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Terex Genie Z-135/70, Service And Repair Manual

The Terex Genie Z-135/70 is a powerful and efficient aerial work platform designed for various construction and maintenance tasks. Ensure proper setup and operation by downloading the Installation Instructions Manual, available for free at manualshive.com. This comprehensive manual provides step-by-step guidance and is a valuable resource for users.

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Service and Repair Manual

 

October 2018 

Engines 

 

 

96 

Z®-135

/70 

Part No. 1268557GT 

 

 

 

How to Remove the Flex Plate 

1 

Disconnect the wiring plug at the electronic 
displacement controller (EDC), located on the 
drive pump. 

2 

Support the drive pump with an appropriate 
lifting device. Then remove all of the pump 
mounting plate to engine bell housing bolts. 

3 

Carefully pull the pump away from the engine 
and secure it from moving. 

4 

Remove the flex plate mounting fasteners, 
then remove the flex plate from the engine 
flywheel. 

How t o i nst all a T ype "A" Flex Pl ate 

How to Install a Type "A" Flex 
Plate 

1 

Install the flex plate onto the engine flywheel 
with the raised spline towards the pump. 

2 

Ford models:

 Torque the flex plate mounting 

bolts in sequence to 14 ft-lbs / 19 Nm. Then 
torque the flex plate mounting bolts in 
sequence to 20 ft-lbs / 27 Nm. 

Deutz models:

 Torque the flex plate mounting 

bolts in sequence to 28 ft-lbs / 38 Nm. Then 
torque the flex plate mounting bolts in 
sequence to 40 ft-lbs / 54 Nm. 

Perkins models:

 Torque the flex plate 

mounting bolts in sequence to 49 ft-lbs / 66 Nm. 
Then torque the flex plate mounting bolts in 
sequence to 70 ft-lbs / 95 Nm. 

Summary of Contents for Genie Z-135/70

Page 1: ...0 from Z13505 101 to Z13513 2000 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1268557GT Rev A4 October 2018 ...

Page 2: ... 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 All...

Page 3: ...Wire Color Legend A2 6 2016 Specifications Performance Specifications Repair Procedures 4 9 6 1 A3 3 2018 Repair Display Module A4 10 2018 Specifications Perfromance Specifications 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: ...ce and Repair Manual October 2018 Introduction iv Z 135 70 Part No 1268557GT Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial label located under cover 5 Serial number stamped on chassis ...

Page 5: ...any 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 R You are trained and qualified to perform maintenance on this machine R You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations R ...

Page 6: ...rushing 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 flam...

Page 7: ...ormance Specifications 1 Hydraulic Specification 2 Hydraulic Component Specifications 5 Deutz BF4L 2011 Engine Specifications 7 Deutz TD2011L04i Engine Specifications 9 Cummins B4 5L Engine Specifications 11 Cummins B3 3T Engine Specifications 13 Perkins 1104C 44 Engine Specifications 15 Perkins 804D 33T Engine Specifications 17 Machine Torque Specifications 19 Hydraulic Hose and Fitting Torque Sp...

Page 8: ...ow to Adjust the Function Speeds 36 How to Adjust the Function Ramp Rate Setting 37 Platform Components 39 2 1 Platform Leveling Cylinder 39 2 2 Platform Rotator 40 How to Bleed the Platform Rotator 41 2 3 Platform Level Sensor How to Calibrate the Platform Level Sensor 42 2 4 Platform Overload System if equipped 43 Jib Boom Components 46 3 1 Jib Boom Cable Track 47 How to Repair the Cable Track 4...

Page 9: ...m Extension Cylinder 78 4 7 Secondary Boom Extension Cylinders 79 4 8 Primary Boom Angle Sensor 81 How to Calibrate the Primary Boom Angle Sensor 82 4 9 Secondary Boom Angle Sensor 88 How to Calibrate the Secondary Boom Angle Sensor 89 Engines 95 5 1 RPM Adjustment 95 5 2 Flex Plate 95 How to install a Type A Flex Plate 96 How to install a Type B Flex Plate 98 Ground Controls 99 6 1 Bypass Recover...

Page 10: ... Adjust the System Relief Valve 128 How to Adjust the Primary Boom Extend Relief Valve 129 8 4 Platform Manifold 131 8 5 Jib Boom Manifold 132 8 6 Flow Control Mainfold 134 8 7 Function Enable Valve 135 8 8 Turntable Rotation Manifold 136 8 9 Steer and Axle Manifold 138 8 10 Valve Adjustments Steer and Axle Manifold 142 8 11 Traction Manifold 144 8 12 Valve Adjustments Traction Manifold 148 8 13 D...

Page 11: ...ow to Calibrate a Replacement Steer Sensor 160 How to Calibrate All Steer Sensors 161 10 2 Steer Cylinders 163 10 3 Axle Extension Cylinders 164 10 4 Axle Angle Sensors 165 How to Calibrate the Axle Angle Sensors 167 Section 4 Fault Codes 171 Introduction 171 Control System Fault Codes 172 Fault Matrix 189 ...

Page 12: ...2011 TD2011L04i Perkins 1104C 44 and 804D 33T 211 Engine Relay and Fuse Panel Legend Cummins B4 5L and B3 3T 212 Electrical Symbols Legend 213 Hydraulic Symbols Legend 214 Perkins 1104C 44 and 804D 33T Engine Electrical Schematic 216 Cummins B4 5L and B3 3 3T Engine Electrical Schematic 217 Generator Wiring Schematic 220 Hydraulic Generator Welder Option 221 Hydraulic Schematic before serial numbe...

Page 13: ...October 2018 Service and Repair Manual Part No 1268557GT Z 135 70 13 This page intentionally left blank ...

Page 14: ......

Page 15: ... 2 8 mph 4 5 km h 40 ft 9 7 sec 12 2 m 9 7 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 5 sec 12 2 m 68 5 sec Braking distance maximum High range on paved surface 3 to 6 ft 1 to 2 m Gradeability See Operator s Manual Boom function speeds maximum from platform controls Jib boom up down 38...

Page 16: ...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 17: ...w 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 hydrau...

Page 18: ... 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 ...

Page 19: ...pe 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 0 76 L min Jib manifold flow regulator 2 gpm 7 6 L min Steer Axl...

Page 20: ...s 4 Nm 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 Proportional solenoid valve schematic items N P R T V 3 5 to 5 5Ω Solenoid valve 3 position 4 way schematic item B 4 to 6Ω Solenoid valve 3 position 4 way schematic items BN BO BP BQ 7 to 9Ω Solenoid valve 3 position 4 way schema...

Page 21: ... 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 11 quarts 10 4 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirement...

Page 22: ...Current draw normal load 140 200A Cranking speed 200 250 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 Alternator output 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 5 to 1...

Page 23: ...haust 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 require the use of alternative engine oils For oil requirements refer...

Page 24: ... 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 Alternator output 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 5 to ...

Page 25: ...he highest cylinder Governor centrifugal mechanical Valve Clearance cold Intake 0 010 in 0 254 mm Exhaust 0 020 in 0 508 mm Lubrication system Oil pressure hot 2000 rpm 50 psi 3 45 bar Oil capacity including filter 9 5 quarts 9 liters Oil viscosity requirements Below 68 F 20 C 5W 30 10 F to 68 F 23 C to 20 C 10W 40 Above 15 F 9 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may req...

Page 26: ...orque 8 18 ft lbs 11 24 Nm Temperature switch point 230 F 110 C Starter motor Current draw no load 125A Brush length minimum 0 72 in 18 3 mm 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 M...

Page 27: ... at least 75 of the highest cylinder Valve Clearance cold Intake 0 014 in 0 35 mm Exhaust 0 020 in 0 508 mm Lubrication system Oil pressure hot 2000 rpm 31 psi 72 bar Oil capacity including filter 9 quarts 8 5 liters Oil viscosity requirements Below 68 F 20 C 5W 30 10 F to 68 F 23 C to 20 C 10W 40 Above 14 F 10 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of a...

Page 28: ...r Current draw maximum load 550A Cranking speed 130 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 Alternator output 120A 12V DC Fan belt deflection 3 8 to 1 2 inch 9 5 to 12 5 ...

Page 29: ... Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 7 3 quarts 6 9 liters Oil viscosity requirements Below 68 F 20 C 5W 20 10 F to 104 F 12 C to 40 C 10W 40 Above 14 F 10 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 e...

Page 30: ...nutes 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 14 quarts 13 2 liters Coolant temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 230 F 110 C Alternator output 85A 13 8V DC Fan belt deflection 3 8 inch 9 5 mm Continuous improvement of our pr...

Page 31: ...ubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 10 6 quarts 10 liters Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 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 engi...

Page 32: ...ry 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 12 5 quarts 11 8 liters Coolant temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 230 F 110 C Alternator output 90A 12V DC Fan belt deflection 3 8 to 1 2 inch 9 5 to 12 5 mm Continuous improvement of ou...

Page 33: ... lubricated 80 ft lbs 108 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm Drive motor mounting bolts lubricated 56 ft lbs 76 Nm Backlash plate mounting bolts lubricated 320 ft lbs 434 Nm Drive motors and hubs Drive hub mounting bolts lubricated 180 ft lbs 217 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm Drive motor mounting bolts lubricated 56 ft lbs 76 Nm Engine vibration isolators Mount...

Page 34: ...8 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 ri...

Page 35: ... 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 36: ... 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 fitt...

Page 37: ...October 2018 Service and Repair Manual Specifications Part No 1268557GT Z 135 70 23 T ...

Page 38: ...n your machine R Be sure that all necessary tools and parts are available and ready for use R Use only Genie approved replacement parts R Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration R Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on...

Page 39: ...rt 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 av...

Page 40: ...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 41: ...platform control box 4 Remove the control 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 ele...

Page 42: ...ld result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 4 Tag and carefully disconnect the ribbon cables from the membrane circu...

Page 43: ...and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 4 Close the control box lid 5 Remove the platform controls decal from the platform control box 6 Carefully remove the membrane decal f...

Page 44: ...he description of each LCD screen control button used in this procedure Plus Minus Previous Enter Drive 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 Use the scroll ...

Page 45: ...ter or neutral position Result The alarm at the ground controls should sound for a successful calibration Secondary boom up down and extend retract functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then pr...

Page 46: ... full stroke in the retract direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Primary boom up down functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for ...

Page 47: ...en return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Turntable rotate functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then press t...

Page 48: ... the enter or previous button on the LCD screen until EXIT is displayed 6 Press the plus button or minus button to select YES and then press the enter button How to Set the Function Thresholds and D efault Functions Speeds How to Set the Function Thresholds and Default Functions Speeds Note Before the threshold and default function speeds can be set the boom function proportional valve coil defaul...

Page 49: ...1 Check the display at the ground controls to be sure there are no calibration faults Note There should be no calibration faults shown on the display If calibration faults exist repeat this procedure Function speeds Note Be sure the machine is in the stowed position and the boom is rotated between the circle end tires Note Perform this procedure with the machine on a firm level surface that is fre...

Page 50: ...16 At the ground controls turn the key switch to the off position wait a moment and then turn the key switch to platform controls 17 Check the display at the ground controls to be sure there are no calibration faults Note There should be no calibration faults shown on the display If calibration faults exist repeat this procedure How to Adj ust the Functi on Speeds How to Adjust the Function Speeds...

Page 51: ...trols the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure with the boom in the stowed position Note Use the following chart to identify the description of each LCD screen control bu...

Page 52: ...djusted is displayed 5 Press the plus button to increase the ramp rate or press the minus button to decrease the ramp rate 6 Press the enter button to save the setting in memory 7 Press the enter or previous button on the LCD screen until EXIT is displayed 8 Press the plus button or minus button to select YES and then press the enter button ...

Page 53: ...e 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 b...

Page 54: ...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 55: ...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 56: ...rial number 321 4 Locate the 2 pin connector in the lower left hand area of the ground control box 5 Remove the connector plug and insert a jumper wire between the two pins of the connector After serial number 320 6 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 7 Temporarily install a control bo...

Page 57: ...be removed before operating the machine 16 Close the ground control box and install the door retaining fasteners After serial number 320 17 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 2 4 Platfor...

Page 58: ...he overload indicator lights flash and the alarm sounds Note The platform will need to be moved up and down and allowed to settle in between adjustments Confirm the setting 5 Start the engine from the platform controls 6 Lift the test weight off the platform floor using a suitable lifting device 7 Place the test weight back onto the center of the platform floor using a suitable lifting device Resu...

Page 59: ... Z 135 70 45 9 Test all machine functions from the platform controls Result All platform control functions should not operate 10 Turn the key switch to ground controls 11 Test all machine functions from the ground controls Result All ground control functions should not operate ...

Page 60: ... No 1268557GT 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 61: ...nnectors 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 62: ...he 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 tog...

Page 63: ...ction 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 Comp...

Page 64: ...r Procedure How to Remove the Platform Rotator 2 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 3 Tag disc...

Page 65: ...rings Do not lose the springs Note There is one spring inside the jib boom pivot pin and one inside the angle sensor Note When the jib boom is installed the jib boom angle sensor will need to be calibrated Refer to repair procedure Jib Boom Bellcrank Angle Sensor for the calibration procedure 14 Attach a lifting strap from an overhead crane to the platform end of the jib boom 15 Support the barrel...

Page 66: ...he 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 Raise the jib boom slightly and place blocks under the platform mounting weldment Lower the jib boom until the platform ...

Page 67: ...How to Remove the Jib Boom Level Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring 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 th...

Page 68: ...d from the machine if not properly supported 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 recommende...

Page 69: ... the lower cable track 8 Remove the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom Remove the clamps 9 Pull the electrical cables out of the lower cable track that lead to the primary boom 10 Attach a lifting strap from a second overhead crane to the pivot end of the jib boom for support Do not apply any lifting pressure 11 Place a block under the ...

Page 70: ...ancing 3 6 Jib Boom Bellcrank Angle Sensor The jib boom bellcrank angle sensor is monitored by the control system to keep the jib boom bellcrank vertical and to help maintain a level platform through boom range of motion If a jib boom bellcrank angle sensor is replaced it must be calibrated prior to machine operation The jib boom bellcrank angle sensor is mounted to the bellcrank pivot pin on the ...

Page 71: ... removal so the new sensor will be installed in the same position 8 Install the new angle sensor onto the mounting bracket 9 Install one spring removed in step 6 into the hex shaped hole in the angle sensor Install the other spring into the hex shaped hole in the center of the boom pivot pin 10 Insert the hex shaped key into the angle sensor 11 Align the side of the sensor with flat area of the bo...

Page 72: ... C alibr ate the Jib Boom Bellcrank Angle Sensor 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 Refer to Repair Procedures How to Calibrate the Primary Boom Angle Sensor or How to Calibrate th...

Page 73: ... the off position Do not turn the key switch to the off position 4 Open the ground control box Before serial number 321 5 Locate the 2 pin connector in the lower left hand area of the ground control box 6 Remove the connector plug and insert a jumper wire between the two pins of the connector After serial number 320 7 Locate the calibration toggle switch at the top of the ground control box Activa...

Page 74: ...up button Fully extend the jib boom level cylinder Note When in service bypass mode the platform level buttons are used to adjust the jib boom level cylinder Note With the jib boom level cylinder is fully extended the jib boom bellcrank angle should be at approximately 60 2 degrees 16 Attach the digital level to the surface of the jib boom bellcrank as shown 1 jib boom angle sensor 2 jib boom bell...

Page 75: ...and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 22 Press and hold a function enable speed select button and raise the jib boom above horizont...

Page 76: ... and press the enter button Note Be sure the number entered at the ground controls is a negative number Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value Note With the ji...

Page 77: ...result in the machine tipping over resulting in death or serious injury The jumper wire must be removed before operating the machine 34 Close the ground control box and install the door retaining fasteners After serial number 320 35 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 cal...

Page 78: ...om 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 79: ...emove 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 pr...

Page 80: ...secondary boom lower end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device 15 Locate the two hydraulic hoses inside the end of the secondary boom that lead to the primary boom cable track 16 Tag disconnect and plug the hydraulic hoses from the unions Cap the fittings on the unions Bodily injury hazard Spraying hy...

Page 81: ...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 82: ... 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 Sp...

Page 83: ...rate 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 t...

Page 84: ... 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 tr...

Page 85: ...ry hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections...

Page 86: ... 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 87: ... 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 deat...

Page 88: ...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 89: ...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 90: ...Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 19 Attach an overhead crane or similar lifting device to the battery box for the auxiliary power unit batteries 20 Remove the battery box retaining fasteners and carefully remove the battery box from the machine Crushing hazard The battery box coul...

Page 91: ... 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 ...

Page 92: ...ylinder 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 dissipa...

Page 93: ...with 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 sec...

Page 94: ...ll 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 extensi...

Page 95: ...ctor from the sensor 4 Remove the angle sensor mounting bracket retaining fasteners 5 Remove the angle sensor and bracket assembly Do not lose the two springs or the hex shaped key 6 Remove the sensor retaining fasteners from the mounting bracket Remove the angle sensor Note Note the sensor orientation on the bracket during removal so the new sensor will be installed in the same position 7 Install...

Page 96: ...o the new sensor 15 Install the primary boom end cover 16 Calibrate the primary boom angle sensor Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor How to C alibr ate the Pri mary Boom Angle Sensor How to Calibrate the Primary Boom Angle Sensor The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity...

Page 97: ... Previous Enter Note Perform this procedure with the machine on a firm level surface with the booms in the fully stowed position in the drive enable zone and the axles fully extended 6 Point Calibration procedure Note Use this procedure for software versions before 4 01 Note For the 2 Point Calibration procedure proceed to step 37 1 Push in the ground controls red Emergency Stop button to the off ...

Page 98: ...th step 14 16 Fully raise the secondary boom The boom is fully raised when the cylinder is fully extended and the boom stops moving 17 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 18 At the ground controls press the plus button or minus button to adjust the display to the exact valu...

Page 99: ...ess 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 27 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to...

Page 100: ... controls 39 Open the ground control box 40 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 41 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 42 Remove the key from t...

Page 101: ...calibration points or values will not be saved 56 Press the enter or previous button on the LCD screen until EXIT is displayed 57 Press the plus button to select YES then press the enter button to accept 58 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass ...

Page 102: ...ener Remove the cover 4 Remove the angle sensor mounting bracket retaining fasteners 5 Remove the angle sensor and bracket assembly Do not lose the two springs or the hex shaped key 6 Remove the sensor retaining fasteners from the mounting bracket Remove the angle sensor Note Note the sensor orientation on the bracket during removal so the new sensor will be installed in the same position 7 Instal...

Page 103: ...s been replaced they must be calibrated first Refer to Repair Procedure How to Calibrate the Axle Angle Senors 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 2 Point Calibration procedure For software versions before 4...

Page 104: ...d control box Activate calibration mode by moving the toggle switch in the left direction 7 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine All models 8 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass...

Page 105: ...n or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 18 Pres...

Page 106: ...e system must detect a change in displayed value to record the calibrated value 26 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 27 Press the enter or previous button on the LCD screen...

Page 107: ... key switch to the off position 37 Turn the key switch to ground controls 38 Open the ground control box 39 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 40 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the togg...

Page 108: ...cy Stop button or all calibration points or values will not be saved 52 Press the enter or previous button on the LCD screen until EXIT is displayed 53 Press the plus button to select YES then press the enter button to accept 54 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be...

Page 109: ... is bolted to the engine flywheel and has a splined center to drive the pump Two different styles of flex plates have been used in the production of your machine model Type A flex plates utilize a flex plate installed onto the flywheel of the engine and a separate coupler installed onto the pump splined shaft Type B flex plates combines the pump coupler as part of the flex plate which is installed...

Page 110: ... the flex plate from the engine flywheel How to i nstall a Type A Flex Pl ate How to Install a Type A Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump 2 Ford models Torque the flex plate mounting bolts in sequence to 14 ft lbs 19 Nm Then torque the flex plate mounting bolts in sequence to 20 ft lbs 27 Nm Deutz models Torque the flex plate mountin...

Page 111: ...r 4 flex plate with raised spline 5 engine flywheel 6 Deutz models 0 188 inch 4 8 mm gap Cummins and Perkins models 0 25 inch 6 4 mm gap 4 Cummins and Perkins models Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 22 ft lbs 30 Nm Deutz models Apply Loctite removable thread sealant to the pump coupler set screw Torque the set screw to 61 ft lbs 83 Nm Com...

Page 112: ...able thread sealant to the flex plate fasteners and loosely install the fasteners 3 Deutz and Perkins models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft lbs 54 Nm Cummins models Torque the flex plate mounting bolts in sequence to 14 ft lbs 19 Nm Then torque the flex plate mounting bolts in sequence to 20 ft lbs ...

Page 113: ...ecovery 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 parameters Recovery is only to be used as a last attempt to lowe...

Page 114: ...isabled 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 115: ...using software version 1 11 and later For machines using software version 1 01 contact Genie Product Support 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 cleare...

Page 116: ...edure 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 watch...

Page 117: ...ttach 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 t...

Page 118: ...l 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 ...

Page 119: ...rol 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 se...

Page 120: ...inus 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 121: ...rn 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 Reset With key switch OFF pres...

Page 122: ...utton and press minus previous previous minus Clear all safety switch faults Reset faults will reset active latching faults will not clear fault history Drive Functions With key switch OFF press and hold the enter button and turn key switch to on position Release the enter button and press plus plus enter enter Forward extended drive speed 120 max 100 default 50 min Forward not stowed drive speed ...

Page 123: ...d 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 rotat...

Page 124: ...cceleration 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 T...

Page 125: ...valve 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 calibratio...

Page 126: ... 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 a...

Page 127: ...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 128: ...and 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 Cutou...

Page 129: ...wo 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 t...

Page 130: ... 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 Pr...

Page 131: ... 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 132: ...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 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 hazar...

Page 133: ...ow 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 th...

Page 134: ... retract 30 35 ft lbs 41 47 Nm 4 Solenoid Valve 2 position 3 way J Secondary boom extend 50 55 ft lbs 68 75 Nm 5 Solenoid Valve 2 position 3 way H Secondary boom up 50 55 ft lbs 68 75 Nm 6 Plug 16 SAE Port plug 130 140 ft lbs 176 190 Nm 7 Relief valve 3100 psi 214 bar L System relief 30 35 ft lbs 41 47 Nm 8 Solenoid Valve 2 position 3 way I Secondary boom down 30 35 ft lbs 41 47 Nm 9 Solenoid Valv...

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Page 136: ...tract circuit regulates pressure drop across primary boom extend retract proportional valve 30 35 ft lbs 41 47 Nm 7 Differential sensing valve 150 psi 10 3 bar U Secondary boom extend retract circuit regulates pressure drop across secondary boom extend retract proportional valve 50 55 ft lbs 68 75 Nm 8 Differential sensing valve 150 psi 10 3 bar S Secondary boom up down circuit regulates pressure ...

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Page 138: ...47 Nm 7 Solenoid Valve 2 position 3 way I Secondary boom down 30 35 ft lbs 41 47 Nm 8 Solenoid Valve 2 position 3 way H Secondary boom up 30 35 ft lbs 41 47 Nm 9 Check valve DF Tank return circuit 130 140 ft lbs 176 190 Nm 10 Solenoid valve 3 position 4 way B Turntable rotate left right 30 35 ft lbs 41 47 Nm 11 Relief valve 3100 psi 214 bar L System relief 30 35 ft lbs 41 47 Nm 12 Differential sen...

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Page 140: ... ft lbs 27 34 Nm 5 Proportional solenoid valve P Primary boom up down circuit 50 55 ft lbs 68 75 Nm 6 Proportional solenoid valve R Primary boom extend retract circuit 50 55 ft lbs 68 75 Nm 7 Proportional solenoid valve V Secondary boom extend retract circuit 50 55 ft lbs 68 75 Nm 8 Proportional solenoid valve T Secondary boom up down circuit 50 55 ft lbs 68 75 Nm 9 Proportional solenoid valve N T...

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Page 142: ...Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specification 5 Hold the relief valve stem with a hex wrench and remove the cap 6 Adjust the internal hex socket Turn it clockwise to increase the pressure Install the relief cap Tip over hazard Do not adjust the relief valve higher than specified 7 Repeat step 4 to confirm relief valve pressure 8 Remove...

Page 143: ...j ust the Pri mar y Boom Extend R elief Val ve How to Adjust the Primary Boom Extend Relief Valve Note Perform this procedure with the axles extended 1 Remove the primary boom end cover from the pivot end of the boom 2 Locate the primary boom extend limit switch on the side of the primary boom 3 Follow the wiring from the switch to the pivot end of the primary boom Locate and disconnect the wire c...

Page 144: ... the relief valve and remove the cap 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 10 Repeat step 7 to confirm relief valve pressure 11 At the pivot end of the primary boom connect the primary boom extend limit switch connector...

Page 145: ... 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 ...

Page 146: ...tion 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 ...

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Page 148: ... 6 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 149: ...unction 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 150: ...otation 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 152: ...rcuit 20 25 ft lbs 27 34 Nm 5 Solenoid valve 3 position 4 way BQ Steer left right right rear steer cylinder 20 25 ft lbs 27 34 Nm 6 Check valve BE Prevents right rear steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 7 Check valve BD Prevents right rear steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 8 Solenoid valve 3 position 4 way BP Steer left right left rea...

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Page 154: ...gpm 5 7 L min BM Right rear steer cylinder retract circuit 20 25 ft lbs 27 34 Nm 16 Flow regulator valve 1 5 gpm 5 7 L min BG Left front steer cylinder retract circuit 20 25 ft lbs 27 34 Nm 17 Flow regulator valve 2 1 gpm 8 L min BF Left front steer cylinder extend circuit 20 25 ft lbs 27 34 Nm 18 Flow regulator valve 2 1 gpm 8 L min BH Right front steer cylinder extend circuit 20 25 ft lbs 27 34 ...

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Page 156: ... 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 t...

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Page 158: ... AW Brake circuit 20 25 ft lbs 27 1 33 9 Nm 6 Shuttle Valve 3 position 3 way AO Charge pressure circuit that directs hot oil out of low pressure side of drive pump 50 55 ft lbs 68 75 Nm 7 Relief valve 250 psi 17 2 bar AN Charge pressure circuit 30 35 ft lbs 40 7 47 5 Nm 8 Solenoid Valve 2 position 3 way AY Brake release 20 25 ft lbs 27 1 33 9 Nm 9 Solenoid Valve 2 position 3 way AX Two speed drive...

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Page 160: ...n 1 mm serial number 102 and after serial number 179 AL Equalizes pressure on both sides of divider combiner valve AM 2 Orifice 0 052 in 1 3 mm AQ Equalizes pressure on both sides of divider combiner valve AP 3 Orifice 0 063 in 1 6 mm AS Equalizes pressure on both sides of divider combiner valve AR 4 Orifice 0 030 in 0 76 mm AV Brake and two speed circuit 5 Check valve 5 psi 0 3 bar AU Drive motor...

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Page 162: ...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 163: ...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 164: ... 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 temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decre...

Page 165: ...n 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 Conne...

Page 166: ...draulic 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 167: ...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 168: ...o 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 the off position 2 Open the ground control box Before serial number 321 3 Locate the 2 pi...

Page 169: ...gle switch is activated 9 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 10 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 1 Run 2 Bypass 3 Recovery Note Th...

Page 170: ...own on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 14 Press the enter or previous button on the LCD screen until SET UN...

Page 171: ...ate the machine 20 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in Before serial number 321 21 Remove the wire jumper from the 2 pin connector in the lower left hand area of the ground control box that was installed in step 4 Install the connector plug Tip over hazard Failure to remove the jumper wire will result in an unsafe configuration which ...

Page 172: ...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 173: ...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 174: ...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 175: ...calibrating the machine All models 5 Turn the key switch to ground controls and pull out the ground controls red Emergency Stop button to the on position 6 Loosen the steer angle sensor cover retaining fasteners Do not remove the fasteners or the sensor cover 7 Using a voltmeter set to DC voltage probe the back of the electrical connector at pins B and C 8 Left front square end blue side and right...

Page 176: ...ALIBRATION is displayed Press the plus button to select YES then press the enter button to accept Note Models before software version 3 0 the LCD screen will display RESET ALL STEER SENSORS 14 Press the enter or previous button on the LCD screen until EXIT is displayed 15 Press the plus button to select YES then press the enter button to accept 16 Proceed to step 22 Delete a Single Steer Sensor Ca...

Page 177: ...ass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine 10 2 Steer Cylinders How to Remove a Steer Cylinder 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...

Page 178: ... 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 pow...

Page 179: ...sensors will need to be calibrated Note Perform this procedure with the axles fully retracted and the boom in the stowed position 1 Locate the axle angle sensor to be replaced 2 Tag and disconnect the angle sensor electrical connector from the chassis harness 3 Remove the angle sensor cover retaining fasteners Remove the angle sensor assembly Note Inspect the sensor activator pin to make sure it i...

Page 180: ...e sensor with the pin and install the sensor on to the pin Note Be sure the actuator pin is engaged into the sensor 6 Rotate the sensor housing in a clockwise direction until the sensor cable is parallel with the drive chassis side plate Refer to illustration 2 7 Install the axle sensor cover retaining fasteners Do not tighten the retaining fasteners 8 Connect the axle sensor assembly cable to the...

Page 181: ...ltmeter set to DC voltage probe the back of the electrical connector at pins 2 and 3 Note If available WebGPI can also be used for this procedure 4 Rotate the sensor cover clockwise or counterclockwise until the voltage reading is between 4 2 to 4 4V DC Tighten the sensor cover retaining fasteners 5 Repeat steps 2 through 4 for the other axle angle sensor if needed 6 Push in the ground controls re...

Page 182: ...s red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 14 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 15 Press the enter or previous button on the LCD screen until DELETE AXLE ANGLE SENSORS CALIBRATION is displayed Press the plus button to select YES then p...

Page 183: ...ol box that was installed in step 8 Install the connector plug Tip over hazard Failure to remove the jumper wire will result in an unsafe configuration which will compromise machine stability Operating the machine in this configuration will result in the machine tipping over resulting in death or serious injury The jumper wire must be removed before operating the machine 24 Close the ground contro...

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Page 185: ...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 R Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine R Be sure that all nece...

Page 186: ...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 187: ... 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 ...

Page 188: ...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 189: ...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 190: ...splay 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 membra...

Page 191: ... 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 192: ...active 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 193: ...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 194: ...as 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 leve...

Page 195: ...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 196: ...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 197: ...device 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 functio...

Page 198: ...ted 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 199: ...ansient 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 z...

Page 200: ...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 201: ...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 202: ...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 203: ...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 204: ...Service and Repair Manual October 2018 190 Z 135 70 Part No 1268557GT This page intentionally left blank ...

Page 205: ...he safety rules and operating instructions in the appropriate operator s manual on your machine R 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 ...

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: ...e 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 ...

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: ...79 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 Interloc...

Page 213: ...r 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 Bellcran...

Page 214: ...Control 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 Functi...

Page 215: ...o 1268557GT Z 135 70 201 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: ...or 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 ...

Page 217: ...nctions 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 t...

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: ...LSS1RS 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 re...

Page 220: ...eutsch 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 fo...

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: ...S 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: ...rs 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 1...

Page 225: ...e Fuel Relay 2 CR17 Hydraulic Oil Cooler Fan Relay 3 CR41 Flashing Beacon Relay 4 CR5 Horn Relay 5 CB10 Circuit Breaker 20A RPM Solenoid 6 F23 Fuse 30A Engine Start Alternator 7 F22 Fuse 60A Glow Plug 8 F7 Fuse 20A Hydraulic Oil Cooler Fan 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 R...

Page 226: ...ernator Relay 2 CR17 Hydraulic Oil Cooler Fan Relay 3 CR41 Flashing Beacon Relay 4 CR5 Horn Relay 5 CB10 Circuit Breaker 20A RPM Solenoid 6 F23 Fuse 30A Engine Start Alternator 7 F22 Fuse 60A Glow Plug 8 F7 Fuse 20A Hydraulic Oil Cooler Fan 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 ...

Page 227: ...nnection 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 228: ...huttle 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 oper...

Page 229: ...October 2018 Service and Repair Manual 215 Perkins 1104C 44 and 804D 33T Engine Electrical Schematic ...

Page 230: ...Service and Repair Manual October 2018 216 Z 135 70 Part No 1268557GT Perkins 1104C 44 and 804D 33T Engine Electrical Schematic ...

Page 231: ...October 2018 Service and Repair Manual Part No 1268557GT Z 135 70 217 Cummins B4 5L and B3 3T Engine Electrical Schematic ...

Page 232: ...Service and Repair Manual October 2018 218 Cummins B4 5L and B3 3T Engine Electrical Schematic ...

Page 233: ...October 2018 Service and Repair Manual 219 Generator Wiring Schematic ...

Page 234: ...Service and Repair Manual October 2018 220 Z 135 70 Part No 1268557GT Generator Wiring Schematic ...

Page 235: ...October 2018 Service and Repair Manual Part No 1268557GT Z 135 70 221 Hydraulic Generator Welder Option ...

Page 236: ...Service and Repair Manual October 2018 222 Hydraulic Generator Welder Option ...

Page 237: ...October 2018 Service and Repair Manual 223 Hydraulic Schematic before serial number 180 except for serial number 102 ...

Page 238: ...Service and Repair Manual October 2018 224 Z 135 70 Part No 1268557GT Hydraulic Schematic before serial number 180 except for serial number 102 ...

Page 239: ...October 2018 Service and Repair Manual Part No 1268557GT Z 135 70 225 Hydraulic Schematic serial number 102 and from serial number 180 to 534 ...

Page 240: ...Service and Repair Manual October 2018 226 Hydraulic Schematic serial number 102 and from serial number 180 to 534 ...

Page 241: ...October 2018 Service and Repair Manual Part No 1268557GT Z 135 70 227 Hydraulic Schematic from serial number 535 ...

Page 242: ...Service and Repair Manual October 2018 228 Hydraulic Schematic from serial number 535 ...

Page 243: ...HIELD NOT USED NOT USED NOT USED NOT USED JIB EXTEND SERV CAL MODE NOT USED LP VALVE RTN 3 J14 WHITE 35 PIN MANIFOLD HARNESS J12 BLACK 35 PIN LIMIT SWITCH HARN J11 BLACK 23 PIN BOOM HARN SEC BM U D FC VLV UNUSED NOT USED NOT USED NOT USED NOT USED NOT USED JIB RETRACT NOT USED NOT USED NOT USED BOOT NOT USED UNUSED UNUSED PROPEL POWER INPUT HYD WELDER PROPEL BYPASS J22 35 PIN WHITE PCON MANIFOLD H...

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