Beruflich Dokumente
Kultur Dokumente
Z®-135/70
from Z13505-101 to
Z13513-2000
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
Introduction
Intr oducti on Intr oducti on
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
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
Introduction
1 Model
2 Model year
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)
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.
Safety Rules
Read each procedure thoroughly. This Be sure to keep sparks, flames and lighted
manual and the decals on the machine, 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.
Indicates a potentially hazardous
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.
Table of Contents
Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Table of Contents
Table of Contents
Engines ................................................................................................................ 95
5-1 RPM Adjustment ............................................................................................ 95
5-2 Flex Plate ....................................................................................................... 95
How to install a Type "A" Flex Plate ................................................................ 96
How to install a Type "B" Flex Plate ................................................................ 98
Table of Contents
Table of Contents
Table of Contents
Specifications
Section 2 Specific ati ons
Hydraulic system (including tank) 123 gallons Primary boom up/down 110 to 125 seconds
466 liters -60° to +70°
Specifications
Specifications
Specifications
Petro-Canada Environ MV 46
Fluid Properties UCON Hydrolube HP-5046 Fluid
ISO Grade 46 Properties
Viscosity index 154 ISO Grade 46
Kinematic Viscosity Viscosity index 192
cSt @ 200°F / 100°C 8.0
Kinematic Viscosity
cSt @ 104°F / 40°C 44.4
cSt @ 149°F / 65°C 22
Flash point 482°F / 250°C cSt @ 104°F / 40°C 46
Pour point -49°F / -45°C cSt @ 0°F / -18°C 1300
Specifications
Specifications
Specifications
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 Engine
High idle 2350 rpm
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
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
Specifications
Specifications
Specifications
Specifications
Low idle 1300 rpm Unit ships with 15W-40. Extreme operating
368 Hz temperatures may require the use of alternative
engine oils. For oil requirements, refer to the Engine
High idle 2350 rpm
Operator Manual for your engine.
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
Valve Clearance, cold
Intake 0.010 in
0.254 mm
Exhaust 0.020 in
0.508 mm
Specifications
Specifications
Low idle 1300 rpm Unit ships with 15W-40. Extreme operating
368 Hz temperatures may require the use of alternative
engine oils. For oil requirements, refer to the Engine
High idle 2350 rpm
Operator Manual for your engine.
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
Valve Clearance, cold
Intake 0.014 in
0.35 mm
Exhaust 0.020 in
0.508 mm
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Torque Procedure
JIC 37° fittings
Seal-Lok™ fittings 1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
1 Replace the O-ring. The O-ring must be
the hex nut to the body hex fitting to hand tight,
replaced anytime the seal has been broken.
approximately 30 in-lbs / 3.4 Nm.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger 2 Using a permanent ink marker, make a
tight. reference mark on one the flats of the hex nut
and continue the mark onto the body of the hex
Note: The O-ring in Parker Seal Lok™ fittings and
fitting. Refer to Illustration 1.
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
torque. Refer to the appropriate torque chart in 1 hex nut
this section. 2 reference mark
3 body hex fitting
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
Specifications
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
Specifications
Repair Procedures
Section 3 Repair Pr oc edures
Machine Configuration:
R 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
R 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 the ground and platform
machine. controls
R Immediately tag and remove from service a · Wheels chocked
damaged or malfunctioning machine.
· All external AC power supply disconnected
R Repair any machine damage or malfunction from the machine
before operating the machine.
· Boom in the stowed position
· Turntable secured with the turntable rotation
Before Repairs Start: lock
R Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
R Be sure that all necessary tools and parts are
available and ready for use.
R Use only Genie approved replacement parts.
R Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Repair Procedures
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.
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
2 jib boom up/down, jib boom extend/retract
joystick controller error occurs or if a joystick is
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
Platform Controls
Platform Controls
How to R emove the LED Circui t Board
Platform Controls
Platform Controls
Platform Controls
Platform Controls
Platform Controls
Platform Controls
How to R es et a Proportional Val ve Coil D efault How to Set the F unc tion T hresholds and D efault Func tions Speeds
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.
Platform Controls
Platform Controls
How to Adj ust the Functi on Speeds
Platform Controls
How to Adj ust the Functi on R amp R ate Setti ng
Platform Controls
Platform Components
Platform Components
Platform Components
How to Bleed the Pl atfor m R otator
Platform Components
Note: Perform this procedure with the machine on a 7 Temporarily install a control box door retaining
firm, level surface. fastener between the door and the box to
prevent the control box door from moving the
Note: Perform this procedure with the boom in the toggle switch while calibrating the machine.
stowed position.
All models:
Note: Use the following chart to identify the
description of each LCD screen control button used 8 Insert the key into the bypass/recovery key
in this procedure. switch and turn it to the bypass position.
Note: The angle sensor calibration values will not
be saved correctly unless the key switch is in the
bypass position and the calibration toggle switch is
activated.
Platform Components
Platform Components
Platform 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
20 Remove the mounting fasteners that attach the
all of the cables through the hose and cable
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
16 Remove the cotter pin from the upper cable unbalanced and fall if not
track tube at the platform end of the jib boom. properly attached to the
Do not discard the washer. overhead crane.
Note: Always replace the cotter pin with a new one.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
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
for the calibration procedure.
8 Remove the mounting fasteners that attach the
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 16 Remove the pin retaining fasteners from the jib
unbalanced and fall if not boom lift cylinder barrel-end pivot pin.
properly attached to the
overhead crane. 17 Use a soft metal drift to remove the jib boom lift
cylinder barrel-end pivot pin.
Component damage hazard. Crushing hazard. The jib boom
Cables and hoses can be could fall when the barrel-end
damaged if they are kinked or pivot pin is removed if not
pinched. properly supported by the
overhead crane.
10 Disconnect the electrical connector from the jib
boom angle sensor located at the jib boom Crushing hazard. The jib boom
pivot pin on the engine side of the machine. lift cylinder may become
11 Remove the cover retaining fasteners from the unbalanced and fall when it is
jib boom angle sensor. Remove the cover. removed from the machine if it is
not properly supported by the
overhead crane.
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.
connections very slowly to allow
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. machine and place it on a structure capable of
Bodily injury hazard. Spraying supporting it.
hydraulic oil can penetrate and
Crushing hazard. The jib boom
burn skin. Loosen hydraulic may become unbalanced and fall
connections very slowly to allow when it is removed from the
the oil pressure to dissipate
machine if it is not properly
gradually. Do not allow oil to
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.
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.
Note: Use the following chart to identify the Before serial number 321:
description of each LCD screen control button used
in this procedure. 5 Locate the 2 pin connector in the lower left
hand area of the ground control box.
6 Remove the connector plug and insert a
jumper wire between the two pins of the
connector.
After serial number 320:
Plus Minus Previous Enter
Digital levels with alternate zero function: 7 Locate the calibration toggle switch at the top
of the ground control box. Activate calibration
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.
10 Press and hold the enter button on the ground
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.
4 Open the ground control box.
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).
12 Press the enter or previous button on the
LCD screen until DELETE JIB LEVEL ANGLE
SENSOR CALIBRATION is displayed.
13 Press the plus button to select YES, then
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
1 jib boom angle sensor
when the engine is started, repeat step 7 and
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.
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
angle shown on the display at the ground controls,
press the plus button or minus button to change
the angle and then change back to the measured
value. The system must detect a change in
displayed value to record the calibrated value.
20 Press and hold a function enable/speed select
button and the platform level down button until
the digital level displays approximately 8 ±
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
press the enter button. press the enter button.
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.
press the plus button or minus button to change
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
the angle and then change back to the measured
value. The system must detect a change in
displayed value to record the calibrated value.
25 Press and hold a function enable/speed select 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.
exact value shown on the digital level and
press the enter button. Note: If the measured angle already matches the
angle shown on the display at the ground controls,
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
value. The system must detect a change in
Note: If the measured angle already matches the
displayed value to record the calibrated value.
angle shown on the display at the ground controls,
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.
displayed value to record the calibrated value.
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.
30 Press the enter or previous button on the
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.
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)
Boom Components
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
Note: Perform this procedure with the machine on a
firm, level surface. 7 Remove the retaining fasteners from the hose
and cable guide at the platform end of the
Note: Perform this procedure with the boom in the primary boom. Remove the hose and cable
stowed position. guide.
1 Remove the cover from the lower jib boom 8 Tag and disconnect the electrical connector
cable track. 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.
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.
16 Tag, disconnect and plug the hydraulic hoses
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
hydraulic oil can penetrate and
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.
Component damage hazard.
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.
Boom Components
How to R epair the Primar y Boom C abl e Tr ac k
Boom Components
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.
cylinder hydraulic hoses. Cap the fittings on
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.
retaining fasteners.
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.
Component damage hazard.
Bodily injury hazard. Spraying Hoses can be damaged if they
hydraulic oil can penetrate and are kinked or pinched.
burn skin. Loosen hydraulic
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.
Boom Components
How to R epair the Sec ondar y Boom C able Tr ac k
Boom Components
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.
7 Disconnect the electrical connector from the
primary boom angle sensor. 11 Place blocks under both ends of the primary
Note: The primary boom angle sensor is located boom lift cylinder for support.
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.
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
18 Attach a 5 ton / 5000 kg overhead crane to Boom Lift Cylinder
both ends of the primary boom. Do not apply
any lifting pressure. Bodily injury hazard. This
procedure requires specific repair
19 Remove the pin retaining fasteners from the skills, lifting equipment and a
primary boom pivot pins. suitable workshop. Attempting
20 Use a soft metal drift to remove the primary this procedure without these skills
boom pivot pins. and tools could result in death or
serious injury and significant
21 Carefully remove the primary boom from the component damage. Dealer
machine and place it on a structure capable of service is strongly recommended.
supporting it.
Note: When removing a hose assembly or fitting,
Crushing hazard. The primary the O-ring (if equipped) on the fitting and/or hose
boom could become unbalanced end must be replaced. All connections must be
and fall when removed from the torqued to specification during installation. Refer to
machine if not properly attached Specifications, Hydraulic Hose and Fitting Torque
to the overhead crane. Specifications.
Note: Perform this procedure with the boom in the
stowed position.
1 Remove the hose and cable clamps from the
primary boom lift cylinder.
2 Remove the cable track retaining fasteners at
the primary boom lift cylinder.
3 Place blocks under both ends of the primary
boom lift cylinder. Place another block under
the cylinder linkage arms under the primary
boom lift cylinder barrel-end pivot pin.
Boom Components
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.
Component damage hazard.
The engine must not be started
with the hydraulic tank shut-off
valves in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
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
turntable cover at the ground controls side of 11 Tag, disconnect and plug the hydraulic hose
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.
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
14 Remove the ground control box mounting box could become unbalanced
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.
watches and other jewelry.
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.
circuits could result in death or
serious injury. Remove all rings, 23 Place a block under the secondary boom lift
watches and other jewelry. cylinder for support.
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
unbalanced and fall when
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.
Boom Components
Boom Components
Bodily injury hazard. This 4 Remove the retaining fasteners from both
procedure requires specific repair secondary boom extend limit switches and
skills, lifting equipment and a remove the limit switches. Do not disconnect
suitable workshop. Attempting the wiring.
this procedure without these skills
Note: Label the location of each limit switch as they
and tools could result in death or
are not the same and their mounting locations
serious injury and significant
cannot be exchanged.
component damage. Dealer
service is strongly recommended. 5 Tag, disconnect and plug all hydraulic hoses
for the 3 secondary boom extension cylinders.
Note: When removing a hose assembly or fitting, Cap the fittings on the cylinder.
the O-ring (if equipped) on the fitting and/or hose
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
the oil pressure to dissipate
Note: Perform this procedure with the machine on a gradually. Do not allow oil to
firm, level surface and in the stowed position with squirt or spray.
the axles extended.
6 Remove the upper extension cylinder retainers
from the saddle blocks.
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.
Boom Components
Boom Components
How to C alibr ate the Pri mary Boom Angle Sens or
Boom Components
Note: If the axle sensor or secondary boom angle 6 Point Calibration procedure
sensor have been removed or replaced, or the Note: Use this procedure for software versions
turntable level sensor has been replaced, they must
before 4.01.
be calibrated first. Refer to Repair Procedures, How
to Calibrate the Axle Angle Sensors or How to Note: For the 2 Point Calibration procedure,
Calibrate the Secondary Boom Angle Sensor or proceed to step 37.
How to Calibrate the Turntable Level Sensor.
1 Push in the ground controls red Emergency
Tip-over hazard. Failure to Stop button to the off position. Do not turn the
properly calibrate the machine key switch to the off position.
could cause the machine to tip
2 Turn the key switch to ground controls.
over resulting in death or serious
injury. 3 Open the ground control box.
Note: For software versions 4.01 and higher, use Before serial number 321:
the 2 Point Calibration procedure. For software 4 Locate the 2 pin connector in the lower left
versions before 4.01, use the 6 Point Calibration hand area of the ground control box.
procedure. The software version is displayed on the
LCD screen when the red Emergency Stop button 5 Remove the connector plug and insert a
is pulled out to the on position. jumper wire between the two pins of the
connector.
Note: A digital level will only be required to perform
the 6 Point Calibration procedure. After serial number 320:
Note: A kit is available through Genie Product 6 Locate the calibration toggle switch at the top
Support (Genie part number 58351). This kit of the ground control box. Activate calibration
includes a digital level with a magnetic base and mode by moving the toggle switch in the left
cable harnesses. direction.
7 Temporarily install a control box door retaining
Note: Use the following chart to identify the
fastener between the door and the box to
description of each LCD screen control button used
prevent the control box door from moving the
in this procedure.
toggle switch while calibrating the machine.
All models:
8 Remove the key from the main key switch.
Insert the key into the bypass/recovery key
switch and turn it to the bypass position.
Plus Minus Previous Enter
Note: Perform this procedure with the machine on a Note: The angle sensor calibration values will not
firm, level surface with the booms in the fully stowed be saved correctly unless the key switch is in the
position, in the drive enable zone and the axles fully bypass position and the calibration toggle switch is
extended. activated.
Boom Components
9 Press and hold the enter button on the ground 17 Press and hold a function enable/speed select
control panel while pulling out the ground button and the primary boom down button and
controls red Emergency Stop button to the on lower the primary boom down until the digital
position. Hold the enter button for level displays -50 degrees.
approximately 5 seconds and then release it.
18 At the ground controls, press the plus button
10 Enter sensor calibration mode by pressing the or minus button to adjust the display to the
buttons at the ground controls in the following exact value shown on the digital level and
sequence: (plus)(enter)(enter)(plus). press the enter button.
11 Press the enter or previous button on the Note: Be sure the number entered at the ground
LCD screen until DELETE PRIMARY BOOM controls is a negative number.
ANGLE SENSOR CALIBRATION is displayed.
Note: If the measured angle already matches the
12 Press the plus button to select YES, then angle shown on the display at the ground controls,
press the enter button to accept. press the plus button or minus button to change
13 Place a digital level that has been calibrated to the angle and then change back to the measured
gravity on top of the primary boom and note value. The system must detect a change in
the angle displayed on the digital level. displayed value to record the calibrated value.
14 At the PRIMARY BOOM ANGLE TO GRAVITY 19 Press and hold a function enable/speed select
0.0 DEG screen, press the plus button or button and the primary boom up button until
minus button to adjust the display to the exact the digital level displays -20 degrees.
value shown on the digital level, then press the 20 At the ground controls, press the plus button
enter button. or minus button to adjust the display to the
Note: If the measured angle already matches the exact value shown on the digital level and
angle shown on the display at the ground controls, press the enter button.
press the plus button or minus button to change Note: Be sure the number entered at the ground
the angle and then change back to the measured controls is a negative number.
value. The system must detect a change in
displayed value to record the calibrated value. Note: If the measured angle already matches the
angle shown on the display at the ground controls,
15 Start the engine from the ground controls. press the plus button or minus button to change
Note: If the system exits out of calibration mode the angle and then change back to the measured
when the engine is started, repeat step 8 and then value. The system must detect a change in
continue with step 14. displayed value to record the calibrated value.
16 Fully raise the secondary boom. 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 digital level displays 10 degrees.
Boom Components
22 At the ground controls, press the plus button 27 Press and hold the engine start button for
or minus button to adjust the display to the approximately 5 seconds to shut off the engine
exact value shown on the digital level and and to save the calibration settings.
press the enter button.
Note: Do not turn the engine off with the key switch
Note: If the measured angle already matches the or red Emergency Stop button or all calibration
angle shown on the display at the ground controls, points or values will not be saved.
press the plus button or minus button to change
the angle and then change back to the measured 28 Press the enter or previous button on the
value. The system must detect a change in LCD screen until EXIT is displayed.
displayed value to record the calibrated value. 29 Press the plus button to select YES, then
press the enter button to accept.
23 Press and hold a function enable/speed select
button and the primary boom up button until 30 Turn the key back to the run position and
the digital level displays 40 degrees. remove the key from the bypass/recovery key
switch. Insert the key into the main key switch
24 At the ground controls, press the plus button
and turn it to ground controls.
or minus button to adjust the display to the
exact value shown on the digital level and Note: Be sure that the bypass/recovery key switch
press the enter button. is in the run position before attempting to operate
the machine.
Note: If the measured angle already matches the
angle shown on the display at the ground controls, 31 Wait approximately 20 seconds and turn the
press the plus button or minus button to change machine off by pressing the red Emergency
the angle and then change back to the measured Stop button in.
value. The system must detect a change in
displayed value to record the calibrated value. Before serial number 321
25 Press and hold a function enable/speed select 32 Remove the wire jumper from the 2 pin
button and the primary boom up button until connector in the lower left hand area of the
the primary boom is fully raised. The boom is ground control box that was installed in step 5.
fully raised when the cylinder is fully extended Install the connector plug.
and the boom stops moving. The angle will be Tip-over hazard. Failure to
70 degrees. remove the jumper wire will
26 At the ground controls, press the plus button result in an unsafe configuration
or minus button to adjust the display to the which will compromise machine
exact value shown on the digital level and stability. Operating the machine
press the enter button. in this configuration will result in
the machine tipping over,
Note: If the measured angle already matches the resulting in death or serious
angle shown on the display at the ground controls, injury. The jumper wire must be
press the plus button or minus button to change removed before operating the
the angle and then change back to the measured machine.
value. The system must detect a change in
displayed value to record the calibrated value. 33 Close the ground control box and install the
door retaining fasteners.
Boom Components
After serial number 320: 2 Point Calibration procedure
34 Remove the fastener that was temporarily Note: Use this procedure for software versions
installed. Close the control box door and install 4.01 and higher.
the door retaining fasteners.
37 Push in the ground controls red Emergency
Note: When the control box door is closed, the Stop button to the off position. Do not turn the
calibration toggle switch is automatically activated key switch to the off position.
to exit out of calibration mode.
38 Turn the key switch to ground controls.
All models:
39 Open the ground control box.
35 Pull out the red Emergency Stop button. Start
the engine and lower the boom to the stowed 40 Locate the calibration toggle switch at the top
position. Be sure there are no calibration faults of the ground control box. Activate calibration
shown on the display. mode by moving the toggle switch in the left
direction.
36 Perform a primary boom angle test. Refer to
Maintenance Procedure in the appropriate 41 Temporarily install a control box door retaining
Service or Maintenance Manual, Test the fastener between the door and the box to
Primary Boom Angle Sensor. prevent the control box door from moving the
toggle switch while calibrating the machine.
42 Remove the key from the main key switch.
Insert the key into the bypass/recovery key
switch and turn it to the bypass position.
43 Note: The angle sensor calibration values will
not be saved correctly unless the key switch is
in the bypass position and the calibration
toggle switch is activated.
44 Press and hold the enter button on the ground
control panel while pulling out the ground
controls red Emergency Stop button to the on
position. Hold the enter button for
approximately 5 seconds and then release it.
45 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).
46 Press the enter or previous button on the
LCD screen until DELETE PRIMARY BOOM
ANGLE SENSOR CALIBRATION is displayed.
Boom Components
47 Press the plus button to select YES, then 58 Turn the key back to the run position and
press the enter button to accept. remove the key from the bypass/recovery key
switch. Insert the key into the main key switch
48 Lower the primary boom to the stowed
and turn it to ground controls.
position.
Note: Be sure that the bypass/recovery key switch
49 Press the enter or previous button on the
is in the run position before attempting to operate
LCD SCREEN UNTIL PRIMARY BOOM FULLY
the machine.
LOWERED is displayed.
50 Press the plus button to select YES, then 59 Wait approximately 20 seconds and turn the
press the enter button to accept. machine off by pressing the red Emergency
Stop button in.
51 Fully raise the secondary boom until it stops at
the end of the cylinder stroke. 60 Remove the fastener that was temporarily
installed. Close the control box door and install
52 Fully raise the primary boom until it stops at the the door retaining fasteners.
end of the cylinder stroke.
Note: When the control box door is closed, the
53 Press the enter or previous button on the calibration toggle switch is automatically activated
LCD screen until PRIMARY BOOM FULLY to exit out of calibration mode.
RAISED is displayed.
61 Pull out the red Emergency Stop button. Start
54 Press the plus button to select YES, then the engine and lower the boom to the stowed
press the enter button to accept. position. Be sure there are no calibration faults
55 Press and hold the engine start button for shown on the display.
approximately 5 seconds to shut off the engine 62 Perform a primary boom angle test. Refer to
and to save the calibration settings. Maintenance Procedure in the appropriate
Note: Do not turn the engine off with the key switch Service or Maintenance Manual, Test the
or red Emergency Stop button or all calibration Primary Boom Angle Sensor.
points or values will not be saved.
56 Press the enter or previous button on the
LCD screen until EXIT is displayed.
57 Press the plus button to select YES, then
press the enter button to accept.
Boom Components
Boom Components
How to C alibr ate the Sec ondar y Boom Angle Sensor
Boom Components
6 Point Calibration procedure 9 Press and hold the enter button on the ground
control panel while pulling out the ground
Note: Use this procedure for software versions controls red Emergency Stop button to the on
before 4.01. position. Hold the enter button for
Note: For the 2 Point Calibration procedure, approximately 5 seconds and then release it.
proceed to step 36. 10 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
1 Push in the ground controls red Emergency
sequence: (plus)(enter)(enter)(plus).
Stop button to the off position. Do not turn the
key switch to the off position.
2 Turn the key switch to ground controls.
3 Open the ground control box.
Before serial number 321:
4 Locate the 2 pin connector in the lower left
hand area of the ground control box.
5 Remove the connector plug and insert a
jumper wire between the two pins of the
connector.
After serial number 320:
6 Locate the calibration toggle switch at the top
of the ground control box. Activate calibration
mode by moving the toggle switch in the left
direction.
7 Temporarily install a control box door retaining
fastener between the door and the box to
prevent the control box door from moving the
toggle switch while calibrating the machine.
All models:
8 Remove the key from the main key switch.
Insert the key into the bypass/recovery key
switch and turn it to the bypass position.
Note: The angle sensor calibration values will not
be saved correctly unless the key switch is in the
bypass position and the calibration toggle switch is
activated.
Boom Components
11 Press the enter or previous button on the 17 At the ground controls, press the plus button
LCD screen until DELETE SECONDARY or minus button to adjust the display to the
BOOM ANGLE SENSOR CALIBRATION is exact value shown on the digital level and
displayed. press the enter button.
12 Press the plus button to select YES, then Note: If the measured angle already matches the
press the enter button to accept. angle shown on the display at the ground controls,
press the plus button or minus button to change
13 Place a digital level that has been calibrated to
the angle and then change back to the measured
the Y axis of the turntable on top of the
value. The system must detect a change in
secondary boom and note the angle displayed
displayed value to record the calibrated value.
on the digital level.
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
press the enter 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.
20 Press and hold a function enable/speed select
15 Start the engine from the ground controls.
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
21 At the ground controls, press the plus button
continue with step 14.
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. Note: If the measured angle already matches the
angle shown on the display at the ground controls,
press the plus button or minus button to change
the angle and then change back to the measured
value. The system must detect a change in
displayed value to record the calibrated value.
Boom Components
22 Press and hold a function enable/speed select 27 Press the enter or previous button on the
button and the secondary boom up button until LCD screen until EXIT is displayed.
the digital level displays 65 degrees.
28 Press the plus button to select YES, then
23 At the ground controls, press the plus button press the enter button to accept.
or minus button to adjust the display to the
29 Turn the key back to the run position and
exact value shown on the digital level and
remove the key from the bypass/recovery key
press the enter button.
switch. Insert the key into the main key switch
Note: If the measured angle already matches the and turn it to ground controls.
angle shown on the display at the ground controls,
Note: Be sure that the bypass/recovery key switch
press the plus button or minus button to change
is in the run position before attempting to operate
the angle and then change back to the measured
the machine.
value. The system must detect a change in
displayed value to record the calibrated value. 30 Wait approximately 20 seconds and turn the
machine off by pressing the red Emergency
24 Press and hold a function enable/speed select
Stop button in.
button and the secondary boom up button.
Fully raise the secondary boom. The boom is Before serial number 321:
fully raised when the cylinder is fully extended
and the boom stops moving.The angle will be 31 Remove the wire jumper from the 2 pin
76 degrees. connector in the lower left hand area of the
ground control box that was installed in step 5.
25 At the ground controls, press the plus button Install the connector plug.
or minus button to adjust the display to the
exact value shown on the digital level and Tip-over hazard. Failure to
press the enter button. remove the jumper wire will
result in an unsafe configuration
Note: If the measured angle already matches the which will compromise machine
angle shown on the display at the ground controls, stability. Operating the machine
press the plus button or minus button to change in this configuration will result in
the angle and then change back to the measured the machine tipping over,
value. The system must detect a change in resulting in death or serious
displayed value to record the calibrated value. injury. The jumper wire must be
26 Press and hold the engine start button for removed before operating the
approximately 5 seconds to shut off the engine machine.
and to save the calibration settings.
32 Close the ground control box and install the
Note: Do not turn the engine off with the key switch door retaining fasteners.
or red Emergency Stop button or all calibration
points or values will not be saved.
Boom Components
After serial number 320: 2 Point Calibration procedure
33 Remove the fastener that was temporarily Note: Use this procedure for software versions
installed. Close the control box door and install 4.01 and higher.
the door retaining fasteners.
36 Push in the ground controls red Emergency
Note: When the control box door is closed, the Stop button to the off position. Do not turn the
calibration toggle switch is automatically activated key switch to the off position.
to exit out of calibration mode.
37 Turn the key switch to ground controls.
All models:
38 Open the ground control box.
34 Pull out the red Emergency Stop button. Start
the engine and lower the boom to the stowed 39 Locate the calibration toggle switch at the top
position. Be sure there are no calibration faults of the ground control box. Activate calibration
shown on the display. mode by moving the toggle switch in the left
direction.
35 Perform secondary boom angle test. Refer to
Maintenance Procedure in the appropriate 40 Temporarily install a control box door retaining
Service or Maintenance Manual, Test the fastener between the door and the box to
Secondary Boom Angle Sensor. prevent the control box door from moving the
toggle switch while calibrating the machine.
41 Remove the key from the main key switch.
Insert the key into the bypass/recovery key
switch and turn it to the bypass position.
Note: The angle sensor calibration values will not
be saved correctly unless the key switch is in the
bypass position and the calibration toggle switch is
activated.
42 Press and hold the enter button on the ground
control panel while pulling out the ground
controls red Emergency Stop button to the on
position. Hold the enter button for
approximately 5 seconds and then release
it.Enter sensor calibration mode by pressing
the buttons at the ground controls in the
following sequence:
(plus)(enter)(enter)(plus).
Boom Components
43 Press the enter or previous button on the 53 Press the plus button to select YES, then
LCD screen until DELETE SECONDARY press the enter button to accept.
BOOM ANGLE SENSOR CALIBRATION is
54 Turn the key back to the run position and
displayed.
remove the key from the bypass/recovery key
44 Press the plus button to select YES, then switch. Insert the key into the main key switch
press the enter button to accept. and turn it to ground controls.
45 Lower the secondary boom to the stowed Note: Be sure that the bypass/recovery key switch
position. is in the run position before attempting to operate
the machine.
46 Press the enter or previous button on the
LCD SCREEN UNTIL SECONDARY BOOM 55 Wait approximately 20 seconds and turn the
FULLY LOWERED is displayed. machine off by pressing the red Emergency
47 Press the plus button to select YES, then Stop button in.
press the enter button to accept. 56 Remove the fastener that was temporarily
48 Fully raise the secondary boom until it stops at installed. Close the control box door and install
the end of the cylinder stroke. the door retaining fasteners.
49 Press the enter or previous button on the Note: When the control box door is closed, the
LCD SCREEN UNTIL SECONDARY BOOM calibration toggle switch is automatically activated
FULLY RAISED is displayed. to exit out of calibration mode.
50 Press the plus button to select YES, then 57 Pull out the red Emergency Stop button. Start
press the enter button to accept. the engine and lower the boom to the stowed
position. Be sure there are no calibration faults
51 Press and hold the engine start button for shown on the display.
approximately 5 seconds to shut off the engine
and to save the calibration settings. 58 Perform secondary boom angle test. Refer to
Maintenance Procedure in the appropriate
Note: Do not turn the engine off with the key switch Service or Maintenance Manual, Test the
or red Emergency Stop button or all calibration Secondary Boom Angle Sensor.
points or values will not be saved.
52 Press the enter or previous button on the
LCD screen until EXIT is displayed.
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 and
Check and Adjust the Engine RPM. 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.
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.
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
Engines
How to i nstall a T ype "B" Flex Pl ate
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
Recovery is only to be used as a last attempt to 3 Recovery
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.
Ground Controls
Note: Before using the Bypass mode, make sure Note: If the Bypass function has been used, there
you understand the fault code or issue affecting the may be faults with the machine. Check the LCD
operation of the machine to be sure the use of screen on the ground control box for machine faults,
bypass is required. then contact trained service personnel.
Ground Controls
How to Us e the R ec overy Mode
Ground Controls
6-2
Circuit Boards How to Remove the LCD Display
The ground control box contains a replaceable
Screen Circuit Board
membrane decal with touch sensitive buttons for 1 Push in the red Emergency Stop button to the
various machine functions. The ground control box off position at both the ground and platform
also contains two printed circuit boards: controls.
The LCD (Liquid Crystal Display) circuit board 2 Remove the ground control box lid fasteners.
is mounted to the inside of the control box lid which 3 Open the ground control box.
controls the LCD display screen.
Electrocution/burn hazard.
The ECM circuit board is the main circuit board for Contact with electrically charged
the machine. All operating parameters and circuits could result in death or
configuration of options for the machine are stored serious injury. Remove all rings,
in the ECM memory. watches and other jewelry.
Note: When the ECM circuit board is replaced, the
machine will need to be fully calibrated. Refer to Component damage hazard.
Repair Procedure, How to Fully Calibrate the Electrostatic discharge (ESD)
Machine. can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.
Ground Controls
Ground Controls
Ground Controls
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.
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.
Battery volts
Display Module
Display Module
Display Module
Display Module
Display Module
Display Module
Display Module
Display Module
Platform Overload
(NONE/WARN/CUTPT/CUTAL/PLFTS)
Work Li ghts (YES/NO)
Hydraulic Pumps
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, Hydraulic Hose and Fitting Torque
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.
5 Start the engine from the ground controls.
6 Check for hydraulic leaks.
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
Hydraulic Pumps
Hydraulic Pumps
How to Prime the Dri ve Pump
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
Manifolds
Manifolds
Manifolds
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
Description Function Torque
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
150 psi / 10.3 bar circuit, regulates pressure drop
across secondary boom
up/down proportional valve
13 Differential sensing valve, U Secondary boom extend/retract 50-55 ft-lbs / 68-75 Nm
150 psi / 10.3 bar circuit, regulates pressure drop
across secondary boom
extend/retract proportional
valve
14 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
Manifolds
Manifolds
Manifolds
Manifolds
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
Manifolds
How to Adj ust the Pri mar y Boom Extend R elief Val ve
Manifolds
Manifolds
8-4
Platform Manifold
The platform manifold is mounted to the platform mounting weldment.
Index Schematic
Description Function Torque
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
Manifolds
8-5
Jib Boom Manifold
The jib boom manifold is mounted inside the primary extension boom at the platform end.
Index Schematic
Description Function Torque
No. Item
1 Pressure compensator valve, X Jib boom up/down circuit, 30-35 ft-lbs / 41-47 Nm
150 psi / 10.3 bar regulates pressure drop across
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
Manifolds
Manifolds
8-6
Flow Control Manifold
The flow control manifold is located at the platform next to the jib manifold.
Index Schematic
Description Function Torque
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
Manifolds
8-7
Function Enable Valve
The function enable valve is mounted behind the medium pressure filter.
Index Schematic
Description Function Torque
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
Manifolds
8-8
Turntable Rotation Manifold
The turntable rotation manifolds are mounted to the turntable rotation drive hub motors.
Index Schematic
Description Function Torque
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
Manifolds
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
Description Function Torque
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 /
from moving when not steering 27-34 Nm
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 /
from moving when not steering 27-34 Nm
7 Check valve BD Prevents right rear steer cylinder 20-25 ft-lbs /
from moving when not steering 27-34 Nm
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
Manifolds
Manifolds
Index Schematic
Description Function Torque
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
Manifolds
Manifolds
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
Description Function Torque
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
Manifolds
Manifolds
Manifolds
Manifolds
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.
4 Start the engine from the ground controls.
5 Press and hold the function enable/high rpm
select button (rabbit symbol) position. Note the
reading on the pressure gauge.
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.
Manifolds
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
Description Function Torque
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
Manifolds
Result: The resistance should be within Solenoid valve, 2 position 2 way 3.5 to
(schematic item A) 5.5Ω
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
Manifolds
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Turntable Level Sensor 5 Locate the calibration toggle switch at the top
of the ground control box. Activate calibration
mode by moving the toggle switch in the left
How to Calibrate the Turntable direction.
Level Sensor 6 Temporarily install a control box door retaining
fastener between the door and the box to
Note: If the Safety Controller (SCON) has been
prevent the control box door from moving the
replaced, the entire machine must be calibrated in a
toggle switch while calibrating the machine.
specific order. Refer to Repair Procedure, Full
Machine Calibration.
1 Run
2 Bypass
3 Recovery
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
angle shown on the display at the ground controls,
press the plus button or minus button to change
the angle and then change back to the measured
value. The system must detect a change in
displayed value to record the calibrated value.
14 Press the enter or previous button on the
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
16 Press the plus button or minus button to 23 Remove the fastener that was temporarily
adjust the display to the exact value shown on installed. Close the control box door and install
the digital level and press the enter button. the door retaining fasteners.
Note: If the measured angle already matches the Note: When the control box door is closed, the
angle shown on the display at the ground controls, calibration toggle switch is automatically activated
press the plus button or minus button to change to exit out of calibration mode.
the angle and then change back to the measured All models:
value. The system must detect a change in
displayed value to record the calibrated value. 24 Start the engine. Be sure there are no
calibration faults shown on the display.
17 Press the enter or previous button on the
LCD screen until EXIT is displayed. 25 Perform level sensor test. Refer to
Maintenance Procedure, Test the Level
18 Press the plus button to select YES, then Sensor.
press the enter button to accept.
19 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.
20 Wait approximately 20 seconds and turn the
machine off by pressing the red Emergency
Stop button in.
Before serial number 321:
21 Remove the wire jumper from the 2 pin
connector in the lower left hand area of the
ground control box that was installed in step 4.
Install the connector plug.
Tip-over hazard. Failure to
remove the jumper wire will
result in an unsafe configuration
which will compromise machine
stability. Operating the machine
in this configuration will result in
the machine tipping over,
resulting in death or serious
injury. The jumper wire must be
removed before operating the
machine.
Axle Components
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
Axle Components
How to C alibr ate a Repl acement Steer Sens or
Axle Components
How to C alibr ate All Steer Sensors
All models:
How to Calibrate All Steer 5 Turn the key switch to ground controls and pull
Sensors out the ground controls red Emergency Stop
button to the on position.
Note: This procedure will only need to be performed
if the ground controls circuit board (TCON) has 6 Loosen the steer angle sensor cover retaining
been replaced. fasteners. Do not remove the fasteners or the
sensor cover.
Note: Perform this procedure with the axles
7 Using a voltmeter set to DC voltage, probe the
retracted and the tires straightened.
back of the electrical connector at pins B and
Note: Use the following chart to identify the C.
description of each LCD screen control button used 8 Left front (square-end, blue side) and right
in this procedure. 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.
Plus Minus Previous Enter Right front (square-end, yellow side) and
left rear (circle-end, blue side) angle
Before serial number 321: sensors: Rotate the sensor cover clockwise or
1 Locate the 2 pin connector in the lower left counterclockwise until the voltage reading is
hand area of the ground control box. between 3.4 to 3.6V DC. Tighten the sensor
cover fasteners.
2 Remove the connector plug and insert a
jumper wire between the two pins of the Note: If available, WebGPI can also be used for this
connector. procedure.
After serial number 320: 9 Remove the key from the main key switch.
Insert the key into the bypass/recovery key
3 Locate the calibration toggle switch at the top switch and turn it to the bypass position.
of the ground control box. Activate calibration
mode by moving the toggle switch in the left Note: The angle sensor calibration values will not
direction. be saved correctly unless the key switch is in the
bypass position and the calibration toggle switch is
4 Temporarily install a control box door retaining activated.
fastener between the door and the box to
prevent the control box door from moving the 10 Push in the red Emergency Stop button to the
toggle switch while calibrating the machine. off position.
Axle Components
11 Press and hold the enter button on the ground Delete all Steer Sensor Calibrations
control panel while pulling out the ground
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
enter button to accept.
Note: Models before software version 3.0, the LCD
screen will display RESET ALL STEER SENSORS.
14 Press the enter or previous button on the
LCD screen until EXIT is displayed.
15 Press the plus button to select YES, then
press the enter button to accept.
16 Proceed to step 22.
Delete a Single Steer Sensor Calibration
17 To calibrate a single steer sensor, delete the
specific steer sensor calibration
18 Press the enter or previous button on the
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
LCD screen until EXIT is displayed.
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.
Axle Components
Axle Components
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.
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
5 Align the sensor with the pin and install the
sensor on to the pin.
Note: Be sure the actuator pin is engaged into the
sensor.
Axle Components
How to C alibr ate the Axl e Angle Sens ors
Axle Components
All models: 13 Press and hold the enter button on the ground
control panel while pulling out 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.
15 Press the enter or previous button on the
LCD screen until DELETE AXLE ANGLE
SENSORS CALIBRATION is displayed.Press
the plus button to select YES, then press the
enter button to accept.
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.
Note: If the system exits out of calibration mode
1 Run when the engine is started, repeat step 13.
2 Bypass
3 Recovery
Axle Components
18 Press the plus button to select YES, then 26 Turn the key back to the run position and
press the enter button to accept. remove the key from the bypass/recovery key
switch. Insert the key into the main key switch
19 Press the enter or previous button on the and turn it to ground controls.
LCD screen until EXIT is displayed.
Note: Be sure that the bypass/recovery key switch
20 Press the plus button to select YES, then is in the run position before attempting to operate
press the enter button to accept. the machine.
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
or red Emergency Stop button or all calibration
points or values will not be saved.
22 Wait approximately 20 seconds and turn the
machine off by pressing the red Emergency
Stop button in.
Before serial number 321:
23 Remove the wire jumper from the 2 pin
connector in the lower left hand area of the
ground control box that was installed in step 8.
Install the connector plug.
Tip-over hazard. Failure to
remove the jumper wire will
result in an unsafe configuration
which will compromise machine
stability. Operating the machine
in this configuration will result in
the machine tipping over,
resulting in death or serious
injury. The jumper wire must be
removed before operating the
machine.
Fault Codes
Section 4 Faul t Codes
Before Troubleshooting:
R Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
R Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
R Troubleshooting and repair procedures shall be R Read each appropriate fault code thoroughly.
completed by a person trained and qualified on Attempting short cuts may produce hazardous
the repair of this machine conditions.
R Immediately tag and remove from service a R Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
R Repair any machine damage or malfunction Electrocution/burn hazard.
before operating the machine. Contact with electrically charged
circuits could result in death or
R Unless otherwise specified, perform each serious injury. Remove all rings,
procedure with the machine in the following watches and other jewelry.
configuration:
· Machine parked on a firm, level surface Note: Two persons will be required to safely
perform some troubleshooting procedures.
· Key switch in the off position with the key
removed
· The red Emergency Stop button in the off
position at both the 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)
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
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
Steer 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
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
Fault Codes
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)
Schematics
Section 5 Schematics
Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
R 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
R Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
R Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine.
connections very slowly to allow
the oil pressure to dissipate
Before Troubleshooting: gradually. Do not allow oil to
squirt or spray.
R Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
R Be sure that all necessary tools and test
equipment are available and ready for use.
Circuit numbering
1 Circuit numbers consist of three parts: the Circuit prefix
circuit prefix, circuit number and circuit suffix.
C Control
The circuit prefix indicates the type of circuit.
The circuit number describes the function of D Data
the circuit. The circuit suffix provides an E Engine
abbreviation for the number or may be used to G Gauges
further define the function of this portion of the
N Neutral
circuit. It also may be used to indicate the final
end of the circuit, i.e., LS or limit sw. P Power
R Relay Output
2 The circuit number may be used more than
once in a circuit. S Safety
V Valve
For Example:
C 74 PL – This is the circuit for the lockout 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.
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
Numbering Legend
Types of Limit Switches LS FA 1 L O
LS Limit FA Front Circuit L Load O Operational
Switch Axle Number moment
There are two types of limit switches, found in
LT Stringpot RA Rear A Angle S Safety
various locations throughout the machine: Axle
mechanical-type operational/safety switches and RS Rotary LF Left Front D Down
Sensor
rotation or angle sensors. As in aircraft, which LR Left Rear E Extend
features redundant safety systems, each RF Right R Retract
mechanical operational switch is backed up with a Front
RR Right
separate, independently functioning safety switch. Rear
J Jib Boom
The mechanical-type operational or safety
P Boom
switches are used to sense a positive displacement
T Turntable
or movement of the limit switch actuator, or arm, as
the machine moves through its range of operational
functions. The rotation or angle sensors utilize Hall
Effect technology and must be calibrated when Limit Switch Numbering
replaced. Included in this group are envelope limit
switches which sense the extended length and LSP1RO Primary boom length retracted
angle of the booms and rotational position of the LSP1EO Primary boom length fully extended
turntable.
LSS1RO Secondary boom fully retracted
For example, when the secondary boom is fully LSS1RS Secondary boom fully retracted, safety
raised and the operational sensor is activated, it LSJ1RO Jib boom length fully retracted
tells the ECM at the ground controls to start
extending the secondary boom. LST1O Drive enable, left direction
LST2O Drive enable, right direction
Another example is the drive enable limit switch,
LST1S Drive enable safety, retracted axles
which disables the drive function anytime the boom
is rotated past the rear tires, indicated by the 'circle' LSFA1ES Front axle fully retracted
end of the drive chassis.In some cases, the engine LSRA1ES Rear axle fully retracted
will be stopped if safety parameters are exceeded.
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
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)
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
Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid
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
215
Service and Repair Manual October 2018
218
October 2018 Service and Repair Manual
219
Service and Repair Manual October 2018
222
October 2018 Service and Repair Manual
Hydraulic Schematic
(before serial number 180, except for serial number 102)
223
Service and Repair Manual October 2018
Hydraulic Schematic
(before serial number 180, except for serial number 102)
Hydraulic Schematic
(serial number 102 and from serial number 180 to 534)
Hydraulic Schematic
(serial number 102 and from serial number 180 to 534)
226
October 2018 Service and Repair Manual
Hydraulic Schematic
(from serial number 535)
228
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
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
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
TURTLE
1
BOOM REVERSE LOAD DI P14-17 VLVRET5-BR Y66 SEC EXT VLV (J65)
2
TO PLD
1
TO
2
uP
SEC. DOWN
1
2
1
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
15
1
BOOM RET PRI_DOWN_VLV P14-08 V02PBD-RD/BK V02PBD-RD/BK Y21=PRI DWN VLV (J60)
2
P9
1
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
2 TO PLD
J14 WHITE 35 PIN
P14-13 C49LP-WH/BK
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
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
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
J120
STRT ASST
SEE OPTIONS PAGES FOR
15
A B C D
P34SA-BK/WH
07GND-BR BK
B3BAT/14-RD
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
RELAY
HORN
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
TO HORN
D1
RD-HOLD
D2
LP P1-08
EXCT.
IND.
STA.
BAT.
CB
5 AUX HYD (AH)
C
FUNC ENABLE (FE)
TROMBETTA
TIME DELAY
S-500-A6
C27AUX-RD
4
B1BAT-RD
ENGINE HARN
PR1
TO
uP
(~SM)+(AH)
GND-
BAT+
AUX+
PUMP
(~SM)+(AH)
AUX.
5V 12V
SUPPLIED
BY DEUTZ
GND
(OE)
F23 ENG/ST/ALT
S139TRF-WH/RD
S137PLL-RD/WH
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
30 A STARTER
W/BAT CBL
PWR HARN
INTEGRAL
RELAY
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)
MULTI FUNCTION VLV RECOVERY SIGNAL
NO
NO
LSS1R0
24 23
AUXILIARY HYD RECOVERY SIGNAL
VERSION S0675100
14 13
C64LS-OR/BK
VERSION S0675110
C64LS-OR/BK RD
Vbb BTS621
432 1
ST OUT 2
IN1 OUT 1
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
WH J125
WH
4321
4 3 21
LST10
8 3
NO
BL
NC
14 13
22 21
8 3
WH RIGHT
J124
C64LS-OR/BK C64LS-OR/BK FST1S
WH/BK WH/BK
21
LOW FUEL
94
94
2 1
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
P_9A
P_11
P_10
P_7R
C142SBS-OR BL
P_22
P_9B
3
P_30
4
6
S20-SEC BM
2
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
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
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
LSP1E0
NC
22 21
14 13
RD
BOOM STOWED P12-31 BR 3'FROM FULLY BK
21
94
2 1
GR/BK
UNIT #130
51
BK/WH
TO
uP
PRESSURE GA P12-27
SNSR PWR P12-26 P109ANG-GR/WH
WH
4
6
4
6
GR
7
BL
3
WH/BK
11 12
11 12
ANG SAFETY RD
1
J20
J114
TO PLD .
LSB2RO P12-18 C64LS-OR/BK
TO
P
uP
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
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
U30
AUXILIARY HYD RECOVERY SIGNAL
P_6R1 P12-03 P53LS-WH/BK 330 OHM S12SB-BL/WH P122-05 SEC. BOOM RET
BOOM DWN RECOVERY SIGNAL
PRI BOOM RETRACTED STATUS
PRI BOOM LENGTH 100' STATUS
P21DCN-WH
O
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
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
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)
UNIT 321 OR
J17
87
86
WH/BK
GREATER
SWITCH
AC
AA
AB
1
1
C
D
E
1
L
C145CAL-RD/WH
R117FB-RD
S132LDS-BL/WH
PLAT
GROUND
PLAT
PLAT
GROUND
PLAT
GROUND
2
2
OFF
OFF
OFF
OFF
OFF
GROUND
BL/WH
PLAT
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
11
BA
BB
C145CAL-RD/WH
W
V
Z
R117FB-RD
2
16 ALARM GND
SPARE P11-08
J4 ON CIRCUIT BOARD
K
ALM PWR-BL
PIN
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
P7R
10 8
GND
P6
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
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
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
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
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
SPARE-WH
AXLE NOT RET RTN P31-09
STEER MODE STEER MODE
DRV SPEED-RD/WH
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
CORD STR-BL/BK 17
AXLE
2
V36RFS-BL Y59-RF STEER RIGHT (J95)
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)
2
DRV ENBL-BL/WH V36RRS-BL Y55-RR STEER RIGHT (J91)
AXLE EXT-GR/WH 12
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)
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
C
(TS17)
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)
SPARE P32-07 BK
C
SPARE P32-06 C111RRS-OR BL
B
A
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