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Service and Repair Manual

October 2016

Ground Controls

92

ZX-135/70

Part No. 1268558

6-4
Full Machine Calibration

Full machine calibration must be completed in the
proper sequence when the ALC-1000 circuit board
(TCON) in the ground control box has been
replaced or the turntable level sensor (SCON) has
been replaced.

How to Fully Calibrate the
Machine

Calibration procedures shall only be completed by
qualified technicians that have Genie factory
service training.

Tip-over hazard. Failure to
calibrate the machine in the
proper sequence could cause the
machine to tip over resulting in
death or serious injury.

Note: A digital level will be required to perform this
procedure.

Note: A kit is available through Genie Product
Support (Genie part number 58351). This kit
includes a digital level with a magnetic base and
cable harnesses.

Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.

Plus

Minus

Previous

Enter

Note: Start this procedure with the booms in the
fully stowed position and the axle retracted.

Full machine calibration must be completed in the
following sequence:

•

Select engine configuration. Refer to Repair

Section, Display Module.

Unit of Measure

and Language

.

•

Joysticks. Refer to Repair Procedure,

How

to Calibrate a Joystick

.

•

Turntable level sensor. Refer to Repair

Procedure,

How to Calibrate the Turntable

Level Sensor

.

•

Platform level sensor. Refer to Repair

Procedure,

How to Calibrate the Platform

Level Sensor

.

•

Axle angle sensors. Refer to Repair

Procedure,

How to Calibrate the Axle Angle

Sensors

.

•

Steer sensors. Refer to Repair Procedure,

How to Calibrate All Steer Sensors

.

•

Secondary boom angle sensor. Refer to

Repair Procedure,

How to Calibrate the

Secondary Boom Angle Sensor

.

•

Primary boom angle sensor. Refer to Repair

Procedure,

How to Calibrate the Primary

Boom Angle Sensor

.

•

Jib boom bellcrank angle sensor. Refer to

Repair Procedure,

How to Calibrate the Jib

Boom Bellcrank Sensor

.

•

Select option configuration. Refer to Repair

Section, Display Module.

Options

.

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Summary of Contents for Genie Z13505-101

Page 1: ...199 Includes ZX13514 2463 ZX13514 2469 ZX13514 2631 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics From ZX135H 3200 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1268558 Rev A4 October 2016 ...

Page 2: ...gn 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 and send in suggestions for improvement A...

Page 3: ...2015 Schematics Page 201 A2 5 2016 Repair Procedure 4 9 A3 9 2016 Introduction Serial Number Legend A4 10 2016 Schematics Hydraulic Schematic Electrical Schematic Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 1 Sequence number 2 Serial label located under cover 3 Serial number stamped on chassis From September 1 2016 1 Model 2 Facility code 3 Sequence number 1 Serial label located under cover 2 Serial number stamped on chassis ...

Page 5: ...y 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...

Page 6: ...ushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from flamm...

Page 7: ... Specifications 8 Perkins 854F 34T Engine Specifications 10 Perkins 1104D 44T Engine Specifications 12 Machine Torque Specifications 14 Hydraulic Hose and Fitting Torque Specifications 15 Torque Procedure 16 Section 3 Repair Procedures 19 Introduction 19 Platform Controls 21 Platform Controls 21 1 1 Platform Circuit Board 22 How to Remove the LED Circuit Board 23 1 2 Joysticks How to Calibrate a J...

Page 8: ...llcrank Angle Sensor How to Calibrate the Jib Boom Bellcrank Angle Sensor 50 Boom Components 56 4 1 Primary Boom Cable Track 57 How to Repair the Primary Boom Cable Track 59 4 2 Secondary Boom Cable Track 60 How to Repair the Secondary Boom Cable Track 62 4 3 Primary Boom 63 4 4 Primary Boom Lift Cylinder 65 4 5 Secondary Boom Lift Cylinder 66 4 6 Primary Boom Extension Cylinder 70 4 7 Secondary B...

Page 9: ...ion Manifold 112 8 3 Platform Manifold 114 8 4 Jib Boom Manifold 116 8 5 Flow Control Mainfold 118 8 6 Function Enable Valve 119 8 7 Turntable Rotation Manifold 120 8 8 Steer and Axle Manifold 122 8 9 Valve Adjustments Steer and Axle Manifold 126 8 10 Traction Manifold Components 128 8 11 Valve Adjustments Traction Manifold 132 8 12 Drive Oil Diverter Manifold Components welder option 133 8 13 Val...

Page 10: ...s 203 Circuit Connector Legend 207 Drive Chassis and Platform Controller Pin Legend 210 Safety Controller Pin Legend 211 Turntable Controller Pin Legend 212 Telematics Connector Pin Legend 213 Engine Relay and Fuse Panel Legend Deutz TD2011L04i 214 Engine Relay and Fuse Panel Legend Deutz TD2 9 215 Engine Relay and Fuse Panel Legend Perkins 1104D 44T 216 Engine Relay and Fuse Panel Legend Perkins ...

Page 11: ...able of Contents Part No 1268558 ZX 135 70 xi Generator Wiring Schematic 233 Hydraulic Schematic to SN ZX13516H 2804 236 Hydraulic Schematic from SN ZX13516H 2805 237 Electrical Schematic 239 Electrical Schematic 240 ...

Page 12: ......

Page 13: ...ypoid gear oil API service classification GL5 Performance Specifications Drive speed maximum Stowed position high speed 3 0 mph 4 8 km h 40 ft 9 1 sec 12 2 m 9 1 sec Raised or extended 0 7 mph 1 1 km h 40 ft 40 sec 12 2 m 40 sec Primary and Secondary booms raised and Primary and Jib extended 0 4 mph 0 6 km h 40 ft 68 sec 12 2 m 68 sec Braking distance maximum High range on paved surface 3 to 6 ft ...

Page 14: ...ube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the ...

Page 15: ... 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A hydraul...

Page 16: ...Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C cSt 1...

Page 17: ...00 psi 200 bar Standby pressure 250 psi 17 bar Auxiliary Pump Type fixed displacement gear pump Displacement per revolution 0 15 cu in 2 47 cc Function manifold System relief valve pressure maximum measured at test port 3100 psi 213 7 bar Primary boom extend relief pressure measured at ptest port 2600 psi 179 bar Jib and platform manifolds Platform rotate and platform level flow regulator 0 2 gpm ...

Page 18: ... SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm Valve coil resistance specifications Solenoid valve 3 position 4 way schematic item A B C D W 7 2Ω Solenoid Valve 2 position 3 way schematic items D E F G I Z 5 6Ω Solenoid Valve 2 position 3 way schematic items P Q 7 2Ω Solenoid Valve 2 position 3 way schematic items AE ...

Page 19: ...C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 22 psi 1 5 ...

Page 20: ...rifugal mechanical Valve Clearance cold Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 12 8 quarts 12 1 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may requ...

Page 21: ... refer to the engine Operator Manual for your engine Starter motor Current draw normal load 140 200A Cranking speed 250 350 rpm Battery Auxiliary power units Type 6V DC Quantity 2 Battery capacity maximum 285 AH Reserve capacity 25A rate 745 minutes Battery Engine starting and control system Type 12V DC Group 31 Quantity 1 Battery capacity maximum 1000A Reserve capacity 25A rate 200 Minutes Altern...

Page 22: ...C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil Pressure switch Installation torque 18 4 ft lbs 25 Nm Pressure switch point 12 psi 0 82 bar Oil Sensor Settings 0 psi 10 ohms 50 psi 120 ohms Fuel injection system Transfer pump press...

Page 23: ... coolant Capacity 50 50 extended life 16 5 quarts 15 6 liters Coolant temperature switch Installation torque 18 4 ft lbs 25 Nm Maximum continuous temperature 226 F 108 C Temperature Sensor Settings 215 F 102 C 37 ohms 170 F 82 C 78 ohms Alternator output 120A 12V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm ...

Page 24: ...ntake 0 008 in 0 2 mm Exhaust 0 018 in 0 45 mm Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 8 3 quarts 7 9 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requi...

Page 25: ...acity 25A rate 745 minutes Battery Engine starting and control system Type 12V DC Group 31 Quantity 1 Battery capacity maximum 1000A Reserve capacity 25A rate 200 Minutes Engine coolant Capacity engine only 9 5 quarts 9 liters Coolant temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 230 F 110 C Temperature Sensor Settings 215 F 102 C 37 ohms 170 F 82 C 78 ohms A...

Page 26: ...g compound 35 ft lbs 47 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 3 4 10 SHC 320 ft lbs 434 Nm Rotate bearing mounting bolts lubricated 5 8 11 SHC 180 ft lbs 244 Nm Rotate drive hub mounting bolts lubricated 80 ft lbs 108 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 ...

Page 27: ... 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE O rin...

Page 28: ... and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex nut ...

Page 29: ...number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitti...

Page 30: ...Service and Repair Manual October 2016 18 ZX 135 70 Part No 1268558 This page intentionally left blank ...

Page 31: ...n your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm ...

Page 32: ...t personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avo...

Page 33: ...djustment The operating parameters of the joysticks are stored in memory at the turntable controls If a joystick controller error occurs or if a joystick is replaced it will need to be calibrated before that particular machine function will operate Refer to Repair Procedure How to Calibrate a Joystick Controller Each joystick controller should operate smoothly and provide proportional speed contro...

Page 34: ...l cable receptacle 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 circuit board mounted to the inside of the platform control box 7 Attach a grounded wrist strap to the ground screw inside the control box Electrocution burn hazard Contact with electrically charged circuits could result ...

Page 35: ...brane circuit board 5 Remove the circuit board mounting fasteners 6 Carefully remove the LED circuit board from the platform control box lid Do not lose the plastic spacers Note When installing the LED circuit board be sure the plastic spacers are installed between the circuit board and the control box lid 1 2 Joysticks How to Calibrate a Joystick The joystick controllers on this machine utilize d...

Page 36: ...he center or neutral position Result The alarm at the ground controls should sound for a successful calibration Steer functions 1 Turn the key switch to the off position 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 U...

Page 37: ...or 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Primary boom extend retract functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus...

Page 38: ...n the down direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Jib boom up down functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 secon...

Page 39: ...ful calibration How to R eset a Proportional Val ve Coil D efault How to Reset a Proportional Valve Coil Default Note Use the following chart to identify the description of each LCD screen control button used in this procedure Plus Minus Previous Enter Note This procedure only needs to be performed if a proportional valve has been replaced Note After the valve coil defaults have been set each mach...

Page 40: ...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 7 While holding the joystick in positi...

Page 41: ...the rotate joystick full stroke in either the left or right direction until the alarm sounds Return the joystick to center Turntable rotate function primary boom extended Extend the primary boom approximately 4 ft 1 2 m Move the rotate joystick full stroke in either the left or right direction until the alarm sounds Return the joystick to center Turntable rotate function primary and jib booms exte...

Page 42: ...d control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the plus button twice then press the minus button twice 4 Press the previous 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 mem...

Page 43: ...LCD screen control button used in this procedure Plus Minus Previous Enter 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 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 plus button twice then press the previous button t...

Page 44: ...e from the electrical outlet box Do not disconnect the wiring Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 8 Remove the power to platform electrical outlet box from the platform and lay it to the side 9 Remove the weld cable from the platform if equipped Electrocution burn hazard Contact with...

Page 45: ... platform leveling cylinder barrel end pivot pin is accessible 2 Raise the jib boom slightly and place blocks under the platform 3 Lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Place a block under the platform leveling cylinder for support 5 Remove the external snap rings from the ba...

Page 46: ...cations 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Tag and disconnect the electrical connector from the platform angle sensor 3 Remove the platform angle sensor retaining fasteners Remove the platform angle sensor from the platform rotator Component damage hazard The platform angle sensor is a very sensitive instrument It can be damaged internally if is dropped or...

Page 47: ...d fall if it is not properly supported 12 Support the platform rotator with a suitable lifting device Do not apply any lifting pressure 13 Place a block under the platform leveling cylinder for support 14 Remove the pin retaining fasteners from the platform leveling cylinder rod end pivot pin Do not remove the pin 15 Remove the pin retaining fasteners from the jib boom to platform rotator pivot pi...

Page 48: ...r retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 6 Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 7 Pres...

Page 49: ... center of the platform floor Determine the limit switch trigger point 4 Gently move the platform up and down by hand so it bounces approximately 1 to 2 inches 2 5 to 5 cm Allow the platform to settle Result The overload indicator light and the alarm is on Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off Note The plat...

Page 50: ...an 2 second delay before the overload indicator lights and alarm turn off 8 Add an additional 15 lbs 6 8 kg test weight to the original test weight to overload the platform Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and platform overload should be displayed on the LCD screen at the ground controls Note There may be a 2 seco...

Page 51: ...n 2 Press and hold the enter button on the ground control panel while turning the key switch to ground controls Hold the enter button for approximately 5 seconds 3 Press the buttons on the ground controls in the following sequence plus minus minus plus 4 Press the enter or previous button on the LCD screen until CLEAR OVERLOAD RECOVERY is displayed 5 Press the plus button or the minus button to se...

Page 52: ...rt No 1268558 1 primary extension boom 2 jib boom manifold 3 bellcrank 4 cable track tube 5 platform rotator 6 platform leveling cylinder 7 jib boom 8 jib extension boom 9 hose and cable junction box 10jib boom lift cylinder 11jib boom cable track 12jib boom leveling cylinder ...

Page 53: ...nectors inside the cable track junction box 4 Tag disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to the platform manifold Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note The jib ...

Page 54: ...e cotter pin from the upper cable track tube at the platform end of the jib boom Do not discard the washer Note Always replace the cotter pin with a new one 17 Remove the fasteners from the cable track tube guide at the platform end of the jib boom Remove the cable track tube guide from the jib boom 18 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks toge...

Page 55: ...tion of cable track to be replaced Remove the rollers 4 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Cables and hoses 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 Compo...

Page 56: ...d the platform rotator Refer to Repair Procedure How to Remove the Platform Rotator 3 Tag disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to the platform manifold Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not al...

Page 57: ...oom angle sensor Remove the cover 13 Remove the jib boom angle sensor mounting bracket fasteners from the side of the primary extension boom 14 Carefully remove the bracket and sensor assembly Note the location of the springs Do not lose the springs Note There is one spring inside the jib boom pivot pin and one inside the angle sensor Note When the jib boom is installed the jib boom angle sensor w...

Page 58: ...lanced and fall when it is removed from the machine if it is not properly supported by the overhead crane 3 3 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specifica...

Page 59: ...ow to Remove the Jib Boom Level Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Extend the primary boom until the...

Page 60: ...ported 3 5 Jib Boom Extension Cylinder How to Remove the Jib Boom Extension Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the...

Page 61: ...the lower cable track 9 Remove the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom Remove the clamps 10 Pull the electrical cables out of the lower cable track that lead to the primary boom 11 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 12 Place a block under the ...

Page 62: ...calibrated prior to machine operation The jib boom bellcrank angle sensor is mounted to the bellcrank pivot pin on the engine side of the machine How to Calibrate the Jib Boom Bellcrank Angle Sensor Note If the primary boom or secondary boom angle sensors have been removed or replaced or the turntable level sensor has been replaced they must be calibrated before the jib boom bellcrank angle sensor...

Page 63: ...he off position 4 Open the ground control box 5 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 6 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 7 Remove the key from...

Page 64: ...nd the platform level down button until the digital level displays approximately 34 2 degrees 17 At the ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change th...

Page 65: ...tal level and press the enter button Note Be sure the number entered at the ground controls is a negative number Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 25 Pres...

Page 66: ...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 2 Point Calibration procedure Note Use this procedure for software versions 4 01 and higher 33 Fully extend the axles with the booms in the stowed positions 34 Raise the jib boom to a slightly less than horizontal position 35 Push in the ground controls red ...

Page 67: ...splayed 49 Press the plus button to select YES then press the enter button to accept 50 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 51 Press the enter or previous button on the LCD s...

Page 68: ...m 3 cable track 4 primary extension boom 5 jib boom manifold 6 secondary boom lift cylinder 7 secondary boom cable track inside of secondary boom 8 primary boom lift cylinder 9 number 1 secondary boom tube 10number 2 secondary boom tube 11number 3 secondary boom tube 12lower primary boom lift cylinder linkage arm 13number 4 secondary boom tube ...

Page 69: ...move the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom Remove the clamps 4 Pull the electrical cables out of the lower cable track that lead to the primary boom Component damage hazard Cables can be damaged if they are kinked or pinched 5 Tag and disconnect the electrical connectors from the jib boom manifold located at the platform end of the pri...

Page 70: ...econdary boom lower end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device 15 Locate the two hydraulic hoses inside the end of the secondary boom that lead to the primary boom cable track 16 Tag disconnect and plug the hydraulic hoses from the unions Cap the fittings on the unions Bodily injury hazard Spraying hyd...

Page 71: ...amaged if they are kinked or pinched How to R epair the Primar y Boom C abl e Tr ack How to Repair the Primary Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Service Parts Department 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Support the cabl...

Page 72: ...It can be repaired link by link without removing the cables and hoses that run through it Removal of the secondary boom cable track is required to repair it How to Remove the Secondary Boom Cable Track Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Spe...

Page 73: ...ate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Pull the hydraulic hoses just removed through the turntable bulkhead Component damage hazard Hoses can be damaged if they are kinked or pinched 11 Working at the counterweight end of the secondary boom tag disconnect and plug the hydraulic hoses from th...

Page 74: ...How to R epair the Secondar y Boom C able Tr ack How to Repair the Secondary Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Service Parts Department 1 Remove the secondary boom cable track Refer to Repair Procedure How to Remove the Secondary Boom Cable Track 2 Visually inspect the cable tra...

Page 75: ...quires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specifi...

Page 76: ... need to be calibrated Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor 9 Remove the hose and cable guide fasteners at the primary boom pivot pin Remove the hose and cable guide 10 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraul...

Page 77: ...raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death...

Page 78: ...anced and fall if it is not properly supported when it is removed from the machine Crushing hazard The primary boom lift cylinder linkage arms may fall if not properly supported when the barrel end pivot pin is removed 4 5 Secondary Boom Lift Cylinder How to Remove the Secondary Boom Lift Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable ...

Page 79: ...uel tank Clean up any fuel that may have spilled 7 Close the two hydraulic tank shut off valves at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 8 Remove th...

Page 80: ...lectrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 19 Attach an overhead crane or similar lifting device to the battery box for the auxiliary power unit batteries 20 Remove the battery box retaining fasteners and carefully remove the battery box from the machine Crushing hazard The battery box could...

Page 81: ...pivot pin retaining fasteners Do not remove the pin 28 Attach a lifting strap from a second overhead crane to each end of the secondary boom lift cylinder Note Protect the hoses and cables underneath the cylinder from damage 29 Use a slide hammer to remove the barrel end pivot pin Component damage hazard Hoses and cables can become damaged if the barrel end of the secondary boom lift cylinder is a...

Page 82: ...linder rod end pivot pin is accessible in the primary boom extension tube 2 Remove the access cover from the pivot end of the primary boom 3 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipat...

Page 83: ...ith the machine on a firm level surface and in the stowed position with the axles extended 1 Raise the primary boom approximately 10 feet 3 m Turn the machine off 2 Working at the platform end of the secondary boom support and secure the secondary boom end cover to a suitable lifting device 3 Remove the cover retaining fasteners and remove the cover from the secondary boom Crushing hazard The seco...

Page 84: ...l when removed from the secondary boom if not properly supported Note During removal the overhead crane strap will need to be adjusted for proper balancing 10 Repeat steps 6 through 9 for the remaining secondary boom extension cylinders Note The secondary boom extension cylinders must be installed in the same order they were removed Note When installing the middle and upper secondary boom extensio...

Page 85: ...sor has been replaced they must be calibrated first Refer to Repair Procedures How to Calibrate the Axle Angle Sensors or How to Calibrate the Secondary Boom Angle Sensor or How to Calibrate the Turntable Level Sensor Tip over hazard Failure to properly calibrate the machine could cause the machine to tip over resulting in death or serious injury Note For software versions 4 01 and higher use the ...

Page 86: ...n 2 Turn the key switch to ground controls 3 Open the ground control box 4 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 5 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the ma...

Page 87: ...h step 14 14 Fully raise the secondary boom The boom is fully raised when the cylinder is fully extended and the boom stops moving 15 Press and hold a function enable speed select button and the primary boom down button and lower the primary boom down until the digital level displays 50 degrees 16 At the ground controls press the plus button or minus button to adjust the display to the exact value...

Page 88: ...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 25 Press and hold the engine start button for approximately 5 seconds to shut off the engine and ...

Page 89: ...tton for approximately 5 seconds and then release it 41 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 42 Press the enter or previous button on the LCD screen until DELETE PRIMARY BOOM ANGLE SENSOR CALIBRATION is displayed 43 Press the plus button to select YES then press the enter button to accept 44 Lower the primary b...

Page 90: ...tion mode 57 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 Perform a primary boom angle test Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual Test the Primary Boom Angle Sensor 4 9 Secondary Boom Angle Sensor The secondary boom angle sensor is used to limi...

Page 91: ... Push in the ground controls red Emergency Stop button to the off position Do not turn the key switch to the off position 2 Turn the key switch to ground controls 3 Open the ground control box 4 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 5 Temporarily install a control box door retaining fast...

Page 92: ... or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 16 Press...

Page 93: ...e system must detect a change in displayed value to record the calibrated value 24 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 25 Press the enter or previous button on the LCD screen...

Page 94: ...und controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 39 Press the enter or previous button on the LCD screen until DELETE SECONDARY BOOM ANGLE SENSOR CALIBRATION is displayed 40 Press the plus button ...

Page 95: ...oximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 52 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 53 Pull out the red Emergency Stop button Start the engin...

Page 96: ...t is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it...

Page 97: ...mp shaft and flex plate 4 Install the pump plate and pump assembly onto the engine Grease Specification Shell Alvania Grease CG NLGI 0 1 or equivalent Deutz and Perkins models How to Install the Pump Plate 1 Using a suitable lifting device install the pump plate and pump assembly onto the engine 2 Deutz engines Torque the pump plate mounting bolts in sequence to 23 ft lbs 31 Nm Then torque the pum...

Page 98: ...e control box is the Bypass Recovery key switch Bypass and Recovery modes are only intended for certain circumstances and are not part of normal machine operation If either the Bypass or the Recovery function is required this indicates there may be faults with the machine Contact trained personnel immediately Bypass is used for a platform out of level condition and calibrating certain machine para...

Page 99: ...sabled Use of the Bypass mode will allow the platform to be manually adjusted to within the normal operating envelope 4 5 Only auxiliary power can be used to correct an out of level platform fault 1 Turn the engine off 2 Turn the main key switch to ground controls Remove the key from the main key switch and insert the key into the bypass recovery key switch Note The main key switch must remain in ...

Page 100: ...form controls to exit the platform 1 Turn the main key switch to ground controls Remove the key from the main key switch and insert the key into the bypass recovery key switch Note If this procedure is performed with the main key switch in the off position an active latched safety fault will be set and will have to be cleared 2 Turn and hold the bypass recovery key switch to the recovery position ...

Page 101: ...dure How to Fully Calibrate the Machine How to Remove the LCD Display Screen Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the ground control box lid fasteners 3 Open the ground control box Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watche...

Page 102: ...tach a grounded wrist strap to the ground screw inside the control box Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all ti...

Page 103: ... at the ECM circuit board Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR u...

Page 104: ...ol button used in this procedure Plus Minus Previous Enter Note Start this procedure with the booms in the fully stowed position and the axle retracted Full machine calibration must be completed in the following sequence Select engine configuration Refer to Repair Section Display Module Unit of Measure and Language Joysticks Refer to Repair Procedure How to Calibrate a Joystick Turntable level sen...

Page 105: ...nus Previous Enter Activation of the enter or previous buttons scrolls through the screens To change parameter values or select a setting use the plus button to increase or scroll forward and the minus button to decrease or scroll backwards Then press the enter button to save the new value to memory An audible beep will indicate a save to memory Use the enter and previous buttons to scroll to the ...

Page 106: ...hold the enter button and turn key switch to on position Release the enter button and press plus minus minus plus Metric English measurement units English German French Spanish Portuguese Italian Dutch and Swedish Set engine Deutz TD2011L04i DL04i Perkins 1104D 44T P1104 Overload Recovery software V3 07 and later Clear Overload Recovery YES NO A passcode is required to clear the message Default Re...

Page 107: ... 100 default 50 min Forward not stowed drive speed 120 max 100 default 50 min Forward low drive speed 120 max 100 default 50 min Forward high drive speed 120 max 100 default 50 min Reverse extended drive speed 120 max 100 default 50 min Reverse not stowed drive speed 120 max 100 default 50 min Reverse low drive speed 120 max 100 default 50 min Reverse high drive speed 120 max 100 default 50 min Dr...

Page 108: ... not stowed Primary boom down speed stowed Primary boom down speed not stowed Primary boom extend speed Primary boom retract speed Secondary boom up speed stowed Secondary boom up speed not stowed Secondary boom down speed stowed 120 max 50 min Secondary boom down speed not stowed 100 default Secondary boom extend speed Secondary boom retract speed Turntable rotate speed retracted Turntable rotate...

Page 109: ...celeration Primary boom up down ramp deceleration Primary boom extend retract ramp acceleration Primary boom extend retract ramp deceleration 150 max and 50 min 100 default Secondary boom up down ramp acceleration 5 increment Secondary boom up down ramp deceleration Secondary boom extend retract ramp acceleration Secondary boom extend retract ramp deceleration Turntable rotate ramp acceleration Tu...

Page 110: ...alve calibration Delete secondary boom up down and extend retract valve calibration Delete turntable rotate valve calibration YES NO Allow primary boom up down speed calibration Allow primary boom extend retract speed calibration Allow secondary boom up down speed calibration Allow turntable rotate speed calibration Delete drive joystick calibration Delete primary boom up down joystick calibration...

Page 111: ...NO Delete blue end yellow side steer sensor FR calibration YES NO Use buttons to adjust Delete yellow end yellow side steer sensor RR calibration YES NO Delete secondary boom angle sensor calibration YES NO secondary boom angle to gravity 3 5 secondary boom angle to gravity 20 secondary boom angle to gravity 35 secondary boom angle to gravity 50 secondary boom angle to gravity 65 secondary boom an...

Page 112: ...ted YES NO YES Axle angle fully extended YES NO Delete all steer sensors calibrations YES NO Delete blue end blue side steer sensor FL calibration YES NO Delete yellow end blue side steer sensor RL calibration YES NO Delete blue end yellow side steer sensor FR calibration YES NO Use buttons to adjust Delete yellow end yellow side steer sensor RR calibration YES NO Delete secondary boom angle senso...

Page 113: ...nd Descent TD AL Lift Drive No NO CO Drive cut out while not stored DCONS Lifting or driving LORDR Proximity Kill Switch NONE PROX Platform Overload NONE WARN CUTPT CUTAL 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 NONE Chassis Tilt Cutout COALL Drive Tilt Cutout CODRV Cutout All Cutout...

Page 114: ...o hydraulic tank valves at the hydraulic tank Close the valves Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 2 Tag disconnect and plug the function pump hydraulic hoses Cap th...

Page 115: ...open the valve for the drive pump 3 When hydraulic fluid begins to come out of the case drain port of the function pump install the function pump case drain hose 4 Clean up any oil that may have spilled Properly discard the used oil 5 Start the engine from the ground controls 6 Check for hydraulic leaks How to Adj ust the Functi on Pump Standby Pr essure How to Adjust the Function Pump Standby Pre...

Page 116: ... on the function manifold 3 Start the engine from the ground controls and change the rpm to high idle 4 Push and hold the high speed function enable button rabbit symbol Do not activate any boom functions 5 Observe the pressure reading on the pressure gauge Result The gauge should show 2900 psi 200 bar Result If the gauge does not show 2900 psi 200 bar proceed to step 6 to adjust the function pump...

Page 117: ...he fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank Close the valves open closed Component damage hazard...

Page 118: ...w to Prime the Drive Pump Component damage hazard Be sure to open the two hydraulic tank valves before performing this procedure 1 Connect a 0 to 600 psi 0 to 50 bar pressure gauge to either the A or B test port on the drive pump 2 Perkins models Disconnect the engine wiring harness from the fuel shutoff solenoid at the injector pump Deutz models Hold the manual fuel shutoff valve clockwise to the...

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Page 120: ... boom retract 33 37 ft lbs 45 50 Nm 8 Solenoid Valve 2 position 3 way Z Secondary boom retract 33 37 ft lbs 45 50 Nm 9 Solenoid Valve 2 position 3 way Y Secondary boom extend 50 55 ft lbs 68 75 Nm 10 Differential sensing valve 150 psi 10 3 bar FF Secondary boom extend retract circuit regulates pressure drop across secondary boom extend retract proportional valve 50 55 ft lbs 68 75 Nm 11 Solenoid V...

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Page 122: ... Nm 20 Check valve 5 psi 0 34 bar V Pump circuit 90 100 ft lbs 122 136 Nm 21 Proportional solenoid valve GG Secondary boom extend retract circuit 50 55 ft lbs 68 75 Nm 22 Proportional solenoid valve T Primary boom extend retract circuit 33 37 ft lbs 45 50 Nm 23 Differential sensing valve 150 psi 10 3 bar P Primary boom extend retract circuit regulates pressure drop across primary boom extend retra...

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Page 124: ...al turns Do not allow the relief valve to come apart Tighten the lock nut 3 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 4 Simultaneously push and hold the auxiliary power button and the primary boom retract button with the primary boom fully retracted Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Spe...

Page 125: ...the ground controls and press and release the rpm select button until the engine changes to high idle 7 Simultaneously push and hold the function enable high speed button and the primary boom extend button with the primary boom fully extended Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specifications 8 Turn the engine off Use a wrench to hold the ...

Page 126: ... mounting weldment Index No Description Schematic Item Function Torque 1 Solenoid valve 3 position 4 way AH Platform rotate left right 20 25 ft lbs 27 34 Nm 2 Proportional solenoid valve 3 position 4 way AI Platform level up down 20 25 ft lbs 27 34 Nm 3 Flow control valve 0 2 gpm 0 76 L min AG Platform rotate left right circuit 20 25 ft lbs 27 34 Nm ...

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Page 128: ...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 ...

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Page 130: ...5 Flow Control Manifold The flow control manifold is located at the platform next to the jib manifold Index No Description Schematic Item Function Torque 1 Flow regulator valve 0 5 gpm 1 9 L min AC Controls flow in the jib and platform manifold recirculation circuit 20 ft lbs 27 Nm ...

Page 131: ...nction Enable Valve The function enable valve is mounted behind the medium pressure filter Index No Description Schematic Item Function Torque 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 ...

Page 132: ...tation drive hub motors Index No Description Schematic Item Function Torque 1 Counterbalance valve CA Turntable rotate right 25 30 ft lbs 34 41 Nm 2 Counterbalance valve CB Turntable rotate left 25 30 ft lbs 34 41 Nm 3 Shuttle valve 2 position 3 way CC Turntable rotation brake release 8 10 ft lbs 11 14 Nm 4 Orifice Plug 0 030 inch 0 76 mm CD Turntable rotation brake release ...

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Page 134: ... Prevents left front steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 7 Flow control valve 2 1 gpm 8 L min K Right rear steer cylinder extend circuit 20 25 ft lbs 27 34 Nm 8 Solenoid valve 3 position 4 way D Steer left right right rear steer cylinder 20 25 ft lbs 27 34 Nm 9 Check valve X Prevents right rear steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 10 Che...

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Page 136: ...it 20 25 ft lbs 27 34 Nm 19 Check valve W Prevents right rear steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 20 Flow control valve 1 5 gpm 5 7 L min O Right rear steer cylinder retract circuit 20 25 ft lbs 27 34 Nm 21 Flow control valve 1 5 gpm 5 7 L min L Left front steer cylinder retract circuit 20 25 ft lbs 27 34 Nm 22 Flow control valve 2 1 gpm 8 L min H Left front steer cy...

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Page 138: ...2 Locate the axle relief valve on the steer and axle manifold Hold the relief valve with a wrench and remove the cap 3 Start the engine from the platform controls and press down the foot switch Press and hold the axle extend button at the platform controls Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specifications 4 Turn the engine off 5 Adjust th...

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Page 140: ...n 3 way D Charge pressure circuit that directs hot oil out of low pressure side of drive pumpp 50 55 ft lbs 67 8 74 6 Nm 6 Relief valve 250 psi 17 23 bar E Charge pressure circuit 20 25 ft lbs 27 1 33 9 Nm 7 Orifice Plug 0 030 inch 0 762 mm S Brake and two speed circuit 20 25 ft lbs 27 1 33 9 Nm 8 Check valve 5 psi 0 3 bar N Drive motor anti cavitation 20 25 ft lbs 27 1 33 9 Nm 9 Check valve 5 psi...

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Page 142: ...er valve B 30 35 ft lbs 40 7 47 5 Nm 14 Flow control valve 4 0 gpm 15 1 L m F Equalizes pressure on both sides of divider combiner valve A 30 35 ft lbs 40 7 47 5 Nm 15 Check valve 5 psi 0 3 bar J Drive motor anti cavitation 20 25 ft lbs 27 1 33 9 Nm 16 Flow divider combiner valve A Controls flow to circle end drive motors in forward and reverse 90 100 ft lbs 122 135 6 Nm 17 Flow divider combiner v...

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Page 144: ...rom the ground controls 5 Press and hold the function enable high rpm select button rabbit symbol position Note the reading on the pressure gauge 6 Turn the engine off 7 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 8 Hold the hot oil relief valve and remove the cap 9 Start the engine from the ground controls 10 Press and hold the...

Page 145: ...the engine compartment Index No Description Schematic Item Function Torque 1 Directional valve BV Diverter valve 80 90 ft lbs 108 122 Nm 2 Orifice 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...

Page 146: ...njury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temp...

Page 147: ... the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connec...

Page 148: ...raulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 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 6 ...

Page 149: ...s into the turntable bearing ring gear 5 Loosen the lock nut on the adjustment bolt 6 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts 7 Turn the adjustment bolt 1 2 to 3 4 turn counterclockwise Tighten the lock nut on the adjustment bolt 8 Pull the backlash pivot plate away fr...

Page 150: ...es a digital level with a magnetic base and cable harnesses Note Use the following chart to identify the description of each LCD screen control button used in this procedure Plus Minus Previous Enter Note Perform this procedure with the machine on a firm level surface with the booms in the fully stowed position and the axles fully extended 1 Push in the ground controls red Emergency Stop button to...

Page 151: ...enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 8 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 9 Press the enter or previous button on the LCD screen until SET UNIT X AXIS LE...

Page 152: ...wn 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 15 Press the enter or previous button on the LCD screen until EXIT is displayed 16 Press the plus button to select YES then press the enter button to accept 17 Turn the key bac...

Page 153: ...There is a steer sensor mounted to the top of each steer yoke upper pivot pin How to Replace a Steer Sensor Note When the steer sensor is replaced both the sensor and magnet must be replaced as a set 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 poss...

Page 154: ...ged into the sensor 6 Rotate the sensor housing in a clockwise direction until the sensor cable is pointing away from the machine Refer to Illustration 2 7 Install the steer sensor cover retaining fasteners Do not tighten the cover retaining fasteners 8 Connect the steer sensor assembly cable to the main harness 9 Calibrate the steer sensor Refer to Repair Procedure How to Calibrate a Replacement ...

Page 155: ...eer Sensor How to Calibrate a Replacement Steer Sensor Note If a steer angle sensor has been removed or replaced the steer angle sensors will need to be calibrated Note Perform this procedure with the axles retracted and the tires straightened Note Two people will be required to perform this procedure Note Be sure the yoke pivot pin retaining plate is fully engaged into the pivot pin and that the ...

Page 156: ...gency Stop button to the on position 4 Loosen the steer angle sensor cover retaining fasteners Do not remove the fasteners or the sensor cover 5 Using a voltmeter set to DC voltage probe the back of the electrical connector at pins B and C 6 Left front square end blue side and right rear circle end yellow side angle sensors Rotate the sensor cover clockwise or counterclockwise until the voltage re...

Page 157: ...isplayed Press the plus button to select YES then press the enter button to accept 12 Press the enter or previous button on the LCD screen until EXIT is displayed 13 Press the plus button to select YES then press the enter button to accept 14 Proceed to step 20 Delete a Single Steer Sensor Calibration 15 To calibrate a single steer sensor delete the specific steer sensor calibration 16 Press the e...

Page 158: ...ng the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the axles extended 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying...

Page 159: ...allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the axle extension limit switch cover fasteners Remove the cover 3 Remove the limit switch mounting fasteners and remove the limit switch Do not disconnect the wiring 4 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension cylinder Note Connect the pressure hose from the powe...

Page 160: ...ntrols and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Open the ground control box 3 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 4 Temporarily install a control box door retaining fastener between the door and the box to prevent the control ...

Page 161: ...ton on the LCD screen until EXIT is displayed 13 Press the plus button to select YES then press the enter button to accept 14 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 15 Wait appr...

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Page 163: ...ked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessar...

Page 164: ...al Alarm sounds Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Value Too High Value Too Low Value at 0 V Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Joystick Just calibrated Initiate one second beep of audible warn...

Page 165: ...default speed Perform auto calibrate procedure Primary Extend Retract Speed Not calibrated Display message on LCD and allow operation at default speed Perform auto calibrate procedure Primary Boom Extend Valve Fault Check Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary P...

Page 166: ...resulting in shorts or opens Repair wiring or replace TCON Safety Switch P7R Fault Check Display message on LCD P7R SAFETY SWITCH FAULT Function enable button was held down during startup Recycle power with the function button released Safety Switch DCON P7R Fault Check Display message on LCD DCON P7R SAFETY SWITCH FAULT Check wiring for circuit S56PRV red wire for damage resulting in shorts or op...

Page 167: ...AULT Recycle power Safety Switch P22 Fault Check Display message on LCD P22 SAFETY SWITCH FAULT Re level platform Check for wiring damage on circuit P56PRV red white Safety Switch P22R Fault Check Display message on LCD P22R SAFETY SWITCH FAULT Re level platform Repair or replace PCON Safety Switch P30 Fault Check Display message on LCD P30 SAFETY SWITCH FAULT Recycle power and check wiring on cir...

Page 168: ...play message on LCD Engine is overheating Check sender water or oil level or radiator heat exchanger Oil Pressure Sender Fault Check Display message on LCD Check wiring to senders for opens or shorts Repair or replace senders Water Oil Temp Sender Axle Extend Retract Buttons Fault Check both buttons pressed Axle extend retract disabled Display message on LCD Check ribbon and connector from membran...

Page 169: ... Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Value Too Low Operational Primary Boom Angle Sensor Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Value Too High Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of r...

Page 170: ...ctive from TCON activate alarm Perform calibration procedure per service manual Just calibrated Initiate one second beep of audible warning device Self clearing transient Secondary Boom Joystick Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute ...

Page 171: ...t zero and neutral Alarm sounds Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Secondary Boom Down Sequence Valve Fault Check Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Operational Secondary Boom Angle Se...

Page 172: ...s necessary Out of Tolerance Primary up Secondary up down and Extend disabled Alarm sounds Recalibrate sensor Not calibrated Secondary up only active from TCON activate alarm Perform calibration procedure per service manual Just calibrated Initiate one second beep of audible warning device Self clearing transient Operational Turntable Level Sensor X Direction Value at 5 0 V Flash unit out of level...

Page 173: ...nd allow operation at default speed Perform auto calibrate procedure Turntable Rotate Flow Valve Not calibrated Normal function except threshold for one or the other direction is zero Display message on LCD Perform calibration procedure Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Limited Speed and Direction frozen at zero and neutral Al...

Page 174: ...udible warning device Self clearing transient Platform Rotate Clockwise Valve Fault Check Fault Check Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Platform Rotate Counterclockwise Valve Jib Extend Retract Valve Fault Check Fault Check Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as ne...

Page 175: ...evice Self clearing transient Value Too High Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Value Too Low Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for shorts to ground in the wiring Replace coil if necessary Platform Rotate Switches Fault Check both closed Affected function...

Page 176: ...ed Joystick Speed and Direction frozen at zero and neutral Calibrate Joystick Just calibrated Initiate one second beep of audible warning device Self clearing transient Front Axle Angle Sensor Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Value Too High Primary up Secondary up down and Extend disabled Alarm sounds ...

Page 177: ...nsient Propel Joystick Value at 5 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Value Too High Value Too Low Value at 0 V Not calibrated Joystick Speed and Direction frozen at ze...

Page 178: ...rcuit going to the sensor Value Too High Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Value Too Low Value at 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that t...

Page 179: ...r is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Value Too Low Value at 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Steer Valves LF RF LR RR Fault Check Li...

Page 180: ...m extend retract command or they have changed state when the secondary boom is not fully raised Inhibit Secondary Boom Down until the fault is cleared Check switch for proper operation or damage Use TCON display menu or laptop with WebGPI to clear faults Jib Angle Sensor Operational RSJ1AO Value at 5 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Power up controller with p...

Page 181: ...ndary Boom safety not retracted and not raised OFF OFF OFF Axle safety not stowed not faulted primary and secondary stowed OFF OFF OFF OFF Axle crosscheck angle sensor versus safety switch OFF OFF OFF OFF Axle not fully extended and Turntable rotate stowed and in drive disable zone OFF OFF Turntable tilt angle crosscheck SCON internal sensors 3 in a delta configuration OFF OFF OFF OFF OFF Primary ...

Page 182: ...EGR Valve signal range check low 51 5 1223 Actuator EGR Valve open load 51 6 1014 Actuator error EGR Valve signal range check high SPN FMI KWP Description 51 6 1022 Actuator error EGR Valve signal range check high 51 6 1224 Actuator EGR Valve over current 51 6 1230 Actuator error EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible 51 11 1231 Actuator error E...

Page 183: ...shold exceeded 105 3 994 Sensor error charged air temperature signal range check high 105 4 995 Sensor error charged air temperature signal range check low SPN FMI KWP Description 108 3 412 Sensor error ambient air press signal range check high 108 4 413 Sensor error ambient air press signal range check low 110 0 98 High coolant temperature warning threshold exceeded 110 0 99 High coolant temperat...

Page 184: ...9 Sensor ambient air temperature plausibility error 172 2 983 Intake air sensor plausibility error 172 3 981 Sensor error intake air signal range check high 172 4 982 Sensor error intake air sensor signal range check low SPN FMI KWP Description 174 0 481 High low fuel temperature warning threshold exceeded 174 0 482 High Low fuel temperature shut off threshold exceeded 175 0 740 Physical range che...

Page 185: ...ignal range check high 411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Receive Fr...

Page 186: ...ector 4 in firing order 654 5 571 Injector 4 in firing order interruption of electric connection 676 11 543 Cold start aid relay error 676 11 544 Cold start aid relay open load SPN FMI KWP Description 677 3 956 Starter relay high side short circuit to battery 677 3 960 Starter relay low side short circuit to battery 677 4 957 Starter relay high side short circuit to ground 677 4 961 Starter relay ...

Page 187: ...ust gas temperature upstream turbine warning threshold exceeded 1180 1 1194 Physical range check low for exhaust gas temperature upstream turbine 1180 1 1461 Turbocharger Wastegate CAN feedback shut off threshold exceeded SPN FMI KWP Description 1180 1 1463 Exhaust gas temperature upstream turbine shut off threshold exceeded 1180 3 1067 Sensor error exhaust gas temperature upstream turbine signal ...

Page 188: ... AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 SPN FMI KWP Description 2798 4 1338 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 1 2798 4 1339 Injector diagnostics short circuit to ground monitoring Test in Cyl Bank 0 2798 4 1340 Injector diagnostics short circuit to ground...

Page 189: ...exhaust gas temperature downstream DOC signal range check low 523006 3 34 Controller mode switch short circuit to battery 523006 4 35 Controller mode switch short circuit to ground 523008 1 648 Manipulation control was triggered SPN FMI KWP Description 523008 2 649 Timeout error in Manipulation control 523009 9 825 Pressure Relief Valve PRV reached maximun allowed opening count 523009 10 833 Press...

Page 190: ...or of CAN Receive Frame TSC1AR Retarder 523612 12 387 Internal software error ECU injection cut off 523612 12 612 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 613 Internal ECU monitoring detection reported error 523612 12 614 Internal ECU monitoring detection reported error 523612 12 615 Internal ECU monitoring detection reported error 523612 12 616 Internal E...

Page 191: ...xceeded RailMeUn3 523613 2 864 Setpoint of metering unit in overrun mode not plausible 523615 3 594 Metering unit Fuel System short circuit to battery highside SPN FMI KWP Description 523615 3 596 Metering unit Fuel System short circuit to battery low side 523615 4 595 Metering unit Fuel System short circuit to ground high side 523615 4 597 Metering Unit Fuel System short circuit to ground low sid...

Page 192: ... 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustment value programming IMA injector 2 in firing order SPN FMI KWP Description 523897 13 561 check of missing injector adjustment value programming IMA injector 3 in firing order 523898 13 562 check of missing injector adjustment value programming IMA injector 4 i...

Page 193: ...nce Control integrator injector 4 in firing order maximum value exceeded 523932 1 118 Fuel Balance Control integrator injector 4 in firing order minimum value exceeded 523935 12 168 Timeout Error of CAN Transmit Frame EEC3VOL1 Engine send messages SPN FMI KWP Description 523936 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zerofuel calibration injector 1 in...

Page 194: ...3998 4 1327 Injector cylinder bank 2 slave short circuit 523999 12 1328 Injector powerstage output Slave defect 524014 1 1254 Air pressure glow plug flush line below limit SPN FMI KWP Description 524016 2 1259 Amount of air is not plausible to pump speed 524016 2 1260 Calculated amount of air is not plausible to HFM reading 524016 11 1258 HFM sensor electrical fault 524021 11 1263 Burner fuel line...

Page 195: ...omRxDPFBrnAirPmp 524104 9 1676 Timeout error of CAN Receive Frame ComRxDPFCtl 524105 9 1668 Timeout error of CAN Transmit Frame ComEGRMsFlw 524106 9 1677 Timeout error of CAN Receive Frame ComRxEGRMsFlw1 524107 9 1678 Timeout error of CAN Receive Frame ComRxEGRMsFlw2 SPN FMI KWP Description 524108 9 1669 Timeout error of CAN Transmit Frame ComEGRTVActr 524109 9 1679 Timeout error of CAN Receive Fr...

Page 196: ... KWP Description 524120 9 1682 Timeout error of CAN Receive Frame ComRxSCRHtDiag 524121 9 1683 Timeout error of CAN Receive Frame ComRxTrbChActr 524122 9 1684 Timeout error of CAN Receive Frame ComRxUQSens 524123 9 1685 Timeout error of CAN Receive Frame ComSCRHtCtl 524124 9 1686 Timeout error of CAN Receive Frame ComTxAT1IMG 524125 9 1687 Timeout error of CAN Receive Frame ComTxTrbChActr ...

Page 197: ...t 97 15 Water In Fuel Indicator High least severe Fuel Contains Water 100 2 Engine Oil Pressure Erratic Intermittent or Incorrect Switch Circuits Test 100 17 Engine Oil Pressure Low least severe 1 Oil Pressure Is Low 102 3 Engine Intake Manifold 1 Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 102 4 Engine Intake Manifold 1 Pressure Voltage Below Normal Engine Pres...

Page 198: ...re Problem 157 2 Engine Injector Metering Rail 1 Pressure Erratic Intermittent or Incorrect Fuel Rail Pressure Problem 157 3 Engine Injector Metering Rail 1 Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 157 4 Engine Injector Metering Rail 1 Pressure Voltage Below Normal Engine Pressure Sensor Open or Short Circuit Test 157 10 Engine Injector Metering Rail 1 Pressu...

Page 199: ...tic Intermittent or Incorrect Idle Validation Switch Circuit Test 593 31 Engine Idle Shutdown has Shutdown Engine This code indicates that an engine idle shutdown is about to occur This code does not represent a fault If equipped the warning lamp will come on 594 31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shut down has occurred This code does not represent a ...

Page 200: ...54 5 Engine Injector Cylinder 04 Current Below Normal Injector Solenoid Circuit Test 654 6 Engine Injector Cylinder 04 Current Above Normal Injector Solenoid Circuit Test 654 20 Engine Injector Cylinder 04 Data Drifted High Injector Data Incorrect Test 654 21 Engine Injector Cylinder 04 Data Drifted Low Injector Data Incorrect Test 676 5 Engine GloW Plug Relay Current Below Normal Glow Plug Starti...

Page 201: ...ld Air Pressure Is Low 1188 5 Engine Turbocharger Wastegate Actuator 1 Position Current Below Normal Solenoid Valve Test 1188 6 Engine Turbocharger Wastegate Actuator 1 Position Current Above Normal Solenoid Valve Test 1209 3 Engine Exhaust Gas Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 1209 4 Engine Exhaust Gas Pressure Voltage Below Normal Engine Pressure Sen...

Page 202: ...ECU Instance Special Instruction Electrical Power Supply Test 2880 2 Engine Operator Primary Intermediate Speed Select Erratic Intermittent or Incorrect Throttle Switch Circuit Test 2880 3 Engine Operator Primary Intermediate Speed Select Voltage Above Normal Throttle Switch Circuit Test 2880 4 Engine Operator Primary Intermediate Speed Select Voltage Below Normal Throttle Switch Circuit Test 2970...

Page 203: ...51 3 Particulate Trap Differential Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 3251 4 Particulate Trap Differential Pressure Voltage Below Normal Engine Pressure Sensor Open or Short Circuit Test 3251 7 Particulate Trap Differential Pressure Not Responding Properly Diesel Particulate Filter Has Differential Pressure Problem 3251 10 Particulate Trap Differential ...

Page 204: ...g 1 Not Responding Properly Glow Plug Starting Aid Test 5325 7 Engine Glow Plug 2 Not Responding Properly Glow Plug Starting Aid Test 5326 7 Engine Glow Plug 3 Not Responding Properly Glow Plug Starting Aid Test 5327 7 Engine Glow Plug 4 Not Responding Properly Glow Plug Starting Aid Test 5419 5 Engine Throttle Actuator 1 Current Below Normal Motorized Valve Test 5419 6 Engine Throttle Actuator 1 ...

Page 205: ...safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watch...

Page 206: ...or control 74 is the number of the circuit for the primary 1 lock out valve PL stands for Primary Lockout S 62 BST This is the circuit that communicates to the onboard computers of the machine that the boom is fully stowed S stands for safety 62 is the number of the circuit for boom stowed and BST stands for Boom Stowed P 48 LP P stands for power 48 is the circuit number for work lamps and LP stan...

Page 207: ... Left DER Drive Enable Right DTH Data High DTL Data Low EDC Electrical Displacement Control ENL Envelope Lockout ENV Envelope Light ERL Extend Retract Lockout ESL Engine Status Lamp Suffix Definition ESP Engine Speed Select FAP Axle Front Position FB Flashing Beacon FE Function Enable FL Fuel Select gas LP FLR Filter Restricted FLT Filter Switch FP Fuel Pump FS Float Switch FSL Fuel Solenoid FTS F...

Page 208: ... Control PEL Primary Ext Ret Lockout PER Primary Boom Extend Retract Flow Control PES Primary Boom Up Down Signal PL Primary Lockout PLD Platform Level Down Suffix Definition PLF Platform Level Flow Control PLL Propel Lockout PLS Primary Boom Extend Retract Signal PLU Platform Level Up PRC Platform Rotate Control PRF Platform Rotate Flow Control PRL Platform Rotate Left CCW PRR Platform Rotate Rig...

Page 209: ...SCW Steering Valve CW SEN Sensor SER Sec Boom Extend Retract Flow Control SHD CAN Shield SLD Secondary Boom Lockout Valve riser down SLE Secondary Boom Lockout Valve extend SP Spare SS Speed Sensor STC Steer Control Signal Suffix Definition STR Starter SUD Sec Boom Up Down Flow Control TAX Tilt Alarm X axis TAY Tilt Alarm Y axis TCN Ground Control TCN Ground Control Panel TET Tether TRF Turntable ...

Page 210: ...alve wiring is striped Wire Color Legend BL Blue BL BK Blue Black BL RD Blue Red BL WH Blue White BK Black BK RD Black Red BK WH Black White BK YL Black Yellow BR Brown GR Green GR BK Green Black GR WH Green White RD Red RD BK Red Black RD WH Red White OR Orange OR BK Orange Black OR RD Orange Red WH White WH BK White Black WH RD White Red YL Yellow Power Circuits P9A Primary boom down valve P9B E...

Page 211: ... valve driver GR BK 18 Platform rotate right valve driver GR WH 19 Jib select valve driver circuit RD 20 12V DC battery supply WH 21 12V DC ignition supply BK 22 Key switch power to platform WH 23 Power to platform RD 24 Power to warning senders WH BK 25 Power to oil pressure sender Color Circuit Primary Function WH RD 26 Power to temp sender RD 27 Auxiliary Power RD BK 28 Platform level alarm RD ...

Page 212: ...9 Power from TCON ESTOP N A 80 Can 2 0 J1939 Shield GR 81 Can 2 0 J1939 Low YL 82 Can 2 0 J1939 High GR WH 83 Tilt signal X axis GR BK 84 Tilt signal Y axis GR 85 Tilt sensor power Color Circuit Primary Function OR 86 Hydraulic Filter restricted RD 87 Platform Level Safety Power RD BK 88 Platform Level Safety Output BR 89 Platform Level Safety Ground RD BK 90 Proximity Kill RD WH 91 Gate Interlock...

Page 213: ... P_38 RD BK 138 Primary Boom Up Secondary Boom Down Extend P_11 30 WH RD 139 Turntable Rotate Flow Control Safety P_39 OR RD 140 Boom Envelope Safety Color Circuit Primary Function RD 141 Primary Boom Angle Signal Safety OR 142 Secondary Boom Angle Signal Safety BL RD 143 Drive Enable Left BL WH 144 Drive Enable Right RD WH 145 Calibrate BL 146 Jib Bellcrank Up Flow Control BL BK 147 Jib Bellcrank...

Page 214: ...ontrol Module Status Light GR 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 Color Circuit Primary Function GR 188 Safety cross check BK 189 Data Receive BK WH 190 Data Transmit WH RD 191 Multi Functio...

Page 215: ...No 1268558 ZX 135 70 203 Limit Switch Legend 1 RSP1AO 2 RSP1AS 3 LSP1RO 4 LST2O 5 LST1O 6 LST1S 7 LSS1RS 8 LSS1RO 9 RSS1AO 10RSS1AS 11LSP1EO 12RSJ1AO 13LSJ1RO 14Plat Angle Sensor 15PCON 16SCON 17RSRA1SO 18LSRA1ES 19RSLR1SO 20RSRR1SO 21DCON 22RSRF1SO 23RSLF1SO 24LSFA1ES 25RSFA1SO ...

Page 216: ...r example when the secondary boom is fully raised and the operational sensor is activated it tells the ECM at the ground controls to start extending the secondary boom Another example is the drive enable limit switch which disables the drive function anytime the boom is rotated past the rear tires indicated by the circle end of the drive chassis In some cases the engine will be stopped if safety p...

Page 217: ...ctions with the axles retracted Switch closes when axles are fully extended LSRA1ES Limit switch Rear Axle 1 Extended Safety Prevents boom functions with the axles retracted Switch closes when axles are fully extended LST1O Limit switch Turntable 1 Operational Activates the drive enable zone when the turntable is rotated in the left direction LST2O Limit switch Turntable 2 Operational Activates th...

Page 218: ...ety Backup safety angle sensor for RSS1AO Cuts power to circuits P9B P_11 and P_30 if the secondary boom drifts down while still extended RSFA1O Rotary Sensor Front Axle 1 Operational Provides front axle positioning information for adjusting steering neutral setting during axle extension RSRA1O Rotary Sensor Rear Axle 1 Operational Provides front axle positioning information for adjusting steering...

Page 219: ...SS1RS J49 4 pin Deutsch connector on sec boom retract LSS1RO J55 6 pin Deutsch connector on platform tilt sensor J57 3 pin Deutsch connector on RPM solenoid J58 2 pin Deutsch connector for pri boom up down flow control Number Description J59 2 pin Deutsch connector for primary boom up valve J60 2 pin Deutsch connector for primary boom down valve J61 2 pin Deutsch connector for primary boom ext ret...

Page 220: ...utsch connector for left front steer sensor J114 6 pin Deutsch connector for primary boom angle sensor PBAS J119 2 pin Deutsch connector for jib not retracted J120 4 pin Weatherpack EDC connection Number Description J121 12 pin Deutsch gray SCON connector J122 12 pin Deutsch black SCON connector J124 2 pin Deutsch connector for drive enable right limit switch LST1O J125 2 pin Deutsch connector for...

Page 221: ...e angle sensor J161 4 pin Deutsch connector for rear axle angle sensor J162 3 pin Deutsch connector for jib bellcrank angle sensor J163 2 pin Deutsch connector for secondary boom up down flow control J164 2 pin Deutsch connector for secondary boom extend retract flow control J165 12 pin Deutsch connector located at PCON J166 6 pin Deutsch connector for jib bellcrank sensor J168 1 way 0 25 inch sli...

Page 222: ... OR BK 17 C56FTS RD 18 C154JBR BK WH 19 P85RET BR 20 C84TAY GR BK 21 P85PTS GR 22 P87RET BR 23 P87PTS RD 24 UNUSED 25 UNUSED 26 UNUSED 27 UNUSED 28 V146JBU BL 29 V147JBD BL BK 30 P109JBS GR WH 31 P110JBS BK 32 C148JBS BL WH 33 UNUSED 34 VLVRET2 BR 35 UNUSED J32 Drive Chassis 1 VLVRET1 BR 2 V61AXRT GR 3 V60AXEX GR WH 4 V29MS RD WH 5 UNUSED 6 UNUSED 7 UNUSED 8 V36RRS BL 9 V37RRS BL BK 10 C111RRS OR ...

Page 223: ...s J122 Safety Controller 1 S132LDS BL WH 1 P21DCON WH 2 S73SLE BL RD 2 C142SBS OR 3 UNUSED 3 C141PBS RD 4 C145CAL RD WH 4 C60AXE GR WH 5 UNUSED 5 S12SB BL WH 6 D82CAN YL 6 S13DE BL RD 7 D81CAN GR 7 P53LS WH BK 8 S59CNK GR WH 8 S140ENL OR RD 9 S56PRV RD 9 P54ENG BK WH 10 S137PLL RD WH 10 P58LS RD BK 11 S139TRF WH RD 11 S56PRV RD 12 GNDSCON BR 12 C61AXR GR ...

Page 224: ...BK 19 C70PBR BL WH 20 C71PBE BL BK 21 UNUSED 22 UNUSED 23 UNUSED 24 UNUSED 25 SNSR GND BR 26 P109ANG GR WH 27 UNUSED 28 C143DEL BL RD 29 UNUSED 30 UNUSED 31 UNUSED 32 C123PBS RD BK 33 C124SBS OR BK 34 S140ENL OR RD 35 GND16 BR J13 Turntable Controller 1 UNUSED 2 C35RPM BK RD 3 C21IGN WH 4 C34SA BK WH 5 UNUSED 6 UNUSED 7 C46HRN WH 8 UNUSED 9 C33STR BK 10 C30EDC WH 11 C31EDC WH BK 12 C25PSR WH BK 13...

Page 225: ... Monitor Engine Hours 4 Digital Output 2 12 VDC Key Switch Activation 12V key switch on 0V key switch off Monitor machine utilization 5 Digital Output 3 12 VDC Foot switch 12V active 0V inactive Monitor machine utilization 6 Digital Input 1 12 VDC Remote Disable Engine Start Remotely Prevent Engine Start 7 Databus H CAN HIGH Genie Databus J1939 Engine Messages Receive Proprietary Genie Telematics ...

Page 226: ...y 2 CR17 Hydraulic Oil Cooler Fan Relay 3 CR41 Flashing Beacon Relay 4 CR5 Horn Relay 5 CB10 Circuit Breaker 20A Hydraulic Oil Cooler Horn 6 F23 Fuse 30A Eng Start Alt 7 F22 Fuse 60A Glow Plug 8 F7 Fuse 20A Hydraulic Oil Cooler Horn 9 B1PBAT Power from Battery 10 B3PBAT Fused Power from B1 11 R21PIGN Ignition Fuse 20A RPM Solenoid 12 02PGND Ground 13 CR1 Start Relay 14 CR15 Glow Plug Relay ...

Page 227: ...R2 Engine Alt Relay 3 CR17 Hydraulic Oil Cooler Fan Relay 4 CR28 Fuel Pump 5 CR41 Flashing Beacon Relay 6 CR5 Horn Relay 7 F27 Fuse 30A ECU Power 8 F23 Fuse 30A Eng Start Alt 9 F22 Fuse 60A Glow Plug 10 F7 Fuse 20A Hydraulic Oil Cooler Horn 11 B3BAT Fused Power from B1 12 B3BAT Fused Power from B1 13 R21IGN Ignition 14 02GND Ground 15 CR39 Engine Shutdown 16 CR15 Glow Plug Relay ...

Page 228: ...28 Start Relay 3 CR17 Hydraulic Oil Cooler Fan Relay 4 CR41 Flashing Beacon Relay 5 CR5 Horn Relay 6 CB10 Circuit Breaker 20A Hydraulic Oil Cooler Horn 7 F23 Fuse 30A Eng Start Alt 8 F22 Fuse 60A Glow Plug 9 F7 Fuse 20A Hydraulic Oil Cooler Horn 10 B3PBAT Fused Power from B1 11 B1PBAT Power from Battery 12 R21PIGN Ignition Fuse 20A RPM Solenoid 13 02PGND Ground 14 CR1 Start Relay 15 CR15 Glow Plug...

Page 229: ...Alt 3 CR17 Hydraulic Oil Cooler Fan Relay 4 FX1 Fuse 30A ECU Power 5 FX2 Fuse 20A Key Switch Power 6 CR41 Flashing Beacon Relay 7 CR5 Horn Relay 8 F27 Fuse 20A RPM Solenoid 9 F23 Fuse 30A Eng Start Alt 10 F22 Fuse 60A Glow Plug 11 F7 Fuse 20A Hydraulic Oil Cooler Horn 12 B3BAT Fused Power from B1 13 B1BAT Power from Battery 14 R21PIGN Ignition 15 02PGND Ground 16 CR1 Engine Starter 17 CR81 ECU Pow...

Page 230: ...nection no terminal Battery separator Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Main Key switch Service Bypass Key switch Steer sensor Auxiliary Pump Tilt sensor Relay Power relay Emergency Stop button Hydraulic oil cooling fan Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally open Oil pressure switch normally ...

Page 231: ...uttle valve 2 position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator Solenoid operated proportional valve Pressure reducing valve Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid opera...

Page 232: ...Service and Repair Manual October 2016 220 ZX 135 70 Part No 1268558 This page intentionally left blank ...

Page 233: ...October 2016 Service and Repair Manual 221 Perkins 1104D 44T Engine Electrical Schematic ...

Page 234: ...Service and Repair Manual October 2016 222 ZX 135 70 Part No 1268558 Perkins 1104D 44T Engine Electrical Schematic ...

Page 235: ...October 2016 Service and Repair Manual 223 Perkins 854F 34T Engine Electrical Schematic ...

Page 236: ...Service and Repair Manual October 2016 224 ZX 135 70 Part No 1268558 Perkins 854F 34T Engine Electrical Schematic ...

Page 237: ...October 2016 Service and Repair Manual Part No 1268558 ZX 135 70 225 Perkins 854F 34T Engine Harness ...

Page 238: ...Service and Repair Manual October 2016 226 Perkins 854F 34T Engine Harness ...

Page 239: ...October 2016 Service and Repair Manual 227 Deutz TD2 9 Engine Electrical Schematic ...

Page 240: ...Service and Repair Manual October 2016 228 ZX 135 70 Part No 1268558 Deutz TD2 9 Engine Electrical Schematic ...

Page 241: ...October 2016 Service and Repair Manual Part No 1268558 ZX 135 70 229 Deutz TD2 9 Engine Harness ...

Page 242: ...Service and Repair Manual October 2016 230 Deutz TD2 9 Engine Harness ...

Page 243: ...October 2016 Service and Repair Manual 231 Hydraulic Generator Welder Option ...

Page 244: ...Service and Repair Manual October 2016 232 ZX 135 70 Part No 1268558 Hydraulic Generator Welder Option ...

Page 245: ...October 2016 Service and Repair Manual Part No 1268558 ZX 135 70 233 Generator Wiring Schematic ...

Page 246: ...Service and Repair Manual October 2016 234 Generator Wiring Schematic ...

Page 247: ...October 2016 Service and Repair Manual 235 Hydraulic Schematic to SN ZX13516H 2804 ...

Page 248: ...Service and Repair Manual October 2016 236 ZX 135 70 Part No 1268558 Hydraulic Schematic to SN ZX13516H 2804 ...

Page 249: ...October 2016 Service and Repair Manual Part No 1268558 ZX 135 70 237 Hydraulic Schematic from SN ZX13516H 2805 ...

Page 250: ...Service and Repair Manual October 2016 238 Hydraulic Schematic from SN ZX13516H 2805 ...

Page 251: ...NSR GND BR SNSR GND BR 14 NO 13 BK BR RD WH 22 21 NC LSS1RS 3 EXT J46 NO 13 NC 14 WH 21 22 BK BR RD LST1S DRV EN J126 C144DER BL WH C67SBD BL C64LS OR BK C71PBE BL BK C64LS OR BK C64LS OR BK C70PBR BL WH C64LS OR BK C64LS OR BK TCON MODE P53LS WH BK S13DE BL RD C143DEL BL RD C64LS OR BK C64LS OR BK S12SB BL WH C163PES BL WH C16PRL OR RD C157JER BK RD C145CAL RD WH TO uP Y85 JIB BELLCRANK UP J135 Y...

Page 252: ...R WH P109ANG GR WH SNSR GND BR SNSR GND BR SNSR GND BR 14 NO 13 BK BR RD WH 22 21 NC LSS1RS 3 EXT J46 NO 13 NC 14 WH 21 22 BK BR RD LST1S DRV EN J126 C144DER BL WH C67SBD BL C64LS OR BK C71PBE BL BK C64LS OR BK C64LS OR BK C70PBR BL WH C64LS OR BK C64LS OR BK TCON MODE P53LS WH BK S13DE BL RD C143DEL BL RD C64LS OR BK C64LS OR BK S12SB BL WH C163PES BL WH C16PRL OR RD C157JER BK RD C145CAL RD WH T...

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