Manual de Servicio y Reparación Genie S 125

Service and Repair Manual
Serial Number Range
Z-135/70
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. 1268557

Rev A1
November 2015
Service and Repair Manual November 2015
Introduction
Intr oducti on Intr oducti on
Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical skills are communications will be carefully considered for
required to perform most procedures. However, future printings of this and all other manuals.
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that Contact Us:
maintenance and repair be performed at an
authorized Genie dealer service center. Internet: www.genielift.com
E-mail: awp.techpub@terex.com
Compliance Find a Manual for this Model

Go to http://www.genielift.com
Machine Classification
Use the links to locate Operator's, Parts,
Group B/Type 3 as defined by ISO 16368
Maintenance, and Service and Repair manuals.
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2015 by Terex Corporation

1268557 Rev A, September 2015
First Edition, First Printing

Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“Z” is a trademark of Terex South Dakota, Inc.
ii Z-135/70 Part No. 1268557

November 2015 Service and Repair Manual
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 11/2015 Page 199
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Part No. 1268557 Z-135/70 iii

Introduction
Serial Number Legend
1 Model
2 Model year
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)
iv Z-135/70 Part No. 1268557

Safety Rules
Section 1 Safety R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance

Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 1268557 Z-135/70 v

Safety Rules
Personal Safety Workplace Safety

Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
Be aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
vi Z-135/70 Part No. 1268557

November 2015
Table of Contents
Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules .......................................................................................................... v

General Safety Rules ............................................................................................. v
Section 2 Specifications ....................................................................................................... 1

Machine Specifications ........................................................................................... 1
Performance Specifications .................................................................................... 1
Hydraulic Specification ........................................................................................... 2
Hydraulic Component Specifications...................................................................... 4
Deutz BF4L 2011 Engine Specifications ................................................................ 6
Deutz TD2011L04i Engine Specifications .............................................................. 8
Cummins B4.5L Engine Specifications ................................................................ 10
Cummins B3.3T Engine Specifications ................................................................ 12
Perkins 1104C-44 Engine Specifications ............................................................. 14
Perkins 804D-33T Engine Specifications ............................................................. 16
Machine Torque Specifications ............................................................................ 18
Hydraulic Hose and Fitting Torque Specifications ............................................... 19
Torque Procedure ................................................................................................ 20
SAE and Metric Fasteners Torque Charts ........................................................... 22
Part No. 1268557 Z-135/70 vii

November 2015
Table of Contents
Section 3 Repair Procedures ............................................................................................. 23

Introduction .......................................................................................................... 23
Platform Controls ............................................................................................... 25

Platform Controls ................................................................................................. 25
1-1 Platform Circuit Board .................................................................................... 26
How to Remove the LED Circuit Board .......................................................... 27
1-2 Membrane Decal ........................................................................................... 28
1-3 Joysticks - How to Calibrate a Joystick ......................................................... 29
How to Reset a Proportional Valve Coil Default ............................................. 33
How to Set the Function Thresholds and Default Functions Speeds ............. 33
How to Adjust the Function Speeds ............................................................... 35
How to Adjust the Function Ramp Rate Setting ............................................. 36
Platform Components ....................................................................................... 38

2-1 Platform Leveling Cylinder ............................................................................. 38
2-2 Platform Rotator ............................................................................................. 39
How to Bleed the Platform Rotator ................................................................. 41
2-3 Platform Level Sensor - How to Calibrate the Platform Level Sensor ........... 41
2-4 Platform Overload System (if equipped) ........................................................ 43
Jib Boom Components ...................................................................................... 45

3-1 Jib Boom Cable Track ................................................................................... 46
How to Repair the Cable Track....................................................................... 48
3-2 Jib Boom ........................................................................................................ 49
3-3 Jib Boom Lift Cylinder .................................................................................... 51
3-4 Jib Boom Level Cylinder ................................................................................ 52
3-5 Jib Boom Extension Cylinder ......................................................................... 53
3-6 Jib Boom Bellcrank Angle Sensor ................................................................. 55
How to Calibrate the Jib Boom Bellcrank Angle Sensor ................................ 57
viii Z-135/70 Part No. 1268557

November 2015
Table of Contents
Boom Components ............................................................................................ 63

4-1 Primary Boom Cable Track ............................................................................ 64
How to Repair the Primary Boom Cable Track ............................................... 66
4-2 Secondary Boom Cable Track ....................................................................... 67
How to Repair the Secondary Boom Cable Track .......................................... 69
4-3 Primary Boom ................................................................................................ 70
4-4 Primary Boom Lift Cylinder ............................................................................ 72
4-5 Secondary Boom Lift Cylinder ....................................................................... 73
4-6 Primary Boom Extension Cylinder ................................................................. 77
4-7 Secondary Boom Extension Cylinders ........................................................... 78
4-8 Primary Boom Angle Sensor .......................................................................... 80
How to Calibrate the Primary Boom Angle Sensor ......................................... 81
4-9 Secondary Boom Angle Sensor ..................................................................... 86
How to Calibrate the Secondary Boom Angle Sensor .................................... 87
Engines ................................................................................................................ 92
5-1 RPM Adjustment ............................................................................................ 92
5-2 Flex Plate ....................................................................................................... 92
How to install a Type "A" Flex Plate ................................................................ 93
How to install a Type "B" Flex Plate ................................................................ 95
Ground Controls ................................................................................................. 96

6-1 Bypass/Recovery Key Switch ........................................................................ 96
How to Use the Recovery Mode ..................................................................... 98
6-2 Circuit Boards ................................................................................................. 99
6-3 Membrane Decal .......................................................................................... 101
6-4 Full Machine Calibration............................................................................... 102
Display Module ................................................................................................. 103
Hydraulic Pumps .............................................................................................. 111

7-1 Function Pump ............................................................................................. 111
How to Prime the Function Pump ................................................................. 112
How to Adjust the Function Pump Standby Pressure ................................... 112
How to Adjust the Function Pump Pressure Compensator .......................... 113
7-2 Drive Pump................................................................................................... 114
How to Prime the Drive Pump ....................................................................... 115
Part No. 1268557 Z-135/70 ix

November 2015
Table of Contents
Manifolds .......................................................................................................... 116

8-1 Function Manifold - (before serial number 440)........................................... 116
8-2 Function Manifold - (after serial number 439) .............................................. 120
8-3 Valve Adjustments - Function Manifold ....................................................... 124
How to Adjust the System Relief Valve ........................................................ 124
How to Adjust the Primary Boom Extend Relief Valve ................................. 125
8-4 Platform Manifold ......................................................................................... 127
8-5 Jib Boom Manifold ....................................................................................... 128
8-6 Flow Control Mainfold .................................................................................. 130
8-7 Function Enable Valve ................................................................................. 131
8-8 Turntable Rotation Manifold......................................................................... 132
8-9 Steer and Axle Manifold............................................................................... 134
8-10 Valve Adjustments - Steer and Axle Manifold ........................................... 138
8-11 Traction Manifold ....................................................................................... 140
8-12 Valve Adjustments - Traction Manifold ...................................................... 144
8-13 Drive Oil Diverter Manifold (welder option) ................................................ 145
8-14 Valve Coils ................................................................................................. 146
How to Test a Coil Diode .............................................................................. 147
Turntable Rotation Components .................................................................... 148

9-1 Turntable Rotation Assembly....................................................................... 148
How to Adjust the Turntable Rotation Gear Backlash .................................. 149
9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor ..... 150
Axle Components............................................................................................. 154

10-1 Steer Sensors ............................................................................................ 154
How to Calibrate a Replacement Steer Sensor ............................................ 156
How to Calibrate All Steer Sensors .............................................................. 157
10-2 Steer Cylinders .......................................................................................... 159
10-3 Axle Extension Cylinders ........................................................................... 160
10-4 Axle Angle Sensors ................................................................................... 161
How to Calibrate the Axle Angle Sensors ..................................................... 163
x Z-135/70 Part No. 1268557

November 2015
Table of Contents
Section 4 Fault Codes ....................................................................................................... 167

Introduction ......................................................................................................... 167
Control System Fault Codes .............................................................................. 168
Fault Matrix ......................................................................................................... 185
Section 5 Schematics........................................................................................................ 187

Introduction ......................................................................................................... 187
Wire Circuit Legend ............................................................................................ 188
Wire Color Legend ............................................................................................. 192
Limit Switches and Angle Sensors ..................................................................... 197
Circuit Connector Legend ................................................................................... 201
Drive Chassis and Platform Controller Pin Legend ............................................ 204
Safety Controller Pin Legend ............................................................................. 205
Turntable Controller Pin Legend ........................................................................ 206
Engine Relay and Fuse Panel Legend -
Deutz BF4L 2011, TD2011L04i, Perkins 1104C-44 and 804D-33T ........... 207
Engine Relay and Fuse Panel Legend - Cummins B4.5L and B3.3T ................ 208
Electrical Symbols Legend ................................................................................. 209
Hydraulic Symbols Legend ................................................................................. 210
Perkins 1104C-44 and 804D-33T Engine Electrical Schematic ......................... 212
Cummins B4.5L and B3-3.3T Engine Electrical Schematic ............................... 213
Generator Wiring Schematic .............................................................................. 216
Hydraulic Generator (Welder Option) ................................................................. 217
Hydraulic Schematic
(before serial number 180, except for serial number 102) ......................... 220
Hydraulic Schematic
(serial number 102 and from serial number 180 to 534) ............................ 221
Hydraulic Schematic (from serial number 535) .................................................. 223
Electrical Schematic ........................................................................................... 225
Part No. 1268557 Z-135/70 xi

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12 Z-135/70 Part No. 1268557

Specifications
Section 2 Specific ati ons
Machine Specifications Performance Specifications

Tires and wheels Drive speed, maximum
Tire size 445/65D22.5, FF Stowed position, high speed 2.8 mph
Tire ply rating 18 4.5 km/h
40 ft / 9.7 sec
Tire weight, new foam-filled 815 lbs 12.2 m / 9.7 sec
(minimum) 370 kg
Raised or extended 0.7 mph
Overall tire diameter 46.5 in 1.1 km/h
118.1 cm 40 ft / 40 sec
Wheel diameter 22.5 in 12.2 m / 40 sec
57.2 cm Primary and Secondary booms 0.4 mph
Wheel width 13 in raised, and Primary and Jib 0.6 km/h
33 cm extended 40 ft / 68.5 sec
12.2 m / 68.5 sec
Wheel lugs 10 @ 3/4 -16
Braking distance, maximum
Lug nut torque, dry 420 ft-lbs
569.4 Nm High range on paved surface 3 to 6 ft
1 to 2 m
Lug nut torque, lubricated 320 ft-lbs
433.9 Nm Gradeability See Operator's
Manual
Fluid capacities
Boom function speeds, maximum from platform
Fuel tank 40 gallons controls
151.4 liters
Jib boom up/down 38 to 43 seconds
Hydraulic tank 65 gallons
246 liters Jib boom extend/retract 38 to 42 seconds
Hydraulic system (including tank) 123 gallons Primary boom up/down 88 to 105 seconds
466 liters -60° to +70°
Drive hubs 47 fl oz Primary boom extend/retract 35 to 48 seconds

1390 cc Secondary boom up/down 80 to 95 seconds
Turntable rotation drive hub 40 fl oz Secondary boom extend/retract 88 to 98 seconds
1183 cc
Turntable rotate, 360° 88 to 92 seconds
Drive hub oil type: SAE 90 multipurpose hypoid gear oil fully stowed
API service classification GL5
Turntable rotate, 360°jib or 160 to 180 seconds
primary booms extended
Turntable rotate, 360°jib and 280 to 350 seconds
primary booms extended
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
Part No. 1268557 Z-135/70 1

Specifications
Hydraulic Oil Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties.
component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium Hydraulic Fluid Temperature
Viscosity grade 32 Range
Viscosity index 200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable Petro Canada Environ MV 46
Fire resistant UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for Ambient air temperature
the approved optional fluids. Consult Genie Product
Support before use. 1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
Optional fluids may not have the 3 UCON Hydrolube HP-5046D
same hydraulic lifespan and 4 Chevron Rando HD premium oil MV
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 hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
2 Z-135/70 Part No. 1268557

Specifications
Chevron Rando HD Premium Oil Continued use of Chevron

5606A hydraulic fluid, or
MV Fluid Properties equivalent, when ambient
ISO Grade 32 temperatures are consistently
above 32°F / 0°C may result in
Viscosity index 200
component damage
Kinematic Viscosity
cSt @ 200°F / 100°C 7.5
cSt @ 104°F / 40°C 33.5
Brookfield Viscosity
Petro-Canada Environ MV 46
cP @ -4°F / -20°C 1040 Fluid Properties
cP @ -22°F / -30°C 3310
ISO Grade 46
Flash point 375°F / 190°C
Viscosity index 154
Pour point -58°F / -50°C
Kinematic Viscosity
Maximum continuous operating 171°F / 77°C
cSt @ 200°F / 100°C 8.0
temperature
cSt @ 104°F / 40°C 44.4
Note: An hydraulic oil heating system is Flash point 482°F / 250°C
recommended when the ambient temperature is
consistently below 0°F / -18°C. Pour point -49°F / -45°C
Note: Do not operate the machine when the temperature
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
UCON Hydrolube HP-5046 Fluid
Chevron 5606A Hydraulic Oil Properties
Fluid Properties ISO Grade 46
Viscosity index 192
ISO Grade 15
Kinematic Viscosity
Viscosity index 300
cSt @ 149°F / 65°C 22
Kinematic Viscosity cSt @ 104°F / 40°C 46
cSt @ 200°F / 100°C 5.5 cSt @ 0°F / -18°C 1300
cSt @ 104°F / 40°C 15.0
Flash point None
cSt @ -40°F / -40°C 510
Flash point 180°F / 82°C
temperature
temperature
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Part No. 1268557 Z-135/70 3

Specifications
Hydraulic Component Auxiliary Pump
Specifications Type: fixed displacement gear pump

Displacement per revolution 0.15 cu in
Drive Pump 2.47 cc
Type: bi-directional variable displacement piston pump Function manifold
Displacement per revolution 2.8 cu in System relief valve pressure, maximum 3100 psi
46 cc (measured at test port) 213.7 bar
Flow rate @ 2350 rpm 28.5 gpm Primary boom extend relief pressure 2600 psi
108 L/min (measured at ptest port) 179 bar
Drive pressure, maximum 3625 psi Jib and platform manifolds
250 bar
Platform rotate and platform level flow 0.2 gpm
Charge Pump regulator 0.76 L/min
Type gerotor Jib manifold flow regulator 2 gpm
Displacement per revolution 0.85 cu in 7.6 L/min
13.9 cc Steer/Axle Manifold
Flow rate @ 2350 rpm 9 gpm Axle extend relief pressure 2400 psi
34 L/min 165 bar
Charge pressure @ 2350 rpm 315 ps Traction Manifold
Neutral position i21.7 bar
Hot oil relief pressure 250 psi
Function pump 17.2 bar
Type: variable displacement piston pump Hydraulic Filters
Displacement per revolution 0 to 2.75 cu in High pressure filter: Beta 3 ≥ 200
0 to 45 cc
High pressure filter bypass pressure 102 psi
Flow rate @ 2350 rpm 0 to 28 gpm 7 bar
0 to 106 L/min
Medium pressure filter Beta 3 ≥ 200
Pressure, maximum 2900 psi
200 bar Medium pressure filter bypass pressure 51 psi
3.5 bar
Pressure compensator 2900 psi
200 bar Hydraulic tank return filter 10 micron
with 25 psi / 1.7 bar bypass
Standby pressure 250 psi
17 bar Drive motor case drain return filter Beta 10 ≥ 2
4 Z-135/70 Part No. 1268557

Specifications
Brakes Manifold Component Specifications

Brake relief pressure 190 psi Plug torque
13 bar
SAE No. 2 36 in-lbs / 4 Nm
Drive Motors
SAE No. 4 10 ft-lbs / 13 Nm
(before serial number 180)
(see note below) SAE No. 6 14 ft-lbs / 19 Nm
Displacement per revolution, high 0.8 cu in SAE No. 8 38 ft-lbs / 51 Nm
speed 13.3 cc SAE No. 10 41 ft-lbs / 55 Nm
Displacement per revolution, low 2.7 cu in SAE No. 12 56 ft-lbs / 76 Nm
speed (square end) 45 cc
Valve coil resistance specifications
Displacement per revolution, low 1.5 cu in
speed (circle end) 25 cc Proportional solenoid valve 3.5 to
(schematic items N, P, R, T, V) 5.5Ω
Drive Motors
(after serial number 179) Solenoid valve, 3 position 4 way 4 to 6Ω
(schematic item B)
Displacement per revolution, high 0.8 cu in
speed 13.3 cc Solenoid valve, 3 position 4 way 7 to 9Ω
(schematic items BN, BO, BP, BQ)
speed (square end) 45 cc Solenoid valve, 3 position 4 way 8 to 10Ω
(schematic item AH)
speed (circle end) 25 cc Proportional solenoid valve, 3 position 4 way 8 to 10Ω
(schematic items Y, AI)
Note: Serial number 102 is equipped with drive
Solenoid Valve, 2 position 3 way 5.5 to
motors equal to those used on machines after serial
(schematic items F and AD) 7.5Ω
number 179.
Solenoid Valve, 2 position 3 way 8 to 10Ω
(schematic items AE, AF)
Solenoid valve, 2 position, 2 way 3.5 to
(schematic items H, J) 5.5Ω
(schematic items C, D, G, I, K, AX, AY, BU, BT) 9.5Ω
Solenoid valve, 2 position, 2 way 3.5 to
(schematic item A) 5.5Ω
Part No. 1268557 Z-135/70 5

Specifications
Deutz BF4L 2011 Engine Lubrication system

Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
Displacement 189.6 cu. in 2.8 to 4.1 bar
3.1 liters
Oil capacity (including filter) 11 quarts
Number of cylinders 4 10.4 liters
Bore and Stroke 3.7 x 4.409 inches Oil viscosity requirements
94 x 112 mm
-22°F to 86°F / -30°C to 30°C 5W-30
Horsepower net intermittent (synthetic)
Continuous @ 2500 rpm 69 hp / 51 kW
Net intermittent @ 2500 rpm 73 hp / 54 kW -4°F to 90°F / -20°C to 32°C 10W-40
Firing order 1-3-4-2 Above 23°F / -5°C 20W-50
Low idle 1500 rpm Unit ships with 15W-40. Extreme operating
383 Hz temperatures may require the use of alternative
engine oils. For oil requirements, refer to the
High idle 2350 rpm
Engine Operator Manual for your engine.
599 Hz
Compression ratio 17.5:1 Oil temperature switch
Compression pressure pressure (psi or bar) of the Installation torque 8 - 18 ft-lbs
lowest cylinder must be at least 75% of the highest 11 - 24 Nm
cylinder Temperature switch point 275°F
Governor centrifugal 135°C
mechanical Oil Pressure switch
Valve Clearance, cold Installation torque 8 - 18 ft-lbs
Intake 0.012 in 11 - 24 Nm
0.3 mm Pressure switch point 7 psi
Exhaust 0.020 in 0.48 bar
0.5 mm
6 Z-135/70 Part No. 1268557

Specifications
Deutz BF4L 2011 cont.

Fuel injection system Motorpal
Injection pump pressure, 15,000 psi
maximum 1034 bar
Injector opening pressure 3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Starter motor
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 12.5 mm
Part No. 1268557 Z-135/70 7

Specifications
Deutz TD2011L04i Engine Lubrication system

3.62 liters
Oil capacity (including filter) 12.8 quarts
96 x 125 mm
-22°F to 86°F / -30°C to 30°C 5W-30
Horsepower net intermittent @ (synthetic)
2400 rpm 74 hp / 55 kW
-4°F to 104°F / -20°C to 40°C 10W-40
Induction system turbocharged
Above 5°F / -15°C 15W-40
Firing order 1-3-4-2
Unit ships with 15W-40. Extreme operating
Low idle 1500 rpm temperatures may require the use of alternative
383 Hz engine oils. For oil requirements, refer to the
High idle 2350 rpm Engine Operator Manual for your engine.
599 Hz
Oil temperature switch
Compression ratio 17.5:1
Installation torque 8 - 18 ft-lbs
Compression pressure pressure (psi or bar) of the
11 - 24 Nm
lowest cylinder must be at least 75% of the highest
cylinder Temperature switch point 275°F
135°C
Governor centrifugal mechanical
Oil Pressure switch
Valve Clearance, cold
Intake 0.012 in
11 - 24 Nm
0.3 mm
Pressure switch point 22 psi
Exhaust 0.020 in
1.5 bar
0.5 mm
8 Z-135/70 Part No. 1268557

Specifications
Deutz TD2011L04i cont.

Fuel injection system Motorpal
maximum 1034 bar
210 bar
Fuel requirement
Starter motor
Type 6V DC
Quantity 2
Quantity 1
9.5 to 12.5 mm
Part No. 1268557 Z-135/70 9

Specifications
Cummins B4.5L Engine Lubrication system

Oil pressure, hot (@ 2000 rpm) 50 psi
Displacement 275 cu. in 3.45 bar
4.5 liters
Number of cylinders 4 9 liters
102 x 138 mm
Below 68°F / 20°C 5W-30
Horsepower net intermittent @
2200 rpm 80 hp / 60 kW -10°F to 68°F / -23°C to 20°C 10W-40
High idle 2350 rpm
599 Hz
Compression ratio 18:1 Continuous improvement of our products is a
Compression pressure pressure (psi or bar) of the Genie policy. Product specifications are
lowest cylinder must be at least 75% of the highest subject to change without notice or obligation.
cylinder
Governor centrifugal mechanical
Intake 0.010 in
0.254 mm
Exhaust 0.020 in
0.508 mm
10 Z-135/70 Part No. 1268557

Specifications
Cummins B4.5L cont.

Fuel injection system Delphi
Injection pump pressure, 3480 to 3680 psi
maximum 240 to 254 bar
240 bar
Fuel requirement
Engine coolant
Capacity 17 quarts
16 liters
Coolant temperature switch
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
Type 6V DC
Quantity 2
Quantity 1
9.5 to 12.5 mm
Part No. 1268557 Z-135/70 11

Specifications
Cummins B3.3T Engine Lubrication system

Oil pressure, hot (@ 2000 rpm) 31 psi
Displacement 199 cu. in 72 bar
3.26 liters
Oil capacity (including filter) 9 quarts
95 x 115 mm
Below 68°F / 20°C 5W-30
Horsepower net intermittent @
2200 rpm 80 hp / 60 kW -10°F to 68°F / -23°C to 20°C 10W-40
High idle 2350 rpm
599 Hz
Compression ratio 17:1 Continuous improvement of our products is a
Compression pressure pressure (psi or bar) of the Genie policy. Product specifications are
lowest cylinder must be at least 75% of the highest subject to change without notice or obligation.
cylinder
Intake 0.014 in
0.35 mm
Exhaust 0.020 in
0.508 mm
12 Z-135/70 Part No. 1268557

Specifications
Cummins B3.3T cont.

Fuel injection system Zexel
maximum 827 bar
Fuel requirement
Engine coolant
Capacity 9.1 quarts
8.6 liters
Starter motor
Current draw, maximum load 550A
Cranking speed 130 rpm
Type 6V DC
Quantity 2
Quantity 1
9.5 to 12.5 mm
Part No. 1268557 Z-135/70 13

Specifications
Perkins 1104C-44 Lubrication system

4.4 liters
Bore and Stroke 4.13 x 5 inches Oil viscosity requirements
105 x 127 mm
Below 68°F / 20°C 5W-20
Horsepower net intermittent
Gross intermittent @ 2400 rpm 86 hp / 64 kW 10°F to 104°F / -12°C to 40°C 10W-40
Net intermittent @ 2400 rpm 83 hp / 62 kW Above 14°F / -10°C 15W-40
Firing order 1-3-4-2 Unit ships with 15W-40. Extreme operating
Low idle temperatures may require the use of alternative engine
1300 rpm
oils. For oil requirements, refer to the Engine Operator
312 Hz
High idle 2350 rpm
Oil Pressure switch
572 Hz
Compression ratio 18.2:1
11 - 24 Nm
Compression pressure pressure (psi or bar) of the Pressure switch point 8 psi
lowest cylinder must be at least 75% of the highest 0.55 bar
cylinder
Fuel injection system
Governor centrifugal
mechanical Injection pump make Bosch
Valve Clearance, cold Injector opening pressure 2200 psi
152 bar
Intake 0.008 in
0.2 mm Fuel requirement
Exhaust 0.018 in For fuel requirements, refer to the engine Operator
0.45 mm Manual for your engine.
14 Z-135/70 Part No. 1268557

Specifications
Perkins 1104C-44 cont.

Starter motor
Type 6V DC
Quantity 2
Quantity 1
Engine coolant
Capacity 14 quarts
13.2 liters
11 - 24 Nm
110°C
Alternator output 85A @ 13.8V DC
Fan belt deflection 3/8 inch
9.5 mm
Part No. 1268557 Z-135/70 15

Specifications
Perkins 804D-33T Lubrication system

Displacement 203 cu. in 2.8 to 4.1 bar
3.33 liters
Number of cylinders 4 10 liters
94 x 120 mm
Below 86°F / 30°C 5W-20
Horsepower net intermittent
Gross intermittent @ 2200 rpm 83 hp / 62 kW -4°F to 104°F / -20°C to 40°C 10W-30
Induction system turbocharged Above 14°F / -10°C 15W-40

Unit ships with 15W-40. Extreme operating
Firing order 1-3-4-2
temperatures may require the use of alternative engine
Low idle 1300 rpm oils. For oil requirements, refer to the Engine Operator
316 Hz Manual for your engine.
High idle 2350 rpm Oil Pressure switch
572 Hz
Compression ratio 19.5:1 11 - 24 Nm
Compression pressure pressure (psi or bar) of the Pressure switch point 8 psi
lowest cylinder must be at least 75% of the highest 0.55 bar
cylinder Fuel injection system
Governor centrifugal Injection pump make Bosch
mechanical
Valve Clearance, cold 152 bar
Intake 0.0098 in Fuel requirement
0.25 mm
Exhaust 0.0098 in Manual for your engine.
0.25 mm
16 Z-135/70 Part No. 1268557

Specifications
Perkins 804D-33T cont.

Starter motor
Current draw, normal load 200A
Cranking speed 250 rpm
Type 6V DC
Quantity 2
Quantity 1
Engine coolant
Capacity 12.5 quarts
11.8 liters
11 - 24 Nm
110°C
9.5 to 12.5 mm
Part No. 1268557 Z-135/70 17

Specifications
Machine Torque Specifications Drive motors and hubs

Drive hub mounting bolts, lubricated 180 ft-lbs
Platform Rotator 217 Nm
1-8 center bolt, GR 5 480 ft-lbs Drive motor mounting bolts, dry 75 ft-lbs
651 Nm 102 Nm
3/8 -16 bolts, GR 8 44 ft-lbs Drive motor mounting bolts, lubricated 56 ft-lbs
60 Nm 76 Nm
Turntable rotate assembly Engine vibration isolators
Rotate bearing mounting bolts, lubricated 320 ft-lbs Mounting bolts, dry 60 ft-lbs
(3/4 -10 SHC) 434 Nm 81 Nm
Rotate bearing mounting bolts, lubricated 180 ft-lbs Mounting bolts, lubricated 45 ft-lbs
(5/8 -11 SHC) 244 Nm 61 Nm
Rotate drive hub mounting bolts, lubricated 80 ft-lbs Continuous improvement of our products is a
108 Nm
Drive motor mounting bolts, dry 75 ft-lbs subject to change without notice or obligation.
102 Nm
Drive motor mounting bolts, lubricated 56 ft-lbs
76 Nm
Backlash plate mounting bolts, lubricated 320 ft-lbs
434 Nm
18 Z-135/70 Part No. 1268557

Specifications
Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque
specifications require that fittings and hose ends be -4 14 ft-lbs / 19 Nm
torqued to specification when they are removed -6 23 ft-lbs / 31.2 Nm
and installed or when new hoses or fittings are
installed. -8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings
-16 125 ft-lbs / 169.5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204.7 Nm
SAE Dash Size Torque
-24 184 ft-lbs / 249.5 Nm
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm Adjustable Fitting Non-adjustable fitting
1 jam nut
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats SAE O-ring Boss Port
(tube fitting - installed into Steel)
-4 7/16-20 2
SAE Dash Size Torque
-6 9/16-18 1¼
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-8 3/4-16 1
ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
-10 7/8-14 1 37° (Non-adj) 22 ft-lbs / 30 Nm
-12 1 1/16-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-20 1 5/8-12 1
-24 1 7/8-12 1
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
Part No. 1268557 Z-135/70 19

Specifications
Torque Procedure JIC 37° fittings

1 Align the tube flare (hex nut) against the nose
Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
1 Replace the O-ring. The O-ring must be
approximately 30 in-lbs / 3.4 Nm.
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or 2 Using a permanent ink marker, make a
hose end has been tightened beyond finger reference mark on one the flats of the hex nut
tight. and continue the mark onto the body of the hex
fitting. Refer to Illustration 1.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut finger
tight. Illustration 1
5 Tighten the nut or fitting to the appropriate 1 hex nut
torque. Refer to the appropriate torque chart in 2 reference mark
this section. 3 body hex fitting
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
20 Z-135/70 Part No. 1268557

Specifications
3 Working clockwise on the body hex fitting,

make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct 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 fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
Part No. 1268557 Z-135/70 21

Specifications
22 Z-135/70 Part No. 1268557

Repair Procedures
Section 3 Repair Pr oc edures
Machine Configuration:
 Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
Observe and Obey: removed
 Repair procedures shall be completed by a • The red Emergency Stop button in the off
person trained and qualified on the repair of this position at both ground and platform controls
machine.
• Wheels chocked
 Immediately tag and remove from service a
damaged or malfunctioning machine. • All external AC power supply disconnected
from the machine
 Repair any machine damage or malfunction
before operating the machine. • Boom in the stowed position
• Turntable secured with the turntable rotation
lock
Before Repairs Start:
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and parts are
available and ready for use.
 Use only Genie approved replacement parts.
 Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Part No. 1268557 Z-135/70 23

Repair Procedures
About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point where
repairs can be completed. Then to re-assemble,
perform the disassembly steps in reverse order.
Symbols Legend
Safety alert symbol—used to alert
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.

situation which, if not avoided,
could result in death or serious
injury.

may cause minor or moderate
injury.

may result in property damage.
Indicates that a specific result is expected after

performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
24 Z-135/70 Part No. 1268557

Platform Controls
Platform Controls
The platform controls contains two printed circuit
boards:
The LED circuit board is mounted to the underside
of the control box lid which contains the LEDs. The
LED circuit board sends the input from the operator
to the platform controls circuit board (PCON). The
circuit board (PCON) sends the data to the
turntable control box (TCON) for processing.
The platform controls ECM circuit board
communicates with the turntable controls. The
joystick controllers at the platform controls utilize
Hall Effect technology and require no adjustment.
The operating parameters of the joysticks are
1 platform controls ALC-1000 circuit board
stored in memory at the turntable controls. If a
joystick controller error occurs or if a joystick is 2 jib boom up/down, jib boom extend/retract
and platform rotate left right joystick
replaced, it will need to be calibrated before that
3 secondary boom up/extend and
particular machine function will operate. Refer to
down/retract joystick
Repair Procedure, How to Calibrate a Joystick
4 drive/steer joystick controller
Controller.
5 LED circuit board
Each joystick controller should operate smoothly 6 primary boom up/down, primary boom
and provide proportional speed control over its extend/retract and turntable rotate left/right
entire range of motion. joystick
For further information or assistance, consult Genie

Product Support.
Part No. 1268557 Z-135/70 25

Platform Controls
1-1 7 Attach a grounded wrist strap to the ground

screw inside the control box.
Platform Circuit Board
Electrocution/burn hazard.
Electrocution/burn hazard. Contact with electrically charged
Contact with electrically charged circuits could result in death or
circuits could result in death or serious injury. Remove all rings,
serious injury. Remove all rings, watches and other jewelry.
watches and other jewelry.
Component damage hazard.
Note: When the platform circuit board is replaced, Electrostatic discharge (ESD)
jib bellcrank and platform level will need to be can damage printed circuit board
calibrated. Refer to Repair Procedures, How to
components. Maintain firm
Calibrate the Jib Boom Bellcrank Angle Sensor or
contact with a metal part of the
How to Calibrate the Platform Level Sensor.
machine that is grounded at all
times when handling printed
How to Remove the Circuit Board circuit boards OR use a
1 Push in the red Emergency Stop button to the grounded wrist strap.
off position at both the ground and platform
controls. 8 Tag and carefully disconnect the wire
connectors from the circuit board.
2 Locate the cables that connect to the bottom of
the control box. Number each cable and its 9 Tag and disconnect the ribbon cable from the
location at the control box. LED circuit board.
3 Disconnect the cables from the bottom of the 10 Remove the circuit board mounting fasteners.
platform control box. 11 Carefully remove the circuit board from the
4 Remove the control cable receptacle retaining control box.
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.
26 Z-135/70 Part No. 1268557

Platform Controls
How to R emove the LED Circui t Board
How to Remove the LED Circuit

Board
1 Push in the red Emergency Stop button to the
controls.
2 Remove the platform control box lid retaining
3 Locate the circuit board mounted to the inside
of the platform control box.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,

Electrostatic discharge (ESD)
can damage printed circuit board
circuit boards OR use a
grounded wrist strap.
4 Tag and carefully disconnect the ribbon cables

from the membrane circuit board.
5 Remove the circuit board mounting fasteners.
6 Carefully remove the LED circuit board from
the platform control box lid. Do not lose the
plastic spacers.
Note: When installing the LED circuit board, be sure
the plastic spacers are installed between the circuit
board and the control box lid.
Part No. 1268557 Z-135/70 27

Platform Controls
1-2 4 Close the control box lid.
Membrane Decal 5 Remove the platform controls decal from the

platform control box.
How to Replace the Membrane 6 Carefully remove the membrane decal from
Decal the control box lid while guiding the ribbon
cables out of the control box lid.
The membrane decal is a special decal that
7 Remove any decal adhesive from the control
consists of a decal with an electronic membrane on
box lid with a mild solvent.
the backside. The membrane contains touch
sensitive areas that, when pushed, activate the Note: Do not allow any solvent to come in contact
machine functions. The membrane contains touch with the membrane circuit board.
sensitive areas that activate the machine functions.
8 Install the new membrane decal while guiding
1 Push in the red Emergency Stop button to the the ribbon cables through the control box lid.
Note: Be sure that all LED locations on the
controls.
membrane decal align with the LEDs on the
2 Remove the platform control box lid retaining membrane circuit board.
9 Install a new platform controls decal over the
3 Tag and carefully disconnect the two ribbon membrane decal.
cables from the membrane circuit board.
10 Open the control box lid and carefully connect
Electrocution/burn hazard. the ribbon cables from the membrane decal to
Contact with electrically charged the membrane circuit board.

Electrostatic discharge (ESD)
28 Z-135/70 Part No. 1268557

Platform Controls
1-3 Drive functions:
Joysticks 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
How to Calibrate a Joystick platform controls. Hold the enter button for
The joystick controllers on this machine utilize approximately 5 seconds.
digital Hall Effect technology for proportional control.
3 Press the minus button twice, then press the
If a joystick controller is disconnected or replaced, it
enter button twice.
must be calibrated before that particular machine
function will operate. 4 Use the scroll button to scroll through the
menu until DELETE DRIVE JOYSTICK
Note: The joystick must be calibrated before the DEFAULTS is displayed.
threshold, max-out or ramping can be set.
5 Press the plus button to select YES, then
Note: After each joystick is calibrated, check the press the enter button.
display at the ground control box. There should be
no calibration faults shown on the display. If 6 Do not start the engine.
calibration faults exist, repeat procedure for that 7 Locate the drive/steer joystick.
joystick controlled function.
8 Move the drive/steer joystick full stroke in the
Note: Perform this procedure with the engine off. forward direction and hold for 5 seconds, then
return to the center or neutral position.
Note: Use the following chart to identify the
description of each LCD screen control button used 9 Move the drive/steer joystick full stroke in the
in this procedure. reverse direction and hold for 5 seconds, then
Result: The alarm at the ground controls
should sound for a successful calibration.
Plus Minus Previous Enter
Part No. 1268557 Z-135/70 29

Platform Controls
Steer functions: Secondary boom up/down and extend/retract

functions:
1 Turn the key switch to the off position.
control panel while turning the key switch to 2 Press and hold the enter button on the ground
platform controls. Hold the enter button for control panel while turning the key switch to
approximately 5 seconds. platform controls. Hold the enter button for
approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice. 3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through the
menu until DELETE STEER JOYSTICK 4 Use the scroll button to scroll through the
DEFAULTS is displayed. menu until DELETE SECONDARY BOOM
JOYSTICK DEFAULTS is displayed.
press the enter button. 5 Press the plus button to select YES, then
press the enter button.
6 Do not start the engine.
6 Do not start the engine.
7 Locate the drive/steer joystick.
7 Locate the secondary boom up/down and
8 Move the drive/steer joystick or thumb rocker
extend/retract joystick.
switch (if equipped) full stroke in the left
direction and hold for 5 seconds, then return to 8 Move the secondary boom up/down and
the center or neutral position. extend/retract joystick full stroke in the
up/extend direction and hold for 5 seconds,
9 Move the drive/steer joystick or thumb rocker
then return to the center or neutral position.
switch (if equipped) full stroke in the right
direction and hold for 5 seconds, then return to 9 Move the secondary boom up/down and
the center or neutral position. extend/retract joystick full stroke in the
down/retract direction and hold for 5 seconds,
then return to the center or neutral position.
30 Z-135/70 Part No. 1268557

Platform Controls
Primary boom extend/retract functions: Primary boom up/down functions:

1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the ground 2 Press and hold the enter button on the ground
control panel while turning the key switch to control panel while turning the key switch to
platform controls. Hold the enter button for platform controls. Hold the enter button for
approximately 5 seconds. approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until DELETE PRIMARY BOOM menu until DELETE PRIMARY BOOM
EXTEND/RETRACT JOYSTICK DEFAULTS UP/DOWN JOYSTICK DEFAULTS is
is displayed. displayed.
5 Press the plus button to select YES, then 5 Press the plus button to select YES, then
press the enter button. press the enter button.
6 Do not start the engine. 6 Do not start the engine.
7 Locate the thumb rocker switch on top of the 7 Locate the primary boom/turntable rotate
primary boom/turntable rotate joystick. joystick.
8 Move the primary boom extend/retract thumb 8 Move the boom/turntable rotate joystick full
rocker switch full stroke in the extend direction stroke in the up direction and hold for
and hold for 5 seconds, then return to 5 seconds, then return to the center or neutral
thecenter or neutral position. position.
9 Move the primary boom extend/retract thumb 9 Move the boom/turntable rotate joystick full
rocker switch full stroke in the retract direction stroke in the down direction and hold for
and hold for 5 seconds, then return to the 5 seconds, then return to the center or neutral
center or neutral position. position.
Result: The alarm at the ground controls Result: The alarm at the ground controls
should sound for a successful calibration. should sound for a successful calibration.
Part No. 1268557 Z-135/70 31

Platform Controls
Jib boom up/down functions: Turntable rotate functions:

1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the ground 2 Press and hold the enter button on the ground
control panel while turning the key switch to control panel while turning the key switch to
platform controls. Hold the enter button for platform controls. Hold the enter button for
approximately 5 seconds. approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until RESET JIB BOOM UP/DOWN menu until DELETE TURNTABLE ROTATE
JOYSTICK DEFAULTS is displayed. JOYSTICK DEFAULTS is displayed.
5 Press the plus button to select YES, then 5 Press the plus button to select YES, then
6 Do not start the engine. 6 Do not start the engine.
7 Locate the jib boom joystick. 7 Locate the primary boom/turntable rotate
joystick.
8 Move the jib boom joystick full stroke in the up
direction and hold for 5 seconds, then return to 8 Move the boom/turntable joystick full stroke in
the center or neutral position. the left direction and hold for 5 seconds, then
9 Move the jib boom joystick full stroke in the
down direction and hold for 5 seconds, then 9 Move the boom/turntable joystick full stroke in
return to the center or neutral position. the right direction and hold for 5 seconds, then
should sound for a successful calibration. Result: The alarm at the ground controls
32 Z-135/70 Part No. 1268557

Platform Controls
How to R es et a Proportional Val ve Coil D efault How to Set the F unction T hresholds and D efault Func tions Speeds
How to Reset a Proportional Valve How to Set the Function

Coil Default Thresholds and Default Functions
Note: Use the following chart to identify the Speeds
description of each LCD screen control button used Note: Before the threshold and default function
in this procedure. speeds can be set, the boom function proportional
valve coil defaults must be set first. Refer to Repair
Procedure, How to Reset a Proportional Valve Coil
Default.
Note: If a boom function proportional valve coil has
Plus Minus Previous Enter not been replaced and just want to reset the
function speed to original factory settings, proceed
Note: This procedure only needs to be performed if
to Function speeds procedure.
a proportional valve has been replaced.
1 Start the engine from the platform controls.
Note: After the valve coil defaults have been set,
each machine function threshold and default 2 Press down the foot switch.
function speed must be set. Refer to Repair
Procedure, How to Set the Function Thresholds Note: Be sure the engine rpm is set to foot switch
and Default Function Speeds. activated high idle.
Function threshold:
2 Press and hold the enter button on the ground 3 Select a joystick controlled function that needs
control panel while turning the key switch to to have the threshold set.
platform controls. Hold the enter button for 4 Slowly move the joystick off center in either
approximately 5 seconds. direction just until the machine function starts
3 Press the minus button twice, then press the to move, then move the joystick very slowly
enter button twice. towards the neutral or center position just
before the machine function stops. Do not let
4 Use the previous button to scroll through the go of the joystick.
menu until the function valve that needs to be
reset is displayed. Press the plus button to 5 While holding the joystick in position, press the
select yes, then press the enter button to save engine start button at the platform controls to
the setting. set the joystick controller threshold.
5 Press 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.
Part No. 1268557 Z-135/70 33

Platform Controls
6 Slowly move the joystick off center in the Function speeds:

opposite direction just until the machine
function starts to move, then move the joystick Note: Be sure the machine is in the stowed position
very slowly towards the neutral or center and the boom is rotated between the circle end
position just before the machine function tires.
stops. Do not let go of the joystick. Note: Perform this procedure with the machine on a
7 While holding the joystick in position, press the firm, level surface that is free of obstructions.
engine start button at the platform controls to
Note: Unless the LCD screen displays NOT
set the joystick controller threshold.
CALIBRATED, it will be necessary to enter the
8 Repeat steps for each joystick controlled valve calibration menu.
machine function:
• Primary boom up/down
13 Select a function that needs the function speed
• Turntable rotate left/right set.
• Primary boom extend/retract 14 Primary boom up/down and extend/retract
functions: Move the joystick full stroke in the
• Secondary up/down and extend/retract up or extend direction. When the alarm
• Drive forward/reverse sounds, move the joystick in the opposite
direction full stroke until the alarm sounds
9 Once the threshold has been set, press and again. Return the joystick to center.
hold the engine start button until the engine
shuts off. Do not press the red Emergency Secondary boom up and down functions:
Stop button. Starting from the stowed position, move the
joystick full stroke in the up direction. When the
Note: Approximately 3 seconds after the engine alarm sounds, move the joystick in the down
shuts off, the alarm at the ground controls will direction full stroke until the alarm sounds
sound to indicate the settings are being saved in again. Return the joystick to center.
memory.
Turntable rotate function, fully retracted:
10 At the ground controls, turn the key switch to Move the rotate joystick full stroke in either the
the off position, wait a moment and then turn left or right direction until the alarm sounds.
the key switch to platform controls. Return the joystick to center.
11 Check the display at the ground controls to be
sure there are no calibration faults.
Note: There should be no calibration faults shown
on the display. If calibration faults exist, repeat this
procedure.
34 Z-135/70 Part No. 1268557

Platform Controls
How to Adj ust the Functi on Speeds
Turntable rotate function, primary boom How to Adjust the Function

extended: Extend the primary boom
approximately 4 ft / 1.2 m. Move the rotate
Speeds
joystick full stroke in either the left or right Note: Perform this procedure with the boom in the
direction until the alarm sounds. Return the stowed position.
joystick to center.
Turntable rotate function, primary and jib description of each LCD screen control button used
booms extended: With the primary boom in this procedure.
extended approximately 4 ft / 1.2 m, extend
the jib boom approximately 1 ft / 0.3 m. Move
the rotate joystick full stroke in either the left or
right direction until the alarm sounds. Return
the joystick to center.
15 Once the function speeds have been set, Plus Minus Previous Enter
press and hold the engine start button until the 1 Pull out the red Emergency Stop button to the
engine shuts off. Do not press the red on position at both the ground and platform
Emergency Stop button. controls.
Note: Approximately 3 seconds after the engine 2 Press and hold the enter button on the ground
shuts off, the alarm at the ground controls will control panel while turning the key switch to
sound to indicate the settings are being saved in platform controls. Hold the enter button for
memory. approximately 5 seconds.
16 At the ground controls, turn the key switch to 3 Press the plus button twice, then press the
the off position, wait a moment and then turn minus button twice.
the key switch to platform controls.
4 Press the previous button until the function to
17 Check the display at the ground controls to be be adjusted is displayed.
sure there are no calibration faults.
5 Press the plus button to increase the speed or
Note: There should be no calibration faults shown press the minus button to decrease the speed.
on the display. If calibration faults exist, repeat this
procedure.
Part No. 1268557 Z-135/70 35

Platform Controls
How to Adj ust the Functi on R amp R ate Setti ng
6 Press the enter button to save the setting in How to Adjust the Function Ramp
memory.
Rate Setting
The ramp rate setting of a joystick controls the time
at which it takes for the joystick to reach maximum
8 Press the plus button or minus button to output, when moved out of the neutral position. The
select YES and then press the enter button. ramp rate settings of a joystick can be changed to
compensate for hydraulic pump wear to maintain
9 Continue to perform this procedure until the
peak performance from the machine.
machine function speed meets specification.
Refer to Specifications, Performance Note: Perform this procedure with the boom in the
Specifications. stowed position.
description of each LCD screen control button used
in this procedure.

1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
platform controls. Hold the enter button for
approximately 5 seconds.
3 Press the plus button twice, then press the
previous button twice.
36 Z-135/70 Part No. 1268557

Platform Controls
4 Press the previous button until the function to

be adjusted is displayed.
5 Press the plus button to increase the ramp
rate or press the minus button to decrease the
ramp rate.
6 Press the enter button to save the setting in
memory.
8 Press the plus button or minus button to
select YES and then press the enter button.
Part No. 1268557 Z-135/70 37

Platform Components
2-1 4 Place a block under the platform leveling

cylinder for support.
Platform Leveling Cylinder
5 Remove the external snap rings from the
The platform leveling cylinder keeps the platform barrel-end pivot pin. Use a soft metal drift to
level through the entire range of boom motion. The remove the barrel-end pivot pin.
platform is maintained level to the turntable. To
6 Support the rod end of the platform level
accomplish this, the ECM at the ground controls
cylinder.
compares the difference in readings between the
platform angle sensor and the turntable level 7 Remove the pin retaining fasteners from the
sensor, which then sends a signal to the platform platform leveling cylinder rod-end pivot pin.
controls to open or close the appropriate platform Use a soft metal drift to remove the barrel-end
level proportional valve on the platform manifold to pivot pin.
maintain a level platform. The platform leveling
cylinder is equipped with counterbalance valves to 8 Carefully pull the platform leveling cylinder out
prevent movement in the event of a hydraulic line of the boom to access the hydraulic hoses.
failure. 9 Tag, disconnect and plug the hydraulic hoses
from the platform leveling cylinder. Cap the
How to Remove the Platform fittings on the cylinder.
Leveling Cylinder Bodily injury hazard. Spraying
Note: When removing a hose assembly or fitting, hydraulic oil can penetrate and
the O-ring (if equipped) on the fitting and/or hose burn skin. Loosen hydraulic
end must be replaced. All connections must be connections very slowly to allow
torqued to specification during installation. Refer to the oil pressure to dissipate
Specifications, Hydraulic Hose and Fitting Torque gradually. Do not allow oil to
Specifications. squirt or spray.
1 Extend the jib boom until the platform leveling 10 Remove the platform leveling cylinder from the
cylinder barrel-end pivot pin is accessible. machine.
2 Raise the jib boom slightly and place blocks Crushing hazard. The platform
under the platform. leveling cylinder may fall if not
3 Lower the jib boom until the platform is resting properly supported when
on the blocks just enough to support the removed from the machine.
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
38 Z-135/70 Part No. 1268557

Platform Components
2-2 3 Remove the platform angle sensor retaining

fasteners. Remove the platform angle sensor
Platform Rotator from the platform rotator.
The platform rotator is a hydraulically activated Component damage hazard. The
helical gear assembly used to rotate the platform platform angle sensor is a very
160 degrees. sensitive instrument. It can be
damaged internally if is dropped
How to Remove the Platform or sustains any physical shock,
even if the damage is not visible.
Rotator
4 Tag, disconnect and plug the hydraulic hoses
Component damage hazard. from the platform rotator manifold. Cap the
Mark the platform mounting fittings on the manifold.
weldment and the rotator flange
before removing the platform Bodily injury hazard. Spraying
mounting weldment. The hydraulic oil can penetrate and
platform mounting weldment burn skin. Loosen hydraulic
must be replaced in the exact connections very slowly to allow
same position on the rotator the oil pressure to dissipate
flange as it was before removal. gradually. Do not allow oil to
If a new rotator is installed or the squirt or spray.
rotator is disassembled, proper
alignment can be achieved by 5 Tag, disconnect and plug the hydraulic hoses
rotating the rotator all the way to from the platform manifold. Cap the fittings on
the left and then installing the the manifold.
platform mounting weldment all
the way in the left position. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Note: When removing a hose assembly or fitting, burn skin. Loosen hydraulic
the O-ring (if equipped) on the fitting and/or hose connections very slowly to allow
end must be replaced. All connections must be the oil pressure to dissipate
torqued to specification during installation. Refer to gradually. Do not allow oil to
Specifications, Hydraulic Hose and Fitting Torque squirt or spray.
Specifications.
6 Remove the power to platform electrical outlet
1 Remove the platform. Refer to Repair box bracket mounting fasteners. Do not
Procedure, How to Remove the Platform. disconnect the wiring.
2 Tag and disconnect the electrical connector
from the platform angle sensor.
Part No. 1268557 Z-135/70 39

Platform Components
7 Remove the hose and cable guide retaining 13 Place a block under the platform leveling
fasteners and remove the guide from the cylinder for support.
platform support.
14 Remove the pin retaining fasteners from the
8 Remove the weld cable from the platform (if platform leveling cylinder rod-end pivot pin. Do
equipped). not remove the pin.
Electrocution/burn hazard. 15 Remove the pin retaining fasteners from the jib
Contact with electrically charged boom to platform rotator pivot pin. Do not
circuits could result in death or remove the pin.
serious injury. Remove all rings, 16 Use a soft metal drift to remove both pins and
watches and other jewelry. remove the platform rotator from the machine.
9 Support the platform mounting weldment, but Crushing hazard. The platform
do not apply any lifting pressure. rotator could fall when removed
10 Remove the eight mounting bolts from the from the machine if not properly
supported.
platform mounting weldment.
11 Remove the center bolt and slide the platform
mounting weldment off of the platform rotator.
Crushing hazard. The platform
mounting weldment may
become unbalanced and fall if it
is not properly supported.
12 Support the platform rotator with a suitable

lifting device. Do not apply any lifting pressure.
40 Z-135/70 Part No. 1268557

Platform Components
How to Bleed the Pl atfor m R otator
How to Bleed the Platform Rotator 2-3

Note: Do not start the engine. Use auxiliary power Platform Level Sensor
for all machine functions in this procedure.
The platform level sensor is mounted to the side of
1 Rotate the platform full right, then full left until the platform rotator. The platform level sensor is
air is completely out of the rotator. Bleeding the monitored by the control system to maintain a level
valve is not necessary. platform through boom range of motion. If a
platform level sensor is replaced, it must be
calibrated prior to machine operation.
How to Calibrate the Platform

Level Sensor
Note: Perform this procedure with the machine on a
firm, level surface.
Note: Perform this procedure with the boom in the
stowed position.
in this procedure.

1 Secure a digital level to one of the side railings
of the platform.
2 Start the machine and level the platform to
gravity. Turn the machine off.
3 Open the ground control box.
Part No. 1268557 Z-135/70 41

Platform Components
Before serial number 321: 11 Press the enter or previous button on the
LCD screen until SET PLATFORM LEVEL
4 Locate the 2 pin connector in the lower left SENSOR TO GRAVITY is displayed.
hand area of the ground control box.
5 Remove the connector plug and insert a press the enter button to accept.
jumper wire between the two pins of the
connector. 13 Press the enter or previous button on the
After serial number 320:
6 Locate the calibration toggle switch at the top press the enter button to accept.
of the ground control box. Activate calibration
mode by moving the toggle switch in the left Before serial number 321:
direction.
15 Remove the wire jumper from the 2 pin
7 Temporarily install a control box door retaining connector in the lower left hand area of the
fastener between the door and the box to ground control box that was installed in step 5.
prevent the control box door from moving the Install the connector plug.
toggle switch while calibrating the machine.
Tip-over hazard. Failure to
All models: remove the jumper wire will
result in an unsafe configuration
8 Insert the key into the bypass/recovery key which will compromise machine
switch and turn it to the bypass position. stability. Operating the machine
Note: The angle sensor calibration values will not in this configuration will result in
be saved correctly unless the key switch is in the the machine tipping over,
bypass position and the calibration toggle switch is resulting in death or serious
activated. injury. The jumper wire must be
removed before operating the
9 Press and hold the enter button on the ground machine.
ground controls. Hold the enter button for 16 Close the ground control box and install the
approximately 5 seconds. door retaining fasteners.
10 Enter sensor calibration mode by pressing the After serial number 320:
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus). 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.
42 Z-135/70 Part No. 1268557

Platform Components
2-4 Determine the limit switch trigger point:

Platform Overload System 4 Gently move the platform up and down by
(if equipped) hand, so it bounces approximately 1 to
2 inches / 2.5 to 5 cm. Allow the platform to
Proper calibration of the platform overload system settle.
is essential to safe machine operation. Continued Result: The overload indicator light and the
use of an improperly calibrated platform overload alarm is on. Slowly tighten the load spring
system could result in the system failing to sense an adjustment nut by turning it clockwise just until
overloaded platform. The stability of the machine is the overload indicator light and alarm turns off.
compromised and it could tip over.
Note: The platform will need to be moved up and
down and allowed to settle in between adjustments.
How to Calibrate the Platform
Note: There may be a 2 second delay before the
Overload System (if equipped) overload indicator lights flash and the alarm
Note: Perform this procedure with the machine on a sounds.
Result: The overload indicator light and
1 Level the platform. alarm is off. Slowly loosen the load spring
adjustment nut by turning it counterclockwise
2 Determine the maximum platform capacity. just until the overload indicator light and alarm
Refer to the machine serial plate. turn on.
3 Using a suitable lifting device, place an Note: There may be a 2 second delay before the
appropriate test weight equal to that of the overload indicator lights flash and the alarm
maximum platform capacity at the center of the sounds.
platform floor.
Note: The platform will need to be moved up and
down and allowed to settle in between adjustments.
Part No. 1268557 Z-135/70 43

Platform Components
Confirm the setting: 9 Test all machine functions from the platform
controls.
Result: All platform control functions should
6 Lift the test weight off the platform floor using a not operate.
suitable lifting device.
10 Turn the key switch to ground controls.
7 Place the test weight back onto the center of
the platform floor using a suitable lifting device. 11 Test all machine functions from the ground
controls.
Result: The alarm should be off. The platform
overload indicator light should be off at the Result: All ground control functions should not
platform controls and there should be no error operate.
message on the LCD display at the ground
controls.
Note: There may be an 2 second delay before the
overload indicator lights and alarm turn off.
8 Add an additional 15 lbs / 6.8 kg test weight to
the original test weight to overload the
platform.
Result: The alarm should be sounding. The
platform overload indicator light should be
flashing at the platform controls and platform
overload should be displayed on the LCD
screen at the ground controls.
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
44 Z-135/70 Part No. 1268557

Jib Boom Components
1 primary extension boom 7 jib boom

2 jib boom manifold 8 jib extension boom
3 bellcrank 9 hose and cable junction box
4 cable track tube 10 jib boom lift cylinder
5 platform rotator 11 jib boom cable track
6 platform leveling cylinder 12 jib boom leveling cylinder
Part No. 1268557 Z-135/70 45

Jib Boom Components
3-1 4 Tag, disconnect and plug the two hydraulic

hoses from the jib boom manifold that lead to
Jib Boom Cable Track the platform manifold. Cap the fittings on the
The jib boom cable track guides the cables and manifold.
hoses running up the jib boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire jib boom burn skin. Loosen hydraulic
cable track is only necessary when performing connections very slowly to allow
major repairs that involve removing the jib boom. the oil pressure to dissipate
gradually. Do not allow oil to
How to Remove the Jib Boom squirt or spray.
Cable Track
Note: The jib boom manifold is located at the
Note: When removing a hose assembly or fitting, platform end of the primary extension boom.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 5 Pull the hoses out of the plastic hose guide
torqued to specification during installation. Refer to located on the primary extension boom near
Specifications, Hydraulic Hose and Fitting Torque the jib boom manifold.
Specifications. 6 Tag, disconnect and plug the jib boom lift
1 Raise the jib boom to a horizontal position. cylinder hydraulic hoses. Cap the fittings on
Turn the machine off. the cylinder.
2 Remove the cover from the hose and cable Bodily injury hazard. Spraying
junction box under the jib boom cable track. hydraulic oil can penetrate and
burn skin. Loosen hydraulic
3 Tag and disconnect the electrical connectors connections very slowly to allow
inside the cable track junction box. the oil pressure to dissipate
squirt or spray.
7 Remove the hose and cable clamp retaining

fasteners from the jib boom cable track
junction box. Remove the clamps.
8 Pull the jib boom lift cylinder hydraulic hoses
out of the jib boom cable track junction box.
46 Z-135/70 Part No. 1268557

Jib Boom Components
9 Remove the hose and cable clamp retaining 17 Remove the fasteners from the cable track
fasteners at the platform end of the jib boom tube guide at the platform end of the jib boom.
cable track tube. Remove the clamps. Remove the cable track tube guide from the jib
boom.
10 Tag and disconnect the electrical connectors
from the platform manifold. 18 Place blocks between the upper and lower
cable tracks and secure the upper and lower
11 Tag and disconnect the electrical connectors
tracks together.
from the platform box.
12 Tag and disconnect the electrical connector Crushing hazard. If the upper
from the foot switch. and lower cable tracks are not
properly secured together, the
13 Tag and disconnect the electrical connector cable track could become
from the platform angle sensor. unbalanced and fall when
14 Tag, disconnect and plug the hydraulic hoses removed from the machine.
from the "P" and "T" ports on the platform
19 Attach a lifting strap from an overhead crane to
manifold.
the cable track.
15 Pull the two hydraulic hoses just removed and
all of the cables through the hose and cable 20 Remove the mounting fasteners that attach the
guide at the platform support. lower cable track to the jib boom.
21 Carefully remove the cable track from the
Component damage hazard. machine and lay it on a structure capable of
Cables and hoses can be supporting it.
damaged if they are kinked or
pinched. Crushing hazard. The cable track
could become unbalanced and
16 Remove the cotter pin from the upper cable fall if not properly attached to the
track tube at the platform end of the jib boom. overhead crane.
Do not discard the washer.
Note: Always replace the cotter pin with a new one. Component damage hazard.
Cables and hoses can be
pinched.
Part No. 1268557 Z-135/70 47

Jib Boom Components

How to R epair the C abl e Tr ac k
How to Repair the Cable Track 6 Lift up the hoses and cables and carefully
insert the new 4-link section of cable track.
The boom cable track can be Component damage hazard.
damaged if it is twisted. Cables and hoses can be
Note: A cable track repair kit is available through pinched.
the Genie Service Parts Department.
7 Connect the ends of the replacement cable
1 Visually inspect the cable track and determine track section to the existing cable track using
which 4-link section needs to be replaced. the pins and snap rings.
2 Carefully remove the snap rings and pins from 8 Install the rollers onto the new section of cable
each end of the damaged section of cable track.
track.
9 Operate the jib boom extend/retract function
3 Remove the retaining fasteners from the upper through a full cycle to ensure smooth operation
black rollers from the 4-link section of cable of the new section of cable track.
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.
pinched.
5 Remove the upper rollers from the

replacement section of cable track.
48 Z-135/70 Part No. 1268557

Jib Boom Components
3-2 2 Tag, disconnect and plug the two hydraulic

hoses from the jib boom manifold that lead to
Jib Boom the platform manifold. Cap the fittings on the
manifold.
How to Remove the Jib Boom
Bodily injury hazard. Spraying
Bodily injury hazard. This hydraulic oil can penetrate and
procedure requires specific repair burn skin. Loosen hydraulic
skills, lifting equipment and a connections very slowly to allow
suitable workshop. Attempting the oil pressure to dissipate
this procedure without these skills gradually. Do not allow oil to
and tools could result in death or squirt or spray.
serious injury and significant
component damage. Dealer 3 Tag, disconnect and plug the jib boom lift
service is strongly recommended. cylinder hydraulic hoses from the jib boom
manifold. Cap the fittings on the manifold.
stowed position. Bodily injury hazard. Spraying
Note: When removing a hose assembly or fitting, burn skin. Loosen hydraulic
the O-ring (if equipped) on the fitting and/or hose connections very slowly to allow
end must be replaced. All connections must be the oil pressure to dissipate
torqued to specification during installation. Refer to gradually. Do not allow oil to
Specifications, Hydraulic Hose and Fitting Torque squirt or spray.
Specifications.
4 Remove the cotter pin from the upper cable
1 Remove the platform mounting weldment and
track tube at the platform end of the jib boom.
the platform rotator. Refer to Repair
Procedure, How to Remove the Platform Note: Always replace the cotter pin with a new one.
Rotator.
5 Remove the cable track guide fasteners from
the cable track guide at the platform end of the
jib boom and remove the cable track guide
from the jib boom.
Part No. 1268557 Z-135/70 49

Jib Boom Components
6 Place blocks between the upper and lower 12 Remove the jib boom angle sensor mounting
cable tracks and secure the upper and lower bracket fasteners from the side of the primary
tracks together. extension boom.
Crushing hazard. If the upper 13 Carefully remove the bracket and sensor
and lower cable tracks are not assembly. Note the location of the springs. Do
properly secured together, the not lose the springs.
cable track could become Note: There is one spring inside the jib boom pivot
unbalanced and fall when pin and one inside the angle sensor.
removed from the machine.
Note: When the jib boom is installed, the jib boom
7 Attach a lifting strap from an overhead crane to angle sensor will need to be calibrated. Refer to
the cable track. repair procedure, Jib Boom Bellcrank Angle Sensor
8 Remove the mounting fasteners that attach the for the calibration procedure.
lower cable track to the jib boom. 14 Attach a lifting strap from an overhead crane to
9 Remove the cable track from the machine and the platform end of the jib boom.
lay to the side. 15 Support the barrel end of the jib boom lift
cylinder with another suitable lifting device.
Crushing hazard. The cable track
could become unbalanced and 16 Remove the pin retaining fasteners from the jib
fall if not properly attached to the boom lift cylinder barrel-end pivot pin.
overhead crane.
17 Use a soft metal drift to remove the jib boom lift
cylinder barrel-end pivot pin.
Cables and hoses can be Crushing hazard. The jib boom
damaged if they are kinked or could fall when the barrel-end
pinched. pivot pin is removed if not
properly supported by the
10 Disconnect the electrical connector from the jib overhead crane.
boom angle sensor located at the jib boom
pivot pin on the engine side of the machine. Crushing hazard. The jib boom
11 Remove the cover retaining fasteners from the lift cylinder may become
jib boom angle sensor. Remove the cover. unbalanced and fall when it is
removed from the machine if it is
not properly supported by the
overhead crane.
50 Z-135/70 Part No. 1268557

Jib Boom Components

18 Secure the jib boom lift cylinder to the jib boom 3-3
with a strap or other suitable device.
Jib Boom Lift Cylinder
19 Raise the jib boom to a horizontal position
using the overhead crane.
20 Attach a second lifting strap from the overhead How to Remove the Jib Boom Lift
crane to the pivot end of the jib boom. Cylinder
21 Remove the pin retaining fastener from the jib Note: Perform this procedure with the boom in the
boom pivot pin. Do not remove the pin. stowed position.
22 Place a block under the jib boom level cylinder Note: When removing a hose assembly or fitting,
for support. Protect the cylinder rod from the O-ring (if equipped) on the fitting and/or hose
damage. end must be replaced. All connections must be
23 Use a soft metal drift to tap the pin halfway out torqued to specification during installation. Refer to
in one direction and lower one side of the jib Specifications, Hydraulic Hose and Fitting Torque
boom bellcrank. Tap the pin in the other Specifications.
direction and lower the other side of the jib
1 Raise the jib boom slightly and place blocks
boom bellcrank.
under the platform mounting weldment. Lower
24 Use a soft metal drift to remove the jib boom the jib boom until the platform is resting on the
pivot pin. Remove the jib boom from the blocks just enough to support the platform.
machine and place it on a structure capable of
Note: Do not rest the entire weight of the boom on
supporting it.
the blocks.
Crushing hazard. The jib boom
2 Tag, disconnect and plug the jib boom lift
may become unbalanced and fall
cylinder hydraulic hoses. Cap the fittings on
when it is removed from the
the cylinder.
machine if it is not properly
supported by the overhead Bodily injury hazard. Spraying
crane. hydraulic oil can penetrate and
connections very slowly to allow
the oil pressure to dissipate
squirt or spray.
3 Support the rod end of the jib boom lift cylinder

with a suitable lifting device.
Part No. 1268557 Z-135/70 51

Jib Boom Components
4 Remove the pin retaining fasteners from the jib 3-4

boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin and let the
Jib Boom Level Cylinder
cylinder hang down.
5 Attach a lifting strap from an overhead crane to How to Remove the Jib Boom
the barrel end of jib boom lift cylinder. Level Cylinder
6 Remove the pin retaining fasteners from the jib Note: Perform this procedure with the boom in the
boom lift cylinder barrel-end pivot pin. Use a stowed position.
soft metal drift to remove the pin.
Note: When removing a hose assembly or fitting,
7 Remove the jib boom lift cylinder from the
machine.
end must be replaced. All connections must be
Crushing hazard. The jib boom torqued to specification during installation. Refer to
lift cylinder may become Specifications, Hydraulic Hose and Fitting Torque
unbalanced and fall when it is Specifications.
removed from the machine if it is
1 Extend the primary boom until the jib boom
not properly supported by the
level cylinder barrel-end pivot pin is
overhead crane.
accessible.
2 Raise the jib boom above horizontal.
3 Attach an overhead crane to the jib boom
assembly for support.
4 Place a block under the jib boom level cylinder
for support. Protect the cylinder rod from
damage.
5 Remove the pin retaining fasteners from the jib
boom level cylinder rod-end pivot pin. Use a
could fall if not properly
supported when the jib boom
level cylinder rod-end pivot pin is
removed.
52 Z-135/70 Part No. 1268557

Jib Boom Components
6 Remove the external snap rings from the jib 3-5

boom level cylinder barrel-end pivot pin. Use a
Jib Boom Extension Cylinder
7 Tag, disconnect and plug the jib boom level How to Remove the Jib Boom
cylinder hydraulic hoses from the jib boom
manifold. Cap the fittings on the manifold. Extension Cylinder
Bodily injury hazard. Spraying Bodily injury hazard. This
hydraulic oil can penetrate and procedure requires specific repair
burn skin. Loosen hydraulic skills, lifting equipment and a
connections very slowly to allow suitable workshop. Attempting
the oil pressure to dissipate this procedure without these skills
gradually. Do not allow oil to and tools could result in death or
squirt or spray. serious injury and significant
component damage. Dealer
8 Attach an overhead crane or other suitable service is strongly recommended.
device to the jib boom level cylinder for
support. Note: Perform this procedure with the boom in the
stowed position.
9 Carefully remove the jib boom level cylinder
from the machine. Note: When removing a hose assembly or fitting,
Crushing hazard. The jib boom end must be replaced. All connections must be
level cylinder could become torqued to specification during installation. Refer to
unbalanced and fall when Specifications, Hydraulic Hose and Fitting Torque
removed from the machine if not Specifications.
properly supported.
1 Remove the jib boom lift cylinder. Refer to
Repair Procedure, How to Remove the Jib
Boom Lift Cylinder.
2 Attach a lifting strap from an overhead crane to
the platform end of the jib boom for support.
Raise the jib boom to a horizontal position
using the overhead crane.
Part No. 1268557 Z-135/70 53

Jib Boom Components
3 Extend the jib boom until the jib boom 9 Pull the electrical cables out of the lower cable
extension cylinder rod-end pivot pin is track that lead to the primary boom.
accessible.
10 Attach a lifting strap from a second overhead
4 Tag, disconnect and plug the two hydraulic crane to the pivot end of the jib boom for
hoses from the jib boom manifold that lead to support. Do not apply any lifting pressure.
the platform manifold. Cap the fittings on the
11 Place a block under the jib boom level cylinder
manifold.
for support. Protect the cylinder rod from
Bodily injury hazard. Spraying damage.
hydraulic oil can penetrate and 12 Remove the pin retaining fastener from the jib
burn skin. Loosen hydraulic boom pivot pin. Do not remove the pin.
the oil pressure to dissipate 13 Use a soft metal drift to tap the pin halfway out
gradually. Do not allow oil to in one direction and lower one side of the jib
squirt or spray. boom bellcrank. Tap the pin in the other
direction and lower the other side of the jib
5 Tag, disconnect and plug the jib boom lift boom bellcrank.
cylinder and jib boom extension cylinder 14 Use a soft metal drift to remove the jib boom
hydraulic hoses from the jib boom manifold. pivot pin. Remove the jib boom from the
Cap the fittings on the manifold.
Bodily injury hazard. Spraying supporting it.
burn skin. Loosen hydraulic may become unbalanced and fall
when it is removed from the
machine if it is not properly
supported by the overhead
squirt or spray.
crane.
6 Remove the cover from the lower jib boom
15 Remove the pin retaining fasteners from the jib
cable track.
boom extension cylinder rod-end pivot pin.
7 Tag and disconnect the electrical connectors Use a soft metal drift to remove the pin.
inside the lower cable track.
8 Remove the hose and cable clamp retaining
fasteners from lower cable track at the pivot
end of the jib boom. Remove the clamps.
54 Z-135/70 Part No. 1268557

Jib Boom Components
16 Attach a lifting strap from an overhead crane to 3-6

the barrel end of the jib boom extension
cylinder.
Jib Boom Bellcrank Angle Sensor
17 Remove the pin retaining fasteners from the jib The jib boom bellcrank angle sensor is monitored
boom extension cylinder barrel-end pivot pin. by the control system to keep the jib boom bellcrank
Use a soft metal drift to remove the pin. vertical and to help maintain a level platform
through boom range of motion. If a jib boom
18 Carefully slide the jib boom extension cylinder bellcrank angle sensor is replaced, it must be
out of the jib boom and place it on a structure calibrated prior to machine operation. The jib boom
capable of supporting it. bellcrank angle sensor is mounted to the bellcrank
Crushing hazard. The jib boom pivot pin on the engine side of the machine.
extension cylinder could become
unbalanced and fall when How to Replace the Jib Boom
removed from the jib boom if not Bellcrank Angle Sensor
properly supported.
Note: During removal, the overhead crane strap will firm, level surface with the boom in the stowed
need to be adjusted for proper balancing. position.
1 Locate the jib boom bellcrank angle sensor
where the jib boom bellcrank connects to the
primary boom.
2 Disconnect the electrical connector from the
sensor. Remove any tie wraps securing the
wiring.
3 Remove the retaining fasteners from the angle
sensor guard. Remove the guard from the
machine.
Part No. 1268557 Z-135/70 55

Jib Boom Components
4 Remove the angle sensor cover retaining 11 Align the side of the sensor with flat area of the
fastener. Remove the cover. boom pivot pin as shown below.
5 Remove the angle sensor mounting bracket
retaining fasteners.
6 Remove the angle sensor and bracket
assembly. Do not lose the two springs or the
hex-shaped key.
7 Remove the sensor retaining fasteners from
the mounting bracket. Remove the angle
sensor.
Note: Note the sensor orientation on the bracket
during removal so the new sensor will be installed in
the same position.
8 Install the new angle sensor onto the mounting
bracket.
9 Install one spring, removed in step 6, into the
hex-shaped hole in the angle sensor. Install 1 flat area
the other spring into the hex-shaped hole in the 2 angle sensor
center of the boom pivot pin. 3 hex-shaped hole
10 Insert the hex-shaped key into the angle 12 Insert the hex-shaped key into the bellcrank
sensor. pivot pin allowing free clockwise rotation of the
angle sensor mounting bracket.
Note: Be sure the hex-shaped key remains
engaged in the sensor.
56 Z-135/70 Part No. 1268557

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How to C alibr ate the Jib Boom Bellcrank Angle Sens or
13 Rotate the angle sensor mounting bracket, How to Calibrate the Jib Boom
while holding the key in the sensor, clockwise
until the mounting bracket fits into the
Bellcrank Angle Sensor
machined pocket. Note: If the primary boom or secondary boom angle
sensors have been removed or replaced, or the
14 Install the angle sensor bracket retaining
turntable level sensor has been replaced, they must
fasteners.
be calibrated before the jib boom bellcrank angle
15 Install the angle sensor cover and install the sensor. Refer to Repair Procedures, How to
cover retaining fasteners. Calibrate the Primary Boom Angle Sensor or How
to Calibrate the Secondary Boom Angle Sensor or
16 Connect the electrical connector to the new
How to Calibrate the Turntable Level Sensor.
sensor.
17 Install the angle sensor guard over the angle Note: Perform this procedure with the machine on a
sensor. firm, level surface and in the stowed position with
the axles extended.
18 Calibrate the jib boom bellcrank angle sensor.
Refer to Repair Procedure, How to Calibrate Note: A digital level will be required to perform this
the Jib Boom Bellcrank Angle Sensor. procedure.
Note: A kit is available through Genie Product
Support (Genie part number 58351). This kit
includes a digital level with a magnetic base and
cable harnesses.
Part No. 1268557 Z-135/70 57

Jib Boom Components
Note: Use the following chart to identify the Before serial number 321:
in this procedure. 5 Locate the 2 pin connector in the lower left
6 Remove the connector plug and insert a
connector.
Digital levels with alternate zero function: 7 Locate the calibration toggle switch at the top
1 Prepare the digital level by placing it vertically mode by moving the toggle switch in the left
on a known surface that is perpendicular to direction.
gravity. Zero out the level with the alternate
zero function. 8 Temporarily install a control box door retaining
fastener between the door and the box to
Note: When the level is calibrated correctly, it prevent the control box door from moving the
should read 0° on a vertical surface. toggle switch while calibrating the machine.
Digital levels without alternate zero function: All models:
Note: If your digital level does not have an alternate 9 Remove the key from the main key switch.
zero function, it will read 90° on a vertical surface. Insert the key into the bypass/recovery key
During calibration, the measured value will need to switch and turn it to the bypass position.
be subtracted from 90 degrees to get the correct
Note: The angle sensor calibration values will not
number to enter into the system.
be saved correctly unless the key switch is in the
2 Raise the jib boom to a slightly less than bypass position.
horizontal position.
3 Push in the ground controls red Emergency control panel while pulling out the ground
Stop button to the off position. Do not turn the controls red Emergency Stop button to the on
key switch to the off position. position. Hold the enter button for
approximately 5 seconds and then release it.
58 Z-135/70 Part No. 1268557

Jib Boom Components
11 Enter sensor calibration mode by pressing the 16 Attach the digital level to the surface of the jib
buttons at the ground controls in the following boom bellcrank as shown.
sequence: (plus)(enter)(enter)(plus).
LCD screen until DELETE JIB LEVEL ANGLE
SENSOR CALIBRATION is displayed.
press the enter button to accept.
14 At the jib level calibration deg 60.0deg screen,
start the engine.
Note: If the system exits out of calibration mode
when the engine is started, repeat step 7 and 1 jib boom angle sensor
continue to step 12. 2 jib boom bellcrank
3 place level on this surface
15 Press and hold a function enable/speed select
button and the platform level up button. Fully 17 At the ground controls, press the plus button
extend the jib boom level cylinder. or minus button to adjust the display to the
exact value shown on the digital level and
Note: When in service/bypass mode, the platform press the enter button.
level buttons are used to adjust the jib boom level
cylinder. Note: If the measured angle already matches the
angle shown on the display at the ground controls,
Note: With the jib boom level cylinder is fully press the plus button or minus button to change
extended, the jib boom bellcrank angle should be at the angle and then change back to the measured
approximately 60 ± 2 degrees. value. The system must detect a change in
displayed value to record the calibrated value.
Part No. 1268557 Z-135/70 59

Jib Boom Components
18 Press and hold a function enable/speed select 22 Press and hold a function enable/speed select
button and the platform level down button until button and raise the jib boom above horizontal
the digital level displays approximately 34 ± to provide additional ground clearance for the
2 degrees. remaining calibration points.
19 At the ground controls, press the plus button 23 Press and hold a function enable/speed select
or minus button to adjust the display to the button and the platform level down button until
exact value shown on the digital level and the digital level displays approximately 18 ±
press the enter button. 2 degrees.
Note: If the measured angle already matches the
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
button and the platform level down button until
the digital level displays approximately 8 ±
2 degrees. Calibration angles
21 At the ground controls, press the plus button 24 At the ground controls, press the plus button
or minus button to adjust the display to the or minus button to adjust the display to the
exact value shown on the digital level and exact value shown on the digital level and
Note: If the measured angle already matches the Note: Be sure the number entered at the ground
angle shown on the display at the ground controls, controls is a negative number.
the angle and then change back to the measured Note: If the measured angle already matches the
value. The system must detect a change in angle shown on the display at the ground controls,
displayed value to record the calibrated value. press the plus button or minus button to change
60 Z-135/70 Part No. 1268557

Jib Boom Components
25 Press and hold a function enable/speed select 28 At the ground controls, press the plus button
button and the platform level down button until or minus button to adjust the display to the
the digital level displays approximately 44 ± exact value shown on the digital level and
2 degrees. press the enter button.
26 At the ground controls, press the plus button Note: Be sure the number entered at the ground
or minus button to adjust the display to the controls is a negative number.
press the enter button. Note: If the measured angle already matches the
Note: Be sure the number entered at the ground press the plus button or minus button to change
controls is a negative number. the angle and then change back to the measured
press the plus button or minus button to change Note: With the jib boom level cylinder fully retracted,
the angle and then change back to the measured the jib boom bellcrank angle should be at
value. The system must detect a change in approximately 70 degrees.
29 Press and hold the engine start button for
27 Press and hold a function enable/speed select approximately 5 seconds to shut off the engine
button and the platform level down button until and to save the calibration settings.
the digital level displays approximately 70 ±
2 degrees. The jib boom level cylinder should Note: Do not turn the engine off with the key switch
be fully retracted at this point. or red Emergency Stop button or all calibration
points or values will not be saved.
LCD screen until EXIT is displayed.Press the
plus button to select YES, then press the
enter button to accept.
31 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/recovery key switch
is in the run position before attempting to operate
the machine.
32 Wait approximately 20 seconds and turn the
machine off by pressing the red Emergency
Stop button in.
Part No. 1268557 Z-135/70 61

Jib Boom Components

Before serial number 321: After serial number 320:
33 Remove the wire jumper from the 2 pin 35 Remove the fastener that was temporarily
connector in the lower left hand area of the installed. Close the control box door and install
ground control box that was installed in step 6. the door retaining fasteners.
Install the connector plug.
Tip-over hazard. Failure to calibration toggle switch is automatically activated
remove the jumper wire will to exit out of calibration mode.
which will compromise machine All models:
stability. Operating the machine
36 Pull out the red Emergency Stop button. Start
in this configuration will result in
the engine and lower the boom to the stowed
the machine tipping over,
position. Be sure there are no calibration faults
resulting in death or serious
shown on the display.
injury. The jumper wire must be
machine.
34 Close the ground control box and install the

door retaining fasteners.
62 Z-135/70 Part No. 1268557

Boom Components
1 upper primary boom lift cylinder linkage arm 8 primary boom lift cylinder
2 primary boom 9 number 1 secondary boom tube
3 cable track 10 number 2 secondary boom tube
4 primary extension boom 11 number 3 secondary boom tube
5 jib boom manifold 12 lower primary boom lift cylinder linkage arm
6 secondary boom lift cylinder 13 number 4 secondary boom tube
7 secondary boom cable track (inside of
secondary boom)
Part No. 1268557 Z-135/70 63

Boom Components
4-1 4 Pull the electrical cables out of the lower cable

track that lead to the primary boom.
Primary Boom Cable Track
The primary boom cable track guides the cables Cables can be damaged if they
and hoses running up the boom. It can be repaired are kinked or pinched.
link by link without removing the cables and hoses
that run through it. Removing the entire primary 5 Tag and disconnect the electrical connectors
boom cable track is only necessary when from the jib boom manifold located at the
performing major repairs that involve removing the platform end of the primary extension boom.
primary boom.
6 Tag, disconnect and plug the two hydraulic
How to Remove the Primary hoses from the jib boom manifold that lead to
the platform manifold. Cap the fittings on the
Boom Cable Track manifold.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the machine on a squirt or spray.
7 Remove the retaining fasteners from the hose
Note: Perform this procedure with the boom in the and cable guide at the platform end of the
stowed position. primary boom. Remove the hose and cable
guide.
1 Remove the cover from the lower jib boom
cable track. 8 Tag and disconnect the electrical connector
from the limit switch on the side of the primary
2 Tag and disconnect the electrical connectors boom. Do not remove the limit switch.
inside the lower cable track.
9 Remove the cotter pin from the upper cable
3 Remove the hose and cable clamp retaining track tube at the platform end of the primary
fasteners from lower cable track at the pivot extension boom.
end of the jib boom. Remove the clamps.
Note: Always replace the cotter pin with a new one.
64 Z-135/70 Part No. 1268557

Boom Components
10 Remove the retaining fasteners from the cable 15 Locate the two hydraulic hoses inside the end
track guide at the platform end of the boom. of the secondary boom that lead to the primary
Remove the cable track guide from the boom cable track.
machine.
11 Place blocks between the upper and lower from the unions. Cap the fittings on the unions.
cable tracks and secure the upper and lower
tracks together. Bodily injury hazard. Spraying
Crushing hazard. If the upper burn skin. Loosen hydraulic
and lower cable tracks are not connections very slowly to allow
properly secured together, the the oil pressure to dissipate
cable track could become gradually. Do not allow oil to
unbalanced and fall when squirt or spray.
removed from the machine.
17 Disconnect the electrical connectors for the
12 Remove the hose and cable clamps from the electrical cables that lead to the cable track at
primary boom lift cylinder. the end of the secondary boom.
13 At the counterweight end of the secondary 18 Pull all hydraulic hoses and electrical cables
boom, support and secure the secondary that lead to the cable track out of the
boom lower end cover to a suitable lifting secondary boom riser.
device.
14 Remove the cover retaining fasteners and Cables and hoses can be
remove the cover from the end of the damaged if they are kinked or
secondary boom. pinched.
Crushing hazard. The secondary 19 Attach a lifting strap to each end of the cable
boom lower end cover could
track from an overhead crane for support. Do
become unbalanced and fall
not apply any lifting pressure.
when removed from the
secondary boom if not properly
supported and secured to the
lifting device.
Part No. 1268557 Z-135/70 65

Boom Components
How to R epair the Primar y Boom C abl e Tr ac k
20 Remove the mounting fasteners that attach the How to Repair the Primary Boom
lower cable track to the primary boom lift
cylinder.
Cable Track
21 Remove the mounting fasteners that attach the Component damage hazard.
cable track to the primary boom. The boom cable track can be
damaged if it is twisted.
22 Carefully remove the cable track from the
machine and lay it on a structure capable of Note: A cable track repair kit is available through
supporting it. the Genie Service Parts Department.
Crushing hazard. The primary 1 Visually inspect the cable track and determine
boom cable track could become which 4-link section needs to be replaced.
unbalanced and fall when
removed from the primary boom 2 Support the cable track assembly above the
if not properly supported by the section to be replaced.
overhead crane. 3 Carefully remove the snap rings and pins from
each end of the damaged section of cable
Component damage hazard. The track.
boom cable track can be
4 Remove the retaining fasteners from the upper
damaged if it is twisted.
black rollers from the 4-link section of cable
Cables and hoses can be 5 Lift up the hoses and cables and carefully
damaged if they are kinked or remove the damaged 4-link section of cable
pinched. track.
pinched.
66 Z-135/70 Part No. 1268557

Boom Components
6 Remove the upper rollers from the 4-2

Secondary Boom Cable Track
insert the new 4-link section of cable track. The secondary boom cable track guides the cables
and hoses running up through the inside of the
Component damage hazard. secondary boom. It can be repaired link by link
Cables and hoses can be without removing the cables and hoses that run
damaged if they are kinked or through it. Removal of the secondary boom cable
pinched. track is required to repair it.
8 Connect the ends of the replacement cable How to Remove the Secondary
track section to the existing cable track using
the pins and snap rings. Boom Cable Track
9 Install the rollers onto the new section of cable Note: When removing a hose assembly or fitting,
track. the O-ring (if equipped) on the fitting and/or hose
10 Operate the primary boom extend/retract torqued to specification during installation. Refer to
function through a full cycle to ensure smooth Specifications, Hydraulic Hose and Fitting Torque
operation of the new section of cable track. Specifications.
1 Working at the counterweight end of the
secondary boom, support and secure the
secondary boom end cover to a suitable lifting
device.
2 Remove the cover retaining fasteners and
remove the cover from the secondary boom.
Crushing hazard. The secondary
boom end cover could become
removed from the secondary
boom if not properly supported
and secured to the lifting device.
3 Working at the platform end of the secondary

boom, support and secure the secondary
boom end cover to a suitable lifting device.
Part No. 1268557 Z-135/70 67

Boom Components
4 Remove the cover retaining fasteners and 10 Pull the hydraulic hoses just removed through
remove the cover from the secondary boom. the turntable bulkhead.
Crushing hazard. The secondary Component damage hazard.
boom end cover could become Hoses can be damaged if they
unbalanced and fall when are kinked or pinched.
removed from the secondary
boom if not properly supported 11 Working at the counterweight end of the
and secured to the lifting device. secondary boom, tag, disconnect and plug the
hydraulic hoses from the unions that lead to
5 Working at the platform end of the secondary the cable track.
boom, remove the hose and cable U-bolt
12 Working at the counterweight end of the
fasteners near the upper cable track tube.
secondary boom, tag and disconnect the
6 Working at the platform end of the secondary electrical connectors to all of the cables that
boom, remove the upper cable track tube lead to the secondary boom cable track.
retaining fasteners. Remove the curved hose
13 Tag, disconnect and plug the primary boom lift
guide.
7 Working at the platform end of the secondary the cylinder.
boom, remove the lower cable track retaining
14 Tag, disconnect and plug the primary boom
fasteners.
extension cylinder hydraulic hoses at the
8 Working at the counterweight end of the unions located above the primary boom lift
secondary boom, remove the lower cable track cylinder. Cap the fittings on the unions.
15 Pull the hydraulic hoses for the primary boom
9 Tag, disconnect and plug the hydraulic hoses lift cylinder and extension cylinder out through
from the following ports of the function the hole in the number 4 secondary boom
manifold: PE, PR, P2, T1, PU and PD. Cap the tube.
fittings on the manifold.
Bodily injury hazard. Spraying Hoses can be damaged if they
hydraulic oil can penetrate and are kinked or pinched.
connections very slowly to allow 16 Working at the platform end of the secondary
the oil pressure to dissipate boom, place blocks between the upper and
gradually. Do not allow oil to lower cable tracks for support.
squirt or spray.
68 Z-135/70 Part No. 1268557

Boom Components
How to R epair the Sec ondar y Boom C able Tr ac k
17 Working at the counterweight end of the How to Repair the Secondary

secondary boom, attach a lifting strap from an
overhead crane to the secondary boom cable
Boom Cable Track
track. Component damage hazard.
18 Carefully pull the secondary boom cable track The boom cable track can be
out of the counterweight end of the boom. damaged if it is twisted.
19 Remove the secondary boom cable track from Note: A cable track repair kit is available through
the machine and place it on a structure the Genie Service Parts Department.
capable of supporting it.
1 Remove the secondary boom cable track.
Crushing hazard. The secondary Refer to Repair Procedure, How to Remove
boom cable track could become the Secondary Boom Cable Track.
unbalanced and fall if not
properly supported when 2 Visually inspect the cable track and determine
removed from the machine. which 4-link section needs to be replaced.
3 Carefully remove the snap rings and pins from
Component damage hazard. each end of the damaged section of cable
Cables and hoses can be track.
4 Remove the retaining fasteners from the upper
pinched.
black rollers from the 4-link section of cable
Component damage hazard. The
secondary boom cable track can 5 Lift up the hoses and cables and carefully
be damaged if it is twisted. remove the damaged 4-link section of cable
track.
Note: During removal, the overhead crane strap will
need to be adjusted for proper balancing. Component damage hazard.
pinched.
Note: If the section of cable track being replaced

has clamps or wear pads, those items will need to
be transferred to the replacement section of cable
track.
Part No. 1268557 Z-135/70 69

Boom Components
6 Remove the upper rollers from the 4-3

Primary Boom
insert the new 4-link section of cable track. How to Remove the Primary
Component damage hazard. Boom
damaged if they are kinked or Bodily injury hazard. This
pinched. procedure requires specific repair
skills, lifting equipment and a
8 Connect the ends of the replacement cable suitable workshop. Attempting
track section to the existing cable track using this procedure without these skills
the pins and snap rings. and tools could result in death or
serious injury and significant
9 Install the rollers onto the new section of cable component damage. Dealer
track. service is strongly recommended.
10 Install the secondary boom cable track into the
secondary boom.
11 Operate the secondary boom up/extend and end must be replaced. All connections must be
down/retract functions through a full cycle to torqued to specification during installation. Refer to
ensure smooth operation of the new section of Specifications, Hydraulic Hose and Fitting Torque
cable track. Specifications.
stowed position.
1 Remove the platform.
2 Remove the platform mounting weldment and
the platform rotator. Refer to Repair
Procedure, How to Remove the Platform
Rotator.
3 Remove the jib boom. Refer to Repair
Procedure, How to Remove the Jib Boom.
Note: When the jib boom is installed, the jib boom
angle sensor will need to be calibrated. Refer to
Repair Procedure, How to Calibrate the Jib Boom
Bellcrank Angle Sensor.
70 Z-135/70 Part No. 1268557

Boom Components
4 Remove the primary boom cable track. Refer 10 Tag, disconnect and plug the primary boom
to repair procedure, How to Remove the Cable extension cylinder hydraulic hoses. Cap the
Track. fittings on the cylinder.
5 Remove the end cover from the pivot end of Bodily injury hazard. Spraying
the primary boom. hydraulic oil can penetrate and
6 Remove the limit switch mounting fasteners burn skin. Loosen hydraulic
from the limit switch on the ground controls connections very slowly to allow
side of the primary boom. Do not disconnect the oil pressure to dissipate
the wiring. Remove the limit switch. gradually. Do not allow oil to
squirt or spray.
primary boom angle sensor. 11 Place blocks under both ends of the primary
boom lift cylinder for support.
Note: The primary boom angle sensor is located
inside the primary boom at the pivot end. 12 Attach a lifting strap from an overhead crane to
the rod end of the primary boom lift cylinder.
8 Remove the primary boom angle sensor
bracket mounting fasteners and remove the 13 Remove the pin retaining fasteners from the
primary boom angle sensor from the primary primary boom lift cylinder rod-end pivot pin.
boom. Do not remove the angle sensor from
14 Use a soft metal drift to remove the rod-end
the bracket. Note the location of the springs. pivot pin. Rest the rod end of the primary boom
Do not lose the springs. lift cylinder on the blocks.
Note: There is one spring inside the primary boom
15 Support both upper primary boom lift cylinder
pivot pin and one inside the angle sensor.
linkage arms with a suitable lifting device. Do
Note: When the primary boom is installed, the not apply any lifting pressure.
primary boom angle sensor will need to be 16 Remove the pin retaining fasteners from the
calibrated. Refer to Repair Procedure, How to upper primary boom lift cylinder linkage arm
Calibrate the Primary Boom Angle Sensor. pivot pin where it connects to the primary
boom.
9 Remove the hose and cable guide fasteners at
the primary boom pivot pin. Remove the hose
and cable guide.
Part No. 1268557 Z-135/70 71

Boom Components
17 Use a soft metal drift to tap the pin halfway out 4-4
and lower one of the linkage arms down. Tap
the pin in the other direction and lower the
Primary Boom Lift Cylinder
other linkage arm down. The primary boom lift cylinder raises and lowers the
Crushing hazard. The upper primary boom. The primary boom lift cylinder is
primary boom lift cylinder linkage equipped with a counterbalance valve to prevent
arms could fall if not properly movement in the event of a hydraulic line failure.
supported when the pivot pins are
removed. How to Remove the Primary
Boom Lift Cylinder
18 Attach a 5 ton / 5000 kg overhead crane to
both ends of the primary boom. Do not apply Bodily injury hazard. This
any lifting pressure. procedure requires specific repair
skills, lifting equipment and a
19 Remove the pin retaining fasteners from the suitable workshop. Attempting
primary boom pivot pins. this procedure without these skills
20 Use a soft metal drift to remove the primary and tools could result in death or
boom pivot pins. serious injury and significant
21 Carefully remove the primary boom from the service is strongly recommended.
supporting it. Note: When removing a hose assembly or fitting,
Crushing hazard. The primary
boom could become unbalanced
and fall when removed from the
machine if not properly attached
Specifications.
to the overhead crane.
stowed position.
1 Remove the hose and cable clamps from the
primary boom lift cylinder.
2 Remove the cable track retaining fasteners at
the primary boom lift cylinder.
3 Place blocks under both ends of the primary
boom lift cylinder. Place another block under
the cylinder linkage arms under the primary
boom lift cylinder barrel-end pivot pin.
72 Z-135/70 Part No. 1268557

Boom Components
4 Tag, disconnect and plug the primary boom lift 4-5

the cylinder.
Secondary Boom Lift Cylinder
Bodily injury hazard. Spraying How to Remove the Secondary
hydraulic oil can penetrate and Boom Lift Cylinder
connections very slowly to allow Bodily injury hazard. This
the oil pressure to dissipate procedure requires specific repair
gradually. Do not allow oil to skills, lifting equipment and a
squirt or spray. suitable workshop. Attempting
this procedure without these skills
5 Attach a lifting strap from an overhead crane to and tools could result in death or
the rod end of the primary boom lift cylinder. serious injury and significant
Do not apply any lifting pressure. component damage. Dealer
6 Remove the pin retaining fasteners from the service is strongly recommended.
primary boom lift cylinder rod-end pivot pin.
Use a soft metal drift to remove the pin and Note: When removing a hose assembly or fitting,
rest the cylinder on the block. the O-ring (if equipped) on the fitting and/or hose
7 Attach a lifting strap from a second overhead torqued to specification during installation. Refer to
crane to the barrel end of the primary boom lift Specifications, Hydraulic Hose and Fitting Torque
cylinder. Do not apply any lifting pressure. Specifications.
8 Remove the primary boom lift cylinder Note: Perform this procedure with the machine on a
barrel-end pivot pin retaining fasteners. firm, level surface and in the stowed position with
9 Use a soft metal drift to remove the barrel-end the axles extended.
pivot pin. Carefully remove the primary boom 1 Tag, disconnect and plug the hydraulic hoses
lift cylinder from the machine. from the secondary boom lift cylinder. The
Crushing hazard. The boom lift hoses can be accessed from under the
cylinder may become turntable.
unbalanced and fall if it is not Bodily injury hazard. Spraying
properly supported when it is hydraulic oil can penetrate and
removed from the machine. burn skin. Loosen hydraulic
Crushing hazard. The primary the oil pressure to dissipate
boom lift cylinder linkage arms gradually. Do not allow oil to
may fall if not properly squirt or spray.
supported when the barrel-end
pivot pin is removed.
Part No. 1268557 Z-135/70 73

Boom Components
2 Remove the engine pivot plate retaining 6 Tag, disconnect and plug the fuel hoses from
fastener. Swing the engine pivot plate out the fuel tank. Clean up any fuel that may have
away from the machine. spilled.
7 Close the two hydraulic tank shut-off valves at
the hydraulic tank.
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
1 engine pivot plate anchor hole switch and tag the machine to
2 engine pivot plate retaining fastener inform personnel of the
condition.
3 Locate the engine pivot plate anchor hole at
the pivot end of the engine pivot plate. 8 Remove the drain plug from the hydraulic tank
4 Install the bolt that was just removed into the and completely drain the tank into a container
anchor hole to secure the engine pivot plate of suitable capacity. Refer to Specifications,
from moving. Fluid Capacity Specifications.
9 Tag, disconnect and plug the two suction
Crushing hazard. Failure to install
hoses from the hydraulic tank.
the bolt into the engine pivot plate
to secure it from moving could 10 Tag, disconnect and plug the two supply hoses
result in death or serious injury. for the auxiliary power units. Cap the fittings on
the hydraulic tank.
5 Remove the retaining fasteners from the fixed
11 Tag, disconnect and plug the hydraulic hose
turntable cover at the ground controls side of
the machine. Remove the fixed turntable cover from the drive motor case drain filter at the
from the machine. hydraulic tank. Cap the fitting on the hydraulic
tank.
12 Tag, disconnect and plug the hydraulic hose at
the return filter. Cap the fitting on the return
filter housing.
74 Z-135/70 Part No. 1268557

Boom Components
13 Remove the turntable cover using a suitable 19 Attach an overhead crane or similar lifting
lifting device. device to the battery box for the auxiliary
power unit batteries.
Crushing hazard. The turntable
cover may become unbalanced 20 Remove the battery box retaining fasteners
and fall if not properly supported and carefully remove the battery box from the
and secured to a suitable lifting machine.
device.
Crushing hazard. The battery
box could become unbalanced
14 Remove the ground control box mounting
and fall when removed from the
fasteners. Move the ground control box out of
machine if not properly
the way.
supported.
15 Remove the hydraulic tank retaining fasteners.
16 Remove the cover from the auxiliary power Bodily injury hazard. Batteries
unit batteries. contain acid. Avoid spilling or
contacting battery acid.
17 Tag and disconnect the cables from the Neutralize battery acid spills with
auxiliary power unit batteries. baking soda and water.
Electrocution/burn hazard. 21 Support the hydraulic tank with 2 lifting straps.
Contact with electrically charged Place one lifting strap at each end of the tank
circuits could result in death or and attach the lifting straps to an appropriate
serious injury. Remove all rings, lifting device.
22 Remove the hydraulic tank from the machine.
18 Tag and disconnect the cables from the engine
starting/controls battery located on the engine Crushing hazard. The hydraulic
side of the machine. tank could become unbalanced
and fall if not properly supported
Electrocution/burn hazard. when removed from the
Contact with electrically charged machine.
serious injury. Remove all rings, 23 Place a block under the secondary boom lift
watches and other jewelry. cylinder for support.
Part No. 1268557 Z-135/70 75

Boom Components
24 Remove the secondary boom lift cylinder 29 Use a slide hammer to remove the barrel-end
rod-end pivot pin retaining fasteners. Use a pivot pin.
soft metal drift to remove the pin through the
access holes in the turntable bulkheads. Component damage hazard.
Hoses and cables can become
25 Attach an overhead crane with a minimum damaged if the barrel end of the
capacity of 7 tons / 7000 kg to the secondary boom lift cylinder is
counterweight end of the secondary boom. allowed to fall when the
26 Raise the boom assembly with the overhead barrel-end pivot pin is removed.
crane approximately 20 feet / 6 m.
30 Carefully remove the secondary boom lift
Crushing hazard. The boom cylinder from the machine.
assembly can fall if not properly
supported by the overhead Crushing hazard. The secondary
crane. boom lift cylinder could become
27 Remove the secondary boom lift cylinder removed from the machine if not
barrel-end pivot pin retaining fasteners. Do not properly attached to the
remove the pin. overhead crane.
28 Attach a lifting strap from a second overhead Component damage hazard.

crane to each end of the secondary boom lift Hoses and cables can be
cylinder. damaged if the secondary boom
Note: Protect the hoses and cables underneath the lift cylinder is pulled across them.
cylinder from damage.
76 Z-135/70 Part No. 1268557

Boom Components
4-6 2 Remove the access cover from the pivot end of

the primary boom.
Primary Boom Extension Cylinder
3 Tag, disconnect and plug the primary boom
The primary boom extension cylinder extends and extension cylinder hydraulic hoses. Cap the
retracts the primary boom extension tube.The fittings on the cylinder.
primary boom extension cylinder is equipped with
counterbalance valves to prevent movement in the Bodily injury hazard. Spraying
event of a hydraulic line failure. hydraulic oil can penetrate and
How to Remove the Primary connections very slowly to allow
Boom Extension Cylinder gradually. Do not allow oil to
Bodily injury hazard. This squirt or spray.
procedure requires specific repair
skills, lifting equipment and a 4 At the platform end, remove the external snap
suitable workshop. Attempting rings from the extension cylinder rod-end pivot
this procedure without these skills pin. Use a soft metal drift to remove the pin.
and tools could result in death or 5 Remove the extension cylinder retainers from
serious injury and significant the saddle blocks.
service is strongly recommended. 6 Attach a lifting strap from an overhead crane to
the barrel end of the primary boom extension
Note: When removing a hose assembly or fitting, cylinder.
the O-ring (if equipped) on the fitting and/or hose 7 Using the overhead crane, lift the extension
end must be replaced. All connections must be cylinder to clear the saddle blocks.
Specifications, Hydraulic Hose and Fitting Torque 8 Support and slide the primary boom extension
Specifications. cylinder out of the primary boom and place it
on a structure capable of supporting it.
firm, level surface and in the stowed position with Crushing hazard. The extension
the axles extended. cylinder could become
1 Extend the primary boom until the primary removed from primary boom
boom extension cylinder rod-end pivot pin is extension tube if not properly
accessible in the primary boom extension supported.
tube.
need to be adjusted for proper balancing.
Note: Note the length of the cylinder after removal.
The cylinder must be at the same length for
installation.
Part No. 1268557 Z-135/70 77

Boom Components
4-7 1 Raise the primary boom approximately 10 feet

/ 3 m. Turn the machine off.
Secondary Boom Extension
Cylinders 2 Working at the platform end of the secondary
boom, support and secure the secondary
The secondary boom extension cylinders extend boom end cover to a suitable lifting device.
and retract the secondary boom. The secondary 3 Remove the cover retaining fasteners and
boom extension system consists of 3 hydraulic remove the cover from the secondary boom.
cylinders and each are equipped with
counterbalance valves to prevent movement in the Crushing hazard. The secondary
event of a hydraulic line failure. boom end cover could become
How to Remove the Secondary removed from the secondary
boom if not properly supported
Boom Extension Cylinders and secured to the lifting device.
Bodily injury hazard. This
procedure requires specific repair 4 Remove the retaining fasteners from both
skills, lifting equipment and a secondary boom extend limit switches and
suitable workshop. Attempting remove the limit switches. Do not disconnect
this procedure without these skills the wiring.
and tools could result in death or Note: Label the location of each limit switch as they
serious injury and significant are not the same and their mounting locations
component damage. Dealer cannot be exchanged.
service is strongly recommended.
5 Tag, disconnect and plug all hydraulic hoses
Note: When removing a hose assembly or fitting, for the 3 secondary boom extension cylinders.
the O-ring (if equipped) on the fitting and/or hose Cap the fittings on the cylinder.
torqued to specification during installation. Refer to Bodily injury hazard. Spraying
Specifications, Hydraulic Hose and Fitting Torque hydraulic oil can penetrate and
Specifications. burn skin. Loosen hydraulic
Note: Perform this procedure with the machine on a the oil pressure to dissipate
firm, level surface and in the stowed position with gradually. Do not allow oil to
the axles extended. squirt or spray.
6 Remove the upper extension cylinder retainers

from the saddle blocks.
78 Z-135/70 Part No. 1268557

Boom Components
7 Attach a lifting strap from an overhead crane to Note: When installing the middle and upper
the rod end of the upper extension cylinder. secondary boom extension cylinders, be sure the
grooved wear pads are correctly aligned with the
8 Using the overhead crane, lift the extension channels on the top of the cylinders.
cylinder to clear the saddle blocks.
9 Support and slide the upper extension cylinder
out of the secondary boom and place it on a
structure capable of supporting it.
Crushing hazard. The extension
cylinder could fall when removed
from the secondary boom if not
properly supported.

need to be adjusted for proper balancing.
10 Repeat steps 6 through 9 for the remaining
secondary boom extension cylinders.
1 upper extension cylinder (#1)
Note: The secondary boom extension cylinders 2 middle extension cylinder (#2)
must be installed in the same order they were 3 bottom extension cylinder (#3)
removed. 4 cylinder grooved wear pads
5 channels
Part No. 1268557 Z-135/70 79

Boom Components
4-8 7 Install the new angle sensor onto the mounting

bracket.
Primary Boom Angle Sensor
The primary boom angle sensor is used to limit the hex-shaped hole in the angle sensor. Install
angle of the primary boom relative to the angle of the other spring into the hex-shaped hole in the
the secondary boom and gravity. center of the boom pivot pin.
How to Replace the Primary 9 Insert the hex-shaped key into the angle
sensor.
Boom Angle Sensor
10 Align the side of the sensor with flat area of the
Note: Perform this procedure with the machine on a boom pivot pin as shown below while holding
firm, level surface with the boom in the stowed the bracket away from key insertion.
position.
1 Remove the retaining fasteners from the boom
end cover at the pivot end of the primary boom.
Remove the cover from the machine.
2 Locate the primary boom angle sensor inside
the primary boom at the boom pivot pin.
sensor.
hex-shaped key.
the mounting bracket. Remove the angle 1 flat area
sensor. 2 angle sensor
3 hex-shaped hole
the same position.
80 Z-135/70 Part No. 1268557

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How to C alibr ate the Pri mar y Boom Angle Sensor
11 While holding the hex-shaped key in position, How to Calibrate the Primary
rotate the angle sensor mounting bracket
clockwise until it aligns with the machined
Boom Angle Sensor
pocket. Do not allow the key to rotate while The primary boom angle sensor is used to limit the
holding it. angle of the primary boom relative to the angle of
the secondary boom and gravity.
12 Insert the hex-shaped key into the boom pivot
pin and the bracket into the machined pocket. The primary boom maximum angle is gradually
Note: Be sure the hex-shaped key remains reduced as the downhill slope (positive degree Y
engaged in the sensor. axis) is increased. A flat level surface of 0° allows
the primary boom maximum operational angle to
13 Install the angle sensor bracket retaining reach 68°. On a 5° downhill slope the primary boom
fasteners. maximum operational angle is reduced to 43°.
14 Connect the electrical connector to 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.
0° slope, 68° boom angle 5° slope, 43° boom angle
Part No. 1268557 Z-135/70 81

Boom Components
Note: If the axle sensor or secondary boom angle 1 Push in the ground controls red Emergency
sensor have been removed or replaced, or the Stop button to the off position.
turntable level sensor has been replaced, they must 2 Turn the key switch to ground controls.
be calibrated first. Refer to Repair Procedures, How
to Calibrate the Axle Angle Sensors or How to 3 Open the ground control box.
Calibrate the Secondary Boom Angle Sensor or Before serial number 321:
How to Calibrate the Turntable Level Sensor.
4 Locate the 2 pin connector in the lower left
Tip-over hazard. Failure to hand area of the ground control box.
properly calibrate the machine
could cause the machine to tip 5 Remove the connector plug and insert a
over resulting in death or serious jumper wire between the two pins of the
injury. connector.
Note: A digital level will be required to perform this
procedure. 6 Locate the calibration toggle switch at the top
Note: A kit is available through Genie Product mode by moving the toggle switch in the left
Support (Genie part number 58351). This kit direction.
cable harnesses. 7 Temporarily install a control box door retaining
Note: Use the following chart to identify the prevent the control box door from moving the
description of each LCD screen control button used toggle switch while calibrating the machine.
in this procedure.
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 position.
Plus Minus Previous Enter Note: The angle sensor calibration values will not
Note: Perform this procedure with the machine on a bypass position.
firm, level surface with the booms in the fully stowed
position and the axles fully extended.
82 Z-135/70 Part No. 1268557

Boom Components
9 Press and hold the enter button on the ground 16 Fully raise the secondary boom. The boom is
control panel while pulling out the ground fully raised when the cylinder is fully extended
controls red Emergency Stop button to the on and the boom stops moving.
position. Hold the enter button for
button and the primary boom down button and
10 Enter sensor calibration mode by pressing the lower the primary boom down until the digital
buttons at the ground controls in the following level displays -50 degrees.
sequence: (plus)(enter)(enter)(plus).
18 At the ground controls, press the plus button
11 Press the enter or previous button on the or minus button to adjust the display to the
LCD screen until DELETE PRIMARY BOOM exact value shown on the digital level and
ANGLE SENSOR CALIBRATION is displayed press the enter button.
12 Press the plus button to select YES, then Note: Be sure the number entered at the ground
press the enter button to accept. controls is a negative number.
13 Place a digital level that has been calibrated to Note: If the measured angle already matches the
gravity on top of the primary boom and note angle shown on the display at the ground controls,
the angle displayed on the digital level. press the plus button or minus button to change
14 At the PRIMARY BOOM ANGLE TO GRAVITY the angle and then change back to the measured
0.0 DEG screen, press the plus button or value. The system must detect a change in
minus button to adjust the display to the exact displayed value to record the calibrated value.
value shown on the digital level, then press the 19 Press and hold a function enable/speed select
enter button. button and the primary boom up button until
Note: If the measured angle already matches the the digital level displays -20 degrees.
15 Start the engine from the ground controls.
when the engine is started, repeat step 8 and then
continue with step 14.
Part No. 1268557 Z-135/70 83

Boom Components
Note: Be sure the number entered at the ground Note: If the measured angle already matches the
controls is a negative number. angle shown on the display at the ground controls,
Note: If the measured angle already matches the the angle and then change back to the measured
angle shown on the display at the ground controls, value. The system must detect a change in
press the plus button or minus button to change displayed value to record the calibrated value.
value. The system must detect a change in 25 Press and hold a function enable/speed select
displayed value to record the calibrated value. button and the primary boom up button until
the primary boom is fully raised. The boom is
21 Press and hold a function enable/speed select fully raised when the cylinder is fully extended
button and the primary boom up button until and the boom stops moving. The angle will be
the digital level displays 10 degrees. 70 degrees.
Note: If the measured angle already matches the Note: If the measured angle already matches the
angle shown on the display at the ground controls, angle shown on the display at the ground controls,
press the plus button or minus button to change press the plus button or minus button to change
the angle and then change back to the measured the angle and then change back to the measured
value. The system must detect a change in value. The system must detect a change in
displayed value to record the calibrated value. displayed value to record the calibrated value.
button and the primary boom up button until
the digital level displays 40 degrees.
84 Z-135/70 Part No. 1268557

Boom Components
27 Press and hold the engine start button for Before serial number 321:
approximately 5 seconds to shut off the engine 32 Remove the wire jumper from the 2 pin
and to save the calibration settings. connector in the lower left hand area of the
Note: Do not turn the engine off with the key switch ground control box that was installed in step 5.
or red Emergency Stop button or all calibration Install the connector plug.
points or values will not be saved.
28 Press the enter or previous button on the remove the jumper wire will
LCD screen until EXIT is displayed. result in an unsafe configuration
which will compromise machine
29 Press the plus button to select YES, then stability. Operating the machine
press the enter button to accept. in this configuration will result in
30 Turn the key back to the run position and the machine tipping over,
remove the key from the bypass/recovery key resulting in death or serious
switch. Insert the key into the main key switch injury. The jumper wire must be
and turn it to ground controls. removed before operating the
machine.
is in the run position before attempting to operate 33 Close the ground control box and install the
the machine. door retaining fasteners.
31 Wait approximately 20 seconds and turn the After serial number 320:
machine off by pressing the red Emergency
Stop button in. 34 Remove the fastener that was temporarily
All models:
36 Perform a primary boom angle test. Refer to
Maintenance Procedure, Test the Primary
Boom Angle Sensor.
Part No. 1268557 Z-135/70 85

Boom Components
4-9 7 Install the new angle sensor onto the mounting

bracket.
Secondary Boom Angle Sensor
The secondary boom angle sensor is used to limit hex-shaped hole in the angle sensor. Install
the angle of the primary boom relative to the angle the other spring into the hex-shaped hole in the
of the secondary boom and gravity. center of the boom pivot pin.
How to Replace the Secondary 9 Insert the hex-shaped key into the angle
sensor.
Boom Angle Sensor
10 Align the side of the sensor with flat area of the
Note: Perform this procedure with the machine on a boom pivot pin as shown below. Hold the
firm, level surface with the boom in the stowed bracket out to clear the side of the turntable
position. side plate.
1 Locate the secondary boom angle sensor on
the turntable riser bulkhead at the ground
controls side of the machine.
sensor. Remove any tie wraps securing the
wiring.
3 Remove the angle sensor cover retaining
fastener. Remove the cover.
hex-shaped key.
the mounting bracket. Remove the angle
sensor.
the same position. 1 flat area
2 angle sensor
3 hex-shaped hole
86 Z-135/70 Part No. 1268557

Boom Components
How to C alibr ate the Sec ondar y Boom Angle Sensor
11 While holding the hex-shaped key in position, How to Calibrate the Secondary
rotate the angle sensor mounting bracket
clockwise until it aligns with the machined
Boom Angle Sensor
pocket. Do not allow the key to rotate while Note: If the axle sensor has been removed or
holding it. replaced, or the turntable level sensor has been
replaced, they must be calibrated first. Refer to
Note: Be sure the hex-shaped key remains
Repair Procedure, How to Calibrate the Axle Angle
engaged in the sensor only.
Senors or How to Calibrate the Turntable Level
12 Insert the hex-shaped key into the boom pivot Sensor.
pin and the bracket into the machined pocket.
13 Install the angle sensor bracket retaining properly calibrate the machine
fasteners. could cause the machine to tip
14 Install the angle sensor cover and retaining over resulting in death or serious
fasteners. injury.
15 Connect the electrical connector to the new Note: A digital level will be required to perform this
sensor. procedure.
16 Calibrate the secondary boom angle sensor. Note: A kit is available through Genie Product
Refer to Repair Procedure, How to Calibrate Support (Genie part number 58351). This kit
the Secondary Boom Angle Sensor. includes a digital level with a magnetic base and
cable harnesses.
in this procedure.
Part No. 1268557 Z-135/70 87

Boom Components
1 Push in the ground controls red Emergency All models:
Stop button to the off position.
2 Turn the key switch to ground controls.
3 Open the ground control box. switch and turn it to the bypass position.
Before serial number 321: Note: The angle sensor calibration values will not
4 Locate the 2 pin connector in the lower left bypass position.
5 Remove the connector plug and insert a control panel while pulling out the ground
jumper wire between the two pins of the controls red Emergency Stop button to the on
connector. position. Hold the enter button for
After serial number 320: approximately 5 seconds and then release it.
6 Locate the calibration toggle switch at the top 10 Enter sensor calibration mode by pressing the
of the ground control box. Activate calibration buttons at the ground controls in the following
mode by moving the toggle switch in the left sequence: (plus)(enter)(enter)(plus).
direction. 11 Press the enter or previous button on the
7 Temporarily install a control box door retaining LCD screen until DELETE SECONDARY
fastener between the door and the box to BOOM ANGLE SENSOR CALIBRATION is
prevent the control box door from moving the displayed.
toggle switch while calibrating the machine. 12 Press the plus button to select YES, then
13 Place a digital level that has been calibrated to
the Y axis of the turntable on top of the
secondary boom and note the angle displayed
on the digital level.
88 Z-135/70 Part No. 1268557

Boom Components
14 At the SECONDARY BOOM ANGLE TO 18 Press and hold a function enable/speed select
GRAVITY -3.5DEG screen, press the plus button and the secondary boom up button until
button or minus button to adjust the display to the digital level displays 35 degrees.
the exact value shown on the digital level and
19 At the ground controls, press the plus button
or minus button to adjust the display to the
Note: Be sure the number entered at the ground exact value shown on the digital level and
controls is a negative number. press the enter button.
Note: If the measured angle already matches the Note: If the measured angle already matches the
angle shown on the display at the ground controls, angle shown on the display at the ground controls,
press the plus button or minus button to change press the plus button or minus button to change
the angle and then change back to the measured the angle and then change back to the measured
value. The system must detect a change in value. The system must detect a change in
displayed value to record the calibrated value. displayed value to record the calibrated value.
15 Start the engine from the ground controls. 20 Press and hold a function enable/speed select
button and the secondary boom up button until
Note: If the system exits out of calibration mode the digital level displays 50 degrees.
when the engine is started, repeat step 8 and then
continue with step 14. 21 At the ground controls, press the plus button
or minus button to adjust the display to the
16 Press and hold a function enable/speed select exact value shown on the digital level and
button and the secondary boom up button until press the enter button.
the digital level displays 20 degrees.
17 At the ground controls, press the plus button angle shown on the display at the ground controls,
or minus button to adjust the display to the press the plus button or minus button to change
exact value shown on the digital level and the angle and then change back to the measured
press the enter button. value. The system must detect a change in
Note: If the measured angle already matches the displayed value to record the calibrated value.
Part No. 1268557 Z-135/70 89

Boom Components
22 Press and hold a function enable/speed select 26 Press and hold the engine start button for
button and the secondary boom up button until approximately 5 seconds to shut off the engine
the digital level displays 65 degrees. and to save the calibration settings.
23 At the ground controls, press the plus button Note: Do not turn the engine off with the key switch
or minus button to adjust the display to the or red Emergency Stop button or all calibration
exact value shown on the digital level and points or values will not be saved.
Note: If the measured angle already matches the LCD screen until EXIT is displayed.
press the plus button or minus button to change 28 Press the plus button to select YES, then
the angle and then change back to the measured press the enter button to accept.
value. The system must detect a change in 29 Turn the key back to the run position and
displayed value to record the calibrated value. remove the key from the bypass/recovery key
button and the secondary boom up button.
Fully raise the secondary boom. The boom is Note: Be sure that the bypass/recovery key switch
fully raised when the cylinder is fully extended is in the run position before attempting to operate
and the boom stops moving.The angle will be the machine.
76 degrees.
30 Wait approximately 20 seconds and turn the
25 At the ground controls, press the plus button machine off by pressing the red Emergency
or minus button to adjust the display to the Stop button in.
90 Z-135/70 Part No. 1268557

Boom Components
Before serial number 321:

connector in the lower left hand area of the
ground control box that was installed in step 5.
remove the jumper wire will
resulting in death or serious
machine.

33 Remove the fastener that was temporarily
All models:
35 Perform secondary boom angle test. Refer to
Maintenance Procedure, Test the Secondary
Boom Angle Sensor.
Part No. 1268557 Z-135/70 91

Engines
5-1 5-2
RPM Adjustment Flex Plate
Refer to Maintenance Procedure in the appropriate The flex plate acts as a coupler between the engine
Service or Maintenance Manual for your machine, and the pump. It is bolted to the engine flywheel
Check and Adjust the Engine RPM. and has a splined center to drive the pump.
Two different styles of flex plates have been used in
the production of your machine model.
Type "A" flex plates utilize a flex plate installed onto
the flywheel of the engine and a separate coupler
installed onto the pump splined shaft.
Type "B" flex plates combines the pump coupler, as
part of the flex plate, which is installed onto the
engine flywheel.
1 Type "A" (flex plate with separate coupler)

2 Type "B" (flex plate with coupler combined)
92 Z-135/70 Part No. 1268557

Engines
How to i nstall a T ype "A" Flex Pl ate
How to Remove the Flex Plate How to Install a Type "A" Flex
1 Disconnect the wiring plug at the electronic Plate
displacement controller (EDC), located on the 1 Install the flex plate onto the engine flywheel
drive pump. with the raised spline towards the pump.
2 Support the drive pump with an appropriate 2 Ford models: Torque the flex plate mounting
lifting device. Then remove all of the pump bolts in sequence to 14 ft-lbs / 19 Nm. Then
mounting plate to engine bell housing bolts. torque the flex plate mounting bolts in
3 Carefully pull the pump away from the engine sequence to 20 ft-lbs / 27 Nm.
and secure it from moving. Deutz models: Torque the flex plate mounting
4 Remove the flex plate mounting fasteners, bolts in sequence to 28 ft-lbs / 38 Nm. Then
then remove the flex plate from the engine torque the flex plate mounting bolts in
flywheel. 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.
Part No. 1268557 Z-135/70 93

Engines
3 Install the pump coupler onto the pump shaft
with the set screw toward the pump. Leave the
appropriate gap between the coupler and
pump end plate for your engine.
1 pump
2 pump shaft
3 pump coupler
4 flex plate with raised spline
Ford and Deutz models 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.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.
Perkins models
94 Z-135/70 Part No. 1268557

Engines
How to i nstall a T ype "B" Flex Pl ate
How to Install a Type "B" Flex

Plate
1 Deutz and Perkins models: Install the flex
plate onto the engine flywheel with the rubber
vibration isolators towards the pump.
Cummins models: Install the flex plate onto
the engine flywheel with the rubber vibration
isolators towards the engine flywheel.
2 Apply Loctite® removable thread sealant to the
flex plate fasteners and loosely install the
fasteners.
3 Deutz and Perkins models: Torque the flex
plate mounting bolts in sequence to 28 ft-lbs / Deutz and Perkins models
38 Nm. Then torque the flex plate mounting
bolts in sequence to 40 ft-lbs / 54 Nm.
Cummins models: Torque the flex plate
mounting bolts in sequence to 14 ft-lbs / 19 Nm.
Then torque the flex plate mounting bolts in
sequence to 20 ft-lbs / 27 Nm.
4 Apply a high viscosity coupling grease (Genie
part number 128025) to the splines of the
pump shaft and flex plate.
Grease Specification
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
Cummins models
Part No. 1268557 Z-135/70 95

Ground Controls
6-1
Bypass/Recovery Key Switch
The turntable control box (TCON) is the
communication and operations center for the
machine. The turntable control box contains two
key switches. The main key switch towards the top
of the control box is for selection of ground or
platform controls. The key switch at the bottom of
the control box is the Bypass/Recovery key switch.
Bypass and Recovery modes are only intended for
certain circumstances and are not part of normal
machine operation. If either the Bypass or the
Recovery function is required, this indicates there
may be faults with the machine. Contact trained
personnel immediately.
Bypass is used for a platform out-of-level condition 1 Run
and calibrating certain machine parameters. 2 Bypass
3 Recovery
Recovery is only to be used as a last attempt to
lower the platform when the operator in the platform Note: The bypass/recovery key switch is located on
is unable to do so, system failure or in emergency the lower right side of the control box from serial
situations. number Z13512-1712.
96 Z-135/70 Part No. 1268557

Ground Controls
How to Use the Bypass Mode 3 Turn the bypass/recovery key switch to the
bypass position.
Tip-over hazard. Operating the
machine outside of the operating 4 Using auxiliary power, operate the ground
envelope while in Bypass mode control buttons to level the platform.
will result in death or serious injury Note: Only the auxiliary power unit can be used to
if proper operating procedures correct an out of level platform fault.
and safety precautions are not
followed. Do not use this mode if 5 Turn the bypass/recovery key switch to the run
you are not trained and familiar position.
with the operating envelope of the 6 Remove the key from the bypass/recovery key
machine. switch and insert the key into the main key
switch.
Note: Before using the Bypass mode, make sure
you understand the fault code or issue affecting the Note: If the Bypass function has been used, there
operation of the machine to be sure the use of may be faults with the machine. Check the LCD
bypass is required. screen on the ground control box for machine faults,
then contact trained service personnel.
The Bypass mode will allow the platform to be
manually leveled when an out-of-level condition
exists. In the event that the platform angle is greater
than 10° from level, the boom angle and platform
level functions are disabled. Use of the 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 the
ground control position.
Part No. 1268557 Z-135/70 97

Ground Controls
How to Us e the R ec overy Mode
How to Use the Recovery Mode Note: This procedure is for machines using
software version 1.11 and later. For machines
Recovery is only to be used as a last attempt to using software version 1.01, contact Genie Product
lower the platform when the operator in the platform Support.
is unable to do so, system failure or in emergency
situations. 1 Turn the main key switch to ground controls.
Remove the key from the main key switch and
Bodily injury hazard. When using insert the key into the bypass/recovery key
recovery mode, the platform may switch.
not fully lower to the ground when
the recovery mode is completed. Note: If this procedure is performed with the main
Failure to use only suitable key switch in the off position an active latched
equipment and/or practices to safety fault will be set and will have to be cleared.
allow the operator to safely exit 2 Turn and hold the bypass/recovery key switch
the platform could result in death to the recovery position. The switch must be
or serious injury. held in the recovery position.
Bodily injury hazard. Platform Result: The auxiliary power unit will turn on
leveling is not active when using and the boom will begin the following recovery
recovery mode. The platform sequence.
could reach high out-of-level • The primary boom will retract.
conditions when using this mode.
The operator will need to secure • The secondary boom will retract.
themself to the platform to • The primary boom will lower.
prevent falling injury.
Note: The key switch must be held in the recovery
The Recovery mode allows the platform to be position until the recovery sequence is complete or
lowered in the event the operator in the platform is until the operator in the platform can safely exit the
unable to lower the platform using the platform platform.
controls, system failure or emergency situations.
The recovery sequence will automatically retract Note: If any boom safety limit switches are faulty,
the primary boom, retract the secondary boom and the boom will only retract and not lower and the
then lower the primary boom using the auxiliary operator will need to be recovered from that point.
power unit to allow the operator at the platform
Note: If the Recovery function has been used, this
controls to exit the platform. may indicate there may be faults with the machine.
Tag and remove the machine from service until the
fault has been corrected by trained personnel.
98 Z-135/70 Part No. 1268557

Ground Controls
6-2 How to Remove the LCD Display

Circuit Boards Screen Circuit Board
The ground control box contains a replaceable 1 Push in the red Emergency Stop button to the
membrane decal with touch sensitive buttons for off position at both the ground and platform
various machine functions. The ground control box controls.
also contains two printed circuit boards: 2 Remove the ground control box lid fasteners.
The LCD (Liquid Crystal Display) circuit board 3 Open the ground control box.
is mounted to the inside of the control box lid which
controls the LCD display screen. Electrocution/burn hazard.
The ECM circuit board is the main circuit board for circuits could result in death or
the machine. All operating parameters and serious injury. Remove all rings,
configuration of options for the machine are stored watches and other jewelry.
in the ECM memory.
Note: When the ECM circuit board is replaced, the Electrostatic discharge (ESD)
machine will need to be fully calibrated. Refer to can damage printed circuit board
Repair Procedure, How to Fully Calibrate the components. Maintain firm
Machine. contact with a metal part of the
4 Carefully disconnect the LCD circuit board

ribbon cable from the ECM circuit board.
5 Remove the LCD display circuit board
6 Carefully remove the LCD display circuit board
from the ground control box lid.
Part No. 1268557 Z-135/70 99

Ground Controls
How to Remove the ALC-1000 6 Attach a grounded wrist strap to the ground
screw inside the control box.
Circuit Board
Note: If the ALC-1000 circuit board (TCON) has Contact with electrically charged
been replaced, the entire machine must be circuits could result in death or
calibrated in a specific order. Refer to Repair serious injury. Remove all rings,
Procedure, Full Machine Calibration. watches and other jewelry.
off position at both the ground and platform Component damage hazard.
controls. Electrostatic discharge (ESD)
2 Remove the ground control box lid fasteners. components. Maintain firm
3 Open the ground control box. contact with a metal part of the
4 Tag and disconnect the harnesses from the times when handling printed
ground control box. circuit boards OR use a
5 Remove the control cable receptacle retaining grounded wrist strap.
fasteners from the side of the control box.
7 Tag and carefully disconnect the wire
connectors from the circuit board.
8 Carefully disconnect the LCD circuit board
ribbon cable from the ECM circuit board.
9 Carefully disconnect the two ribbon cables
from the membrane decal at the ECM circuit
board.
10 Remove the circuit board mounting fasteners.
11 Carefully remove the circuit board from the
control box.
100 Z-135/70 Part No. 1268557

Ground Controls
6-3 4 Carefully disconnect the two ribbon cables

from the membrane decal at the ECM circuit
Membrane Decal board.
The membrane decal is a special decal that Electrocution/burn hazard.
consists of a decal with an electronic membrane on Contact with electrically charged
the backside. The membrane contains touch circuits could result in death or
sensitive areas that, when pushed, activate the serious injury. Remove all rings,
machine functions. The membrane contains touch watches and other jewelry.
sensitive areas that activate the machine functions.
How to Replace the Membrane Electrostatic discharge (ESD)
Decal components. Maintain firm
1 Turn the key switch to the off position and push contact with a metal part of the
in the red Emergency Stop button to the off machine that is grounded at all
position at both the ground and platform times when handling printed
controls. circuit boards OR use a
2 Remove the ground control box lid fasteners.
3 Open the ground control box. 5 Carefully remove the membrane decal from
the control box lid while guiding the ribbon
cables out of the control box lid.
6 Remove any decal adhesive from the control
box lid with a mild solvent.
Note: Do not allow any solvent to come in contact
with the LCD display screen.
7 Install the new membrane decal while guiding
the ribbon cables through the control box lid.
8 Connect the ribbon cables to the ECM circuit
board.
9 Close the control box lid and install the
Part No. 1268557 Z-135/70 101

Ground Controls
6-4 Note: Start this procedure with the booms in the

fully stowed position and the axle retracted.
Full Machine Calibration
Full machine calibration must be completed in the
Full machine calibration must be completed in the following sequence:
proper sequence when the ALC-1000 circuit board
(TCON) in the ground control box has been • Select engine configuration. Refer to Repair
replaced or the turntable level sensor (SCON) has Section, Display Module. Unit of Measure
been replaced. and Language.
• Joysticks. Refer to Repair Procedure, How
How to Fully Calibrate the to Calibrate a Joystick.
Machine • Turntable level sensor. Refer to Repair

Procedure, How to Calibrate the Turntable
Calibration procedures shall only be completed by Level Sensor.
qualified technicians that have Genie factory
service training. • Platform level sensor. Refer to Repair
Procedure, How to Calibrate the Platform
Tip-over hazard. Failure to Level Sensor.
calibrate the machine in the
• Axle angle sensors. Refer to Repair
proper sequence could cause the
Procedure, How to Calibrate the Axle Angle
machine to tip over resulting in
Sensors.
death or serious injury.
• Steer sensors. Refer to Repair Procedure,
Note: A digital level will be required to perform this How to Calibrate All Steer Sensors.
procedure.
• Secondary boom angle sensor. Refer to
Note: A kit is available through Genie Product Repair Procedure, How to Calibrate the
Support (Genie part number 58351). This kit Secondary Boom Angle Sensor.
cable harnesses. • Primary boom angle sensor. Refer to Repair
Procedure, How to Calibrate the Primary
Note: Use the following chart to identify the Boom Angle Sensor.
• Jib boom bellcrank angle sensor. Refer to
in this procedure.
Repair Procedure, How to Calibrate the Jib
Boom Bellcrank Sensor.
• Select option configuration. Refer to Repair
Section, Display Module. Options.
102 Z-135/70 Part No. 1268557

Display Module
This table lists the various screens and menu options of the operating software. Some display menus are for
informational purpose only, while others can be used to change the machine operating parameters.
Tip-over hazard. Calibration and parameter settings must be completed by a person

trained and qualified on the repair of this machine. Failure to properly calibrate or set
parameters could cause the machine to tip over resulting in death or serious injury.
Note:The key switch must be in the off position before entering the programming mode.
Note: Use the following chart to identify the description of each LCD screen control button used in this
procedure.

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 EXIT menu. Use the plus
button to change to YES and use the enter button to exit.
Screen or Menu Procedure Description Range or Selection

Operator Default Hourmeter (on power up)
Engine speed
Engine oil pressure PSI (English)
Engine oil pressure kPa (metric)
Engine temperature °F (Engiish) engine temp will not display

until temp is >100°F
Engine temperature °C (metric) engine temp will not display
until temp is >38°C
Primary boom angle to gravity
Turntable level sensor X° direction
Turntable level sensor Y° direction
Platform level sensor degree
Battery volts
Part No. 1268557 Z-135/70 103

Display Module
Screen or Procedure Description Range or Selection

Menu
Machine Status With key switch on, press the Hydraulic pressure PSI 0-4500 PSI
(plus)(minus) buttons at the same (English)
time.
Hydraulic pressure kPa (metric) 0-31000 kPa
Primary boom to secondary +22° to +136°

boom angle
Primary boom length =0', >0', >22
Secondary boom angle* -3.5° to 76°
Secondary boom length =0FT, >0 FT
Jib bellcrank angle -10° to +10°

*(referenced to chassis
tilt angle)
DPF Regeneration Mode
(Auto / Force / Inhibit)
Unit of With key switch OFF, press and hold Metric/English (measurement English, German,
Measure and the enter button and turn key switch to units) French, Spanish,
Language on position. Portuguese, Italian,
Release the enter button and press Dutch, and Swedish.
(plus)(minus)(minus)(plus).
Set engine Deutz TD2011L04i

(DL04i)
Perkins 1104D-44T
(P1104)
Overload Recovery Clear Overload Recovery YES/NO
(software V3.07 and later) A passcode is required to
clear the message
Default Reset With key switch OFF, press and hold Delete drive functions
the enter button and turn key switch to
Delete boom function speed
on position.
Release the enter button and press
Delete lift function ramps
(minus)(minus)(previous)(previous)
Delete all (Contact Genie

Product Support before using
this option)
Delete Faults Delete faults will reset
active latching faults.
Delete faults will not
clear fault history.
104 Z-135/70 Part No. 1268557

Display Module

Drive Functions With key switch OFF, press and hold Forward extended drive 120% (max) 100%
the enter button and turn key switch speed % (default) 50% (min)
to on position.
Forward not stowed drive 120% (max) 100%
Release the enter button and press speed % (default) 50% (min)
(plus)(plus)(enter)(enter).
Forward low drive speed % 120% (max) 100%
(default) 50% (min)
Forward high drive speed % 120% (max) 100%
(default) 50% (min)
Reverse extended drive 120% (max) 100%
speed % (default) 50% (min)
Reverse not stowed drive 120% (max) 100%
speed % (default) 50% (min)
Reverse low drive speed % 120% (max) 100%
(default) 50% (min)
Reverse high drive speed % 120% (max) 100%
(default) 50% (min)
Drive acceleration % 125% (max) 100%
(default) 25% (min)
Drive deceleration % 125% (max) 100%
(default) 25% (min)
Speed limit on steer angle 100% (max) 50%
(default) 0%
Part No. 1268557 Z-135/70 105

Display Module

Menu
Boom With key switch OFF, press and hold Primary boom up speed stowed
Function the enter button and turn key switch
Speeds to on position.
Release the enter button and press Primary boom up speed not stowed
(plus)(plus)(minus)(minus)
Primary boom down speed stowed
Primary boom down speed not stowed
Primary boom extend speed
Primary boom retract speed
Secondary boom up speed stowed
Secondary boom up speed not stowed
Secondary boom down speed stowed 120% max, 50% min,
Secondary boom down speed not stowed 100% (default)
Secondary boom extend speed
Secondary boom retract speed
Turntable rotate speed retracted
Turntable rotate speed not retracted
Turntable rotate speed extended
Jib up speed retracted
Jib up speed not retracted
Jib down speed retracted
Jib down speed not retracted
106 Z-135/70 Part No. 1268557

Display Module

Lift Functions With key switch OFF, press and Primary boom up/down ramp
Ramps hold the enter button and turn key acceleration %
switch to on position.
Primary boom up/down ramp
Release the enter button and deceleration %
press
(plus)(plus)(previous)(previous). Primary boom extend/retract ramp
acceleration %
Primary boom extend/retract ramp 150% max and 50%
deceleration % min 100% (default),
Secondary boom up/down ramp 5% increment
acceleration %
Secondary boom up/down ramp
deceleration %
Secondary boom extend/retract ramp
acceleration %
Secondary boom extend/retract ramp
deceleration %
Turntable rotate ramp acceleration %
Turntable rotate ramp deceleration %
Jib boom up/down ramp acceleration % 120% max and 50%

min, 100% (default),
5% incr
Jib boom up/down ramp deceleration %
Part No. 1268557 Z-135/70 107

Display Module

Menu
Valve With key switch OFF, press and hold the Delete drive valve calibration
Calibration enter button and turn key switch to on
position.
Delete primary boom up/down
Release the enter button and press valve calibration
(minus)(minus)(enter)(enter).
Delete primary boom
extend/retract valve calibration
Delete secondary boom up/down
and extend/retract valve
calibration
Delete turntable rotate valve YES/NO
calibration
Allow primary boom up/down
speed calibration
Allow primary boom extend/retract
speed calibration
Allow secondary boom up/down
speed calibration
Allow turntable rotate speed
calibration
Delete drive joystick calibration
Delete primary boom up/down

joystick calibration
Delete primary boom
extend/retract joystick calibration
Delete secondary boom joystick
calibration
Delete turntable rotate joystick
calibration
Delete steer joystick calibration
Delete jib up/down joystick

calibration
108 Z-135/70 Part No. 1268557

Display Module
Screen or Procedure Description Range or

Menu Selection
Sensor With key switch OFF, press and Set unit X-axis to gravity
Calibration hold the enter button and turn
key switch to on position.
Set unit Y-axis to gravity
Release the enter button and
press Set platform level to gravity (YES/NO)
(plus)(enter)(enter)(plus).
Platform level sensor millivolts/degree
Delete axles angle sensors calibration? (YES/NO)
YES: Axle angle fully retracted (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? Use +/- buttons to
(YES/NO) 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°
Delete primary boom angle sensor calibration? (YES/NO)
primary boom angle to gravity 0°
primary boom angle to gravity -50°
primary boom angle to gravity -20°
Delete level angle sensor calibration? (YES/NO)
jib level calibration deg to gravity 60°
jib level calibration deg to gravity -18°
Part No. 1268557 Z-135/70 109

Display Module

Menu
Options With key switch OFF, press and hold Boom Function Limit No LT= No limit; EXT
the enter button and turn key switch (NO LT/EXT LT) LT= secondary
to on position. boom extend
AC Generator
Release the enter button and press inhibited
(NONE/BELT/HILO/HYDRL/GHG10)
(minus)(minus)(plus)(plus).
Alarm No (NO AL)/Motion (MO AL)
Travel (TR AL)/ Descent (DE AL)/

Travel 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) Cutout All
Drive Tilt Cutout (CODRV) Cutout Drive
Foot Switch Lockout (0-30 minutes) 30.0 max and
0.0 min, 10.0
(default)
Platform Always Level to Gravity
(NO/YES)
Axle Motion Only While Driving
(NO/YES)
Holding +/- button
will cause display to
scroll through
options or increment
number settings
automatically at
0.2 min
increase/decrease
110 Z-135/70 Part No. 1268557

Hydraulic Pumps
7-1 2 Tag, disconnect and plug the function pump

hydraulic hoses. Cap the fittings on the pump.
Function Pump
The function pump is a pressure compensated, hydraulic oil can penetrate and
variable displacement piston pump. Any internal burn skin. Loosen hydraulic
service to the pump should be performed at an connections very slowly to allow
authorized Sauer-Danfoss service center. Contact the oil pressure to dissipate
Genie Product Support to locate your local gradually. Do not allow oil to
authorized service center. squirt or spray.
How to Remove the Function 3 Support the pump with a suitable lifting device.
Pump 4 Remove the two pump mounting fasteners.
Note: When removing a hose assembly or fitting, Carefully remove the pump.
the O-ring (if equipped) on the fitting and/or hose Component damage hazard. Be
end must be replaced. All connections must be sure to open the two hydraulic
torqued to specification during installation. Refer to tank valves and prime the pump
Specifications, Hydraulic Hose and Fitting Torque after installing the pump.
Specifications.
1 Locate the two hydraulic tank valves at the
hydraulic tank. Close the valves.
with the hydraulic tank shut-off
the tank valves are closed, open closed
switch and tag the machine to
inform personnel of the
condition.
Part No. 1268557 Z-135/70 111

Hydraulic Pumps
How to Prime the F uncti on Pump How to Adj ust the Functi on Pump Standby Pr ess ure
How to Prime the Function Pump How to Adjust the Function Pump
Note: When removing a hose assembly or fitting, Standby Pressure
the O-ring (if equipped) on the fitting and/or hose 1 Connect a 0 to 5000 psi / 0 to 350 bar
end must be replaced. All connections must be pressure gauge to the test port on the function
torqued to specification during installation. Refer to manifold
Specifications. 2 Start the engine from the ground controls and
allow the engine to run at low idle.
1 Remove the case drain hydraulic hose from
the top of the function pump. 3 Observe the pressure reading on the pressure
gauge.
Note: The case drain hose is the smaller of the two
hoses on top of the function pump and closest to Result: The gauge should show 250 psi /
the drive pump. 17 bar.
2 Locate and open the hydraulic tank shut-off Result: If the gauge does not show 250 psi /
valve at the hydraulic tank that supplies 17 bar, proceed with step 4 to adjust the
hydraulic oil to the function pump. Do not open function pump standby pressure.
the valve for the drive pump. 4 Loosen the set screw for the standby pressure
3 When hydraulic fluid begins to come out of the adjustment screw.
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.
6 Check for hydraulic leaks.
1 standby pressure set screw

2 standby pressure adjustment screw
112 Z-135/70 Part No. 1268557

Hydraulic Pumps
5 Adjust the function pump standby pressure. 6 Loosen the set screw for the pressure
Turn the adjustment screw clockwise to compensator adjustment screw.
increase the pressure or counterclockwise to
decrease the pressure. Tighten the set screw.
6 Turn the engine off and remove the pressure
gauge.
How to Adj ust the Functi on Pump Press ure Compens ator
How to Adjust the Function Pump

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

200 bar, proceed to step 6 to adjust the
function pump pressure compensator.
Part No. 1268557 Z-135/70 113

Hydraulic Pumps
7-2 2 Locate the two hydraulic tank valves at the

hydraulic tank. Close the valves.
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump
should be performed at an authorized
Sauer-Danfoss service center. Contact Genie
open closed
Product Support to locate your local authorized
service center. Component damage hazard.
How to Remove the Drive Pump with the hydraulic tank shut-off
Component damage hazard. The component damage will occur. If
work area and surfaces where the tank valves are closed,
this procedure will be performed remove the key from the key
must be clean and free of debris switch and tag the machine to
that could get into the hydraulic inform personnel of the
system and cause severe condition.
service is recommended. 3 Tag, disconnect and plug the hydraulic hoses
from the drive and function pumps. Cap the
Note: When removing a hose assembly or fitting, fittings on the pumps.
end must be replaced. All connections must be Bodily injury hazard. Spraying
torqued to specification during installation. Refer to hydraulic oil can penetrate and
Specifications, Hydraulic Hose and Fitting Torque burn skin. Loosen hydraulic
Specifications. connections very slowly to allow
1 Disconnect the wiring plug at the electronic gradually. Do not allow oil to
displacement controller (EDC), located on the squirt or spray.
drive pump.
4 Support the pumps with a suitable lifting device
and remove the two drive pump mounting
fasteners.
114 Z-135/70 Part No. 1268557

Hydraulic Pumps
How to Prime the Dri ve Pump
5 Carefully pull the drive pump out until the pump How to Prime the Drive Pump
coupler separates from the flex plate.
Component damage hazard. Be
6 Remove the drive pump from the machine. sure to open the two hydraulic
Component damage hazard. tank valves before performing
The pump(s) may become this procedure.
unbalanced and fall if not
properly supported. 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.
The engine must not be started 2 Perkins models: Disconnect the engine
with the hydraulic tank shut-off wiring harness from the fuel shutoff solenoid at
valves in the closed position or the injector pump.
Deutz models: Hold the manual fuel shutoff
the tank valves are closed,
valve clockwise to the closed position.
switch and tag the machine to 3 Have another person crank the engine with the
inform personnel of the starter motor for 15 seconds, wait 15 seconds,
condition. then crank the engine an additional
15 seconds or until the pressure reaches
approximately 250 psi / 17 bar.
4 Perkins models: Connect the engine wiring
harness to the fuel solenoid.
Deutz models: Release the manual fuel
shutoff valve.
6 Check for hydraulic leaks.
Part No. 1268557 Z-135/70 115

Manifolds
8-1
Function Manifold - View 1 (before serial number 440)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
Description Function Torque
No. Item
1 Check valve W Prevents the draining of 30-35 ft-lbs / 41-47 Nm
hydraulic oil from the jib
manifold and platform
manifold
2 Solenoid Valve, 2 position 3 way C Primary boom up 30-35 ft-lbs / 41-47 Nm
3 Solenoid Valve, 2 position 3 way G Primary boom retract 30-35 ft-lbs / 41-47 Nm
4 Solenoid Valve, 2 position 3 way J Secondary boom extend 50-55 ft-lbs / 68-75 Nm
5 Solenoid Valve, 2 position 3 way H Secondary boom up 50-55 ft-lbs / 68-75 Nm
6 Plug, 16 SAE Port plug 130-140 ft-lbs / 176-190 Nm
7 Relief valve, 3100 psi / 214 bar L System relief 30-35 ft-lbs / 41-47 Nm
8 Solenoid Valve, 2 position 3 way I Secondary boom down 30-35 ft-lbs / 41-47 Nm
9 Solenoid Valve, 2 position 3 way K Secondary boom retract 30-35 ft-lbs / 41-47 Nm
10 Solenoid Valve, 2 position 3 way F Primary boom extend 30-35 ft-lbs / 41-47 Nm
11 Solenoid valve, 3 position 4 way B Turntable rotate left/right 30-35 ft-lbs / 41-47 Nm
12 Solenoid Valve, 2 position 3 way D Primary boom down 30-35 ft-lbs / 41-47 Nm
116 Z-135/70 Part No. 1268557

Manifolds
Part No. 1268557 Z-135/70 117

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

Index Schematic
No. Item
1 Check valve DB Prevents hydraulic pressure from
flowing back into auxiliary pump #1
2 Check valve DC Prevents hydraulic pressure from
flowing back into auxiliary pump #2
3 Differential sensing valve, M Turntable rotate circuit, regulates 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar pressure drop across turntable
rotate proportional valve
4 Differential sensing valve, O Primary boom up/down circuit, 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar regulates pressure drop across
primary boom up/down
proportional valve
5 Relief valve, 2600 psi / 179 bar E Primary boom extend 20-25 ft-lbs / 27-34 Nm
6 Differential sensing valve, Q Primary boom extend/retract 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar circuit, regulates pressure drop
across primary boom
extend/retract proportional valve
7 Differential sensing valve, U Secondary boom extend/retract 50-55 ft-lbs / 68-75 Nm
across secondary boom
extend/retract proportional valve
8 Differential sensing valve, S Secondary boom up/down circuit, 50-55 ft-lbs / 68-75 Nm
secondary boom up/down
proportional valve
9 Proportional solenoid valve T Secondary boom up/down circuit 50-55 ft-lbs / 68-75 Nm
10 Check valve DD Prevents hydraulic pressure from 130-140 ft-lbs / 176-190 Nm
flowing back into the function pump
11 Proportional solenoid valve V Secondary boom extend/retract 50-55 ft-lbs / 68-75 Nm
circuit
12 Proportional solenoid valve R Primary boom extend/retract circuit 50-55 ft-lbs / 68-75 Nm
13 Proportional solenoid valve P Primary boom up/down circuit 50-55 ft-lbs / 68-75 Nm
14 Proportional solenoid valve N Turntable rotate left/right circuit 50-55 ft-lbs / 68-75 Nm
118 Z-135/70 Part No. 1268557

Manifolds
Part No. 1268557 Z-135/70 119

Manifolds
8-2
Function Manifold - View 1 (after serial number 439)
The function manifold is mounted to the turntable next to the ground controls.
Index Schematic
No. Item
1 Solenoid Valve, 2 position 3 way D Primary boom up/down 30-35 ft-lbs / 41-47 Nm
2 Solenoid Valve, 2 position 3 way C Primary boom up 30-35 ft-lbs / 41-47 Nm
3 Solenoid Valve, 2 position 3 way G Primary boom retract 30-35 ft-lbs / 41-47 Nm
4 Solenoid Valve, 2 position 3 way F Primary boom extend 30-35 ft-lbs / 41-47 Nm
5 Solenoid Valve, 2 position 3 way K Secondary boom retract 30-35 ft-lbs / 41-47 Nm
6 Solenoid Valve, 2 position 3 way J Secondary boom extend 30-35 ft-lbs / 41-47 Nm
7 Solenoid Valve, 2 position 3 way I Secondary boom down 30-35 ft-lbs / 41-47 Nm
8 Solenoid Valve, 2 position 3 way H Secondary boom up 30-35 ft-lbs / 41-47 Nm
9 Check valve DF Tank return circuit 130-140 ft-lbs / 176-190 Nm
10 Solenoid valve, 3 position 4 way B Turntable rotate left/right 30-35 ft-lbs / 41-47 Nm
11 Relief valve, 3100 psi / 214 bar L System relief 30-35 ft-lbs / 41-47 Nm
12 Differential sensing valve, S Secondary boom up/down 50-55 ft-lbs / 68-75 Nm
up/down proportional valve
13 Differential sensing valve, U Secondary boom extend/retract 50-55 ft-lbs / 68-75 Nm
extend/retract proportional
valve
14 Differential sensing valve, Q Primary boom extend/retract 30-35 ft-lbs / 41-47 Nm
across primary boom
extend/retract proportional
valve
120 Z-135/70 Part No. 1268557

Manifolds
Part No. 1268557 Z-135/70 121

Manifolds
Function Manifold - View 2 (after serial number 439)

Index Schematic
No. Item
1 Check valve DB Prevents hydraulic pressure from
flowing back into auxiliary pump
#1
2 Check valve W Prevents the draining of 30-35 ft-lbs / 41-47 Nm
hydraulic oil from the jib manifold
and platform manifold
3 Differential sensing valve, O Primary boom up/down circuit, 30-35 ft-lbs / 41-47 Nm
primary boom up/down
proportional valve
4 Relief valve, E Primary boom extend 20-25 ft-lbs / 27-34 Nm
2600 psi / 179 bar
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 50-55 ft-lbs / 68-75 Nm
circuit
7 Proportional solenoid valve V Secondary boom extend/retract 50-55 ft-lbs / 68-75 Nm
circuit
8 Proportional solenoid valve T Secondary boom up/down circuit 50-55 ft-lbs / 68-75 Nm
9 Proportional solenoid valve N Turntable rotate left/right circuit 50-55 ft-lbs / 68-75 Nm
10 Differential sensing valve, M Turntable rotate circuit, regulates 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar pressure drop across turntable
rotate proportional valve
11 Check valve DD Prevents hydraulic pressure from 130-140 ft-lbs / 176-190 Nm
flowing back into the function
pump
12 Check valve DC Prevents hydraulic pressure from
flowing back into auxiliary pump
#2
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Part No. 1268557 Z-135/70 123

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8-3 4 Simultaneously push and hold the auxiliary

power button and the primary boom retract
Valve Adjustments - Function button with the primary boom fully retracted.
Manifold Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
How to Adjust the System Relief Component Specification.
Valve (before serial number 440) 5 Hold the relief valve stem with a hex wrench
and remove the cap.
stowed position. 6 Adjust the internal hex socket. Turn it
clockwise to increase the pressure. Install the
Note: Auxiliary power will be used to perform this relief cap.
procedure. Do not start the engine.
Tip-over hazard. Do not adjust
Note: Refer to Function Manifold Component list to the relief valve higher than
locate the system relief valve. specified.
1 Hold the relief valve stem with a hex wrench
7 Repeat step 4 to confirm relief valve pressure.
and remove the cap.
8 Remove the pressure gauge.
2 Turn the internal hex socket counterclockwise How to Adj ust the System Reli ef Val ve
several turns. Do not allow the relief valve to How to Adjust the System Relief
come apart. Install the relief cap.
Valve (after serial number 439)
3 Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the test port on the function Note: Perform this procedure with the boom in the
manifold stowed position.
Note: Auxiliary power will be used to perform this
procedure. Do not start the engine.
Note: Refer to Function Manifold Component list to
locate the system relief valve.
1 Hold the relief valve stem with a hex wrench
and loosen the lock nut.
2 Turn the valve stem counterclockwise several
turns. Do not allow the relief valve to come
apart. Tighten the lock nut.
pressure gauge to the test port on the function
manifold
124 Z-135/70 Part No. 1268557

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How to Adj ust the Pri mar y Boom Extend R elief Val ve
4 Simultaneously push and hold the auxiliary How to Adjust the Primary Boom
power button and the primary boom retract
button with the primary boom fully retracted.
Extend Relief Valve
Observe the pressure reading on the pressure Note: Perform this procedure with the axles
gauge. Refer to Specifications, Hydraulic extended.
Component Specification.
1 Remove the primary boom end cover from the
5 Hold the relief valve stem with a hex wrench pivot end of the boom.
and loosen the lock nut.
2 Locate the primary boom extend limit switch on
6 Adjust the valve stem. Turn it clockwise to the side of the primary boom.
increase the pressure. Tighten the lock nut.
3 Follow the wiring from the switch to the pivot
Tip-over hazard. Do not adjust end of the primary boom. Locate and
the relief valve higher than disconnect the wire connector for the primary
specified. boom extend limit switch.
7 Repeat step 4 to confirm relief valve pressure. Note: The correct wire connector will be a 2 pin
connector with a yellow marker on the cable.
4 Start the engine and fully extend the primary
boom. Turn the engine off.
pressure gauge to the ptest port on the
function manifold.
6 Start the engine from the ground controls and
press and release the rpm select button until
the engine changes to high idle.
Part No. 1268557 Z-135/70 125

Manifolds
7 Simultaneously push and hold the function

enable/high speed button and the primary
boom extend button with the primary boom
fully extended. Observe the pressure reading
on the pressure gauge. Refer to
Specifications, Hydraulic Component
Specifications.
8 Turn the engine off. Use a wrench to hold the
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, that was disconnected in step 3.
12 Install the primary boom end cover.
14 Start the engine and fully retract the primary
boom. Turn the engine off.
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8-4
Platform Manifold
The platform manifold is mounted to the platform mounting weldment.
Index Schematic
No. Item
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
Part No. 1268557 Z-135/70 127

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8-5
Jib Boom Manifold
The jib boom manifold is mounted inside the primary extension boom at the platform end.
Index Schematic
No. Item
1 Pressure compensator valve, X Jib boom up/down circuit, 30-35 ft-lbs / 41-47 Nm
jib boom up/down proportional
valve
2 Solenoid Valve, 2 position 3 way AE Jib boom retract 20-25 ft-lbs / 27-34 Nm
3 Solenoid Valve, 2 position 3 way AD Jib boom extend 20-25 ft-lbs / 27-34 Nm
4 Flow regulator valve, 2 gpm / 7.6 AC Jib boom extend/retract circuit 20-25 ft-lbs / 27-34 Nm
L/min
5 Orifice, 0.040 inch / 1 mm AB Jib boom extend/retract circuit
6 Check valve, 25 psi / 1.7 bar AA Holds oil in jib boom manifold 20-25 ft-lbs / 27-34 Nm
7 Shuttle valve Z Jib boom up/down circuit 10-12 ft-lbs / 14-16 Nm
8 Proportional solenoid valve, Y Jib boom up/down 20-25 ft-lbs / 27-34 Nm
3 position 4 way
9 Proportional solenoid valve, AF Jib boom bellcrank level up/down 20-25 ft-lbs / 27-34 Nm
3 position 4 way
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Part No. 1268557 Z-135/70 129

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8-6
Flow Control Manifold
The flow control manifold is located at the platform next to the jib manifold.
Index Schematic
No. Item
1 Flow regulator valve, 0.5 gpm / 1.9 L/min AC Controls flow in the jib and platform 20 ft-lbs / 27 Nm
manifold recirculation circuit
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8-7
Function Enable Valve
The function enable valve is mounted behind the medium pressure filter.
Index Schematic
No. Item
1 Solenoid valve, 2 position, 2 way A Enables lift pump to provide 20-25 ft-lbs /
hydraulic pressure for all boom and 27-34 Nm
steer/axle functions
Part No. 1268557 Z-135/70 131

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8-8
Turntable Rotation Manifold
The turntable rotation manifolds are mounted to the turntable rotation drive hub motors.
Index Schematic
No. Item
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
132 Z-135/70 Part No. 1268557

Part No. 1268557 Z-135/70 133

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8-9
Steer and Axle Manifold
The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine.
Index Schematic
No. Item
1 Flow control valve, 1.5 gpm / 5.7 L/min BI Right front steer cylinder retract 20-25 ft-lbs /
circuit 27-34 Nm
2 Check valve BC Prevents right front steer cylinder 20-25 ft-lbs /
from moving when not steering 27-34 Nm
3 Check valve BB Prevents left front steer cylinder 20-25 ft-lbs /
4 Flow regulator valve, 2.1 gpm / 8 L/min BL Right rear steer cylinder extend 20-25 ft-lbs /
circuit 27-34 Nm
5 Solenoid valve, 3 position 4 way BQ Steer left/right, right rear steer 20-25 ft-lbs /
cylinder 27-34 Nm
6 Check valve BE Prevents right rear steer cylinder 20-25 ft-lbs /
7 Check valve BD Prevents right rear steer cylinder 20-25 ft-lbs /
8 Solenoid valve, 3 position 4 way BP Steer left/right, left rear steer 20-25 ft-lbs /
cylinder 27-34 Nm
9 Flow regulator valve, 2.1 gpm / 8 L/min BJ Left rear steer cylinder extend 20-25 ft-lbs /
circuit 27-34 Nm
10 Flow regulator valve, 7 gpm / 26.5 L/min BS Axle extend/retract circuit 20-25 ft-lbs /
27-34 Nm
11 Solenoid Valve, 2 position 3 way BU Axle retract 30-35 ft-lbs /
41-47 Nm
12 Solenoid Valve, 2 position 3 way BT Axle extend 30-35 ft-lbs /
41-47 Nm
13 Pressure reducing valve BR Axle extend/retract circuit 30-35 ft-lbs /
41-47 Nm
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Part No. 1268557 Z-135/70 135

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Steer and Axle Manifold, continued

The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine.
Index Schematic
No. Item
14 Flow regulator valve, 1.5 gpm / 5.7 L/min BK Left rear steer cylinder retract 20-25 ft-lbs /
circuit 27-34 Nm
15 Flow regulator valve, 1.5 gpm / 5.7 L/min BM Right rear steer cylinder retract 20-25 ft-lbs /
circuit 27-34 Nm
16 Flow regulator valve, 1.5 gpm / 5.7 L/min BG Left front steer cylinder retract 20-25 ft-lbs /
circuit 27-34 Nm
17 Flow regulator valve, 2.1 gpm / 8 L/min BF Left front steer cylinder extend 20-25 ft-lbs /
circuit 27-34 Nm
18 Flow regulator valve, 2.1 gpm / 8 L/min BH Right front steer cylinder extend 20-25 ft-lbs /
circuit 27-34 Nm
19 Solenoid valve, 3 position 4 way BN Steer left/right, left front steer 20-25 ft-lbs /
cylinder 27-34 Nm
20 Solenoid valve, 3 position 4 way BO Steer left/right, right front steer 20-25 ft-lbs /
cylinder 27-34 Nm
136 Z-135/70 Part No. 1268557

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Part No. 1268557 Z-135/70 137

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8-10 4 Turn the engine off.

Valve Adjustments - Steer and 5 Adjust the internal hex socket. Turn it
Axle Manifold clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
How to Adjust the Axle Relief Component damage hazard. Do
Valve not adjust the relief valve
pressures higher than
specifications.
firm, level surface and in the stowed position with
the axles extended.
6 Repeat steps 3 through 5 to confirm relief
Note: Refer to Steer and Axle Manifold list to locate valve pressure.
the axle relief valve. 7 Remove the pressure gauge.
Note: Two people will be required to perform this
procedure.
pressure gauge to the test port on the steer
and axle manifold.
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.
138 Z-135/70 Part No. 1268557

Part No. 1268557 Z-135/70 139

Manifolds
8-11
Traction Manifold - View 1
The traction manifold is mounted inside the manifold box at the blue triangle side of the machine.
Index Schematic
No. Item
20-25 ft-lbs /
1 Check valve, 5 psi / 0.3 bar BA Drive motor anti-cavitation
27.1-33.9 Nm
20-25 ft-lbs /
2 Check valve, 5 psi / 0.3 bar AZ Drive motor anti-cavitation
27.1-33.9 Nm
20-25 ft-lbs /
3 Check valve, 5 psi / 0.3 bar AJ Drive motor anti-cavitation
27.1-33.9 Nm
20-25 ft-lbs /
4 Check valve, 5 psi / 0.3 bar AT Drive motor anti-cavitation
27.1-33.9 Nm
20-25 ft-lbs /
5 Check valve, 5 psi / 0.3 bar AW Brake circuit
27.1-33.9 Nm
Charge pressure circuit that directs hot oil 50-55 ft-lbs /
6 Shuttle Valve, 3 position 3 way AO
out of low pressure side of drive pump 68-75 Nm
30-35 ft-lbs /
7 Relief valve, 250 psi / 17.2 bar AN Charge pressure circuit
40.7-47.5 Nm
20-25 ft-lbs /
8 Solenoid Valve, 2 position 3 way AY Brake release
27.1-33.9 Nm
20-25 ft-lbs /
9 Solenoid Valve, 2 position 3 way AX Two-speed drive motor shift
27.1-33.9 Nm
Controls flow to square end drive motors 90-100 ft-lbs /
10 Flow divider/combiner valve AR
in forward and reverse 122-135.6 Nm
Controls flow to circle end drive motors in 90-100 ft-lbs /
11 Flow divider/combiner valve AM
forward and reverse 122-135.6 Nm
Controls flow to flow divider/combiner 90-100 ft-lbs /
12 Flow divider/combiner valve AP
valves AR and AM in forward and reverse 122-135.6 Nm
140 Z-135/70 Part No. 1268557

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Part No. 1268557 Z-135/70 141

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Traction Manifold - View 2

Index Schematic
No. Item
Orifice, 0.063 in / 1.6 mm
(before serial number Equalizes pressure on both sides
1 AL
180 except for serial number of divider/combiner valve AM
102)
Orifice, 0.039 in / 1 mm (serial
Equalizes pressure on both sides
- number 102 and after serial AL
of divider/combiner valve AM
number 179)
2 Orifice, 0.052 in / 1.3 mm AQ
of divider/combiner valve AP
3 Orifice, 0.063 in / 1.6 mm AS
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 anti-cavitation 20-25 ft-lbs / 27-34 Nm
6 Check valve, 5 psi / 0.3 bar AK Drive motor anti-cavitation 20-25 ft-lbs / 27-34 Nm
142 Z-135/70 Part No. 1268557

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Part No. 1268557 Z-135/70 143

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8-12 8 Hold the hot oil relief valve and remove the
cap.
Valve Adjustments - Traction
Manifold 9 Start the engine from the ground controls.
10 Press and hold the function enable/high rpm
select button (rabbit symbol) position.
How to Adjust the Hot Oil
11 Adjust the internal hex socket until the
Relief Valve pressure reading on the gauge is 40 psi /
Note: The hydraulic oil temperature must be 100°F 2.8 bar less than the pressure reading on the
to 150°F / 38°C to 65.5°C before performing this pump. Turn it clockwise to increase the
procedure. pressure or counterclockwise to decrease the
pressure. Install the relief valve cap.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to either the "A" or "B" test port on the 12 Turn the engine off.
drive pump. 13 Remove the pressure gauge.
2 Locate the hot oil relief valve on the traction
manifold. Hold the relief valve and remove the
cap.
3 Turn the internal hex socket clockwise fully
until it stops. Install the cap.
5 Press and hold the function enable/high rpm
select button (rabbit symbol) position. Note the
reading on the pressure gauge.
6 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.
144 Z-135/70 Part No. 1268557

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8-13
Drive Oil Diverter Manifold (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
No. Item
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 Nm
Part No. 1268557 Z-135/70 145

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8-14 Valve Coil Resistance

Valve Coils Specification
Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
A properly functioning coil provides an valve coil resistance is sensitive to changes in air
electromotive force which operates the solenoid temperature, the coil resistance will typically
valve. Critical to normal operation is continuity increase or decrease by 4% for each 18°F / 10°C
within the coil that provides this force field. that your air temperature increases or decreases
from 68°F / 20°C.
Since coil resistance is sensitive to temperature,
resistance values outside specification can produce Valve Coil Resistance Specification
erratic operation. When coil resistance decreases Proportional solenoid valve 3.5 to
below specification, amperage increases. As (schematic items N, P, R, T, V) 5.5Ω
resistance rises above specification, voltage Solenoid valve, 3 position 4 way 4 to 6Ω
increases. (schematic item B)
While valves may operate when coil resistance is Solenoid valve, 3 position 4 way 7 to 9Ω
outside specification, maintaining coils within (schematic items BN, BO, BP, BQ)
specification will help ensure proper valve function Solenoid valve, 3 position 4 way 8 to
over a wide range of operating temperatures. (schematic item AH ) 10Ω
Proportional solenoid valve, 3 position 4 way 8 to
Electrocution/burn hazard. (schematic items Y, AI) 10Ω
circuits could result in death or (schematic items F, AD) 7.5Ω
watches and other jewelry. Solenoid Valve, 2 position 3 way 8 to
(schematic item AE, AF) 10Ω
1 Tag and disconnect the wiring from the coil to Solenoid Valve, 2 position 3 way 3.5 to
be tested. (schematic items H, J) 5.5Ω
2 Test the coil resistance. Solenoid Valve, 2 position 3 way 7.5 to

(schematic items C, D, G, I, K, AX, AY, BU, BT) 9.5Ω
Result: The resistance should be within Solenoid valve, 2 position, 2 way 3.5 to
specification, plus or minus 30%. (schematic item A) 5.5Ω
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
146 Z-135/70 Part No. 1268557

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How to T est a Coil Di ode
How to Test a Coil Diode

Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.
1 Test the coil for resistance. Refer to Repair 1 multimeter

Procedure, How to Test a Coil. 2 9v DC battery
3 10Ω resistor
2 Connect a 10W resistor to the negative 4 coil
terminal of a known good 9V DC battery.
Connect the other end of the resistor to a 3 Set a multimeter to read DC current.
terminal on the coil.
Note: The multimeter, when set to read DC current,
Resistor 10Ω should be capable of reading up to 800 mA.
Genie part number 27287
4 Connect the negative lead to the other terminal
Note: The battery should read 9V DC or more when on the coil.
measured across the terminals.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
DC battery. Note and record the current
reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
Part No. 1268557 Z-135/70 147

Turntable Rotation Components
9-1 5 Remove the drive hub mounting bolts and

remove the turntable rotation assembly from
Turntable Rotation Assembly the machine.
How to Remove a Turntable 6 Repeat steps 3 through 5 for the other

turntable rotation assembly.
Rotation Assembly
Tip-over hazard. If the turntable
Note: When removing a hose assembly or fitting, rotation lock pin is not properly
the O-ring (if equipped) on the fitting and/or hose installed, machine stability is
end must be replaced. All connections must be compromised and the machine
torqued to specification during installation. Refer to could tip over when the drive hub
Specifications, Hydraulic Hose and Fitting Torque is removed from the machine,
Specifications. which could result in death or
Note: Perform this procedure with the primary boom serious injury.
between the circle-end tires and with the machine
on a firm, level surface. Crushing hazard. The drive hub
could become unbalanced and
1 Secure the turntable from rotating with the fall if not properly supported by an
turntable rotation lock pin. overhead crane or lifting device
2 Remove the ground controls side fixed when removed from the machine.
turntable cover.
Note: When installing a turntable rotation assembly,
3 Tag, disconnect the hydraulic hoses from the the rotation gear backlash must be adjusted. Refer
turntable rotation motor. Cap the fittings on the to Repair Procedure, Adjust the Turntable Rotation
motor. Gear Backlash.
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.
148 Z-135/70 Part No. 1268557


How to Adj ust the Tur ntabl e R otati on Gear Bac klash
How to Adjust the Turntable 7 Turn the adjustment bolt 1/2 to 3/4 turn
counterclockwise. Tighten the lock nut on the
Rotation Gear Backlash adjustment bolt.
1 Secure the turntable from rotating with the 8 Pull the backlash pivot plate away from the
turntable rotation lock pin. turntable until it contacts the adjustment bolt.
2 Remove the fixed turntable cover at the ground Then lubricate the mounting fasteners on the
controls side of the machine. backlash pivot plate and torque to
specification. Refer to Specifications, Machine
3 Loosen the backlash pivot plate mounting Torque Specifications.
bolts.
9 Rotate the turntable through an entire rotation.
4 Push the backlash pivot plate towards the Check for tight spots that could cause binding.
turntable as far as possible (this will push the Readjust if necessary.
rotation pinion gears 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
Part No. 1268557 Z-135/70 149

9-2 Note: Perform this procedure with the machine on a

firm, level surface with the booms in the fully stowed
Turntable Level Sensor position and the axles fully extended.
1 Push in the ground controls red Emergency
How to Calibrate the Turntable Stop button to the off position.
Level Sensor 2 Open the ground control box.
Note: If the Safety Controller (SCON) has been Before serial number 321:
replaced, the entire machine must be calibrated in a
specific order. Refer to Repair Procedure, Full 3 Locate the 2 pin connector in the lower left
Machine Calibration. hand area of the ground control box.
Tip-over hazard. Failure to jumper wire between the two pins of the
properly calibrate the machine connector.
could cause the machine to tip
over resulting in death or serious After serial number 320:
injury.
5 Locate the calibration toggle switch at the top
Note: A digital level will be required to perform this of the ground control box. Activate calibration
procedure. mode by moving the toggle switch in the left
direction.
Note: A kit is available through Genie Product
Support (Genie part number 58351). This kit 6 Temporarily install a control box door retaining
includes a digital level with a magnetic base and fastener between the door and the box to
cable harnesses. prevent the control box door from moving the
toggle switch while calibrating the machine.
in this procedure.
150 Z-135/70 Part No. 1268557

All models: 10 Enter sensor calibration mode by pressing the

buttons at the ground controls in the following
7 Turn the key switch to ground controls. sequence: (plus)(enter)(enter)(plus).
Note: The angle sensor calibration values will not
bypass position and the calibration toggle switch is
activated.
control panel while pulling out the ground
controls red Emergency Stop button to the on
position. Hold the enter button for
1 Run
2 Bypass
3 Recovery
Note: The bypass/recovery key switch is located on

the lower right side of the control box from serial
number Z13512-1712.
LCD screen until SET UNIT X AXIS LEVEL TO
GRAVITY is displayed.
Part No. 1268557 Z-135/70 151

12 Place a digital level that has ben calibrated to 13 Press the plus button or minus button to
gravity on the X axis of the turntable. adjust the display to the exact value shown on
the digital level and press the enter button.
Note: Illustrations shown at the platform end of the
machine. Note: If the measured angle already matches the
X axis LCD screen,until SET UNIT Y AXIS LEVEL TO
GRAVITY is displayed.
15 Place a digital level that has been calibrated to
gravity on the Y axis of the turntable.
Y axis
positive degree side slope
positive degree downhill slope
negative degree uphill slope
negative degree side slope
152 Z-135/70 Part No. 1268557

16 Press the plus button or minus button to Before serial number 321:
adjust the display to the exact value shown on 21 Remove the wire jumper from the 2 pin
the digital level and press the enter button. connector in the lower left hand area of the
Note: If the measured angle already matches the ground control box that was installed in step 4.
angle shown on the display at the ground controls, Install the connector plug.
17 Press the enter or previous button on the stability. Operating the machine
LCD screen until EXIT is displayed. in this configuration will result in
18 Press the plus button to select YES, then resulting in death or serious
press the enter button to accept. injury. The jumper wire must be
19 Turn the key back to the run position and removed before operating the
remove the key from the bypass/recovery key machine.
and turn it to ground controls. 22 Close the ground control box and install the
is in the run position before attempting to operate After serial number 320:
the machine.
20 Wait approximately 20 seconds and turn the installed. Close the control box door and install
machine off by pressing the red Emergency the door retaining fasteners.
Stop button in. Note: When the control box door is closed, the
All models:
24 Start the engine. Be sure there are no
calibration faults shown on the display.
25 Perform level sensor test. Refer to
Maintenance Procedure, Test the Level
Sensor.
Part No. 1268557 Z-135/70 153

Axle Components
10-1 3 Remove the steer sensor cover retaining

fasteners. Remove the steer sensor assembly.
Steer Sensors
Note: If the sensor activator pin needs to be
The steer sensors measure steer angle and replaced, install the new activator pin per
communicates that information to the ground Illustration 1.
controls ECM. The steer sensor on the ground
controls side of the machine at the square-end acts
as the lead sensor when in front wheel steer mode.
In rear wheel steer mode, the steer sensor on the
ground controls side of the machine at the
circle-end acts as the lead sensor. The other three
sensors follow the position, or steer angle, of the
lead sensor. There is a steer sensor mounted to the
top of each steer yoke upper pivot pin.
How to Replace a Steer Sensor

Note: 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 Illustration 1
retracted and the boom in the stowed position. (square end, yellow side and circle end, blue side shown)
1 Align the remaining wheels on the machine so

they are visually parallel to the chassis as
close as possible.
2 Disconnect the steer sensor assembly cable
from the main harness to be replaced.
154 Z-135/70 Part No. 1268557

Axle Components
Left front (square-end, blue side) and right rear 7 Install the steer sensor cover retaining
(circle-end, yellow side) angle sensors: 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
Steer Sensor.
Note: Be sure the yoke pivot pin retaining plate is
fully engaged into the pivot pin and that the
fasteners are securely tightened.
Right front (square-end, yellow side) and left
rear (circle-end, blue side) angle sensors:
Illustration 2
1 starting position
2 installed position
3 sensor cover
4 rotation arrow
4 Position the new steer sensor assembly over

the sensor activator pin with the sensor cable
angled towards the tire. Refer to Illustration 2.
5 Align the sensor with the pin and install the
sensor on to the pin.
Note: Be sure the sensor activator pin is engaged
into the sensor. Illustration 3
6 Rotate the sensor housing in a clockwise 1 installed position

direction until the sensor cable is pointing 2 starting position
away from the machine. Refer to Illustration 2. 3 sensor cover
4 rotation arrow
Part No. 1268557 Z-135/70 155

Axle Components
How to C alibr ate a R epl acement Steer Sensor
10 Position the new steer sensor assembly over How to Calibrate a Replacement
the sensor activator pin with the sensor cable
angled away from the tire. Refer to Illustration
Steer Sensor
3. Note: If a steer angle sensor has been removed or
replaced, the steer angle sensors will need to be
calibrated.
Note: Be sure the sensor activator pin is engaged Note: Perform this procedure with the axles
into the sensor. retracted and the tires straightened.
12 Rotate the sensor housing in a clockwise Note: Two people will be required to perform this
direction until the sensor cable is pointing procedure.
away from the machine. Refer to Illustration 2. Note: Be sure the yoke pivot pin retaining plate is
13 Install the steer sensor cover retaining fully engaged into the pivot pin and that the
fasteners. Do not tighten the cover retaining fasteners are securely tightened.
fasteners.
14 Connect the steer sensor assembly cable to
the main harness. 2 Select the proper steer mode. If a front
(square-end) steer angle sensor has been
15 Calibrate the steer sensor. Refer to Repair replaced, select rear steer mode. If a rear
Procedure, How to Calibrate a Replacement (circle-end) steer angle sensor has been
Steer Sensor. replaced, select front steer mode.
Note: Be sure the yoke pivot pin retaining plate is 3 Have another person press down the foot
fully engaged into the pivot pin and that the switch.
fasteners are securely tightened.
4 At the new steer angle sensor, loosen the steer
angle sensor cover retaining fasteners. Do not
remove the fasteners or the sensor cover.
5 Rotate the sensor cover clockwise or
counterclockwise until the tire is straight in
relation with the other tires. Tighten the sensor
cover fasteners.
Note: If available, WebGPI can also be used for this
procedure.
off position.
156 Z-135/70 Part No. 1268557

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How to C alibr ate All Steer Sensors
How to Calibrate All Steer All models:

Sensors 5 Turn the key switch to ground controls and pull
out the ground controls red Emergency Stop
Note: This procedure will only need to be performed
button to the on position.
if the ground controls circuit board (TCON) has
been replaced. 6 Loosen the steer angle sensor cover retaining
fasteners. Do not remove the fasteners or the
Note: Perform this procedure with the axles sensor cover.
retracted and the tires straightened.
7 Using a voltmeter set to DC voltage, probe the
Note: Use the following chart to identify the back of the electrical connector at pins B and
description of each LCD screen control button used C.
in this procedure.
8 Left front (square-end, blue side) and right
rear (circle-end, yellow side) angle
sensors: Rotate the sensor cover clockwise or
counterclockwise until the voltage reading is
between 1.4 to 1.6V DC. Tighten the sensor
cover fasteners.
Before serial number 321: Right front (square-end, yellow side) and
left rear (circle-end, blue side) angle
1 Locate the 2 pin connector in the lower left sensors: Rotate the sensor cover clockwise or
hand area of the ground control box. counterclockwise until the voltage reading is
between 3.4 to 3.6V DC. Tighten the sensor
cover fasteners.
connector. Note: If available, WebGPI can also be used for this
procedure.
mode by moving the toggle switch in the left
direction. Note: The angle sensor calibration values will not
4 Temporarily install a control box door retaining
bypass position and the calibration toggle switch is
activated.
prevent the control box door from moving the
toggle switch while calibrating the machine. 10 Push in the red Emergency Stop button to the
off position.
Part No. 1268557 Z-135/70 157

Axle Components
11 Press and hold the enter button on the ground Delete all Steer Sensor Calibrations
controls red Emergency Stop button to the on 13 Press the enter or previous button on the
position. Hold the enter button for LCD screen until DELETE ALL STEER
approximately 5 seconds and then release it. SENSORS CALIBRATION is displayed.Press
the plus button to select YES, then press the
Note: Models before software version 3.0, the LCD
screen will display RESET ALL STEER SENSORS.
16 Proceed to step 22.
Delete a Single Steer Sensor Calibration
17 To calibrate a single steer sensor, delete the
specific steer sensor calibration
LCD screen until DELETE _____ STEER
1 Run SENSORS CALIBRATION is displayed.
2 Bypass Example: DELETE BLUE END BLUE SIDE
3 Recovery STEER SENSORS CALIBRATION (FL).
Note: The bypass/recovery key switch is located on 19 Press the plus button to select YES, then
the lower right side of the control box from serial press the enter button to accept.
number Z13512-1712. 20 Press the enter or previous button on the
12 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following 21 Press the plus button to select YES, then
sequence: (plus)(enter)(enter)(plus). press the enter button to accept.
158 Z-135/70 Part No. 1268557

Axle Components
22 Push in the red Emergency Stop button to the 10-2

off position.
Steer Cylinders
Before serial number 321:
How to Remove a Steer Cylinder
connector in the lower left hand area of the Note: When removing a hose assembly or fitting,
ground control box that was installed in step 2. the O-ring (if equipped) on the fitting and/or hose
Install the connector plug. end must be replaced. All connections must be
Tip-over hazard. Failure to Specifications, Hydraulic Hose and Fitting Torque
remove the jumper wire will Specifications.
which will compromise machine Note: Perform this procedure with the axles
stability. Operating the machine extended.
the machine tipping over, 1 Tag, disconnect and plug the hydraulic hoses
resulting in death or serious from the steer cylinder. Cap the fittings on the
injury. The jumper wire must be cylinder.
machine.
After serial number 320: gradually. Do not allow oil to
squirt or spray.
installed. Close the control box door and install 2 Support the steer cylinder with a suitable lifting
the door retaining fasteners. device. Protect the cylinder rod from damage.
Note: When the control box door is closed, the 3 Remove the pin retaining fasteners from both
calibration toggle switch is automatically activated steer cylinder pivot pins.
4 Use a soft metal drift to remove the pins.
All models:
5 Remove the steering cylinder from the
26 Turn the key back to the run position and machine.
switch. Insert the key into the main key switch Crushing hazard. The steer
and turn it to ground controls. cylinder may become unbalanced
and fall if not properly supported
Note: Be sure that the bypass/recovery key switch by the lifting device when
is in the run position before attempting to operate removed from the machine.
the machine.
Part No. 1268557 Z-135/70 159

Axle Components
10-3 4 Connect the hydraulic hoses from a portable

hydraulic power unit to the axle extension
Axle Extension Cylinders cylinder.
How to Remove an Axle Note: Connect the pressure hose from the power
unit to the "R" port of the cylinder and the return
Extension Cylinder hose from the power unit to the "E" port on the
Note: When removing a hose assembly or fitting, cylinder.
5 Support the axle extension cylinder with a
suitable lifting device. Protect the cylinder rod
from damage.
Specifications. 6 Remove the pin retaining fasteners from both
axle extension cylinder pivot pins.
firm, level surface and in the stowed position with 7 Use a soft metal drift to remove the pins.
the axles extended. 8 Using the portable hydraulic power unit, retract
Note: This procedure will require the use of a the axle extension cylinder until the ends of the
portable hydraulic power unit. cylinder clear the axles.
9 Remove the axle extension cylinder from the
machine.
from the axle extension cylinder. Cap the
fittings on the cylinder. Crushing hazard. The axle
extension cylinder may become
unbalanced and fall if not properly
supported by the lifting device.
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.
160 Z-135/70 Part No. 1268557

Axle Components
10-4
Axle Angle Sensors
The axle angle sensors measure the axle angle and
communicates that information to the ground
controls ECM. There are two axle angle sensors.
They are located on opposite axle pivot pins at
each end of the chassis.
How to Install an Axle Angle

Sensor
Note: If an axle angle sensor has been removed or
replaced, the axle angle 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 is not broken or twisted.
Note: If the sensor activator pin needs to be
replaced, install the new activator pin parallel with illustration 1
the drive chassis side plate. Refer to illustration 1.
1 drive chassis side plate
2 activator pin
Part No. 1268557 Z-135/70 161

Axle Components
4 Position the new angle sensor assembly over 6 Rotate the sensor housing in a clockwise
the sensor activator pin as shown. Refer to direction until the sensor cable is parallel with
illustration 2. the drive chassis side plate. Refer to
illustration 2.
7 Install the axle sensor cover retaining
fasteners. Do not tighten the retaining
fasteners.
8 Connect the axle sensor assembly cable to the
chassis harness.
9 Calibrate the axle angle sensor. Refer to
Repair Procedure, How to Calibrate the Axle
Angle Sensors.
illustration 2
1 starting position
2 installed position
3 sensor cover
4 rotation arrow
5 drive chassis side plate
Note: Be sure the actuator pin is engaged into the
sensor.
162 Z-135/70 Part No. 1268557

Axle Components
How to C alibr ate the Axl e Angle Sens ors
How to Calibrate the Axle Angle 4 Rotate the sensor cover clockwise or
counterclockwise until the voltage reading is
Sensors between 4.2 to 4.4V DC. Tighten the sensor
Note: Use the following chart to identify the cover retaining fasteners.
5 Repeat steps 2 through 4 for the other axle
in this procedure.
angle sensor if needed.
6 Push in the ground controls red Emergency
Stop button to the off position.
Plus Minus Previous Enter Before serial number 321:
Note: If an axle angle sensor has been removed or 8 Locate the 2 pin connector in the lower left
replaced, the axle angle sensors will need to be hand area of the ground control box.
calibrated.
Note: Perform this procedure with the axles fully jumper wire between the two pins of the
retracted and the boom in the stowed position. connector.
Note: Two people will be required to perform this After serial number 320:
procedure.
1 Turn the key switch to platform controls and of the ground control box. Activate calibration
pull out the red Emergency Stop button to the mode by moving the toggle switch in the left
on position at both ground and platform direction.
controls. 11 Temporarily install a control box door retaining
2 Loosen the axle angle sensor cover retaining fastener between the door and the box to
fasteners. Do not remove the fasteners or the prevent the control box door from moving the
sensor cover. toggle switch while calibrating the machine.
3 Using a voltmeter set to DC voltage, probe the
back of the electrical connector at pins 2 and 3.
Note: If available, WebGPI can also be used for this
procedure.
Part No. 1268557 Z-135/70 163

Axle Components
All models: 13 Press and hold the enter button on the ground
12 Remove the key from the main key switch. controls red Emergency Stop button to the on
Insert the key into the bypass/recovery key position. Hold the enter button for
switch and turn it to the bypass position. approximately 5 seconds and then release it.
Note: The angle sensor calibration values will not 14 Enter sensor calibration mode by pressing the
be saved correctly unless the key switch is in the buttons at the ground controls in the following
bypass position and the calibration toggle switch is sequence: (plus)(enter)(enter)(plus).
activated.
LCD screen until DELETE AXLE ANGLE
SENSORS CALIBRATION is displayed.Press
the plus button to select YES, then press the
Note: Models before software version 3.0, the LCD
screen will display RESET AXLE ANGLE
SENSORS.
16 At the AXLE ANGLES FULLY RETRACTED
screen, press the plus button to select YES,
then press the enter button to accept.
17 When the AXLE ANGLES FULLY EXTENDED
screen is displayed, start the engine and fully
extend the axles.
1 Run when the engine is started, repeat step 13.
2 Bypass
3 Recovery
Note: The bypass/recovery key switch is located on

the lower right side of the control box from serial
number Z13512-1712.
164 Z-135/70 Part No. 1268557

Axle Components
18 Press the plus button to select YES, then Before serial number 321:
press the enter button to accept. 23 Remove the wire jumper from the 2 pin
19 Press the enter or previous button on the connector in the lower left hand area of the
LCD screen until EXIT is displayed. ground control box that was installed in step 8.
press the enter button to accept. Tip-over hazard. Failure to
21 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 in this configuration will result in
or red Emergency Stop button or all calibration the machine tipping over,
points or values will not be saved. resulting in death or serious
22 Wait approximately 20 seconds and turn the removed before operating the
machine off by pressing the red Emergency machine.
Stop button in.
All models:
26 Turn the key back to the run position and
is in the run position before attempting to operate
the machine.
Part No. 1268557 Z-135/70 165

166 Z-135/70 Part No. 1268557

Fault Codes
Section 4 Faul t Codes
Before Troubleshooting:
 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
Attempting short cuts may produce hazardous
 Troubleshooting and repair procedures shall be conditions.
completed by a person trained and qualified on
the repair of this machine  Be aware of the following hazards and follow
generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both ground and platform controls
• Wheels chocked
• 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)
Part No. 1268557 Z-135/70 167

Fault Codes
Error Source Error Type Effects Recovery Actions
Primary Ext/Ret Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
zero and neutral, Alarm sounds joystick. Check the connections to
Value Too High
ensure the connector terminals have
Value Too Low not backed out. Substitute a known
good joystick. If necessary replace and
Value at 0 V recalibrate joystick.
Not calibrated Joystick Speed and Direction frozen at Calibrate Joystick
zero and neutral
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Primary Up/Down Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
zero and neutral
warning device
Steer Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
zero and neutral
warning device
168 Z-135/70 Part No. 1268557

Fault Codes

Primary Boom Up/Down Fault Check (both Primary Boom Up/Down disabled, Check ribbon and connector from
buttons on TCON buttons pressed) display message on LCD membrane switch. If necessary replace
membrane switch.
Primary Boom Ext/Ret Fault Check (both Primary Boom Ext/Retract disabled, Check ribbon and connector from
buttons on TCON buttons pressed) display message on LCD membrane switch. If necessary replace
membrane switch.
Primary Boom Length Fault Check Stop all boom functions, allow only Check primary boom retracted and
(unknown length) boom retract, once fully retracted allow extended switches for proper contact
boom down. Display message on LCD with the boom. Readjust or shim switch
as necessary.
Primary Up/Down Speed Not calibrated Display message on LCD and allow Perform auto calibrate procedure.
operation at default speed
Primary Extend/Retract Not calibrated Display message on LCD and allow Perform auto calibrate procedure.
Speed operation at default speed
Primary Boom Extend Valve Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Repair or replace as necessary.
Primary Boom Retract Valve
Primary Boom Up Valve
Primary Boom Down Valve
Primary Lock-Out Valve #1
Primary Lock-Out Valve #2
Secondary Boom Not calibrated Normal function except threshold for Perform calibration procedure
Up/Down/Extend/Retract one or the other direction is zero.
Flow Valve Display message on LCD
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds ground. Replace coil if necessary
Value Too Low Limited Speed and Direction frozen at Check for opens in the wiring or a bad
Part No. 1268557 Z-135/70 169

Fault Codes

Safety Switch P3 Fault Check Display message on LCD P3 SAFETY Internal fault not on Z135
SWITCH FAULT
Safety Switch P6R1 Fault Check Display message on LCD P6R1 Check wiring for circuit P53LS
SAFETY SWITCH FAULT (white/black wire) for damage resulting
in shorts or opens. Repair wiring or
replace TCON.
Safety Switch P6R2 Fault Check Display message on LCD P6R2 Check wiring for circuit P54ENG
SAFETY SWITCH FAULT (black/white wire) for damage resulting
replace TCON.
Safety Switch P7 Fault Check Display message on LCD P7 SAFETY Check wiring for circuit S56PRV (red
SWITCH FAULT wire) for damage resulting in shorts or
opens. Repair wiring or replace TCON.
Safety Switch P7R Fault Check Display message on LCD P7R Function enable button was held down
SAFETY SWITCH FAULT during startup. Recycle power with the
function button released.
Safety Switch DCON P7R Fault Check Display message on LCD DCON P7R Check wiring for circuit S56PRV (red
SAFETY SWITCH FAULT wire) for damage resulting in shorts or
opens. Repair wiring or replace DCON.
Safety Switch P9A Fault Check Display message on LCD P9A Check wiring for circuit P53LS
SAFETY SWITCH FAULT (white/black wire) for damage resulting
replace TCON.
Safety Switch P9B Fault Check Display message on LCD P9B Boom has violated the safety limits
SAFETY SWITCH FAULT resulting in the engine being shut off as
a safety feature. Use aux to get the
boom back into operational limits.
Check P54ENG and P58LS between
SCON and TCON for damage. Check
SCON chart for possible fault
conditions.
170 Z-135/70 Part No. 1268557

Fault Codes

Safety Switch P10 Fault Check Display message on LCD P10 SAFETY Recycle power
SWITCH FAULT
Safety Switch P11 Fault Check Display message on LCD P11 SAFETY Recycle power and check wiring on
SWITCH FAULT circuit S140ENL (orange/black)
between SCON and TCON. Check
SCON chart for possible faults.
SWITCH FAULT
SWITCH FAULT
SWITCH FAULT
Safety Switch P22 Fault Check Display message on LCD P22 SAFETY Re-level platform. Check for wiring
SWITCH FAULT damage on circuit P56PRV (red/white).
Safety Switch P22R Fault Check Display message on LCD P22R Re-level platform. Repair or replace
SAFETY SWITCH FAULT PCON.
SWITCH FAULT circuit S140ENL (orange/black)
between SCON and TCON. Check
SCON chart for possible faults.
SWITCH FAULT circuit S137PLL (red/white) between
SCON and TCON. Check SCON chart
for possible faults.
SWITCH FAULT circuit S139TRF (white/red) between
SCON and TCON. Check SCON chart
for possible faults.
Part No. 1268557 Z-135/70 171

Fault Codes

Platform Overload Fault Check Display message on LCD. Disable all Check for an overload in the platform.
(if active) functions from PCON. Limit functions at Check the overload switch mounted on
TCON to AUX Power. FUEL POWER the platform support.
P9B FAULT
Footswitch Timeout Calibration check Display message on LCD Recycle power
Engine Speed Range Check Display message on LCD Engine is running below 50 RPM.
(underspeed) Check fuel system.
Oil Pressure Range Check (low Display message on LCD Oil pressure is low. Check sender and
oil pressure) oil level.
Water/Oil Temperature Range Check Display message on LCD Engine is overheating. Check sender,
(high temp) 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 Axle extend/retract disabled. Display Check ribbon and connector from
buttons pressed) message on LCD membrane switch. If necessary replace
membrane switch.
Axle Valve Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
DCON CAN Bus Fault Check Display message on LCD Disable Check CAN bus wiring from TCON to
propel DCON through rotator. Repair or
replace wiring or DCON.
CAN Bus Fault Check Display message on LCD Check CAN bus wiring from TCON to
SCON/PCON. Repair or replace wiring
or SCON/PCON.
172 Z-135/70 Part No. 1268557

Fault Codes

Primary Boom Up/Down Not calibrated Normal function except threshold for Calibrate Thresholds
Flow Valve one or the other direction is zero.
Display message on LCD
warning device
Value Too Low
Primary Boom Not calibrated Normal function except threshold for Calibrate Thresholds
Extend/Retract Flow Valve one or the other direction is zero.
warning device
Value Too Low
Operational Primary Boom Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Angle Sensor Extend disabled, Alarm sounds to the sensor
Value Too High Primary up, Secondary up/down and Sensor is out of range. Check sensor
Extend disabled, Alarm sounds and actuating pin for proper installation.
Repair or replace sensor and
Value Too Low
recalibrate.
Value at 0 V Primary up, Secondary up/down and Check for 5.0 VDC at the sensor.
Extend disabled, Alarm sounds Check for damaged wiring going to the
sensor. Check that the % .0 VDC LED
is lit on the TCON board. Repair or
replace as necessary
Out of Tolerance Primary up, Secondary up/down and Recalibrate sensor
Extend disabled, Alarm sounds
Not calibrated Primary up only active from TCON, Perform calibration procedure per
activate alarm service manual
warning device
Part No. 1268557 Z-135/70 173

Fault Codes

Safety Primary Boom Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Sensor Extend disabled, Alarm sounds to the sensor
Value Too Low
recalibrate.
warning device
Secondary Boom Joystick Value at 5.0 V Primary up, Secondary up/down and Check for damaged wiring to the
Extend disabled, Alarm sounds joystick. Check the connections to
Value Too High
not backed out. Substitute a known
Value Too Low good joystick. If necessary replace and
recalibrate joystick.
Value at 0 V
Not calibrated Joystick Speed and Direction frozen at
zero and neutral
warning device
Secondary Boom Fault Check (both Secondary boom Up/Ext/Down/Retract Check ribbon and connector from
Up/Extend/Down/Retract buttons pressed) disabled Display message on LCD membrane switch. If necessary replace
Switches on TCON membrane switch.
Secondary Boom Up/Down Not calibrated Display message on LCD and allow See service manual on how to perform
Speed operation at default speed this procedure.
174 Z-135/70 Part No. 1268557

Fault Codes

Secondary Boom Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
Extend Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Retract Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Up Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Down Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Extend Sequence Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Down Sequence Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Operational Secondary Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Boom Angle Sensor Extend disabled, Alarm sounds to the sensor
Value Too Low
recalibrate.
Not calibrated Secondary up only active from TCON, Perform calibration procedure per
warning device
Part No. 1268557 Z-135/70 175

Fault Codes

Safety Secondary Boom Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Angle Sensor Extend disabled, Alarm sounds to the sensor
recalibrate.
Value Too Low
Not calibrated Secondary up only active from TCON, Perform calibration procedure per
warning device
Operational Turntable Level Value at 5.0 V Flash unit out of level icon and LED and Check that SCON is grounded
Sensor X Direction activate alarm
Value Too High Replace SCON
Value Too Low
Value at 0 V
Out of Tolerance
warning device
Safety Turntable Level Value at 5.0 V Flash unit out of level icon and LED and Check that SCON is grounded
Sensor X Direction activate alarm
Value Too Low
Value at 0 V
Out of Tolerance
warning device
176 Z-135/70 Part No. 1268557

Fault Codes

Turntable Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
Value at 0 V
zero and neutral
warning device
Turntable Rotate Buttons on Fault Check (both Turntable rotate disabled Display Check ribbon and connector from
TCON buttons pressed) message on LCD membrane switch. If necessary replace
membrane switch.
Turntable Rotate Speed Not calibrated Display message on LCD and allow Perform auto calibrate procedure.
operation at default speed
Turntable Rotate Flow Valve Not calibrated Normal function except threshold for Perform calibration procedure
one or the other direction is zero.
warning device
Value Too Low Check for shorts to ground in the
wiring. Replace coil if necessary
Turntable Rotate Clockwise Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Turntable Rotate
Counterclockwise Valve
Operational Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded
Sensor Y Direction sounds
Value Too Low
Value at 0 V
Out of Tolerance
warning device
Part No. 1268557 Z-135/70 177

Fault Codes

Safety Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded
Sensor Y Direction sounds
Value Too Low
Value at 0 V
Out of Tolerance
warning device
Platform Level Sensor Y Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded
Direction sounds
Value Too High
Value Too Low
Value at 0 V
warning device
Platform Rotate Clockwise Fault Check Fault Check Check for defective or damaged wiring.
Valve Check for an open or shorted valve coil.
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.
Jib Up/Down Flow Valve(s) Not calibrated Normal function except threshold for Perform calibration procedure
one or the other direction is zero.
warning device
Value Too Low
178 Z-135/70 Part No. 1268557

Fault Codes

Jib Level (Bellcrank) Not calibrated Normal function except threshold for Perform calibration procedure
Up/Down Flow Valve(s) one or the other direction is zero.
warning device
Value Too Low
Platform Level Up / Platform Not calibrated Normal function except threshold for Perform calibration procedure
Level Down Flow Valve one or the other direction is zero.
warning device
Value Too Low Limited Speed and Direction frozen at Check for shorts to ground in the wiring.
zero and neutral, Alarm sounds Replace coil if necessary
Platform Rotate Switches Fault Check (both Affected functions disabled. Display Check ribbon and connector from
closed) message on LCD membrane switch. If necessary replace
membrane switch.
Jib Up/Down Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
Value at 0 V
Not calibrated Joystick Speed and Direction frozen at
zero and neutral
warning device
Part No. 1268557 Z-135/70 179

Fault Codes

Jib Extend/Retract Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
Value Too Low
Value at 0 V
zero and neutral
warning device
Platform Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Power up controller with problem
zero and neutral, Alarm sounds corrected.
Value Too High
Value Too Low
Value at 0 V
zero and neutral
warning device
Front Axle Angle Sensor Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Extend disabled, Alarm sounds to the sensor
Value Too Low
recalibrate.
warning device
180 Z-135/70 Part No. 1268557

Fault Codes

Rear Axle Angle Sensor Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Extend disabled, Alarm sounds to the sensor
Value Too Low
recalibrate.
warning device
Propel Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
Value at 0 V
Not calibrated Joystick Speed and Direction frozen at Calibrate Thresholds
zero and neutral
warning device
Propel Valves Not calibrated Joystick Speed and Direction frozen at Calibrate Thresholds
Forward/Reverse zero and neutral
Propel EDC Just calibrated Initiate one second beep of audible Self-clearing (transient)
Forward/Reverse warning device
Value Too Low Check for shorts to ground in the
wiring. Replace coil if necessary
Motor Valve Speed Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
Brake Valve
Part No. 1268557 Z-135/70 181

Fault Codes

Left Front Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Value Too Low
recalibrate.
Right Front Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Value Too Low
recalibrate.
Left Rear Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Value Too Low
recalibrate.
182 Z-135/70 Part No. 1268557

Fault Codes

Right Rear Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going
Value Too Low
recalibrate.
Steer Valves - LF, RF, LR, Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
RR zero and neutral, Alarm sounds Check for an open or shorted valve coil.
Part No. 1268557 Z-135/70 183

Fault Codes

Secondary Boom Switch Too much time has elapsed Inhibit Secondary Boom If the fault occurs on extend, retract
Timeout from when LSS1RO is Extend if the fault occurs. boom until LSS1RO is engaged and try
released and LSS1RS is again. Check LSS1RS and LSS1RO
released on extend and for physical damage and proper
LSS1RS is engged and operation.
LSS1RO is engaged. Or the
joystick was engaged three
times in the interval.
Secondary Boom Switches Either LSS1RS or LSS1RO Inhibit Secondary Boom Check switch for proper operation or
Intermittence Fault (LSS1RS have changed state without a Down until the fault is damage. Use TCON display menu or
Fault) secondary boom cleared. laptop with WebGPI to clear faults.
extend/retract command or
they have changed state
when the secondary boom is
not fully raised.
Jib Angle Sensor Value at 5.0 V Limited Speed and Power up controller with problem
Operational (RSJ1AO) Direction frozen at zero and corrected.
Value Too High
neutral, Alarm sounds
Value Too Low
Value at 0 V
SCON Tilt Sensor Calibration check Display X direction and Y Re-power after entering tilt x axis and y
direction not calibrated axis matrix information
LSS1RO Fault LSS1RO did not switch within Inhibit secondary boom Check switch for proper operation or
a specified time after the extend and sound an damage. Use TCON display menu or
secondary boom was raised audible warning laptop with WebGPI to clear faults.
184 Z-135/70 Part No. 1268557

Fault Codes
P_38 - Propel P_39 - Turntable P_10 - Primary P_11 - Primary / P_9B - P_30 - Secondary
Rotate Boom Extend Secondary Up Ignition/Fuel Extend/Down
P_38 P_39 P_10 P_11 P_30 P_9B
Turntable tilt Y axis (+5°, secondary boom not stowed) OFF OFF OFF OFF
Primary Boom angle (crosscheck) OFF OFF OFF OFF OFF
Secondary Boom angle (crosscheck) OFF OFF OFF OFF
Secondary 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 OFF OFF
disable zone)
Turntable tilt angle (crosscheck SCON internal sensors 3 in a delta OFF OFF OFF OFF OFF
configuration)
Primary Boom safety (max angle) OFF OFF OFF OFF OFF
Loss of CAN OFF OFF OFF OFF OFF OFF
LSS1RS disconnected (SCON pin #2) OFF OFF
Platform Overload (SCON pin #1) OFF
Secondary Boom length OFF OFF OFF
(crosscheck LSS1RS and LSS1RO)
Part No. 1268557 Z-135/70 185

186 Z-135/70 Part No. 1268557

Schematics
Section 5 Schematics
About This Section

There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: circuits could result in death or
 Troubleshooting and repair procedures shall be watches and other jewelry.
completed by a person trained and qualified on
the repair of this machine
Hydraulic Schematics
damaged or malfunctioning machine. Bodily injury hazard. Spraying
 Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine.
Before Troubleshooting: gradually. Do not allow oil to
squirt or spray.
 Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 1268557 Z-135/70 187

Wire Circuit Legend
Circuit numbering Circuit prefix

1 Circuit numbers consist of three parts: the C Control
circuit prefix, circuit number and circuit suffix. D Data
The circuit prefix indicates the type of circuit.
E Engine
The circuit number describes the function of
the circuit. The circuit suffix provides an G Gauges
abbreviation for the number or may be used to N Neutral
further define the function of this portion of the P Power
circuit. It also may be used to indicate the final
R Relay Output
end of the circuit, i.e., LS or limit sw.
S Safety
2 The circuit number may be used more than
V Valve
once in a circuit.
For Example:
C 74 PL – This is the circuit for the lockout valve #1.
C stands for control, 74 is the number of the circuit
for the primary #1 lock out valve. PL stands for
Primary Lockout.
S 62 BST – This is the circuit that communicates to
the onboard computers of the machine that the
boom is fully stowed. S stands for safety, 62 is the
number of the circuit for boom stowed and BST
stands for Boom Stowed.
P 48 LP – P stands for power. 48 is the circuit
number for work lamps and LP stands for Lamp.
R 48 LP – R stands for relay. In this case it is the
wire that feeds the relay coil for the work lamp. All
other numbers remain the same.
V61AXR – V stands for valve power. Number
61 stands for axle retracted circuit; AXR stands for
Axle retracted.
R46HRN – R stands for Relay output, supplying
power to the horn (HRN). Number 46 is the circuit
number for the horn.
188 Z-135/70 Part No. 1268557

Wire Circuit Legend
Suffix Definition Suffix Definition

ABV Auxiliary Boom Valve ESP Engine Speed Select
AF Alternator Field FAP Axle Front Position
AFV Auxiliary Forward Valve FB Flashing Beacon
AH Auxiliary Hydraulic Pump FE Function Enable
ANG Angle FL Fuel Select (gas/LP)
APV Auxiliary Platform Valve FLR Filter Restricted
ARV Auxiliary Reverse Valve FLT Filter Switch
ASV Auxiliary Steer/Drive Valve FP Fuel Pump
AXE Axle Extend Valve FS Float Switch
AXO Axle Oscillate FSL Fuel Solenoid
AXR Axle Retract Valve FTS Foot switch Signal
BAT Battery FWD Forward
BEX Boom Extended GEN AC Generator
BRK Brake GND Ground
BST Boom Stowed HG Hydraulic Generator
BV Bypass Valves HRN Horn
CAL Calibrate HS High RPM
CAN CAN Signal IGN Ignition
CAT CATS Module JBD Jib Bellcrank Down
CNK Chain Break JBE Jib Extend
DCN Drive Chassis Controller JBR Jib Retract
DE Drive Enable JBS Jib Sensor
DEL Drive Enable Left JBU Jib Bellcrank Up
DER Drive Enable Right JD Jib Down
DTH Data High JER Jib Extend/Retract Control
DTL Data Low JFC Jib Up/Down Flow Control
EDC Electrical Displacement Control JPL Propel Signal
ENL Envelope Lockout JPW Joystick 5V DC Power
ENV Envelope Light JRL Jib Rotate Left (CCW)
ERL Extend/Retract Lockout JRR Jib Rotate Right (CW)
ESL Engine Status Lamp
Part No. 1268557 Z-135/70 189

Wire Circuit Legend

JSV Jib Select Valve PLF Platform Level Flow Control
JU Jib Up PLL Propel Lockout
JUD Jib Up/Down Control PLS Primary Boom Extend/Retract Signal
LDS Load Sensor PLU Platform Level Up
LF Left Front PRC Platform Rotate Control
LFS Left Front Steer Sensor PRF Platform Rotate Flow Control
LO Lockout PRL Platform Rotate Left (CCW)
LOF Low fuel PRR Platform Rotate Right (CW)
LPS Lamps PRV Proportional Valve
LR Left Rear PS Pressure Switches
LRS Left Rear Steer Sensor PSE Program Setup Enable
LS Limit Switch PSL Power to Length Sensor
LS Low RPM PSR Pressure Sender
LSR Lift Speed Reduction PTA Platform Tilt Alarm
MFV Multi Function Valve PTS Platform Tilt Sensor
MS Motor Shift (Speed) PUD Primary Boom Up/Down Flow Control
PBD Primary Boom Down PWR Power
PBE Primary Boom Extend PXS Proximity Sensor
PBL Primary Boom Extend/Retract Lockout RAP Axle Rear Position
Valve RCV Recovery
PBR Primary Boom Retract REC Receptacle
PBS Primary Boom Angle Sensor RET Return
PBU Primary Boom Up REV Reverse
PCE Pressure Comp Enable RF Right Front
PCN Platform Control RFS Right Front Steer Sensor
PEL Primary Ext/Ret Lockout RL Retract Lockout
PER Primary Boom Extend/Retract Flow Control RPM RPM
PES Primary Boom Up/Down Signal RR Right Rear
PL Primary Lockout
PLD Platform Level Down
190 Z-135/70 Part No. 1268557

Wire Circuit Legend

RRS Right Rear Steer Sensor STR Starter
RS Rotary Sensor SUD Sec Boom Up/Down Flow Control
SA Start Aid (Glow Plug or choke) TAX Tilt Alarm X axis
SB Secondary Boom TAY Tilt Alarm Y axis
SBD Sec Boom Down TCN Ground Control
SBE Sec Boom Extend TCN Ground Control Panel
SBL Sec Boom Elevated TET Tether
SBR Sec Boom Retract TRF Turntable Rotate Flow Control
SBS Sec Boom Angle Sensor TRR Turntable Rotate Right (CW)
SBU Sec Boom Up TS Temp Switches
SCC Steering Valve (CCW) TSR Temp Sender
SCW Steering Valve (CW) TSW Test Switch
SEN Sensor TTA Turntable Tilt Alarm
SER Sec Boom Extend/Retract Flow Control TTS Turntable Tilt Sensor
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
Part No. 1268557 Z-135/70 191

Wire Color Legend
Wire Coloring Power Circuits

1 All cylinder extension colors are solid and all P9A Primary boom down valve
retract functions are striped black. When using P9B Engine ignition / Fuel
black wire, the stripe shall be white.
P10 Primary boom extend valve
2 All rotations that are LEFT or CW are solid, P11 Primary boom up valve
RIGHT or CCW are striped and black. When
P30 Secondary boom down and extend
the wire is black, the stripe is white. valves
3 All proportional valve wiring is striped. P38 Propel (drive) valves
P39 Turntable rotate flow control valve
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
192 Z-135/70 Part No. 1268557

Wire Color Legend
Color Circuit # Primary Function Color Circuit # Primary Function

RD 1 Primary boom up driver WH/RD 26 Power to temp sender
RD/BK 2 Primary boom down driver RD 27 Auxiliary Power
RD/WH 3 Primary boom up/down flow RD/BK 28 Platform level alarm
control proportional valve driver RD/WH 29 Drive Motor shift (speed)
WH 4 Turntable rotate left valve driver WH 30 Forward/EDC-A
WH/BK 5 Turntable rotate right valve driver WH/BK 31 Reverse/EDC-B
WH/RD 6 Turntable rotate flow control WH/RD 32 Brake
proportional valve driver
BK 33 Start
BK 7 Primary boom extend
BK/WH 34 Start Aid (glow plug or choke)
BK/WH 8 Primary boom retract
BK/RD 35 High Engine speed select
BK/RD 9 Primary boom Extend/Retract
proportional valve driver BL 36 Steer clockwise
BL 10 Secondary boom up valve driver BL/BK 37 Steer counterclockwise
BL/BK 11 Secondary boom down valve BL/WH 38 Gasoline
driver BL/RD 39 LPG
BL/WH 12 Secondary boom up/down flow OR 40 Limit switch signal stowed
control proportional valve driver
OR/BK 41 RPM signal
BL/RD 13 Drive enable
OR/RD 42 Boom retracted signal
OR 14 Platform level up valve
GR 43 Jib Up
OR/BK 15 Platform level down valve
GR/BK 44 Jib Down
OR/RD 16 Platform up/down flow control
GR/WH 45 AC Generator
proportional valve driver
WH 46 Horn
GR 17 Platform rotate left valve driver
WH/BK 47 Output Power Enable
GR/BK 18 Platform rotate right valve driver
WH/RD 48 Work Lamp
GR/WH 19 Jib select valve driver circuit
WH/BK 49 Motion Lamp
RD 20 12V DC battery supply
BL 50 Auxiliary Boom
WH 21 12V DC ignition supply
BL/WH 51 Auxiliary Steer
BK 22 Key switch power to platform
BL/RD 52 Auxiliary Platform
WH 23 Power to platform
WH/BK 53 Boom envelope safety valve cutoff
RD 24 Power to warning senders
BK/WH 54 Power to safety interlock switches
WH/BK 25 Power to oil pressure sender
(engine)
Part No. 1268557 Z-135/70 193

Wire Color Legend

GR/BK 55 Axle oscillation OR 86 Hydraulic Filter restricted
RD 56 Foot switch/TCON estop power RD 87 Platform Level Safety Power
RD/WH 57 Boom down safety interlock RD/BK 88 Platform Level Safety Output
RD/BK 58 Safety interlock to engine BR 89 Platform Level Safety Ground
GR/WH 59 Chain break circuit RD/BK 90 Proximity Kill
GR/WH 60 Axle extend RD/WH 91 Gate Interlock
GR 61 Axle retract WH/BK 92 Motor Speed (LO/HI)
OR 62 Boom stowed (safety) WH/RD 93 Motor Bypass
OR/RD 63 Power to boom envelope safety WH 94 Load Sensor
switch OR 95 Tether ESTOP return
OR/BK 64 Power for operational switches RD 96 Tether Power
BL/WH 65 Low fuel indication BK 97 Tether ESTOP Power
BL 66 Drive Enable WH 98 J1708 + (high)
BL 67 Secondary boom not stowed BK 99 J1708- (low)
RD 68 Primary Boom lowered WH/RD 100 Outrigger lowered
(operational)
WH/BK 101 Outrigger raised
BL 69 Primary boom #1 extended
OR 102 Pothole protector up
BL/WH 70 Primary boom #2 retracted
OR/RD 103 Pothole protector down
BL/BK 71 Primary boom #2 extended
BK/WH 104 Proprietary Data buss - (I.e. ITT
BL/WH 72 Secondary boom extended or AP)
BL/RD 73 Secondary boom retracted BK/RD 105 Proprietary Data buss + (I.e. ITT
RD 74 Primary #1 Lockout or AP)
RD/WH 75 Primary #2 Lockout GR 106 Spare
BL 76 Primary boom #3 extended RD 107 Alternator Field
WH 77 Lower Angle #1 operational BL/WH 108 Engine Status
WH/BK 78 Upper Angle #2 operational GR/WH 109 Sensor Power
BK 79 Power from TCON ESTOP BK 110 Sensor Return
N/A 80 Can 2.0/J1939 Shield OR 111 Steer Signal
GR 81 Can 2.0/J1939 Low RD 112 Steer Signal to Solenoid Valve
YL 82 Can 2.0/J1939 High OR/RD 113 Multi-function Valve
GR/WH 83 Tilt signal X axis BK/RD 114 Load Moment Overweight
GR/BK 84 Tilt signal Y axis RD/BK 115 Load Moment Underweight
GR 85 Tilt sensor power OR 116 Hydraulic Oil Cooler
194 Z-135/70 Part No. 1268557

Wire Color Legend

RD 117 Flashing Beacon RD 141 Primary Boom Angle Signal
OR 118 Lift Speed Reduction Safety
BL 119 Hydraulic Pressure Sensor Output OR 142 Secondary Boom Angle Signal
Safety
OR 120 Oil Cooler Fan
BL/RD 143 Drive Enable Left
GR 121 Axle Oscillate Left
BL/WH 144 Drive Enable Right
GR/BK 122 Axle Oscillate Right
RD/WH 145 Calibrate
RD/BK 123 Primary Boom Angle Signal
Operational BL 146 Jib Bellcrank Up Flow Control
RD/WH 124 Secondary Boom Angle Signal BL/BK 147 Jib Bellcrank Down Flow Control
Operational BL/WH 148 Jib Bellcrank Sensor
WH/RD 125 Secondary Boom Lockout (Extend GR/WH 149 Jib Up/Down Flow Control
Enable) GR/BK 150 Hydraulic Generator Bypass
WH/BK 126 Secondary Boom Lockout (Riser GR 151 Hydraulic EDC Output
Down Enable)
BK 152 Injector Retard
GR 127 ECU Test Switch
BK 153 Jib Extend
OR/RD 128 Low Engine Speed
BK/WH 154 Jib Retract
RD/BK 129 Descent Alarm
OR/RD 155 Pressure Comp. Enable
WH/RD 130 Travel Alarm
GR/WH 156 Jib Up/Down
BL 131 Motion Alarm
BK/RD 157 Jib Extend/Retract
GR 132 Platform Load Input
BL/RD 158 Steer Signal Rocker
GR/WH 133 Platform Load Alarm
BL/WH 159 Steer Joystick Signal
GR/BK 134 Key Switch power
WH/RD 160 Propel Joystick Signal
BL/WH 135 Fuel Pump
WH/BK 161 Secondary Boom Joystick Signal
RD 136 Power to Safety Module
OR 162 Joystick 5V DC power
RD/WH 137 Drive Power (P_38)
BL/WH 163 Primary Extend/Retract Signal
RD/BK 138 Primary Boom Up/Secondary
Boom Down-Extend (P_11/30) RD/WH 164 Primary Up/Down Signal
WH/RD 139 Turntable Rotate Flow Control WH/RD 165 TT Rotate Signal
Safety (P_39)
OR/RD 140 Boom Envelope Safety
Part No. 1268557 Z-135/70 195

Wire Color Legend

OR 166 Boom Length Signal Safety GR 188 Safety cross check
OR/BK 167 Boom Length Signal Operational BK 189 Data Receive
BL/RD 168 Primary Boom Hydraulic Valve BK/WH 190 Data Transmit
Lockout WH/RD 191 Multi-Function Pressure Relief
GR 169 Envelope Active LED WH/BK 192 Jib Rotate Left
WH/RD 170 Load Sense Relay Source WH/RD 193 Jib Rotate Right
WH/BK 171 Load Sense Relay Sink WH/RD 194 Speed Select Input
BL 172 UP/DN Flow Control Ground OR/RD 195 Electric Brake Source
BK 173 Ext/Ret Flow Control Ground YL 196 2.5V Sensor Power
WH 174 Key Switch Power, Ground WH 197 Hour Meter
Position
RD 198 +12V Sensor Power
WH/BK 175 Load Sensor Signal Operational
WH/RD 199 Thermal Switch
GR/WH 176 Secondary Extend/Retract FC
BL 226 Telematics Remote Disable
BL/RD 177 Extend/Retract Lockout
GR 227 Engine Control
BK 178 Control Module Status Light CAN 2.0 / J1939 Low
GR 179 Drive Power Relay YL 228 Engine Control
BK 180 Lift Power Relay CAN 2.0 / J1939 High
OR 181 48 Volt Alternator field (or Battery) BR N/A Ground or Return
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
196 Z-135/70 Part No. 1268557

Limit Switches and Angle Sensors
Limit Switch Legend
1 RSP1AO 14 Plat Angle Sensor

2 RSP1AS 15 PCON
3 LSP1RO 16 SCON
4 LST20 17 RSRA1SO
5 LST10 18 LSRA1ES
6 LST1S 19 RSLR1SO
7 LSS1RS 20 RSRR1SO
8 LSS1RO 21 DCON
9 RSS1AO 22 RSRF1SO
10 RSS1AS 23 RSLF1SO
11 LSP1EO 24 LSFA1ES
12 RSJ1AO 25 RSFA1SO
13 LSJ1RO
Part No. 1268557 Z-135/70 197

Types of Limit Switches Numbering Legend

LS FA 1 L O
There are two types of limit switches, found in
LS Limit FA Front Circuit L Load O Operational
various locations throughout the machine: Switch Axle Number moment
mechanical-type operational/safety switches and LT Stringpot RA Rear A Angle S Safety
Axle
rotation or angle sensors. As in aircraft, which RS Rotary LF Left Front D Down
features redundant safety systems, each Sensor
LR Left Rear E Extend
mechanical operational switch is backed up with a
RF Right R Retract
separate, independently functioning safety switch. Front
RR Right
The mechanical-type operational or safety Rear
switches are used to sense a positive displacement J Jib Boom
or movement of the limit switch actuator, or arm, as P Boom
the machine moves through its range of operational T Turntable

functions. The rotation or angle sensors utilize Hall
Effect technology and must be calibrated when
replaced. Included in this group are envelope limit
switches which sense the extended length and Limit Switch Numbering
angle of the booms and rotational position of the
LSP1RO Primary boom length retracted
turntable.
LSP1EO Primary boom length fully extended
For example, when the secondary boom is fully LSS1RO Secondary boom fully retracted
raised and the operational sensor is activated, it
LSS1RS Secondary boom fully retracted, safety
tells the ECM at the ground controls to start
extending the secondary boom. LSJ1RO Jib boom length fully retracted
LST1O Drive enable, left direction
Another example is the drive enable limit switch,
LST2O Drive enable, right direction
which disables the drive function anytime the boom
is rotated past the rear tires, indicated by the 'circle' LST1S Drive enable safety, retracted axles
end of the drive chassis.In some cases, the engine LSFA1ES Front axle fully retracted
will be stopped if safety parameters are exceeded. LSRA1ES Rear axle fully retracted
198 Z-135/70 Part No. 1268557

Rotary Sensor Numbering LSFA1ES: Limit switch, Front Axle #1 Extended

Safety. Prevents boom functions with the axles
RSP1AO Primary boom angle sensor retracted. Switch closes when axles are fully
RSP1AS Primary boom angle sensor, safety extended.
RSJ1AO Jib boom angle sensor LSRA1ES: Limit switch, Rear Axle #1 Extended
RSS1AO Secondary boom angle sensor Safety. Prevents boom functions with the axles
RSS1AS Secondary boom angle sensor, safety retracted. Switch closes when axles are fully
RSFA1O Front axle postioning sensor extended.
RSRA1O Rear axle positioning sensor LST1O: Limit switch, Turntable #1 Operational.
RSLF1SO Left front wheel positioning sensor Activates the drive enable zone when the turntable
is rotated in the left direction.
RSRF1SO Right front wheel positioning sensor
RSLR1SO Left rear wheel positioning sensor LST2O: Limit switch, Turntable #2 Operational.
RSRR1SO Right rear wheel positioning sensor Activates the drive enable zone when the turntable
is rotated in the right direction.
Limit Switch Functions LST1S: Limit switch, Turntable #1 Safety. Prevents

the turntable from rotating out past either rear tire
Platform Angle Sensor: Measures the angle of when axles are retracted.
the platform. The range of measurement is +/-
20 degrees. The safety cutout is set at +/- LSS1RO: Limit switch, Secondary Boom #1
10 degrees from gravity and will disable the primary Retracted Operational. NOHC when secondary
and secondary boom up/down functions and the boom is fully retracted. Used to reduce turntable
platform level up/down functions. rotate speed when secondary boom is extended
and to disable secondary boom down unitl fully
Jib Bell Crank Angle Sensor: Measures the angle retracted.
of the jib bell crank. The range of measurement is +
60 / -70 degrees. LSS1RS: Limit switch, Secondary Boom #1 Retract
Safety Switch. Backup switch for LSS1RO. Used to
Safety Controller (SCON): Redundant dual axis cut circuits P9B, P_11 and P_30.
tilt sensors measuring the X and Y tilt angles of the
turntable. Also provides safety switch logic for LSJ1RO: Limit Switch, Jib Boom #1 Retract
function cut-off. Alarm sounds at ±4.5 degrees. Operational. Switch is held closed when the jib
boom fully retracted. Used to limit turntable rotate
speed and drive speed when jib boom is extended.
LSP1EO: Limit Switch, Primary Boom #1 Extend
Operational. Switch closes when the primary boom
is fully extended. NOHC when fully extended.
LSP1RO: Limit Switch, Primary Boom #1 Retract
Operational. Switch closes when the primary boom
is retracted. NOHC when fully retracted
Part No. 1268557 Z-135/70 199

Rotary Sensor Functions RSRA1O: Rotary Sensor, Rear Axle #1

Operational. Provides front axle positioning
RSP1AO: Rotary Sensor, Primary #1 Angle information for adjusting steering neutral setting
Operational. Provides operational primary boom during axle extension.
angle positioning relative to secondary boom angle.
RSLF1SO: Rotary Sensor, Left Front #1 Steer
RSP1AS: Rotary Sensor, Primary #1 Angle Safety. Operational. Provides wheel position information
Provides safety primary boom angle positioning during steering. Master wheel in all steer modes
relative to secondary boom angle. except rear steer.
RSJ1AO: Rotary Sensor, Jib #1 Angle Operational. RSRF1SO: Rotary Sensor, Right Front #1 Steer
Used to level jib bell crank relative to the primary, Operational. Provides wheel position information
secondary and turntable angles. during steering.
RSS1AO: Rotary Sensor, Secondary #1 Angle RSLR1SO: Rotary Sensor, Left Rear #1 Steer
Operational. Used to measure the angle of the Operational. Provides wheel position information
secondary boom. Lowers drive speed when during steering. Master wheel for rear steer mode.
elevated, sequences secondary boom up/extend
and down/retract. RSRR1SO: Rotary Sensor, Right Rear #1 Steer
Operational. Provides wheel position information
RSS1AS: Rotary Sensor, Secondary #1 Angle during steering.
Safety. Backup safety angle sensor for RSS1AO.
Cuts power to circuits P9B, P_11 and P_30 if the
secondary boom drifts down while still extended.
RSFA1O: Rotary Sensor, Front Axle #1
Operational. Provides front axle positioning
information for adjusting steering neutral setting
during axle extension.
200 Z-135/70 Part No. 1268557

Circuit Connector Legend

Number Description Number Description
J9 Ribbon connector from TCON to membrane J59 2 pin Deutsch connector for primary boom up
#1 valve
J10 Ribbon connector from TCON to membrane J60 2 pin Deutsch connector for primary boom
#2 down valve
J11 Black 23 pin AMP connector on TCON J61 2 pin Deutsch connector for primary boom
J12 Black 35 pin AMP connector on TCON ext/ret flow control valve
J13 White 23 pin AMP connector on TCON J62 2 pin Deutsch DT pri boom extend valve
J14 White 35 pin AMP connector on TCON J63 2 pin Deutsch DT pri boom retract valve
J15 Black 4 pin DTP connector on PCON J65 2 pin Deutsch connector for secondary boom
extend valve
J17 16 pin Molex mini fit circuit board to key
switch J66 2 pin Deutsch connector for secondary boom
retract valve
J20 12 pin Deutsch connector lower/upper limit
switch harness J67 2 pin Deutsch connector for secondary boom
up valve
J21 Black 23 pin AMP connector on PCON
J68 2 pin Deutsch connector for secondary boom
J22 White 35 pin AMP connector on PCON down valve
J23 10 pin ribbon connector PCON to LED driver J69 2 pin Deutsch connector for turntable rotate
board flow control
J24 20 pin Molex connector LED driver board J70 2 pin Deutsch connector for turntable rotate
J25 6 pin Deutsch connector on drive/steer CW valve
joystick J71 2 pin Deutsch connector for turntable rotate
J28 6 pin Deutsch connector on secondary boom CCW valve
up/extend and down/retract joystick J76 2 pin Deutsch DT platform rotate CW valve
J29 16 pin Molex conn on PCON PCB (Y70)
J31 Black 23 pin AMP connector on DCON J78 2 pin Deutsch connector for jib boom up valve
J32 White 23 pin AMP connector on DCON J79 2 pin Deutsch connector for jib boom down
valve
J46 4 pin Deutsch connector on LSS1RS
J82 2 pin Deutsch connector for prox kill
J49 4 pin Deutsch connector on sec boom retract
(LSS1RO) J84 2 pin Deutsch connector for platform
footswitch
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
Part No. 1268557 Z-135/70 201


J87 2 pin Deutsch connector for two-speed motor J121 12 pin Deutsch gray SCON connector
stroke valve J122 12 pin Deutsch black SCON connector
J91 2 pin Deutsch connector for right rear steer J124 2 pin Deutsch connector for drive enable
right valve right limit switch (LST1O)
J92 2 pin Deutsch connector for right rear steer J125 2 pin Deutsch connector for drive enable left
left valve limit switch (LST2O)
J93 2 pin Deutsch connector for left rear steer J126 4 pin Deutsch connector for drive enable
right valve safety limit switch (LST1S)
J94 2 pin Deutsch connector for left rear steer left J127 6 pin Deutsch connector for primary boom
valve up/down, ext/ret and turntable joystick
J95 2 pin Deutsch connector for right front steer J128 6 pin Deutsch connector for jib boom
right valve up/down, ext/ret and platform rotate
J96 2 pin Deutsch connector for right front steer J129 2 pin Deutsch connector for boom
left valve composite/lower limit switch harness
J97 2 pin Deutsch connector for left front steer J135 2 pin Deutsch connector for jib boom
right valve bellcrank up
J98 2 pin Deutsch connector for left front steer left J136 2 pin Deutsch connector for jib boom
valve bellcrank down
J99 2 pin Deutsch connector for axle extend valve J137 2 pin Deutsch connector for front axle safety
J100 2 pin Deutsch connector for axle retract valve switch
J106 2 pin Deutsch connector for brake release J138 2 pin Deutsch connector for rear axle safety
valve switch
J107 3 pin Deutsch connector for right rear steer J140 2 pin Deutsch connector for jib extend
sensor J141 2 pin Deutsch connector for jib retract
J108 3 pin Deutsch connector for left rear steer J146 2 way Deutsch connector for lower limit
sensor switch harness/engine harness
J109 3 pin Deutsch connector for right front steer J147 1 way Deutsch connector for platform power
sensor jib/primary
J110 3 pin Deutsch 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
202 Z-135/70 Part No. 1268557


J148 1 way Deutsch connector for platform J223 CAN Gateway 8 pin Molex connector
ground jib/primary J224 Telematics connector
J149 2 pin Deutsch connector, boom composite J228 Gateway to TCON interface connector
J150 4 pin Deutsch connector, boom composite J231 Tier IV A1 or D2.1 ECU connector
J151 3 pin Deutsch connector, CAN connector, J232 Tier IV K1 or D2.2 ECU connector
jib/primary
J233 Tier IV engine interface connector
J152 3 pin SAE Deutsch tee
J153 2 pin Deutsch connector for engine and
manifold harness
angle sensor
J157 2 pin Deutsch connector for PCON
manifold/boom composite harness
J160 4 pin Deutsch connector for front axle angle
sensor
J161 4 pin Deutsch connector for rear axle angle
sensor
J162 3 pin Deutsch connector for jib bellcrank
angle sensor
up/down flow control
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 slide terminal for belt
generator excite
J169 20 pin Molex connector for circuit board to
joystick and switches #2
J175 2 pin Deutsch connector
Part No. 1268557 Z-135/70 203

Drive Chassis and Platform Controller Pin Legend
Pin Numbering - 23 pin connector Pin Numbering - 35 pin connector

J21 Plat Controller J22 Plat Controller J32 Drive Chassis J31 Drive Chassis
1 GNDPCON - BR 1 VLVRET1 - BR 1 VLVRET1 - BR 1 GND-DCON - BR
2 P52PCON - WH 2 V153JBE - BK 2 V61AXRT - GR 2 P21DCON - WH
3 (UNUSED) 3 V18PRR - GR/BK 3 V60AXEX - GR/WH 3 P53LS - WH/BK
4 S56PRV - RD 4 V17PRL - GR 4 V29MS - RD/WH 4 (UNUSED)
5 (UNUSED) 5 V43JU - GR 5 (UNUSED) 5 S56PRV - RD
6 (UNUSED) 6 V44JD - GR/BK 6 (UNUSED) 6 C61AXRT - GR
7 P56PRV - RD/WH 7 V14PLU - OR 7 (UNUSED) 7 (UNUSED)
8 (UNUSED) 8 V15PLD - OR/BK 8 V36RRS - BL 8 (UNUSED)
9 (UNUSED) 9 V154JBR - BK/WH 9 V37RRS - BL/BK 9 (UNUSED)
10 (UNUSED) 10 (UNUSED) 10 C111RRS - OR 10 (UNUSED)
11 (UNUSED) 11 C90PXS - RD/BK 11 C111LRS - OR 11 (UNUSED)
12 (UNUSED) 12 GR/YL 12 C111RFS - OR 12 (UNUSED)
13 C111LFS - OR 13 (UNUSED)
13 (UNUSED) 13 OR
14 VLVRET2 - BR 14 (UNUSED)
14 (UNUSED) 14 BK 15 (UNUSED)
15 V32BRK - WH/RD
15 C47OUT - WH/BK 15 C88PTS - RD/BK 16 (UNUSED)
16 V36LRS - BL
16 C46HN - WH 16 C64LS -OR/BK 17 D81CAN(-) - GR
17 V37LRS - BL/BK
17 D81CAN(-) - GR 17 C56FTS - RD 18 D82CAN(+) - YL
18 V36RFS - BL
18 D82CAN(+) - YL 18 C154JBR - BK/WH 19 (UNUSED)
19 P110RT - BK
19 (UNUSED) 19 P85RET - BR 20 C60FAP - GR/WH
20 P109ANG - GR/WH
20 (UNUSED) 20 C84TAY - GR/BK 21 C60RAP - GR/WH
21 V37RFS - BL/BK
21 (UNUSED) 21 P85PTS - GR 22 (UNUSED)
22 V36LFS - BL
22 (UNUSED) 22 P87RET - BR 23 P61LSA - GR
23 V37LFS - BL/BK
23 P23PCON - BK 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)
204 Z-135/70 Part No. 1268557

Safety Controller Pin Legend

J121 Safety Controller Pin Numbering for 12 pin connectors 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
Part No. 1268557 Z-135/70 205

Turntable Controller Pin Legend
Pin Numbering - 35 pin connector Pin Numbering - 23 pin connector Pin Numbering - 4 pin
connector
J11 Turntable J12 Turntable J13 Turntable J14 Turntable Controller
Controller Controller Controller 1 VLVRET4 - BR
1 GNDPCON - BR 1 GNDSCON - BR 1 (UNUSED)
2 V03PUD - RD/WH
2 P52PCON - WH 2 P21DCON - WH 2 C35RPM - BK/RD 3 V09PER - BK/RD
3 C46HN - WH 3 P53LS - WH/BK 3 C21IGN - WH 4 V06TRF - WH/RD
4 C47OUT - WH/BK 4 P54ENG - BK/WH 4 C34SA - BK/WH 5 V12SUD - BL/WH
5 P23PCON - BK 5 S56PRV - RD 5 (UNUSED) 6 V176SER - GR/WH
6 S56PRV - RD 6 P53LS - WH/BK 6 (UNUSED) 7 VO1PBU - RD
7 P56PRV - RD/WH 7 P58LS - RD/BK 7 C46HRN - WH 8 V02PBD - RD/BK
8 (UNUSED) 8 S59CNK - GR/WH 8 (UNUSED) 9 V07PBE - BK
9 R117FB - RD 9 S140ENL - OR/RD 9 C33STR - BK 10 V08PBR - BK/WH
10 (UNUSED) 10 C61AXR - GR 10 C30EDC - WH 11 (UNUSED)
11 C145CAL - RD/WH 11 (UNUSED) 11 C31EDC - WH/BK 12 V11SBD - BL/BK
12 (UNUSED) 12 (UNUSED) 12 C25PSR - WH/BK 13 (UNUSED)
13 (UNUSED) 13 C64LS - OR/BK 13 C26TSR - WH/RD 14 VLVRET5 - BR
14 (UNUSED) 14 C65LOF - BL/WH 14 (UNUSED) 15 (UNUSED)
15 (UNUSED) 15 C144DER - BL/WH 15 (UNUSED) 16 (UNUSED)
16 (UNUSED) 16 C73SBR - BL/RD 16 (UNUSED) 17 VLVRET5 - BR
17 D81CAN(-) - GR 17 C67SBD - BL 17 S137PLL - RD/WH 18 VLVRET5 - BR
18 D82CAN(+) - YL 18 C64LS - OR/BK 18 C41RPM - OR/BK 19 V10SBU - BL
19 (UNUSED) 19 C70PBR - BL/WH 19 S139TRF - WH/RD 20 V73SBR - GR/BK
20 (UNUSED) 20 C71PBE - BL/BK 20 (UNUSED) 21 V72SBE - GR
21 (UNUSED) 21 (UNUSED) 21 (UNUSED) 22 (UNUSED)
22 (UNUSED) 22 (UNUSED) 22 C45GEN - GR/WH 23 (UNUSED)
23 (UNUSED) 23 (UNUSED) 23 (UNUSED) 24 (UNUSED)
J15 Turntable 24 (UNUSED) 25 V04TRL - WH
Controller 25 SNSR GND - BR 26 V05TRR - WH/BK
1 B1BAT - RD 26 P109ANG - GR/WH 27 VLVRET7 - BR
27 (UNUSED)
2 GND - BR 28 (UNUSED)
28 C143DEL - BL/RD
3 GND - BR 29 (UNUSED)
29 (UNUSED)
4 (UNUSED) 30 VLVRET6 - BR
30 (UNUSED) 31 (UNUSED)
31 (UNUSED) 32 C27AUX - RD
32 C123PBS - RD/BK 33 (UNUSED)
33 C124SBS - OR/BK 34 V155PCE - OR/RD
34 S140ENL - OR/RD 35 V150HG - GR/BK
35 GND16 - BR
206 Z-135/70 Part No. 1268557

Engine Relay and Fuse Panel Legend - Deutz BF4L 2011,

TD2011L04i, Perkins 1104C-44 and 804D-33T
Number Component Description

1 CR28 Engine / 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 Relay
Part No. 1268557 Z-135/70 207

Engine Relay and Fuse Panel Legend - Cummins B4.5L

and B3.3T
Number Component Description

1 CR28 Engine Run / Alternator 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
208 Z-135/70 Part No. 1268557

Electrical Symbols Legend
Battery Motor Horn or alarm Flashing beacon Gauge
Diode Hour meter LED Fuse with amperage Foot switch
Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid
Connection - no Circuits crossing no Quick disconnect Circuit breaker with

Battery separator
terminal connection terminal amperage
Service Bypass Key

Main Key switch Steer sensor Auxiliary Pump Tilt sensor
switch
Emergency Stop Hydraulic oil cooling

Relay Power relay Gauge sending unit
button fan
Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow
normally open switch - normally open normally closed normally open plug or flame ignitor
Part No. 1268557 Z-135/70 209

Hydraulic Symbols Legend
Orifice with size Check valve Shut off valve Brake
Pump, bi-directional Motor, 2 speed

Pump, fixed displacement Motor, bi-directional
variable displacement bi-directional
Pump, prime mover (engine Shuttle valve. 2 position,

Cylinder, double acting Differential sensing valve
or motor) 3 way
Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator
valve setting proportional valve
Solenoid operated
Pilot operated 3 position,
Pressure reducing valve Flow divider/combiner valve 2 position, 3 way directional
3 way shuttle valve
valve
Solenoid operated
Counterbalance valve with Pilot operated 2 position, 2 position, 2 way solenoid
3 position 4 way directional
pressure and pilot ratio 2 way directional valve valve
valve
210 Z-135/70 Part No. 1268557

Perkins 1104C-44 and 804D-33T Engine Electrical Schematic
211
Perkins 1104C-44 and 804D-33T Engine Electrical Schematic
212 Z-135/70 Part No. 1268557

Cummins B4.5L and B3.3T Engine Electrical Schematic
Part No. 1268557 Z-135/70 213

Cummins B4.5L and B3.3T Engine Electrical Schematic
214
Generator Wiring Schematic
215
Generator Wiring Schematic
216 Z-135/70 Part No. 1268557

Hydraulic Generator (Welder Option)
Part No. 1268557 Z-135/70 217

Hydraulic Generator (Welder Option)
218
Hydraulic Schematic
(before serial number 180, except for serial number 102)
219
Hydraulic Schematic
(before serial number 180, except for serial number 102)
220 Z-135/70 Part No. 1268557

Hydraulic Schematic
(serial number 102 and from serial number 180 to 534)
Part No. 1268557 Z-135/70 221

Hydraulic Schematic
(serial number 102 and from serial number 180 to 534)
222
Hydraulic Schematic (from serial number 535)
Part No. 1268557 Z-135/70 223

Hydraulic Schematic
(from serial number 535)
224
J153
J153
MANIFOLD
MANIFOLD
HARNESS
HARNESS
1 HARNESS
HARNESS
ENGINE
ENGINE
TCON MEMBRANE PANEL
1
TO
uP
HYD WELDER PROPEL BYPASS P14-35 V150HG GR/BK V150HG GR/BK Y75 WELDER GEN BYPASS VLV (J167)
2
1
2 PRESS COMP ENABLE VLV P14-34 V155PSE OR/RD V155PSE OR/RD V155PSE OR/RD Y74 FUNCTION ENABLE VALVE (J166)
BOOM CW
TO
uP
SPARE P14-33
Z
3 AUX_RELAY P14-32 C27AUX-RD C27AUX-RD

PLTFRM CW
TO
uP
P14-31
4 TO PLD VALVE_RTN6 P14-30 VLVRET6-BR VLVRTN6-BR
JIB DOWN
P14-29
5 PROPEL POWER INPUT P14-28
PLTFRM DOWN
VALVE_RTN7 P14-27 VLVRET7-BR VLVRTN7-BR
TO
uP
2
1
6 ROTATE_CCW_VLV P14-26 V05TRR-WH/BK C05TRR WH/BK Y53 TT ROT CCW VLV (J71)
PLTFRM UP
2
1
ROTATE_CW_VLV P14-25 V04TRL-WH C04TRL-WH Y52 TT ROT CW VLV (J70)

TO
uP
7 UNUSED P14-24
JIB UP
MULTI_FUNCT_VLV P14-23
TO
TO
V72SBE-GR
uP
V72SBE-GR
uP
8 UNUSED P14-22
PLTFRM CCW V73SBR-GR/BK V73SBR-GR/BK
SEC_EXT_VLV P14-21 V72SBE-GR V10SBU-BL V10SBU-BL
9 TO PLD SEC_RET_VLV P14-20 V73SBR-GR/BK
TO
BOOM CCW
uP
SEC_UP_VLV P14-19 V10SBU-BL

TO
uP
10 BOOM OVERLOAD DI P14-18 VLVRET5-BR

2
TURTLE
1
BOOM REVERSE LOAD DI P14-17 VLVRET5-BR Y66 SEC EXT VLV (J65)
2
TO PLD
1
11 HYD_FILTER2 DI P14-16 Y65 SEC RET VLV (J66)

Y
TO
2
uP
SEC. DOWN
1
HYD_FILTER1 DI P14-15 Y81 SEC UP VLV (J67)

TO
uP
2
1
12 VALVE_RTN5 P14-14 Y82 SEC DWN VLV (J68)

VLVRET5-BR
RABBIT
TO
uP
DRIVE LIGHT RELAY P14-13

13 SEC_DWN_VLV P14-12 V11SBD-BL/BK V11SBD-BL/BK
BOOM EXT
UNUSED P14-11 VLVRET5-BR
2
14
1
BOOM DOWN TO PLD PRI_RET_VALVE P14-10 V08PBR-BK/WH V08PBR-BK/WH Y80 PRI RET VLV (J63)
2
1
TO
PRI_EXTEND_VLV P14-09 V07PBE-BK

uP
V07PBE-BK Y79=PRI EXT VLV (J62)

TO
uP
15
1
BOOM RET PRI_DOWN_VLV P14-08 V02PBD-RD/BK V02PBD-RD/BK Y21=PRI DWN VLV (J60)
2
P9
1
J9 PRI_UP_VLV P14-07 V01PBU-RD V01PBU-RD Y22=PRI UP VLV (J59)

TO
uP
P
1
SEC BM E/R FC VLV P14-06 V176SER-GR/WH V176SER-GR/WH Y78=SEC. BM ER F.C. (J164)

P
1
SEC BM U/D FC VLV P14-05 V12SUD-BL/WH V12SUD-BL/WH Y46=SEC. BM UD F.C. (J163)

P
1
TT ROT FC VLV P14-04 V06TRF-WH/RD V06TRF-WH/RD Y77=TT ROT CW/CCW F.C. (J69)
TO
uP
P
1
PRI BM E/R FC VLV P14-03 V09PER-BK/RD V09PER-BK/RD Y76=PRI BM EXT/RET F.C. (J61)
TO
uP
P
1
PRI BM U/D FC VLV P14-02 V03PUD-RD/WH V03PUD-RD/WH Y45 PRI BM UP/DWN F.C. (J58)
TO
uP
1 VALVE_RTN4 P14-01 VLVRET4-BR VLVRET4-BR

MANIFOLD HARNESS
X
2 TO PLD
J14 WHITE 35 PIN
P14-13 C49LP-WH/BK
C26TSR-WT/RD OIL TEMP SENDER

C21IGN-WH
INPUT WAS FROM
BEFORE S/N 1580

TO
uP
3
JIB EXT
C25PSR-WT/BK OIL PRESSURE
MULTI FUNCTION VLV RECOVERY SIGNAL
86
87a 87 85
TO PLD
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
4
AUXILIARY HYD RECOVERY SIGNAL
JIB RET
30
BOOM DWN RECOVERY SIGNAL
86
BOOM RET RECOVERY SIGNAL
87a 87 85
5
C27AUX-RD
BOOM UP BAT GND-BR

30
FUEL SOLENOID
DRIVE
LAMP
B1ENG-RD
DRIVE LPS
6
SEC. UP
ENG FUEL
RELAY
CR23
RELAY
7
CR28
AUXILIARY
SEE OPTIONS SHEET
8
P6R1
P_39
87 87a
FOR BELT DRIVEN
HYDRAULIC
FAN
P9A
P11
ENG SPEED R116HYD-OR BAT GND-BR

30
AC GENERATOR
OIL COOLER FAN

B3BAT/14-RD
9
GAS/LP COOLER
C21IGN-WH C116HYD-OR BAT GND-BR
W
RELAY
86
COOLER 85
P_22R
OTS1
P_7R
P_10
P_30
N.O.
10 TEMP
+ BUTTON SW
RELAY
CR17
BK
OIL
R21IGN-WH
11
BK
C26TSR-WH/RD
- BUTTON
C25PSR-WH/BK
GLOW PLUGS
C21IGN-WH
DRIVEN GEN
BK IN CYLINDER HEADS
12
J168-BELT
SCRL F/ENT
C45GEN-GR/WH
BK
DEUTZ ENGINE SHOWN
CUMMINS AND PERKINS ENGINES
P34SA-BK/WH R34SA-BK/WH
GLOW 86 30
13
RELAY 85 87
SCROLL R C34SA-BK/WH VLVRET-BR GLOW PLUG

RELAY
14
PLUG
CR15
J120
STRT ASST
SEE OPTIONS PAGES FOR
15
A B C D
START C31EDC-WH/BK DUAL

P10
J10 COIL
GND04-BR EDC
C30EDC-WH
B1ENG-RD
VALVE RTN#3 P1-23

AC GENERATOR P1-22 C45GEN-GR/WH GND04-BR
TT_TILT_Y_AXIS P1-21
TO
uP
P34SA-BK/WH
07GND-BR BK
B3BAT/14-RD
TT_TILT_X_AXIS P1-20 HI/LO SPEED

V
PULL IN
WH-PULL IN WH SOLENOID
P_39 POWER TO TTROT FC P1-19
2
S139TRF-WH/RD HOLD
RD-HOLD RD
C41RPM-OR/BK
J57
ALTERNATOR RPM P1-18

1
P_38 PWR TO PROPEL P1-17 S137PLL-RD/WH

TO
uP
RELAY
HORN
VALVE RTN#2 P1-16

CR5
TO
uP
TT_TILT_SNSR_PWR P1-15 SERVICE

P11
TO
TO
uP
uP
HORN
H1
86
TT_TILT_SNSR_GND P1-14
87 85
VLVRET2-BR
OIL/WATER_TEMP P1-13 C26TSR-WH/RD
P11 TO
R46HRN-WH
30
uP
OIL_PRESSURE P1-12 C25PSR-WH/BK B3BAT/14-RD

87a
C31EDC-WH/BK BAT GND-BR HORN

EDC REV P1-11
(P15)+(ECU POWER) RELAY
EDC FWD P1-10 C30EDC-WH C41RPM-OR/BK
TO
uP
TO HORN
D1
BUTTON STARTER RELAY P1-09 C33STR-BK C107AF-RD

WH-PULL IN
5 VOLT
RD-HOLD
D2
LP P1-08
EXCT.
IND.
STA.
BAT.
SERVICE HRN P1-07 C46HRN-WH

ALTERNATOR
P_7R REV PWM P1-06 ALTERNATOR

REGULATOR
P_7 FWD PWM P1-05

15A
~SLP MODE (~SM)
TO MICRO
CB
5 AUX HYD (AH)
P_6R1 START AID RLY P1-04 C34SA-BK/WH

U
IGN/FUEL P1-03 C21IGN-WH C21IGN-WH

BAT.
+
P_7
C
FUNC ENABLE (FE)
THROTTLE P1-02 C35RPM-BK/RD

P34SA-BK/WH
B3BAT/14-RD
82 OHM PULL UP
100 OHM PULL UP
TROMBETTA
TIME DELAY
VALVE RTN#1 P1-01

MOM N.O.
S-500-A6
C27AUX-RD
4
J13 WHITE 23 PIN
B1BAT-RD
ENGINE HARN
PR1
TO
uP
(~SM)+(AH)
GND-
BAT+
AUX+
PUMP
(~SM)+(AH)
AUX.
5V 12V
SUPPLIED
BY DEUTZ
GND
(OE)
F22 GLOW PLUG

F7 OIL COOLER
F23 ENG/ST/ALT
S139TRF-WH/RD
S137PLL-RD/WH
F20 HI/LO RPM
AUX HYD
C35RPM-BK/RD
PR1 PUMP
(~SM)+(AH)
5 VOLT
12
13
10
74HC08 5
2
9
1
4
PUMP
AUX.
74HC08
74HC08
74HC08
14
7
8
3
14
BAT GND-BR
74HC08
((~SM)+(AH))(P_7)
86
87 85
((~SM)+(AH))(OE)
((~SM)+(AH))(P_22)
C33STR-BK
TO
P22R
30
uP
(TM)(FE)
B1ENG-RD
P7R
P1-04 R33STR-BK STARTER

B1ENG-RD
STARTER
BATECU GND P1-03 GND-BR RELAY

F7 10 A F23
CB SYS BAT GND P1-02 GND-BR
STARTER
30 A STARTER
W/BAT CBL
PWR HARN
INTEGRAL
RELAY
P_7 SYS_BAT_PWR P1-01 B1BAT-RD B1BAT-RD

T
20A F20
CR1
P35RPM-BK/RD
Vbb BTS621
Vbb BTS621
ENGINE BLOCK
IN1 OUT 1
ST OUT 2
IN1 OUT 1
ENG HARN
ST OUT 2
W/BAT CBL
20 A
INTEGRAL
BTS650
BTS650
BTS650
OUT
OUT
P_1
OUT
F22
J15 BLACK 4 PIN
-
GND
GND
POWER HARN
Vbb
Vbb
Vbb
B1
IN2
IN2
IN
IN
60 A
IS
IS
IN
IS
F7 START BAT
B1BAT-RD ELECTRONICS
AUX MAIN 20 A B1BAT-RD BATTERY
B1BAT-RD B1BAT-RD
-
+
-
U32
P_6R2
AUX HYD
B2
B2BAT-RD BATTERY
SEPARATE
4 GA WIRE
SEPARATE
4 GA WIRE
(BM STOWED)
(~SM)+(AH)
U95
S139TRF-WH/RD
10
S137PLL-RD/WH
9
74HC08
HARNESS
HARNESS HARNESS
B3BAT/14-RD
ENGINE
LOWER LS ENGINE
J146
8
GNDDCON-BR
2
S
((~SM)+(AH))(BM STOWED)

NO
NO
LSS1R0
24 23
VERSION S0675100
14 13
C64LS-OR/BK
VERSION S0675110
C64LS-OR/BK RD
Vbb BTS621
432 1
ST OUT 2
IN1 OUT 1
C67SBD-BL C67SBD-BL BR SEC RET

C64LS-OR/BK C64LS-OR/BK BK OPER

BLU
C73SBR-BL/RD C73SBR-BL/RD WH J49

GND
SOFTWARE
SOFTWARE
IN2
OR LOWER
OR LOWER
(PHASE 2)
UNIT #129
UNIT #129
LST20
ORN NO
NC
DRV
14 13
22 21
C64LS-OR/BK C64LS-OR/BK RD
432 1
C143DEL-BL/RD C143DEL-BL/RD BR ENABLE

BK LEFT
YEL
WH J125
WH
4321
4 3 21
LST10
8 3
NO
BL
NC
14 13
22 21
C64LS-OR/BK C64LS-OR/BK RD DRV WH

2 1
8 3
C144DER-BL/WH C144DER-BL/WH BR ENABLE BL

BK
ORN
WH RIGHT
J124
C64LS-OR/BK C64LS-OR/BK FST1S
WH/BK WH/BK
21
LOW FUEL
94
94
2 1
C65LOFL-BL/WH C65LOFL-BL/WH FS BL/BK BL/BK

VLVRET BR VLVRET BR
BOOM STOWED
PWR TO TCON ESTOP
PCON POWER
5 VOLT
C124SBS-OR/BK C124SBS-OR/BK YL
OUT PWR ENABLE
TCON MODE
4
R
(P15)+(ECU POWER)
BK/WH BK/WH
51
51
SNSR GND-BR
TO HORN BUTTON
SNSR GND-BR BR
P_6R1
S19-SEC BM OR/BK OR/BK

5
P_6R2
P_9A
P_11
P_10
P_7R
P109ANG-GR/WH P109ANG-GR/WH OR ANG OPER

P_7
C142SBS-OR BL
P_22
P_9B
3
P_30
SNSR GND-BR BK GR/BK GR/BK

4
4
6
S20-SEC BM
2
P109ANG-GR/WH RD ANG SAFETY BK BK

7
7
5
5
J154
1
RD/BK RD/BK
6
6
2 10
2 10
RD RD
3
3
ORN NO
NC
14 13
22 21
C64LS-OR/BK C64LS-OR/BK RD LST1S GR GR

4321
11 12
11 12
2
S13DE-BL/RD BR DRV EN
BK OR OR
RED
WH J126
J20
J20
OR HIGHER
SOFTWARE
BLU NO
NC
22 21
C64LS-OR/BK
14 13
C64LS-OR/BK RD
UNIT #130
LSS1RS
S0675100
43 21
VERSION
S12SB-BL/WH BR 3' EXT

SOFTWARE (PHASE 2)
C64LS-OR/BK BK
RED
S73SLE-BL/RD WH J46
VERSION S0675110
OR HIGHER
OR/BK
4 3 21
NO
UNIT #130
NC
8 3
22 21
14 13
RD LSP1R0 RD/BK
4 32 1
VLV RET P12-35 BR

Q
C64LS-OR/BK C64LS-OR/BK OR/BK BK 3' EXT

WHT
P_30 P_30 P12-34 S140ENL-OR/RD

8 3
C70PBR-BL/WH C70PBR-BL/WH RD/BK WH J44

SEC ANG INPUT P12-33 C124SBS-OR/BK
PRI ANG INPUT P12-32 C123PBS-RD/BK
NO
LSP1E0
NC
22 21
14 13
RD
BOOM STOWED P12-31 BR 3'FROM FULLY BK
21
94
C64LS-OR/BK C64LS-OR/BK BK BK EXTENDED BL/BK

YEL
94
2 1
LSB14AO P12-30 C71PBE-BL/BK C71PBE-BL/BK BL/BK WH J45

LSB13AO P12-29
OR HIGHER
GR/BK
UNIT #130
51
LST20 DR ENBL L P12-28 C143DEL-BL/RD GR/BK BK/WH

51
BK/WH
TO
uP
PRESSURE GA P12-27
SNSR PWR P12-26 P109ANG-GR/WH
WH
4
6
SNSR GND P12-25 SNSR GND-BR C123PBS-RD/BK C123PBS-RD/BK WH YL

TO
uP
4
6
GR
7
TO PLD P2 SEQ P12-24 SNSR GND-BR SNSR GND-BR GR BR S17-PRI BM

7
LOCKOUT VALVE #1 SIG ANG OPER OR

6
2 10
P1 SEQ P12-23 P109ANG-GR/WH P109ANG-GR/WH OR OR

6
2 10
BL
3
LSS2AO P12-22 C141PBS-RD BL BL

3
WH/BK
11 12
LSS2EO P12-21 SNSR GND-BR WH/BK BK S18-PRI BM

TO
uP
11 12
ANG SAFETY RD
1
LSP1EO P12-20 C71PBE-BL/BK P109ANG-GR/WH RD RD

1
J20
J114
PRI BOOM LENGTH 3' STATUS LSP1RO P12-19 C70PBR-BL/WH

J20
TO PLD .
LSB2RO P12-18 C64LS-OR/BK
TO
P
uP
LSP1AO P12-17 C67SBD-BL

PRI BOOM LENGTH 100' STATUS LSS1RO P12-16
PIN SCON MODULE
C73SBR-BL/RD
TO PLD
PRI BOOM RETRACTED STATUS LST10 DR ENBL R P12-15 C144DER-BL/WH
J122-BLACK 12
ADDED FROM
TO PLD
FST1S-LOW FUEL P12-14 C65LOF-BL/WH
S/N 1225 TO
TO
uP
NO
P12
RESISTOR
NC
C64LS-OR/BK
21
13
OPER SW PWR P12-13 C64LS-OR/BK OR/BK RD

8 3
4 32 1
S/N 1418
C70PBR-BL/WH RD/BK BR
P_18 P12-12 BK
22
WHT
14
VERSION S0675100
WH
P_14 P12-11
P_12 P12-10 C61AXR-GR C61AXR-GR P122-12 P12
OR HIGHER
SOFTWARE
UNIT #130
P_11 P12-09 S140ENL-OR/RD S56PRV-RD P122-11 P7R

P_10 P_10 P12-08 S59CNK-GR/WH P58LS-RD/BK P58LS-RD/BK P122-10 P9B
P_9B P_9B P12-07 P58LS RD/BK P54ENG-BK/WH P122-09 P6R2
P_9A P12-06 P53LS-WH/BK S140ENL-OR/RD S140ENL-OR/RD P122-08 P11+P30
U32
P_7R P12-05 S56PRV-RD P53LS-WH/BK P122-07 P6R1
U31
P_6R2 P12-04 P54ENG-BK/WH P122-06 DRV. ENA.

P_6R2 P54ENG-BK/WH S13DE-BL/RD

U30
P_6R1 P12-03 P53LS-WH/BK 330 OHM S12SB-BL/WH P122-05 SEC. BOOM RET
PRI BOOM RETRACTED STATUS
PRI BOOM LENGTH 100' STATUS
DCON ECU PWR P12-02 C60AXE-GR/WH P122-04 AXLE EXTENDED

PRI BOOM LENGTH 3' STATUS
P21DCN-WH
O
SCON ECU GND P12-01 SCONGND-BR P53LS-WH/BK C141PBS-RD P122-03 RSP1AS

LOCKOUT VALVE #1 SIG
B3BAT/14-RD C142SBS-OR P122-02 RSS1AS

P21DCN-WH P21DCN-WH P122-01 ECU PWR
LIMIT SWITCH HARN
J12 BLACK 35 PIN
SCONGND-BR SCONGND-BR P121-12 GND

S139TRF-WH/RD P121-11 P39
S137PLL-RD/WH P121-10 P38
S56PRV-RD S56PRV-RD P121-09 P7R
S59CNK-GR/WH S59CNK-GR/WH P121-08 P10
D81CAN- -GR P121-07 CAN-
D82CAN+ -YL P121-06 CAN+
P121-05 RD 232
C145CAL-RD/WH P121-04 CALIBRATION IN
P121-03 TD RS232
S73SLE-BL/RD P121-02 SEC SW CONNECTION
SCON MODULE
S132LDS-BL/WH P121-01 LOAD SENSE

GNDDCON-BR
PIN SCON MODULE

P21DCON-WH
P53LS-WH/BK
C145CAL-RD/WH
C61AXR-GR
S132LDS-BL/WH
S56PRV-RD
P117FB-RD
C60AXE-GR/WH
D81CAN- -GR
N
C61AXR-GR
D82CAN+ -YL
J121-GRAY 12
TO MICRO
BM U/D FC O
BM E/R FC O PLD
BM DWN O
BM RET O
RECOVERY PROVIDES
MLT FNC VLV O

PWR TO MINIMAL
PWR IN SERV OR
AUX HYD O
OPER. REC. OR
PRI BM RET ST I
HARDWARE
SERV. OR
BM 3' I
BM 100' I SERVICE OR
RECOVERY MODE
PRI LO#1 O
OUT PWR ENABLE
PWR TO TCON ESTOP
PCON POWER
TCON MODE
TO HORN BUTTON
M
(UNIT 320 OR EARLIER)
ECU POWER
OPER. REC.
P6R1
KEY SWITCH
P_22
P_7
P7R
P11
1
E2
P15
D NC
ESTOP
INSTALL WIRE
C NC
JUMPER TO
CALIBRATE
NC 1
2
SENSORS
2
B1
NC
A NC
PANEL
NC
J175
PANEL
J17
J152B
TCON ESTOP
GND-BR
SRV REC-WH
3
BL/BK
J11 BLACK 23 PIN
BC BC
BB BB
J129-01
J129-02
BOOM HARN
85
30
(CLOSE SWITCH
TO CALIBRATE)
G-P MODE GR/BK BA BA

CALIBRATION
UNIT 321 OR
J17
TO FLASHING BEACON 87a
87
86
WH/BK
GREATER
SWITCH
AC
AA
AB
1
1
C
D
E
PWR TO TCON ESTOP-BL/BK

P117FB-RD
1
L
C145CAL-RD/WH
R117FB-RD
S132LDS-BL/WH
2 TCON ESTOP-BL/WH TET ESTOP RET P11-23

2
GROUND
PLAT
GROUND
PLAT
PLAT
GROUND
PLAT
GROUND
2
2
OFF
OFF
OFF
OFF
OFF
GROUND
BL/WH
PLAT
3 SERV/CAL MODE DIAG/TETHER PWR P11-22

C47OUT WH/BK C47OUT WH/BK 4 ECU POWER DIAG/TETHER GND P11-21
AC
TETHER FUNC ENBL P11-20

AA
AB
P23PCON-BK P23PCON-BK 5 PCON MODE

TCON MODE C47OUT WH/BK 6 OUTPUT PWR ENABLE NOT USED P11-19
P53LS-BK/WH 7 P6R1 CAN HIGH P11-18 D82CAN+ -YL
J152A
BA
S56PRV-RD/BK 8 P7R CAN LOW P11-17 D81CAN- -GR
BB
SRV REC-WH 9 SERV. OR OPER. REC. CAL FREQ 2 P11-16
BA
P56PRV-RD 10 P22 TET ESTOP PWR P11-15
R117FB-RD
OR/BK OPER. REC. CAL FREQ 1 P11-14

BC
11
BA
BB
GR/WH 12 P7-GN/WH NOT USED P11-13

13 P11 NOT USED P11-12
1
C145CAL-RD/WH
W
RD/WH 14 TCON MODE SERV/CAL MODE P11-11

U
V
Z
BL 15 ALARM PWR CAN SHIELD (1939-11) P11-10

RECOVERY
R117FB-RD
2
FLASHING BEACON RLY P11-09

SERV BYPASS
RUN
16 ALARM GND
SPARE P11-08
J4 ON CIRCUIT BOARD
K
P_22 P11-07 P56PRV-RD/WH

U30
DB9 CONNECTOR
P_7 PLAT-GR/WH P_7 P11-06 S56PRV-RD

RS232_GND
RS232_RXD
RS232_TXD
C47OUT WH/BK PWR-PCON ESTOP P11-05 P23PCON-BK

CKT #
P_15-OR/BK OUT PWR ENBL P11-04 C47OUT-WH/BK

HORN RELAY COIL P11-03 C46HN-WH
RECOVERY
S/N 1225 TO S/N 1418
ALM PWR-BL
PIN
PCON POWER P11-02 P52PCON-WH

ALM-GND-BR J147C-1
2
3
5
4
PCON GND
1
P11-01 GNDPCON-BR
330 OHM J148C-1
W
Z
1
ADDED FROM
2
NC
NO
NO 3
V
3X Y
1
RESISTORS
SEE OPTIONS
330 OHM
2
NO 3
NC
GENERATOR/
U
WORK LP
TCON
WORK LP
NC
2
RELAY
TOGGLE
FOR HYD
SWITCH
PANEL
WELDER
ON/OFF
CR45
OPTION
WORK
LAMP
J151B-C
J151B-A
J151B-B
J150B-4
J150B-1
J150B-2
J148B-1
J147B-1
J149B-1
J149B-2
J150B-3
86
85
30
87a 87
GND-BR
C60AXE-GR/WH
P53LS-WH/BK
GNDDCON-BR
P21DCON-WH
S132LDS-BL/WH
D81CAN- -GR
D82CAN+ -YL
C61AXR-GR
C47OUT-WH/BK
P56PRV-RD/WH
S56PRV-RD
GNDPCON-BR
J
P52PCON-WH
P23PCON-BK
D81CAN- -GR
D82CAN+ -YL
S56PRV-RD
10
C46HN-WH
P2 J156
GND-BR
J156
FUEL TYPE 9 P48LPS-WH/RD P20BAT-RD J155
J155
P2
PWR-PCON ESTOP P21-23 P23PCN-BK
8 J150A-1
SPARE 2 NOT USED P21-22
P2
NOT USED P21-21
7
COORD STEER NOT USED P21-20
P2
NOT USED P21-19
J151A-C
MEMBRANE/LED INTERFACE CARD
6
CRAB STEER CAN H P21-18 D82CAN+ -YL D82CAN+ -YL
P2 J151A-A
CAN L P21-17 D81CAN-GR D81CAN-GR
5 J151A-B
REAR STEER HRN RLY CNTRL P21-16 C46HN-WH C46HN-WH
P2 J150A-3
OUT PWR ENBL P21-15 C47OUT-WH/BK C47OUT-WT/BK
4 J150A-2
FRONT STEER NOT USED P21-14
P2 J150A-4
BOOT P21-13
3
DRIVE SPEED NOT USED P21-12
S132LDS-BL/WH
P2
NOT USED P21-11
J24B 10PIN
2
AXLE EXTEND CAN SHIELD P21-10
I
P2
J34-LIMIT SW HARN
J35-LIMIT SW HARN
NOT USED P21-09 J33-BOOM HARN
1
ENGINE SPEED NOT USED P21-08
P2 10
U21
P_22 P21-07
U22
P56PRV-RD/WH P56PRV-RD/WH
VbbBTS621
ST OUT 2
IN1 OUT 1
9 J149A-2
BTS650
OUT
NOT USED P21-06

J24A 10PIN
P7R
10 8
GND
P6
NOT USED P21-05

IN2
P1
Vbb
IN
IS
7
9 P_7 P21-04 S56PRV-RD S56PRV-RD
AXLE RETRACT 6 J149A-1
1
2
1
2
3
4
5
6
A
B
P1 NOT USED P21-03
5
PCON PWR P21-02 P52PCN-WH P52PCN-WH
C
A
B
8
1
2
1
2
3
4
5
6
SPARE 1 4 J147A-1
P1 PCON GND P21-01 GNDPCN-BR GNDPCN-BR
3 J148A-1
GR
J23 10PIN
YL
WH
OR
GR
RD
BR
7
BK
BL
YL
J21 23 PIN BLACK
DRIVE ENABLE 2
BOOM HARNESS
P1
1
DCON PWR
DCON GND
6
C60AXE
RS232_GND
RS232_RXD
START
RS232_TXD
CAN HIGH
HARNESS
CAN LOW
2
FOOTSWITCH
P6R1
SLIP RING
P1
OPTIONAL SWING
P9A
P18
P12
P7R
CKT #
SWING GATE
5
INTERLOCK
GATE WIRING
PCON MEMBRANE PANEL (MS1)
START ASSIST
P1
88
88
88
88
88
88
88
88
88
88
88
1
H
4
74HC08
2 74HC08
PIN
AUXILIARY
6
2
3
5
P1
WH
GR
RD
OR
BR
BK
BL
YL
ON CIRCUIT BOARD
NC
NO
4 3 2 1
3
14 13
RD
GR
21
YL
DB9 CONNECTOR
AC GENERATOR
S132LDS-BL/WH
1
4
BR
5
P1 C56PTS-RD
BK
22
1
C23PTS-WH WH
6
2
2
3
5
4
2
B
A
C
HORN
P1
6
2
3
5
4
B
A
1
2
1
SLP_MODE
J37-DRIVE CHASSIS HARN


P1
ECU
P7
J157-1
P7R
P22
MANIFOLD
P6
J22 35 PIN
HARNESS
VLVRET2-BR VLVRET3-BL/BK
WHITE
PCON
8
VLVRET2-BL
7
6
DRIVE & STEERING
GND1-BR VLVRET1-GR
6
5 C158STC-BL/RD NOT USED P22-35
JOYSTICK (JC3)
C148JBS-BL/WH GR/BK BL
5
VALVE RETURN P22-34
3
4 C160JPL-WH/RD VLVRET2-BR
P110JBS-BK WH/BK BK
4
JIB ELEVATED P22-33
2
3 C159STC-BL/WH S21 JIB BELLCRANK SENSOR
P109JBS-GR/WH WH RD
J166
J165
JIB SENSOR SIGNAL P22-32 C148JBS-BL/WH
1
2 P162JPW-OR
1 JSGND1-BR JIB SENSOR GROUND P22-31 P110JBS-BK V147JBD-BL/BK RD/BK Y86 JIB BELLCRANK DOWN (J136)
2
G
J25 JIB SENSOR POWER P22-30 P109JBS-GR/WH V146JBU-BL RD Y85 JIB BELLCRANK UP (J135)
1
JSGND1-BR 16 JIB BELLCRANK LEVEL DOWN P22-29 V147JBD-BL/BK
EXT/RET JOYSTICK
6 GND2-BR
JSGND4-BR 15 JIB BELLCRANK LEVEL UP P22-28 V146JBU-BL
SEC BM UP/DWN
5
NOT USED P22-27
WH
P162JPW-OR 14
4 C161SB-WH/BK SAFETY CUTOUT
P162JPW-OR 13 NOT USED P22-26
3
6 J55
C165TRS-WH/RD NOT USED P22-25

12 TILT SENSOR
2
(JC5)
P162JPW-OR NOT USED P22-24 PLATFORM

C164PLS-RD/WH
ASSEMBLY
11 POWER FET
(RETRACTED POS)
1 JSGND2-BR POWER FET
C163PES-BL/WH 10 SAFE PL TILT PWR P22-23 P87PTS-RD 10 DEG
5
J28 - 10 DEG -
RETRACTED
SAFE PL TILT GND P22-22 P87RET-BR
PLAT ROT JOYSTICK (JC6)
C161SB-WH/BK 9 U20
4
+ +
J119
NO
NC
RD
13
JIB EXT/RET, UP/DOWN
21
PL TILT SNSR PWR P22-21 P85PTS-GR
JIB NOT
LSJ1RO
6 GND3-BR C160JPL-WH/RD 8 0-20 DEG Y AXIS
3
- BR
PL TILT SNSR P22-20 C84TAY-GR/BK BK
14
5 C157JER-BK/RD C159STC-BL/WH
22
7
PUR
2 1
2
+
WH
4 C16PRL-OR/RD PL TILT SNSR GND P22-19 P85RET-BR PLAT TILT SNSR
C158STC-BL/RD 6
1
FOOTSW (FS1)
3 JIB NOT RETRACTED P22-18 C154JBR-BK/WH C154JBR-BK/WH
C156JUD-GR/WH 5
P162JPW-OR FOOT SW RTN P22-17 C56FTS-RD C56FTS-RD
J84
2 P162JPW-OR 4
1
1 JSGND3-BR 3 LIMIT SWITCH PWR P22-16 C64LS-OR/BK C64LS-OR/BK
P162JPW-OR
OVERLOAD
R90PXS-RD/BK
J128 SAFE PL TILT OUT P22-15 C88PTS-RD/BK
LSP1OLS
LIMIT SW
JSGND3-BR 2
JSGND2-BR LOAD SNSR PWR P22-14 BK BK
KILL SWITCH
PRIMARY BOOM UP/DOWN,
NO
WH
NC
EXT/RET AND TURNTABLE
PROXIMITY
6 GND4-BR
LSP1PROX
OPTIONAL
J29 LOAD SNSR IN P22-13 RD RD
ROTATE JOYSTICK (JC7)
F
(NOHC)
C163PES-BL/WH LOAD SNSR GND P22-12 GR
4
J82
4 C165TRS-WH/RD
PROX KILL CMD P22-11 C90PXS-RD/BK
3 P
3 C90PXS-RD/BK
C164PLS-RD/WH P22-10
2 P162JPW-OR
C60AXE-GR/WH
JIB RETRACT P22-09 V154JBR-BK/WH V154JBR-BK/WH OR/BK Y83 JIB RETRACT (J141)
GNDDCON-BR
P21DCON-WH
D81CAN- -GR
D82CAN+ -YL
P53LS-WH/BK
10
1 JSGND4-BR
C61AXR-GR
S56PRV-RD
PLAT LEVEL DOWN P22-08 V15PLD-OR/BK Y19 PLAT LEVEL DN (J81)
J127 Y20 PLAT LEVEL UP (J80)
PLAT LEVEL UP P22-07 V14PLU-OR
JIB DWN P22-06 V44JD-GR/BK V44JD-GR/BK BK/WH Y73 JIB DWN (J79)
11 12
JIB UP P22-05 V43JU-GR V43JU-GR BK Y72 JIB UP(J78)
PLAT ROT CCW P22-04 V17PRL-GR Y71 PLAT ROT CCW (J77)
J165
20 PWR-PCN ES PLAT ROT CW P22-03 V18PRR-GR/BK Y70 PLAT ROT CW (J76)
ESTOP PWR-RD/BK
ALARM JIB EXTEND P22-02 V153JBE-BK V153JBE-BK OR Y84 JIB EXTEND (J140)
ALARM+ RD/BK 19
9
VLV RTN P22-01 VLVRET1-BR
18 PLAT ROT R
17 PLAT ROT L
ESTOP PWR-RD 16 GND
E-STOP (P2)
15 JIB DN C60AXE-GR/WH
PCON
14 JIB UP
LSRA1ES
E
13
GND1-BR 13 GND RD
21
REAR AXLE
BR
NC
NO
ESTOP RET-BK 12 GND SAFETY SW
GND12-BR C60AXE-GR/WH BK
14
22
J138
2 1
11 BOOT! J2-GR/BK WH
ESTOP RET-BK 10 OUT PWR ENBL PCON
GND2-BR 9 GND
LSFA1ES
13
PLAT LVL DN-OR/BK 8 PLAT LVL DN RD FRONT AXLE
22 21
NO
BR
NC
SAFETY SW
PLATFORM
PLAT LVL DN-OR/BK PLAT LVL UP-OR 7 PLAT LVL UP J2-GR/BK BK J137
14
2 1
GND6-BR 6 GND P61LSA-GR WH
LEVEL
GND6-BR
PLAT LVL UP-OR GND3-BR 5 GND
C157JER-BK/RD 4 JIB EXT/RET
4
RSRA1O
C156JUD-GR/WH 3 BK
JIB UP/DWN REAR AXLE
3
2 BL SENSOR
GND4-BR GND
2
J161
C16PRL-OR/RD 1 PLAT ROT RD
1
AXLE NOT EXT PWR P31-23 P61LSA-GR P61LSA-GR
J169
ALARM
ALARM+ RD/BK
PCON
NOT USED P31-22
4
GND12-BR C60RAP-GR/WH
REAR AXLE POSITION SENSOR P31-21 C60RAP-GR/WH BK RSFA1O
3
FRONT AXLE POSITION SENSOR P31-20 C60FAP-GR/WH C60FAP-GR/WH BL FRONT AXLE
SENSOR
2
D
RS232 GND P31-19 RD J160
1
CAN + P31-18 D82CAN+ -YL
CAN - P31-17 D81CAN- -GR
NOT USED P31-16
AXLE NOT EXT SIG P31-15
NOT USED P31-14
BOOT P31-13
RS232 TXD P31-12
TOGGLE SWITCH AFTERMARKET KIT SCHEMATIC
RS232 RXD P31-11

SPARE
(TSx)
CAN SHIELD P31-10

#1
SPARE-WH
AXLE NOT RET RTN P31-09
STEER MODE STEER MODE
CORD STR-BL/BK DIGIN AXLE RET GND NOT USED P31-08

SELECT
NOT USED P31-07

(TS22)
CRAB STR-BL P12 P31-06 C61AXRT-GR

REAR STR-OR/BK P_7R P31-05 S56PRV-RD
SELECT
NOT USED P31-04

(TS22)
FRONT STR-OR P_6R1 P31-03 P53LS-WH/BK

C
LED/TOGGLE SWITCH INTERFACE PCB
DCON ECU PWR P31-02 P21DCN-WH

DCON ECU GND P31-01 GND-DCN-BR
SPEED
DRIVE
(TS5)
DRV SPEED-RD/WH
J31 23 PIN BLACK

DRIVE CHASSIS
HARNESS
ENGINE
SPEED
(TS4)
VLVRET2-BR
GND2-BR 20
J24 20PIN
ENG SPEED-BK/RD
2
V37LFS-BL/BK Y62-LF STEER LEFT (J98)
FUEL SEL-BL/RD 19
2
V36LFS-BL Y61-LF STEER RIGHT (J97)
AXLE EXT-GR/WH SPARE-WH 18
2
EXT/RET
V37RFS-BL/BK Y60-RF STEER LEFT (J96)

(TS23)
CORD STR-BL/BK 17
AXLE
2
V36RFS-BL Y59-RF STEER RIGHT (J95)
J32 23 PIN WHITE

AXLE RET-GR CRAB STR-BL 16
DRIVE CHASSIS
P_6R1
2
P_7R
V37LRS-BL/BK Y58-LR STEER LEFT (J94)
P12
REAR STR-OR/BK 15
2
V36LRS-BL Y57-LR STEER RIGHT (J93)
HARNESS
FRONT STR-OR 14
ENABLE
2
(TS15)
Y56-RR STEER LEFT (J92)

DRIVE
DRV SPEED-RD/WH 13 V37RRS-BL/BK
2
DRV ENBL-BL/WH V36RRS-BL Y55-RR STEER RIGHT (J91)
AXLE EXT-GR/WH 12
HRN RLY CNTRL

J23 10PIN
ENG SPEED-BK/RD 11
LF STEER LEFT P32-23 V37LFS-BL/BK
GND1-BR
ENGINE
10
LF STEER RIGHT P32-22 BK
START
V36LFS-BL
(TS2)
C
Electrical Schematic
AXLE RET-GR
B
9
ENG START-BK RF STEER LEFT P32-21 V37RFS-BL/BK C111LFS-OR BL
B
NOT USED 8
S14-LF STEER RIGHT
STEER SNSR PWR (5.0 VDC) P32-20 P109ANG-GR/WH P109ANG-GR/WH RD
PCON PWR
J110
A
DRV ENBL-BL/WH
w/ Deutz Engine
7
STEER SNSR GND P32-19 P110RT-BK P110RT-BK
ASSIST
ENG START-BK
START
6
(TS6)
RF STEER RIGHT P32-18 V36RFS-BL

START ASST-BK/WH START ASST-BK/WH 5
LR STEER LEFT P32-17 V37LRS-BL/BK BK
AUX PUMP-RD
C
4
Genie Z-135
LR STEER RIGHT P32-16 V36LRS-BL C111RFS-OR BL
AUXILIARY
GEN ON/OFF-GR/WH 3
B
BRAKE P32-15 V32BRK-WH/RD RD S13-RF STEER RIGHT
PUMP
J109
HORN RET-GR
(TS1)
A
AUX PUMP-RD VALVE RTN2 P32-14 VLVRET2-BR
HORN PWR-RD 1
ES0366J
LF STEER SNSR P32-13 C111LFS-OR
GENERATOR
RF STEER SNSR P32-12 C111RFS-OR BK

ON/OFF
C
(TS17)
LR STEER SNSR P32-11 C111LRS-OR C111LRS-OR BL
B
GEN ON/OFF-GR/WH RR STEER SNSR P32-10 C111RRS-OR S12-LR STEER RIGHT
RD
J108
A
RR STEER LEFT P32-09 V37RRS-BL/BK
HORN RTN-GR
HORN (BN5)
RR STEER RIGHT P32-08 V36RRS-BL

SERVICE
SPARE P32-07 BK
C
SPARE P32-06 C111RRS-OR BL
B
A
HORN PWR-RD SPARE P32-05 RD S11-RR STEER RIGHT SNSR
A
J107
MOTOR SPEED P32-04 V29MS-RD/WH
AXLE EXTEND P32-03 V60AXEX-GR/WH
AXLE RETRACT P32-02 V61AXRT - GR
2
V32BRK-WH/RD Y2-BRAKE RELEASE (J106)
VALVE RTN1 P32-01 VLVRET1-BR
2
V29MS-RD/WH Y27-TWO SPEED MOTOR STROKE (J87)
DCON
2
V60AXEX-GR/WH Y99-AXLE EXTEND (J99)
2
V61AXRT - GR Y100-AXLE RETRACT (J100)
VLVRET1-BR
10
12
13
14
15
16
11
1

Manual de Servicio y Reparación Genie S 125

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Manual de Servicio y Reparación Genie S 125

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Service and Repair Manual

Serial Number Range

For detailed maintenance

Part No. 1268557

Important Technical Publications

Compliance Find a Manual for this Model

Copyright © 2015 by Terex Corporation

First Edition, First Printing

ii Z-135/70 Part No. 1268557

A1 11/2015 Page 199

Part No. 1268557 Z-135/70 iii

Serial Number Legend

iv Z-135/70 Part No. 1268557

Do Not Perform Maintenance

Part No. 1268557 Z-135/70 v

Personal Safety Workplace Safety

Be aware of potential crushing hazards

vi Z-135/70 Part No. 1268557

Section 1 Safety Rules .......................................................................................................... v

Section 2 Specifications ....................................................................................................... 1

Part No. 1268557 Z-135/70 vii

Section 3 Repair Procedures ............................................................................................. 23

Platform Controls ............................................................................................... 25

Platform Components ....................................................................................... 38

Jib Boom Components ...................................................................................... 45

viii Z-135/70 Part No. 1268557

Boom Components ............................................................................................ 63

Ground Controls ................................................................................................. 96

Display Module ................................................................................................. 103

Hydraulic Pumps .............................................................................................. 111

Part No. 1268557 Z-135/70 ix

Manifolds .......................................................................................................... 116

Turntable Rotation Components .................................................................... 148

Axle Components............................................................................................. 154

x Z-135/70 Part No. 1268557

Section 4 Fault Codes ....................................................................................................... 167

Section 5 Schematics........................................................................................................ 187

Part No. 1268557 Z-135/70 xi

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12 Z-135/70 Part No. 1268557

Machine Specifications Performance Specifications

Drive hubs 47 fl oz Primary boom extend/retract 35 to 48 seconds

Part No. 1268557 Z-135/70 1

Hydraulic Oil Specifications Do not top off with incompatible

Note: Extended machine operation can cause the

2 Z-135/70 Part No. 1268557

Chevron Rando HD Premium Oil Continued use of Chevron

Part No. 1268557 Z-135/70 3

Hydraulic Component Auxiliary Pump

Specifications Type: fixed displacement gear pump

4 Z-135/70 Part No. 1268557

Brakes Manifold Component Specifications

Part No. 1268557 Z-135/70 5

Deutz BF4L 2011 Engine Lubrication system

Firing order 1-3-4-2 Above 23°F / -5°C 20W-50

6 Z-135/70 Part No. 1268557

Deutz BF4L 2011 cont.

Part No. 1268557 Z-135/70 7

Deutz TD2011L04i Engine Lubrication system