Clockwise Valve
Platform Rotate
Counterclockwise Valve
Jib Up Valve wiring. Check for an open or
Fault Check Fault Check shorted valve coil. Repair or
Jib Down Valve
replace as necessary.
Jib Level Up Valve
Jib Level Down Valve
Jib Extend Valve
Jib Retract Valve
for one or the other direction is Perform calibration
Not calibrated
zero. Display message on LCD procedure

Just calibrated
Jib
Up/Down Flow Valve Value Too High
necessary
Part No. 106783 Z-135/70 5-9


Not calibrated

Jib Level Just calibrated
Up/Down Flow Valve
Value Too High
necessary

Not calibrated

Platform Level Just calibrated
Up Flow Valve
Value Too High
necessary

Not calibrated

Platform Level Just calibrated
Down Flow Valve
Value Too High
necessary
Value Too Low wiring. Replace coil if necessary
Check ribbon and connector from

Fault Check Affected functions disabled.
Platform Rotate Switches membrane switch. If necessary
(both closed) Display message on LCD
replace membrane switch
Value at 5.0 V Check for damaged wring to the

Value Too High joystick. Check the connections to
Limited speed and direction frozen at ensure the connector terminals
Jib Up/Down Value Too Low zero and neutral, Alarm sounds have not backed out. Substitute a
Joystick Value at 0 V known good joystick. If necessary
Joystick speed and direction frozen replace and recalibrate joystick.
Not calibrated
at zero and neutral

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


Jib Extend/Retract Joystick Value at 0 V


Value at 5.0 V
Limited Speed and Direction frozen Power up controller with
Value Too High problem
Value Too Low corrected
Value at 0 V
Platform Rotate Joystick
Not calibrated Calibrate Joystick

Just calibrated

Value Too Low
Front Axle Primary up, Secondary up/down and Check for damaged wiring going to

Just calibrated
Part No. 106783 Z-135/70 5 - 11


Value Too Low
Rear Axle Primary up, Secondary up/down and Check for damaged wiring going to

Just calibrated

Propel Joystick Value at 0 V


Not calibrated Joystick Speed and Direction Calibrate Joystick

Propel Valves Forward
Propel Valves Reverse Just calibrated
Propel EDC Forward Value Too High bad ground. Replace coil if
Limited Speed and Direction frozen necessary
Propel EDC Reverse Value Too Low Check for shorts to ground in the
Motor Valve Speed

Fault Check Fault Check wire. Check for an open or
Brake Valve shorted valve coil. Repair or
replace as necessary
Auxiliary Propel Valve
5 - 12 Z-135/70 Part No. 106783


Left Front Steer Extend disabled, Alarm sounds installation. Repair or replace
Angle Sensor Value Too Low
Primary up, Secondary up/down and Check for damaged wiring going to
Value at 0 V Extend disabled, Alarm sounds the sensor. Check that the % .0

Right Front Steer Extend disabled, Alarm sounds installation. Repair or replace

Left Rear Steer Extend disabled, Alarm sounds installation. Repair or replace

Right Rear Steer Extend disabled, Alarm sounds installation. Repair or replace
LF Steer Valve
RF Steer Valve wire. Check for an open or
Fault Check shorted valve coil. Repair or
LR Steer Valve replace as necessary
RR Steer Valve
Part No. 106783 Z-135/70 5 - 13


Too much time has
elapsed from when
LSS1RO is released
If the fault occurs on extend,
and LSS1RS is
Secondary Boom retract boom until LSS1RO is
released on extend Inhibit Secondary Boom Extend if
Switch Timeout engaged and try again. Check
and LSS1RS is the fault occurs.
LSS1RS and LSS1RO for physical
engged and
damage and proper operation.
LSS1RO is
engaged. Or the
joystick was
engaged three times
in the interval.
Recycle power by using the
Either LSS1RS or TCON or PCON E-stop. This can
LSS1RO have be done up to three times in an
Secondary Boom Switches changed state attempt to clear the fault. After the
Intermittence Fault without a secondary Inhibit Secondary Boom Down third attempt recycling power will
(LSS1RS Fault) boom extend/retract until the fault is cleared. no longer clear the fault but the
command or they operator will have to use the menu
have changed state to lower the secondary from
when the secondary ground only. Once the secondary
boom is not fully stowed and the switch is repaired
raised. the fault is cleared.
Value at 5.0 V
Value Too High

Jib Angle Sensor Operational Limited Speed and Direction frozen Power up controller with problem
(RSJ1AO) Value Too Low at zero and neutral, Alarm sounds corrected
Value at 0 V
Display X direction and Y direction Re-power after entering tilt x axis

SCON Tilt Sensor Calibration check and y axis matrix information
not calibrated
LSS1RO did not

switch within a Use laptop to clear intermittence
LSS1RO Fault Inhibit secondary boom extend and fault. Check LSS1RO for proper
specified time after
sound an audible warning operation and physical damage
the secondary
boom was raised
5 - 14 Z-135/70 Part No. 106783

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

SCON Fault Matrix REV A
P_9B - Ignition/Fuel
P_30 - Secondary
Turntable Rotate
P_11 - Primary/
P_10 - Primary
Secondary Up
P_38 - Propel
Boom Extend
Extend/Down
X = circuit power is turned off
P_39 -
Turntable tilt Y axis (+5°, secondary boom not stowed) X X X X
Primary Boom angle (crosscheck) X X X X X
Secondary Boom angle (crosscheck) X X X X
Secondary Boom safety (not retracted and not raised) X X X
Axle safety not stowed (not faulted primary and

secondary stowed)
X X X X
Axle crosscheck angle sensor versus safety switch X X X X
Axle(not fully extended) and Turntable rotate (stowed and in

drive disable zone)
X X
Axle safety stowed (not faulted) X
Turntable tilt angle (crosscheck SCON internal sensors 3 in a

delta configuration)
X X X X X
Primary Boom safety (max angle) X X X X X
Boom not stowed (not faulted)
Loss of CAN X X X X X X
LSS1RS disconnected (SCON pin #2) X X
Platform Overload (SCON pin #1) X
Secondary Boom length

(crosscheck LSS1RS and LSS1RO)
X X X
5 - 16 Z-135/70 Part No. 106783

July 2011 Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: could result in death or serious
Troubleshooting and repair procedures shall be and other jewelry.
completed by a person trained and qualified on
the repair of this machine. Hydraulic Schematics
Immediately tag and remove from service a Bodily injury hazard. Spraying
damaged or malfunctioning machine. hydraulic oil can penetrate and
Repair any machine damage or malfunction connections very slowly to allow
before operating the machine. the oil pressure to dissipate
Before Troubleshooting: or spray.
Read, understand and obey the safety rules General Repair Process
and operating instructions printed in the
Genie Z-135/70 Operator's Manual on your
machine.
Be sure that all necessary tools and test
Malfunction Identify Troubleshoot
equipment are available and ready for use. discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 106783 Z-135/70 6-1

Section 6 • Schematics July 2011
Wire Circuit Legend

REV C
Circuit numbering Circuit prefix

1 Circuit numbers consist of three parts: the C .... Control
circuit prefix, circuit number and circuit suffix.
D .... Data
The circuit prefix indicates the type of circuit.
The circuit number describes the function of the E .... Engine
circuit. The circuit suffix provides an
G ... Gauges
abbreviation for the number or may be used to
further define the function of this portion of the N .... Neutral
circuit. It also may be used to indicate the final P .... Power
end of the circuit, i.e., LS or limit sw.
R .... Relay Output
2 The circuit number may be used more than
once in a circuit. S .... Safety
V .... Valve
For Example:
C 74 PL – This is the circuit for the lockout

Circuit suffix
valve #1. C stands for control, 74 is the number of Definition suffix
the circuit for the primary #1 lock out valve. AC Generator GEN
PL stands for Primary Lockout. Alternator Field AF
Angle ANG
S 62 BST – This is the circuit that communicates
Auxiliary Boom Valve ABV
to the onboard computers of the machine that the
Auxiliary Forward Valve AFV
boom is fully stowed. S stands for safety, 62 is the
Auxiliary Hydraulic Pump AH
number of the circuit for boom stowed and BST
Auxiliary Platform Valve APV
stands for Boom Stowed.
Auxiliary Reverse Valve ARV
P 48 LP – P stands for power. 48 is the circuit Auxiliary Steer/Drive Valve ASV
number for work lamps and LP stands for Lamp. Axle Extend Valve AXE
Axle Oscillate AXO
R 48 LP – R stands for relay. In this case it is the Axle Retract Valve AXR
wire that feeds the relay coil for the work lamp. All Axle Front Position FAP
other numbers remain the same. Axle Rear Position RAP
Battery BAT
V61AXR – V stands for valve power. Number 61
Boom Extended BEX
stands for axle retracted circuit; AXR stands for
Boom Stowed BST
Axle retracted.
Brake BRK
R46HN – R stands for Relay output, supplying Bypass Valves BV
power to the horn (HN). Number 46 is the circuit Calibrate CAL
number for the horn. CAN Signal CAN
CAN Shield SHD
CATS Module CAT
Chain Break CNK
Data High DTH
Data Low DTL
Drive Chassis Controller DCN
6-2 Z-135/70 Part No. 106783

REV C WIRE CIRCUIT LEGEND
Drive Enable DE Low RPM LS

Drive Enable Left DEL Low fuel LOF
Drive Enable Right DER Motor Shift (Speed) MS
Electrical Displacement Control EDC Multi Function Valve MFV
Envelope Light ENV Platform Control PCN
Engine Speed Select ESP Primary Ext/Ret Lockout PEL
Engine Status Lamp ESL Platform Level Down PLD
Envelope Lockout ENL Platform Level Flow Control PLF
Extend/Retract Lockout ERL Platform Level Up PLU
Filter Restricted FLR Platform Rotate Flow Control PRF
Filter Switch FLT Platform Rotate Control PRC
Flashing Beacon FB Platform Rotate Left (CCW) PRL
Float Switch FS Platform Rotate Right (CW) PRR
Foot switch Signal FTS Platform Tilt Alarm PTA
Forward FWD Platform Tilt Sensor PTS
Fuel Pump FP Power PWR
Fuel Select (gas/LP) FL Power to Length Sensor PSL
Fuel Solenoid FSL Pressure Comp Enable PCE
Function Enable FE Pressure Sender PSR
Ground Control TCN Pressure Switches PS
Ground GND Primary Boom Angle Sensor PBS
Horn HRN Primary Boom Down PBD
High RPM HS Primary Boom Extend/Retract Lockout Valve PBL
Hydraulic Generator HG Primary Boom Extend PBE
Ignition IGN Primary Boom Extend/Retract Flow Control PER
Jib Bellcrank Down JBD Primary Boom Retract PBR
Jib Bellcrank Up JBU Primary Boom Up PBU
Jib Sensor JBS Primary Boom Up/Down Flow Control PUD
Jib Up/Down Control JUD Primary Boom Extend/Retract Signal PLS
Jib Down JD Primary Boom Up/Down Signal PES
Jib Up/Down Flow Control JFC Primary Lockout PL
Jib Select Valve JSV Propel Signal JPL
Jib Up JU Program Setup Enable PSE
Jib Extend/Retract Control JER Propel Lockout PLL
Jib Extend JBE Proportional Valve PRV
Jib Retract JBR Proximity Sensor PXS
Jib Rotate Left (CCW) JRL Receptacle REC
Jib Rotate Right (CW) JRR Recovery RCV
Joystick 5V DC Power JPW Retract Lockout RL
Lamps LPS Return RET
Left Front LF Reverse REV
Left Front Steer Sensor LFS Right Front RF
Left Rear LR Right Front Steer Sensor RFS
Left Rear Steer Sensor LRS Right Rear RR
Limit Switch LS Right Rear Steer Sensor RRS
Lift Speed Reduction LSR RPM RPM
Load Sensor LDS
Lockout LO
Part No. 106783 Z-135/70 6-3

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

Wire Coloring Color, Circuit #, and Primary function

RD 1 Primary boom up driver
1 All cylinder extension colors are solid and all RD/BK 2 Primary boom down driver
retract functions are striped black. When using
RD/WH 3 Primary boom up/down flow control
black wire, the stripe shall be white. proportional valve driver
2 All rotations that are LEFT or CW are solid, WH 4 Turntable rotate left valve driver
RIGHT or CCW are striped and black. When the
WH/BK 5 Turntable rotate right valve driver
wire is black, the stripe is white.
WH/RD 6 Turntable rotate flow control
3 All proportional valve wiring is striped. proportional valve driver
BK 7 Primary boom extend

Wire Color Legend BK/WH 8 Primary boom retract
BL Blue BK/RD 9 Primary boom Extend/Retract

proportional valve driver
BL/BK Blue/Black
BL/RD Blue/Red BL 10 Secondary boom up valve driver
BL/WH Blue/White BL/BK 11 Secondary boom down valve driver
BK Black
BL/WH 12 Secondary boom up/down
BK/RD Black/Red flow control proportional valve driver
BK/WH Black/White
BL/RD 13 Drive enable
BK/YL Black/Yellow
BR Brown OR 14 Platform level up valve
GR Green OR/BK 15 Platform level down valve
GR/BK Green/Black
GR/WH Green/White OR/RD 16 Platform up/down flow control
RD Red proportional valve driver
RD/BK Red/Black GR 17 Platform rotate left valve driver
RD/WH Red/White
OR Orange GR/BK 18 Platform rotate right valve driver
OR/BK Orange/Black GR/WH 19 Jib select valve driver circuit
OR/RD Orange/Red RD 20 12V DC battery supply
WH White
WH/BK White/Black WH 21 12V DC ignition supply
WH/RD White/Red BK 22 Key switch power to platform
WH 23 Power to platform
RD 24 Power to warning senders
WH/BK 25 Power to oil pressure sender
WH/RD 26 Power to temp sender

Power Circuits
RD 27 Auxiliary Power
P10 .... Primary boom extend valve RD/BK 28 Platform level alarm
P11 .... Primary boom up valve RD/WH 29 Drive Motor shift (speed)
P30 .... Secondary boom down and extend valves WH 30 Forward/EDC-A
P38 .... Propel (drive) valves WH/BK 31 Reverse/EDC-B
P39 .... Turntable rotate flow control valve WH/RD 32 Brake
Part No. 106783 Z-135/70 6-5

BK 33 Start BL 67 Secondary boom not stowed
BK/WH 34 Start Aid (glow plug or choke) RD 68 Primary Boom lowered

(operational)
BK/RD 35 High Engine speed select
BL 69 Primary boom #1 extended
BL 36 Steer clockwise
BL/WH 70 Primary boom #2 retracted
BL/BK 37 Steer counterclockwise
BL/BK 71 Primary boom #2 extended
BL/WH 38 Gasoline
BL/WH 72 Secondary boom extended
BL/RD 39 LPG
BL/RD 73 Secondary boom retracted
OR 40 Limit switch signal stowed
RD 74 Primary #1 Lockout
OR/BK 41 RPM signal
RD/WH 75 Primary #2 Lockout
OR/RD 42 Boom retracted signal
BL 76 Primary boom #3 extended
GR 43 Jib Up
WH 77 Lower Angle #1 operational
GR/BK 44 Jib Down
WH/BK 78 Upper Angle #2 operational
GR/WH 45 AC Generator
BK 79 Power from TCON ESTOP
WH 46 Horn
N/A 80 Can 2.0/J1939 Shield
WH/BK 47 Output Power Enable
GR 81 Can 2.0/J1939 Low
WH/RD 48 Work Lamp
YL 82 Can 2.0/J1939 High
WH/BK 49 Motion Lamp
GR/WH 83 Tilt signal X axis
BL 50 Auxiliary Boom
GR/BK 84 Tilt signal Y axis
BL/WH 51 Auxiliary Steer
GR 85 Tilt sensor power
BL/RD 52 Auxiliary Platform
OR 86 Hydraulic Filter restricted
WH/BK 53 Boom envelope safety valve cutoff
RD 87 Platform Level Safety Power
BK/WH 54 Power to safety interlock switches
(engine) RD/BK 88 Platform Level Safety Output
GR/BK 55 Axle oscillation BR 89 Platform Level Safety Ground
RD 56 Foot switch/TCON estop power RD/BK 90 Proximity Kill
RD/WH 57 Boom down safety interlock RD/WH 91 Gate Interlock
RD/BK 58 Safety interlock to engine WH/BK 92 Motor Speed (LO/HI)
GR/WH 59 Chain break circuit WH/RD 93 Motor Bypass
GR/WH 60 Axle extend WH 94 Load Sensor
GR 61 Axle retract OR 95 Tether ESTOP return
OR 62 Boom stowed (safety) RD 96 Tether Power
OR/RD 63 Power to boom envelope BK 97 Tether ESTOP Power

safety switch
WH 98 J1708 + (high)
OR/BK 64 Power for operational switches
BK 99 J1708- (low)
BL/WH 65 Low fuel indication
WH/RD 100 Outrigger lowered
BL 66 Drive Enable
WH/BK 101 Outrigger raised
6-6 Z-135/70 Part No. 106783

OR 102 Pothole protector up GR/BK 134 Key Switch power
OR/RD 103 Pothole protector down BL/WH 135 Fuel Pump
BK/WH 104 Proprietary Data buss - RD 136 Power to Safety Module

(I.e. ITT or AP)
RD/WH 137 Drive Power (P_38)
BK/RD 105 Proprietary Data buss +
(I.e. ITT or AP) RD/BK 138 Primary Boom Up/Secondary
Boom Down-Extend (P_11/30)
GR 106 Spare
WH/RD 139 Turntable Rotate Flow Control
RD 107 Alternator Field Safety (P_39)
BL/WH 108 Engine Status OR/RD 140 Boom Envelope Safety
GR/WH 109 Sensor Power RD 141 Primary Boom Angle

Signal Safety
BK 110 Sensor Return
OR 142 Secondary Boom Angle
OR 111 Steer Signal Signal Safety
RD 112 Steer Signal to Solenoid Valve BL/RD 143 Drive Enable Left
OR/RD 113 Multi-function Valve BL/WH 144 Drive Enable Right
BK/RD 114 Load Moment Overweight RD/WH 145 Calibrate
RD/BK 115 Load Moment Underweight BL 146 Jib Bellcrank Up Flow Control
OR 116 Hydraulic Oil Cooler BL/BK 147 Jib Bellcrank Down Flow Control
RD 117 Flashing Beacon BL/WH 148 Jib Bellcrank Sensor
OR 118 Lift Speed Reduction GR/WH 149 Jib Up/Down Flow Control
BL 119 Hydraulic Pressure Sensor Output GR/BK 150 Hydraulic Generator Bypass
OR 120 Oil Cooler Fan GR 151 Hydraulic EDC Output
GR 121 Axle Oscillate Left BK 152 Injector Retard
GR/BK 122 Axle Oscillate Right BK 153 Jib Extend
RD/BK 123 Primary Boom Angle BK/WH 154 Jib Retract
Signal Operational
OR/RD 155 Pressure Comp. Enable
RD/WH 124 Secondary Boom Angle
Signal Operational GN/WH 156 Jib Up/Down
WH/RD 125 Secondary Boom Lockout BK/RD 157 Jib Extend/Retract

(Extend Enable)
BL/RD 158 Steer Signal Rocker
WH/BK 126 Secondary Boom Lockout
(Riser Down Enable) BL/WH 159 Steer Joystick Signal
GR 127 ECU Test Switch WH/RD 160 Propel Joystick Signal
OR/RD 128 Low Engine Speed WH/BK 161 Secondary Boom Joystick Signal
RD/BK 129 Descent Alarm OR 162 Joystick 5V DC power
WH/RD 130 Travel Alarm BL/WH 163 Primary Extend/Retract Signal
BL 131 Motion Alarm RD/WH 164 Primary Up/Down Signal
GR 132 Platform Load Input WH/RD 165 TT Rotate Signal
GR/WH 133 Platform Load Alarm OR 166 Boom Length Signal Safety
Part No. 106783 Z-135/70 6-7

OR/BK 167 Boom Length Signal Operational
BL/RD 168 Primary Boom Hydraulic Valve Lockout
GN 169 Envelope Active LED
WH/RD 170 Load Sense Relay Source
WH/BK 171 Load Sense Relay Sink
BL 172 UP/DN Flow Control Ground
BK 173 Ext/Ret Flow Control Ground
WH 174 Key Switch Power, Ground Position
WH/BK 175 Load Sensor Signal Operational
GN/WH 176 Secondary Extend/Retract FC
BL/RD 177 Extend/Retract Lockout
BK 178 Control Module Status Light
GN 179 Drive Power Relay
BK 180 Lift Power Relay
OR 181 48 Volt Alternator field (or Battery)
RD 182 24 Volt Battery
BL 183 Envelope or Load Sense Recovery
WH 184 Program setup Enable
WH 185 Encode A
BL 186 Encode B
BL 187 Bootstrap or Program Enable
GR 188 Safety cross check
BK 189 Data Receive
BK/WH 190 Data Transmit
WH/RD 191 Multi-Function Pressure Relief
WH/BK 192 Jib Rotate Left
WH/RD 193 Jib Rotate Right
WH/RD 194 Speed Select Input
OR/RD 195 Electric Brake Source
YL 196 2.5V Sensor Power
WH 197 Hour Meter
RD 198 +12V Sensor Power
WH/RD 199 Thermal Switch
BR N/A Ground or Return
6-8 Z-135/70 Part No. 106783

Limit Switches and Angle Sensors

REV C
Types of Limit Switches Limit Switch and Sensor

There are two types of limit switches, found in Numbering
various locations throughout the machine: LSP1RO Primary boom length retracted
mechanical-type operational/safety switches and LSP1EO Primary boom length fully extended
rotation or angle sensors. As in aircraft, which LSS1RO Secondary boom fully retracted
features redundant safety systems, each LSS1RS Secondary boom fully retracted,
mechanical operational switch is backed up with a safety
separate, independently functioning safety switch. LSJ1RO Jib boom length fully retracted
The mechanical-type operational or safety LST1O Drive enable, left direction
switches are used to sense a positive displacement LST2O Drive enable, right direction
or movement of the limit switch actuator, or arm, as LST1S Drive enable safety, retracted axles
the machine moves through its range of operational LSFA1ES Front axle fully retracted
functions. The rotation or angle sensors utilize LSRA1ES Rear axle fully retracted
Hall Effect technology and must be calibrated when RSP1AO Primary boom angle sensor
replaced. Included in this group are envelope limit RSP1AS Primary boom angle sensor, safety
switches which sense the extended length and RSJ1AO Jib boom angle sensor
angle of the booms and rotational position of the RSS1AO Secondary boom angle sensor
turntable. RSS1AS Secondary boom angle sensor,
safety
For example, when the secondary boom is fully RSFA1O Front axle postioning sensor
raised and the operational sensor is activated, it RSRA1O Rear axle positioning sensor
tells the ECM at the ground controls to start RSLF1SO Left front wheel positioning sensor
extending the secondary boom. RSRF1SO Right front wheel positioning sensor
RSLR1SO Left rear wheel positioning sensor
Another example is the drive enable limit switch, RSRR1SO Right rear wheel positioning sensor
which disables the drive function anytime the boom
is rotated past the rear tires, indicated by the 'circle'
end of the drive chassis. Numbering Legend
In some cases, the engine will be stopped if safety Circuit number
parameters are exceeded. AX Axle
D Down
A Angle
B Boom L Load moment
T Turntable E Extend
RSP1AO O Operational
RSP1AS LS Limit switch R Retract
LSP1RO S Safety
1
LSS1RO
RSS1AO
LSP1EO LS AX 1 R O
PRIMARY BOOM 2
4 3
SECONDARY 2 1
1
BOOM GROUND
CONTROL RSJ1AO
BOX
SAFETY RSS1AS JIB
CONTROLLER PLATFORM
LSJ1RO CONTROL
(SCON) LSS1RS BOX
2
RSFA1SO LST10
LST20 LST1S
RSLF1SO LSFA1ES
RSLR1SO
RSRA1SO
RSRF1SO RSRR1SO
LSRA1ES
DRIVE CHASSIS PLATFORM
ANGLE
CONTROLLER SENSOR
(DCON)
Part No. 106783 Z-135/70 6-9

LIMIT SWITCHES AND ANGLE SENSORS REV C

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

Drive Chassis and Platform Controller Pin Legend

REV B
J22
WHITE
35 PIN
CONNECTOR
J21
BLACK
23 PIN
CONNECTOR
PCON
PLATFORM
CONTROLLER
J22 J31
1 = VLVRET1 - BR BLACK
23 PIN
2 = V153JBE - BK CONNECTOR
3 = V18PRR - GR/BK J32
WHITE
4 = V17PRL - GR 23 PIN
5 = V43JU - GR CONNECTOR
6 = V44JD - GR/BK
7 = V14PLU - OR
8 = V15PLD - OR/BK
PCON 9 = V154JBR - BK/WH

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

Safety Controller Pin Legend

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

Turntable Controller Pin Legend

REV B
STOP
24
1
J14
WHITE
29
6
1 4 8 35 PIN
CONNECTOR
12
35
16 19 23 00000
J13
16
1
WHITE
19
4
PIN NUMBERING FOR 23 PIN
23 PIN CONNECTOR
23
8
CONNECTORS
J15
4
3
4 PIN
1
CONNECTOR
24
1
1 6 12
J12
BLACK
29
6
24 29 35 35 PIN
CONNECTOR
12
35
PIN NUMBERING FOR

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

Engine Relay and Fuse Panel Legend

REV B
Deutz BF4L 2011

5 6 7 8
B1PBAT
Deutz TD2011L04i
CB10 F23 LABEL DESCRIPTION
CR28 CR17 CR1 START RELAY
F22 F7 CR5 HORN RELAY

B3PBAT
1 2 3 4 CR15 GLOW PLUG RELAY
CR17 HYDRAULIC OIL COOLER FAN RELAY
R21PIGN
CR28 ENGINE / FUEL RELAY
CR41 FLASHING BEACON RELAY
CR41 CR5 CR1 CR15 F7 FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN
CB10 CIRCUIT BREAKER, 20A, RPM SOLENOID
02PGND F22 FUSE, 60A, GLOW PLUG
F23 FUSE, 30A, ENG/STR/ALT
Perkins 1104C-44
5
CB10
6 7
F23
8
B1PBAT
Perkins 804D-33T
LABEL DESCRIPTION
B3PBAT
1 2 3 4
CR15 GLOW PLUG RELAY
CR17 HYDRAULIC OIL COOLER FAN RELAY
R21PIGN CR28 ENGINE / FUEL RELAY
CR41 FLASHING BEACON RELAY
CR41 CR5 CR1 CR15 F7 FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN
CB10 CIRCUIT BREAKER, 20A, RPM SOLENOID
02PGND F22 FUSE, 60A, GLOW PLUG
F23 FUSE, 30A, ENG/STR/ALT
Cummins B4.5L
5 6 7 8
Cummins B3.3T
B1PBAT
CB10 F23 LABEL DESCRIPTION
B3PBAT
1 2 3 4 CR17 HYDRAULIC OIL COOLER FAN RELAY
CR28 ENGINE RUN/ALT RELAY
R21PIGN CR41 FLASHING BEACON RELAY
F7 FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN
CR41 CR5 CR1 CB10 CIRCUIT BREAKER, 20A, RPM SOLENOID
F22 FUSE, 60A, GLOW PLUG
02PGND F23 FUSE, 30A, ENG/STR/ALT
6 - 14 Z-135/70 Part No. 106783

Electrical Symbols Legend

REV A
CB1 FS1
BLK
OPS1 BLK
15A PR1 N.C.
WHT Circuit breaker Foot switch

Quick disconnect with amperage Oil pressure switch
Power relay normally closed
terminal
P1
H1
T-circuits
connect Emergency Stop
Horn or alarm button normally
closed
Toggle switch Sending unit
FB
Connection FAN
no terminal CR4
A B C
Flashing beacon N.O.
PULL IN
HOLD
Hydraulic oil
Control relay contact cooling fan
G1
Circuits crossing normally open
no connection Fuel or RPM
solenoid
Gauge OTS2
Aux
N.O. Pump
HM Oil temperature
Diode switch Auxiliary pump
normally open Coil
Hour meter
+
CTS1 KS2
RUN
SERVICE BYPASS/
N.O. RECOVERY
KEY SWITCH
SERVICE BYPASS
1 2
A-A
RECOVERY
-
L3 Coolant temperature
3 4
A-B
switch 3
B-B
Tilt sensor
Battery
4
normally open
LED 3 4
C-B
2 1
86 30
F1 1 2
C-A
87a
85 87
A B C B-A 5 4
25A 1 2
RD
BK
BL
Fuse Relay
with amperage Service bypass/
Starting aid: recovery
glow plug or key switch
flame ignitor
Steer sensor
OFF
KS1
STARTER
MAIN
PCON A-A
1
KEYSWITCH
2
D1
TCON Power relay
ALTERNATOR
Starter motor 3 4
A-B
Chassis ground EXCT
B-A
BAT BAT 1 2
+ -
AUX MAIN
B-B
STA. 3 4
LS3
REGULATOR
N.O.H.C N.C.H.O
IND.
Current limiting
Battery separator Limit switch ALTERNATOR Main key switch device
Part No. 106783 Z-135/70 6 - 15

Hydraulic Symbols Legend

REV A
25 psi
Solenoid operated 2 position,

Motor 3 way, directional valve
2-speed,
Filter with Pressure reducing valve
bi-directional
bypass valve
3000 psi
relief setting (206.8 bar)
3:1
Pilot operated 3 position,

3 way, shuttle valve
Pump stroke piston Counterbalance valve

Pump with pressure and pilot ratio
fixed displacement
50% 50%
E
Pump prime mover Flow divider/combiner valve
(engine or motor) with pressure balancing orifice
and flow percentages
Pump
variable displacement Directional valve
pilot operated
2 position, 2 way
Double acting
cylinder
Differential
sensing valve
.035"
Motor Orifice with size
Solenoid operated 3 position,
4 way, directional valve
Solenoid operated
Shut off valve proportional valve
Pump 2 position, 3 way, shuttle valve

bi-directional,
variable displacement
Pilot operated
check valve
Flow regulator valve
Check valve Hydraulic oil cooler

200 psi
Motor
bi-directional
Relief valve 2 position, 2 way

with pressure setting solenoid valve Brake
6 - 16 Z-135/70 Part No. 106783

Electrical Connector and Circuit Legend
6 - 17 6 - 18
Electrical Connector and Circuit Legend REV A
A B C D E F G H I J K L M N
Conn No. Description Conn No. Description Conn No. Description Conn No. Description
1 J9 Ribbon connector from TCON to membrane #1 2 pin Deutsch connector for 6 pin Deutsch connector for primary boom J165 12 pin Deutsch connector located at PCON
J91 J127
J10 Ribbon connector from TCON to membrane #2 right rear steer right valve up/down, ext/ret and turntable joystick 6 pin Deutsch connector for jib
J166 bellcrank sensor
J11 Black 23 pin AMP connector on TCON 2 pin Deutsch connector for 6 pin Deutsch connector for jib boom
J92 J128
J12 Black 35 pin AMP connector on TCON right rear steer left valve up/down, ext/ret and platform rotate 1 way 0.25 inch slide terminal for belt
J168 generator excite
J13 White 23 pin AMP connector on TCON 2 pin Deutsch connector for 2 pin Deutsch connector for boom
J93 J129
J14 White 35 pin AMP connector on TCON left rear steer right valve composite/lower limit switch harness 20 pin Molex connector for circuit board
2 J169 to joystick and switches #2
J15 Black 4 pin DTP connector on PCON 2 pin Deutsch connector for 2 pin Deutsch connector for jib boom
J94 J135
J17 16 pin Molex mini fit circuit board to key switch left rear steer left valve bellcrank up J175 2 pin Deutsch connector
J20 12 pin Deutsch connector lower/upper limit switch harness 2 pin Deutsch connector for 2 pin Deutsch connector for jib boom
J95 J136
J21 Black 23 pin AMP connector on PCON right front steer right valve bellcrank down
J22 White 35 pin AMP connector on PCON 2 pin Deutsch connector for 2 pin Deutsch connector for front axle
J96 J137
3 J23 10 pin ribbon connector PCON to membrane driver board right front steer left valve safety switch
J24A 10 pin ribbon conn. mem driver board to membrane switch 2 pin Deutsch connector for 2 pin Deutsch connector for rear axle
J97 J138
J24B 10 pin ribbon conn. mem driver board to membrane switch left front steer right valve safety switch
J25 6 pin Deutsch connector on drive/steer joystick 2 pin Deutsch connector for J140 2 pin Deutsch connector for jib extend
J98
6 pin Deutsch connector on secondary boom up/extend left front steer left valve J141 2 pin Deutsch connector for jib retract
J28
and down/retract joystick 2 pin Deutsch connector for 2 way Deutsch connector for lower limit
4 J99 J146
J29 16 pin Molex mini fit circuit board to joystick and switches axle extend valve switch harness/engine harness
J31 Black 23 pin AMP connector on DCON 2 pin Deutsch connector for 1 way Deutsch connector for platform
J100 J147
J32 White 23 pin AMP connector on DCON axle retract valve power jib/primary
J46 4 pin Deutsch connector on LSS1RS 2 pin Deutsch connector for 1 way Deutsch connector for platform
J106 J148
J49 4 pin Deutsch connector on sec boom retract (LSS1RO) brake release valve ground jib/primary
J55 6 pin Deutsch connector on platform tilt sensor 3 pin Deutsch connector for J149 2 pin Deutsch connector, boom composite
5 J107
J57 3 pin Deutsch connector on RPM solenoid right rear steer sensor J150 4 pin Deutsch connector, boom composite
J58 2 pin Deutsch connector for pri boom up/down flow control 3 pin Deutsch connector for 3 pin Deutsch connector, CAN connector,
J108
J59 2 pin Deutsch connector for primary boom up valve left rear steer sensor J151
jib/primary
J60 2 pin Deutsch connector for primary boom down valve 3 pin Deutsch connector for J152 3 pin SAE Deutsch tee
J109
2 pin Deutsch connector for primary boom ext/ret right front steer sensor
J61 2 pin Deutsch connector for engine and
flow control valve 3 pin Deutsch connector for J153
6 J110 manifold harness
J62 2 pin Deutsch connector for primary boom extend valve left front steer sensor
6 pin Deutsch connector for secondary
J63 2 pin Deutsch connector for primary boom retract valve 6 pin Deutsch connector for J154
J114 boom angle sensor
J65 2 pin Deutsch connector for secondary boom extend valve primary boom angle sensor (PBAS)
2 pin Deutsch connector for PCON
J66 2 pin Deutsch connector for secondary boom retract valve 2 pin Deutsch connector for J157
J119 manifold/boom composite harness
J67 2 pin Deutsch connector for secondary boom up valve jib not retracted
4 pin Deutsch connector for front
7 J68 2 pin Deutsch connector for secondary boom down valve J120 4 pin Weatherpack EDC connection J160
axle angle sensor
J69 2 pin Deutsch connector for turntable rotate flow control J121 12 pin Deutsch gray SCON connector
4 pin Deutsch connector for rear
J70 2 pin Deutsch connector for turntable rotate CW valve J122 12 pin Deutsch black SCON connector J161
axle angle sensor
J71 2 pin Deutsch connector for turntable rotate CCW valve 2 pin Deutsch connector for
J124 3 pin Deutsch connector for jib
J78 2 pin Deutsch connector for jib boom up valve drive enable right limit switch (LST1O) J162
bellcrank angle sensor
J79 2 pin Deutsch connector for jib boom down valve 2 pin Deutsch connector for
8 J125 2 pin Deutsch connector for secondary
J82 2 pin Deutsch connector for prox kill drive enable left limit switch (LST2O) J163
boom up/down flow control
J84 2 pin Deutsch connector for platform footswitch 4 pin Deutsch connector for drive
J126 2 pin Deutsch connector for secondary
J87 2 pin Deutsch connector for two-speed motor stroke valve enable safety limit switch (LST1S) J164
boom extend/retract flow control
6 - 18 Z-135/70 Part No. 106783

Electrical Schematic
Perkins 1104C-44 Engine and Perkins 804D-33T Engine
6 - 19 6 - 20
N
REV B
Continued on View 12
WATER TEMP
C26TSR-WT/RD
SENDER
OIL PRESSURE
C25PSR-WT/BK
SENDER
M
J56
R21IGN-WH FUEL SOLENOID

HOLD
HEAD TEMPERATURE
ENGINE CYLINDER
Continued on View 5
SW28
L
COLD START
R21IGN-WH BAT GND-BR
ENGINE FUEL
ADVANCE
RELAY
CR28
PUMP
FUEL
R21IGN-WH BAT GND-BR FUEL LIFT PUMP

87a
2
87
30
86
85
BAT GND-BR CR2 RELAY

K
R21IGN-WH
FAN
HYDRAULIC OIL
R116HYD-OR COOLER FAN
87a
BAT GND-BR
30
B3BAT/14-RD
87
COOLER RELAY
HYDRAULIC OIL
C21IGN-WH C116HYD-OR BAT GND-BR TEMPERATURE
SWITCH
86
85
OTS1
N.O.
COOLER
RELAY
CR17
OIL
GLOW PLUG
J
J32-ENG HARN
C45GEN-GR/WH
GLOW PLUG
B2BAT-RD
GND-BR
R34SA-BK/WH
GLOW PLUG
R21IGN-WH
RELAY
GLOW
PLUG
CR15
C26TSR-WH/RD
C25PSR-WH/BK
C21IGN-WH
B1ENG-RD
87a
GLOW PLUG
30
87
I
TO AUXILIARY HYDRAULIC POWER UNIT
GLOW PLUG
RELAY
C34SA-BK/WH VLVRET-BR
86
85
J120
BATTERYPNEG TERM (B2)
C31EDC-WH/BK
C
DUAL COIL EDC

B
GND04-BR
A
C30EDC-WH
GND04-BR
P1-23
B1ENG-RD
H
P1-22 C45GEN-GR/WH
4
P1-21
BATGND(A) BK
P34SA/10-BK/WH
PULL IN
P1-20
RPM SOLENOID
B3BAT/14-RD
WH-PULL IN WH
2
HOLD
P1-19 S139TRF-WH/RD
RD-HOLD RD
1
P1-18 C41RPM-OR/BK
J57
P1-17 S137PLL-RD/WH
P1-16
RELAY
HORN
CR5
P1-15
G
HORN
H1
86
85
P1-14
VLVRET2-BR
B1ENG-RD
C26TSR-WH/RD
87
P1-13
R46HRN-WH
30
P1-12 C25PSR-WH/BK B3BAT/14-RD

HORN RELAY
87a
P1-11 C31EDC-WH/BK BAT GND-BR
P1-10 C30EDC-WH C41RPM-OR/BK
P1-09 C33STR-BK C107AF-RD
WH-PULL IN
BATGND(A)
P1-08
RD-HOLD
EXCT.
IND.
STA.
BAT.
P1-07 C46HRN-WH
-
F
ALTERNATOR
P1-06
REGULATOR
ALTERNATOR
P1-05
July 2011
Part No. 106783

P1-04 C34SA-BK/WH
ENGINE HARNESS
P1-03 C21IGN-WH
+
BAT.
B
C
P1-02 C35RPM-BK/RD
P34SA/10-BK/WH
B3BAT/14-RD
P1-01
TROMBETTA
TIME DELAY
S-500
MOM N.O.
C27AUX-RD TO J4-32PWHITE 35 PIN
ENGINE HARNESS
J13 WHITE 23 PIN
E
PR1
GND-
BAT+
B1ENG-RD
AUX+
PUMP
AUX.
AUXILIARY
HYDRAULIC
C35RPM-BK/RD PUMP
PR1
S139TRF-WH/RD
S137PLL-RD/WH
PUMP
AUX.
F22 GLOW PLUG
F23 ENG/ST/ALT
Perkins 1104C-44 Engine and Perkins 804D-33T Engine
OIL COOLER
F20 RPM
BAT GND-BR
F7
86
85
C33STR-BK
D
87
TOGGLE
SWITCH
R33STR-BK STARTER RELAY
30
WORK
P1-04
LAMP
B1ENG-RD B1ENG-RD
10A
F7
P1-03 GND-BR
STARTER
STARTER
P1-02 GND-BR
20A
F23
LAMPS
WORK
RELAY
CR1
P1-01 B2BAT-RD ENGINE BLOCK
GROUND
P35RPM-BK/RD
12-3 CABLE
POWER HARNESS
J15 BLACK 4 PIN
20A
F20
BATTERY CABLE
INTEGRAL WITH
HARNESS
-
POWER
B1
ENGINE START AND
60A
F22
B1BAT-RD B1BAT-RD ELECTRONICS BATTERY
B1BAT-RD
AUX MAIN
C
20A
F7
B1BAT-RD
Z-135/70
B1BAT-RD
-
+
-
AUXILIARY POWER
B2
BATTERIES
B2BAT-RD
SEPARATE
4 GA WIRE
TWO 6V DC
BATTERIES
S139TRF-WH/RD
Continued on
S137PLL-RD/WH
Section 6 • Schematics
HARNESS
ENGINE
J146
View 10
1
2
LOWER LIMIT
HARNESS
A
SWITCH
6 - 20
1
8
REV B Electrical Schematic

Cummins B4.5L Engine and Cummins B3.3T Engine
N M L K J I H G F E D C B A
P1-01
P1-02
P1-03
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-10
P1-11
P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
P1-01
P1-02
P1-03
P1-04
J15 BLACK 4 PIN J13 WHITE 23 PIN
POWER HARNESS ENGINE HARNESS
C45GEN-GR/WH
S139TRF-WH/RD
S137PLL-RD/WH
B2BAT-RD
GND-BR
GND-BR
C35RPM-BK/RD
C21IGN-WH
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
S137PLL-RD/WH
S139TRF-WH/RD
C45GEN-GR/WH TO BELT DRIVEN AC GENERATOR WELD MASTER

2
TO AUXILIARY POWER UNIT
GND-BR
S139TRF-WH/RD
S137PLL-RD/WH
BATTERY NEG TERMINAL (B2)
WORK LAMPS TO AUXILIARY POWER UNIT

B2BAT-RD
BATTERY POS TERMINAL (B2)
WORK LAMP J32-ENGINE HARNESS

TOGGLE
Continued on View 12
AUX
SWITCH
C33STR-BK
MAIN
LOWER
J146 3
ENGINE
LIMIT SWITCH
HARNESS
HARNESS
1
12-3 CABLE
2
C26TSR-WH/RD
INTEGRAL
WITH
BATTERY C25PSR-WH/BK
F7 10A
CABLE
B1BAT-RD
B2BAT-RD
B1BAT-RD
B1BAT-RD
B1ENG-RD B1ENG-RD B1ENG-RD B1ENG-RD
Continued on SEPARATE
4
B1ENG-RD
4 GA WIRE C21IGN-WH
View 10
F7 OIL COOLER
F20 RPM
F7 F20 F23 F23 ENG/ST/ALT 30
SPARE 86 CR28
20A 20A 20A
ENGINE
87a FUEL
85 RELAY
87
C34SA-BK/WH
P35RPM-BK/RD
POWER
HARNESS
R21IGN-WH
B1ENG-RD
B3BAT/14-RD B3BAT/14-RD
C35RPM-BK/RD
5
B3BAT/14-RD
P34SA/4-RD P34SA/4-RD
R21IGN-WH
B3BAT/14-RD
C21IGN-WH
WH-PULL IN
TROMBETTA
TIME DELAY
RD-HOLD
MOM N.O.
B1BAT-RD
F22 275A
B1BAT-RD
B2BAT-RD
CR1 86 BATGND(A)
30 B
STARTER
RELAY BAT+ R21IGN-WH
85
87a 87
A
C25PSR-WT/BK
C26TSR-WT/RD
86
30 CR5
CR17 86
AUX+ HORN 30
OIL
RELAY
85 COOLER
87a 87
ENGINE
GND- C RELAY 85 87 87a 6
C107AF-RD
RD-HOLD
WH-PULL IN
BATGND(A)
HARNESS S-500 CR15
GRID
HEATER
RELAY
C31EDC-WH/BK
C116HYD-OR
R116HYD-OR
VLVRET2-BR
C41RPM-OR/BK
R46HRN-WH
J57
C30EDC-WH
R33STR-BK
GND04-BR
GND04-BR
1 2 3 4
J56
OTS1
ALTERNATOR
N.O.
VLVRET-BR
R34SA/4-RD
WH
RD
BK
EXCT.
7
C27AUX-RD
+
PR1
PR1
BAT. BAT.
+ + -
BAT GND-BR
TWO 6V DC
HOLD
- J120 FAN
BATTERIES
BAT GND-BR
PULL IN
+
AUX. AUX.
HOLD
STA. A B C D
PUMP PUMP
BAT GND-BR
BAT GND-BR
TO J4-32 WHITE 35 PIN
BAT GND-BR
- -
REGULATOR
H1
IND.
B2 B1
8
ELECTRONICS BATTERY
ENGINESTARTING AND
BATTERIES
AUXILIARY POWER
STARTER
STARTER RELAY
UNITS
AUXILIARY POWER
ALTERNATOR
HORN RELAY
HORN
RPM SOLENOID
DUAL COIL EDC
RELAY
PRE-HEATER
PRE-HEATER
SWITCH
TEMPERATURE
HYDRAULIC OIL
OIL COOLER RELAY
COOLER FAN
HYDRAULIC OIL
CR2 RELAY
FUEL SOLENOID
SENDER
OIL PRESSURE
SENDER
WATER TEMPERATURE
GROUND
ENGINE BLOCK
Part No. 106783 Z-135/70 6 - 21

Cummins B4.5L Engine
Cummins B3.3T Engine
6 - 21 6 - 22
Generator Wiring
6 - 23 6 - 24
Generator Wiring REV B
120V AC W/REGULATOR
120V AC W/O REGULATOR
1 CB
87a 3 CB
87a 3
RD
4
110V AC REGULATOR
30A 1 30 RD
RD/12VDC RED 1 30 4
87 30A
87
WT WH WH
86 85 WT
2 5 86 85
BRN BRN GND BRN
2 5
BRN
2 BRN
BK BK
GR
GR
BK/WH BK/WH
WHT-NEUTRAL
WHT-NEUTRAL
3 120V AC
120V AC
AUTO
RESET CB AUTO
RESET CB
BLK-120VAC
15A BLK-120VAC
15A
4
5
220V AC W/REGULATOR
87a 3
RD
1 30 4
220V AC REGULATOR
30A RED/12V RED
87
6 WT WH WH
86 85
2 5
BRN BRN BRN
BK BK
BK/WH BK/WH
7
WHT-NEUTRAL
220V AC
AUTO
RESET CB
8
BLK-220VAC
12.5A
6 - 24 Z-135/70 Part No. 106783

REV A Hydraulic Generator (Welder Option)
PIN# COLOR CKT# J21-17 D81CAN- GR

1
PCON
1 BR GND1 J21-18 D82CAN+ YL
2 WH C30EDC+
3 WH/BK C31EDC-
4 WH P52PCON
5 BR GND3
6 WH C30EDC+(A) J159
7 WH/BK C31EDC-(A)
8 WH P52PCON (A)
9 GR/WH C45GEN
10 GR/BK V150HG
RD B3ENG
J11-17
11
J11-18
J31-17
J31-18
12 WH P52PCON TCON 2
DCON
J13-22
J13-10
J13-11
J32-4
J13-2
RD
TIME DELAY MODULE
3 4 SECOND
D
C
A
ENGINE BLOCK 1K
124 ohms A1 BATTERY + 8 N.C.
GROUND 2 U36 3
EDC+ WH
EDC- WH/BK
A2 SENSOR POWER +5 VDC

1 N.O.
1 A3 BATTERY-
124 ohms 2 COM
V151HG GR B1 VALVE 0 FWD COIL

B2 VALVE 1 NC
J159-3
J159-2
3 GND 5 SW INPUT
V150HG GR/BK B3 DIGITAL OUTPUT BYPASS/OMRON
A RS232TxD C1 TxD
J129 B RS232RxD C2 RxD
J159-10
J159-8
GND
J159-1 GND1
C C3 BOOT
P52PCON WH
B3ENG RD
C45GEN GR/WH
GND
D1 ANALOG 0 JOYSTICK
4
RELAY
HIGH IDLE
CR4
VALVE
MOTOR STROKE
1 3 2 4 8
CR50 D2 ANALOG 1 NC
D3 DIG IN 3 NC
OMRON
WH
WH
RELAY E1 NOT USED

5 6 7 E2 NOT USED
E3 NOT USED
J159-12
J159-11
C57-1
BK-2
Y75-1
J159-9
F1 DIG IN 0
F2 DIG IN 1 GENERATOR ON
5
PRESSURE SWITCH F3 DIG IN 2
(12V STUD)
P52PCON
(RELAY BOX)
B3ENG
J159-4 GND2
J159-7
J159-6
J159-5 GND3
BYPASS COIL
200 PSI SX CONTROLLER

PS4
N.O.
RD-1
WELDER MANIFOLD
WELDER OPTION
J159-4 G1
B
D
C
A
PILOT PRESSURE SIGNAL BV

U4 Y75-2
FROM GENERATOR MANIFOLD
A PMP A MTR A 4 6
DIVERTER MANIFOLD
EDC -
EDC +
DRIVE HYDRAULIC
200 PSI
PUMP ROTARY
BW COUPLER
Ø.030
BX
B PMP B MTR B 3
7
BY 1
Ø.047
24 GENERATOR
270 PSI
OIL COOLER
TO APU SUCTION BZ
G2 CLR
Part No. 106783 Z-135/70 6 - 25

Hydraulic Generator (Welder Option)
6 - 25 6 - 26
Hydraulic Schematic
(before serial number 180, except for serial number 102)
6 - 27 6 - 28
Hydraulic Schematic REV D

(before serial number 180, except for serial number 102)
1 PRIMARY LIFT PRIMARY EXT/RET SECONDARY LIFT

FUNCTION TURNTABLE
CHARGE FILTER 9.0/7.2 GPM 8.5/5.0GPM 13.3(REGEN) 10.5/5.0 GPM SECONDARY EXTENSION CYLINDERS
ENABLE ROTATE
VALVE 17.0/5.6GPM 22.6(REGEN)
6.5 GPM
51 CB CA CB CA CE CF CG CH CI CJ CL CM CO CP CQ
PSI
A
HIGH
PRESSURE
FILTER
1 2
CD CD
2 CK
CN
M1 E D M2 X 102 Ø.030 CC Ø.030 CC

PSI
B JIB UP/DWN
3.3/1.2 GPM
250 PSI
JIB MANIFOLD
CR
Z JU
PMP TEST TRL TRR PU PD PETST PE PR SU SD SE SR
M5 X
315 DD
PSI AX1 H J
A 2900 PSI E 2600
B PSI G
DB
C JD
3 M4 AX2
I K
3625
PSI
M DC
Y
CS
D F
AUXILIARY
E
3625
9 FUNCTION PUMP 1 M M O
Q U
JIB EXT/RET
2.0 GPM 3.8 (REGEN)
DRIVE PUMP L
PSI AUXILIARY S
3100 AC AD
PUMP S L1 PUMP 2 Ø.040
CT
PSI
JE
N
AB 2.0
R T V GPM
P
B L1 L2 M2 S W
P2 P
4 TANK
25
JR
PSI
T1 T
CU
25 25
PSI PSI AA AE
T2 STR FUNCTION MANIFOLD FRONT AXLE REAR AXLE
BELLCRANK LEVEL
EXTENSION EXTENSION 3.6/1.6 GPM
TANK OIL
COOLER AF
CV
LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR JLU
DB DC DD DE
2 4 3 1 5 STEERING STEERING STEERING STEERING
5 2B 2A 4 3 1 5 JLD
P LFE LFR RFE RFR LRE LRR RRE RRR TEST FAE FAR RAE RAR CW
T
P2 T2
BB BC BD BE
T TEST A B PLATFORM ROTATE
0.30 GPM
AJ AK RIGHT P T
RIGHT RRA RFA FRONT 2.1 1.5 2.1 1.5 2.1 1.5 2.1 1.5 CX
REAR GPM GPM GPM GPM GPM GPM GPM GPM BT PRL
0.2
A A BF BG BH BI BJ BK BL BM GPM
6 BU
AO
BS
B B
AG PRR
AN RFB 7.0
RRB BN BO BP BQ 2400 PSI
GPM STEER/AXLE
MANIFOLD AH
CY
50% 50%
BR
AM 250 PSI PLATFORM LEVEL
AR
0.9/0.7 GPM
Ø.063 Ø.063
AI
AL AP
50% 50% AS COUNTERBALANCE VALVES CZ
PLU
7 50% 50% RATIO PRESS P1
AT AU
Ø.052 AQ CT 3:1 1000 PSI
LRB LFB CA CB 3:1 1250 PSI PLD
B
AV B CG 3:1 1500 PSI
Ø.031
CU 4.5:1 2000 PSI PLATFORM MANIFOLD DA
AW CM CP 1:1 2500 PSI

A A
LEFT CL CO CQ 3:1 2500 PSI
AZ BA FRONT
LEFT LRA
AX AY
LFA
CE CF DB DC 3:1 3000 PSI
REAR DD DE CV CW
8 LRBK LFBK
CH CN 4.5:1 3000 PSI
LR2SP LF2SP CX CY 3:1 3300 PSI
RR2SP RF2SP
CR CS CZ DA 1.5:1 3500 PSI
CI 2:1 4000 PSI
RRBK RFBK
CJ CK 4.5:1 4000 PSI
TRACTION MANIFOLD
6 - 28 Z-135/70 Part No. 106783

REV B Hydraulic Schematic

(serial number 102 and from serial number 180 to 534)
PRIMARY LIFT PRIMARY EXT/RET SECONDARY LIFT 1

FUNCTION TURNTABLE
ENABLE ROTATE
VALVE 17.0/5.6GPM 22.6(REGEN)
6.5 GPM
PSI
A
HIGH
PRESSURE
FILTER
1 2
CD CD
CK
CN
2
M1 E D M2 X 102 Ø.030 CC Ø.030 CC
PSI
B JIB UP/DWN
3.3/1.2 GPM
250 PSI
JIB MANIFOLD
CR
Z JU
M5 X
315 DD
PSI AX1 H J
A 2900 PSI C E 2600
B PSI G
DB JD
AFTER SERIAL I K
M4 AX2 NUMBER 439 3
3625
PSI
M DC
100 Y
CS
PSI DF D F
AUXILIARY
E
3625
Q U
JIB EXT/RET
2.0 GPM 3.8 (REGEN)
DRIVE PUMP L
PSI AUXILIARY S
3100 AC AD
CT
PSI
JE
N
AB 2.0
R T V GPM
P
B L1 L2 M2 S W
TANK P2 P
JR
25
PSI
4
T1 T
CU
25 25
PSI PSI AA AE
BELLCRANK LEVEL
TANK OIL
COOLER AF
CV
DB DC DD DE
2B 2A 4 3 1 5 JLD 5
T
P2 T2
BB BC BD BE
0.30 GPM
AJ AK RIGHT P T
0.2
BU
AO
BS
6
B B
AG PRR
AN RFB 7.0
GPM STEER/AXLE
MANIFOLD AH
CY
50% 50%
BR
AR
0.9/0.7 GPM
Ø.039 Ø.063
AI
AL AP
29% 71% AS COUNTERBALANCE VALVES CZ
PLU
50% 50% RATIO PRESS P1
AU
Ø.052 AQ CT 3:1 1000 PSI 7
AT
LRB LFB CA CB 3:1 1250 PSI PLD
B
AV B CG 3:1 1500 PSI
Ø.031
CU 4.5:1 2000 PSI PLATFORM MANIFOLD DA

A A
LEFT CL CO CQ 3:1 2500 PSI
AZ BA FRONT
LEFT LRA
AX AY
LFA
CE CF DB DC 3:1 3000 PSI
REAR DD DE CV CW
LRBK LFBK
CH CN 4.5:1 3000 PSI 8
LR2SP LF2SP CX CY 3:1 3300 PSI
RR2SP RF2SP
CI 2:1 4000 PSI
RRBK RFBK
CJ CK 4.5:1 4000 PSI
TRACTION MANIFOLD
HS0080F
Part No. 106783 Z-135/70 6 - 29

Hydraulic Schematic
(serial number 102 and from serial number 180 to 534)
6 - 29 6 - 30
REV A Hydraulic Schematic

(from serial number 535)
PRIMARY LIFT PRIMARY EXT/RET SECONDARY LIFT

FUNCTION TURNTABLE
ENABLE ROTATE 17.0/5.6GPM 22.6(REGEN)
1
VALVE
6.5 GPM
PSI
A
HIGH
PRESSURE
FILTER
1 2
CD CD
CN
M1 E D M2 X 102
PSI
Ø.030 CC Ø.030 CC CK
2
B JIB UP/DWN
3.3/1.2 GPM
250 PSI
JIB MANIFOLD
CR
Z JU
M5 X
315 DD
PSI AX1 H J
A 2900 PSI C E 2600
B PSI G
DB JD
AFTER SERIAL I K
M4 AX2 NUMBER 439
3625
PSI
M DC
100 Y
CS
3
PSI DF D F
AUXILIARY
E
3625
Q U
JIB EXT/RET
2.0 GPM 3.8 (REGEN)
DRIVE PUMP L
PSI AUXILIARY S
3100 AC AD
CT
PSI
JE
N
AB 2.0
R T V GPM
P
B L1 L2 M2 S W
TANK P2 P
25
JR
PSI
T1 T
25 25
CU
4
PSI PSI AA AE
BELLCRANK LEVEL
TANK OIL
COOLER AF
CV
DB DC DD DE
2B 2A 4 3 1 5 JLD
5
T
P2 T2
BB BC BD BE
0.30 GPM
AJ AK RIGHT P T
0.2
BU
AO
BS
B AN RFB B 7.0
AG PRR 6
GPM STEER/AXLE
MANIFOLD AH
CY
50% 50%
BR
AR
0.9/0.7 GPM
Ø.039 Ø.063
AL AP
29% 71% AS COUNTERBALANCE VALVES AI
CZ
PLU
50% 50% RATIO PRESS
P1
Ø.052 AQ
CT 3:1 1000 PSI
AT AU
LRB LFB CA CB 3:1 1250 PSI
PLD
7
AV B
CG 3:1 1500 PSI
B
CU (before serial number 558) 4.5:1 2000 PSI
Ø.031 PLATFORM MANIFOLD DA

A A CL CO CQ 3:1 2500 PSI
LEFT
LEFT AZ BA AX AY FRONT CE CF DB DC
LRA LFA
REAR DD DE CV CW
3:1 3000 PSI
LRBK LFBK CU
(from serial number
558 to 658)
LR2SP LF2SP CH CN 4.5:1 3000 PSI 8

CX CY 3:1 3300 PSI
RR2SP RF2SP
RRBK RFBK CI 2:1 4000 PSI
TRACTION MANIFOLD CJ CK 4.5:1 4000 PSI
CU (after serial number 657) 2:1 3000 PSI HS0080J
Part No. 106783 Z-135/70 6 - 31

Hydraulic Schematic
(from serial number 535)
6 - 31 6 - 32
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

Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia Genie China

Phone +46 31 575100 Phone +86 21 53852570
Fax +46 31 579020 Fax +86 21 53852569
Genie France Genie Malaysia

Phone +33 (0)2 37 26 09 99 Phone +65 98 480 775
Fax +33 (0)2 37 26 09 98 Fax +65 67 533 544
Genie Iberica Genie Japan

Phone +34 93 579 5042 Phone +81 3 3453 6082
Fax +34 93 579 5059 Fax +81 3 3453 6083
Genie Germany Genie Korea

Phone +49 (0)4202 88520 Phone +82 25 587 267
Fax +49 (0)4202 8852-20 Fax +82 25 583 910
Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566

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Introduction July 2011

Machine Design Life

Printed on recycled paper

ii Z-135/70 Part No. 106783

Serial Number Legend

Rated work load (including occupants): 600 lb / 273 kg

Terex South Dakota, Inc.

Part No. 106783 Z-135/70 iii

This page intentionally left blank.

iv Z-135/70 Part No. 106783

Do Not Perform Maintenance

Part No. 106783 Z-135/70 v

Personal Safety Workplace Safety

Be aware of potential crushing hazards

vi Z-135/70 Part No. 106783

Section 1 Safety Rules

Section 2 Rev Specifications

Part No. 106783 Z-135/70 vii

Section 3 Rev Scheduled Maintenance Procedures

viii Z-135/70 Part No. 106783

Section 3 Rev Scheduled Maintenance Procedures, continued

Part No. 106783 Z-135/70 ix

Section 3 Rev Scheduled Maintenance Procedures, continued

x Z-135/70 Part No. 106783

Section 4 Rev Repair Procedures

Part No. 106783 Z-135/70 xi

Section 4 Rev Repair Procedures, continued

xii Z-135/70 Part No. 106783

Section 4 Rev Repair Procedures, continued

Part No. 106783 Z-135/70 xiii

Section 5 Rev Fault Codes

Section 6 Rev Schematics

xiv Z-135/70 Part No. 106783

Tire size 445/65D22.5, FF Stowed position, high speed 2.8 mph

Wheel lugs 10 @ 3/4 -16 Braking distance, maximum

Turntable rotate, 360° 280 to 350 seconds

Part No. 106783 Z-135/70 2-1

Hydraulic Specifications Component damage hazard.

Biodegradable Petro Canada Environ MV 46

Fire resistant UCON Hydrolube HP-5046

Mineral based Shell Tellus T32

Continuous improvement of our products is a

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

Drive pump Function manifold

Charge pump Jib manifold flow regulator 2 gpm

Function pumps Hydraulic filters

Displacement 0 to 2.75 cu in High pressure filter 102 psi

Type: fixed displacement gear pump

Continuous improvement of our products is a

Part No. 106783 Z-135/70 2-3

Brakes Manifold Component

Displacement per revolution, 0.8 cu in SAE No. 4 10 ft-lbs / 13 Nm

Drive motors SAE No. 10 41 ft-lbs / 55 Nm

3 position 4 way proportional 8 to 10

2 position 3 way solenoid valve 5.5 to 7.5

2 position 3 way solenoid valve 8 to 10

2 position 3 way solenoid valve 3.5 to 5.5

2 position 3 way solenoid valve 7.5 to 9.5

2 position 2 way solenoid valve 3.5 to 5.5

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

Deutz BF4L 2011 Engine Oil viscosity requirements

Displacement 189.6 cu in -22°F to 86°F / -30°C to 30°C 5W-30

Number of cylinders 4 -4°F to 90°F / -20°C to 32°C 10W-40

Firing order 1-3-4-2 Oil temperature switch