257_Service Manual.pdf - mateco

Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378

September 2013

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Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-30/20NOperator's Manual or the Z-34/22 and Z-34/22NOperator's Manual before attempting anymaintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting faultcodes and repair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealer servicecenter.

Compliance

Machine ClassificationGroup B/Type 3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degreeof accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject tochange without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

Copyright © 2011 Terex Corporation

139378 Rev B June 2011Third Edition, Second Printing

Genie and "Z" are registered trademarks ofTerex South Dakota, Inc. in the USA and manyother countries.

Printed on recycled paper

Printed in U.S.A.

Serial Number Information

Genie offers the following Service Manuals forthese models:

Title Part No.

Z-30/20N Service Manual(before serial number 5934) ................................ 35532

Z-30/20N Service Manual(from serial number 5934 to 11499) ..................106373

Z34/22N (before serial number 6291)Z-34/22DC (before serial number 5427) .............. 36540

Introduction

http://www.genielift.come-mail: [email protected]

Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N

September 2013

Serial Number Legend

INTRODUCTION

iii

Z30N 05 - 12345

Model

Year ofmanufacture

Sequencenumber

Country of manufacture: USA

This machine complies with:

Model: Z-30/20N

Serial number: Z30N05-12345

Electrical schematic number: ESXXXX

Machine unladen weight:

Rated work load (including occupants): XXX lb / XXX kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : XXX lb / XXX N

Maximum number of platfrm occupants: X

Model year: Manufacture date: 04/12/052005

Maximum wind speed : XX mph/ XX m/s

Maximum platform height : XX ft / XX m

Maximum platform reach : XX ft / XX m

Serial numberstamped on chassis

Serial label(located under cover)

Serial numberstamped on chassis

Serial label(located under cover)

Z-30/20NZ-30/20N RJ

Z-34/22Z-34/22N

Terex South Dakota, Inc.500 Oak Wood RoadPO Box 1150Watertown, SD 57201USA


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DangerFailure to obey the instructions and safety rulesin this manual and the Genie Z-30/20N Operator’sManual or the Z-34/22 and Z-34/22N Operator'sManual will result in death or serious injury.

Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance on this machine.

You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksite

regulations- applicable governmental regulations

You have the appropriate tools, liftingequipment and a suitable workshop.

Safety Rules

Section 1 • Safety Rules


September 2013

SAFETY RULES

vi

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Indicates an imminently hazardoussituation which, if not avoided, willresult in death or serious injury.

Indicates a potentially hazardoussituation which, if not avoided,could result in death or seriousinjury.

Indicates a potentially hazardoussituation which, if not avoided,may cause minor or moderateinjury.

Indicates a potentially hazardoussituation which, if not avoided,may result in property damage.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.



September 2013

Table of Contents

vii

Introduction

Important Information ................................................................................................... ii

Serial Number Information............................................................................................ ii

Serial Number Legend ................................................................................................. iii

Section 1 Safety Rules

General Safety Rules .................................................................................................. v

Section 2 Rev Specifications

C Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 2

Hydraulic Oil Specifications ................................................................................... 2 - 3

Hydraulic Component Specifications ...................................................................... 2 - 3

Manifold Component Specifications ....................................................................... 2 - 4

Machine Torque Specifications .............................................................................. 2 - 4

Hydraulic Hose and Fitting Torque Specifications .................................................. 2 - 5

SAE and Metric Fasteners Torque Charts .............................................................. 2 - 6

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

A Checklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 6

A-2 Perform Pre-operation Inspection ................................................................ 3 - 7

A-3 Perform Function Tests ............................................................................... 3 - 7

A-4 Perform 30 Day Service ............................................................................... 3 - 8

A-5 Grease the Turntable Rotation Bearing and Worm Drive Gear ...................... 3 - 8

A-6 Replace the Drive Hub Oil ............................................................................ 3 - 9



September 2013

TABLE OF CONTENTS

viii

Section 3 Rev Scheduled Maintenance Procedures, continued

B Checklist B Procedures

B-1 Check the Batteries.................................................................................... 3 - 10

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 11

B-3 Test the Key Switch ................................................................................... 3 - 12

B-4 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 13

B-5 Confirm the Proper Brake Configuration...................................................... 3 - 13

B-6 Check the Oil Level in the Drive Hubs and Mounting Bolt Torque ............... 3 - 14

B-7 Test the Ground Control Override ............................................................... 3 - 14

B-8 Test the Platform Self-leveling ................................................................... 3 - 15

B-9 Test the Drive Brakes ................................................................................ 3 - 15

B-10 Test the Drive Speed - Stowed Position ..................................................... 3 - 16

B-11 Test the Drive Speed - Raised or Extended Position .................................. 3 - 16

B-12 Test the Alarm Package (if equipped) ........................................................ 3 - 17

B-13 Test the Turntable Rotation Stop ................................................................ 3 - 18

B-14 Check the Electrical Contactors ................................................................. 3 - 18

B-15 Perform Hydraulic Oil Analysis ................................................................... 3 - 19

A Checklist C Procedures

C-1 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 20

C-2 Test the Platform Overload System (if equipped) ....................................... 3 - 20


September 2013

Section 3 Rev Scheduled Maintenance Procedures, continued

A Checklist D Procedures

D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 23

D-2 Check the Free-wheel Configuration ........................................................... 3 - 24

D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 25

D-4 Replace the Drive Hub Oil .......................................................................... 3 - 26

D-5 Replace the Hydraulic Tank Return Filter Element ..................................... 3 - 26

D-6 Inspect for Turntable Bearing Wear ............................................................ 3 - 27

A Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 29

E-2 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 31

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

A Platform Controls

1-1 Controllers .................................................................................................... 4 - 2

A Platform Components

2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 4

2-2 Platform Rotator ........................................................................................... 4 - 5

2-3 Platform Overload System (if equipped) ....................................................... 4 - 7

A Jib Boom Components

3-1 Jib Boom...................................................................................................... 4 - 9

3-2 Jib Boom Bell Crank (models without rotating jib boom) ............................. 4 - 10

3-3 Jib Boom Rotator (models with rotating jib boom) ....................................... 4 - 11

3-4 Jib Boom Lift Cylinder ................................................................................ 4 - 13

TABLE OF CONTENTS

ix


September 2013

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Section 4 Rev Repair Procedures, continued

A Primary Boom Components

4-1 Cable Track ................................................................................................ 4 - 14

4-2 Primary Boom ............................................................................................ 4 - 14

4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 18

4-4 Extension Cylinder ..................................................................................... 4 - 19

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 20

A Secondary Boom Components

5-1 Secondary Boom........................................................................................ 4 - 23

5-2 Secondary Boom Lift Cylinder .................................................................... 4 - 28

A Hydraulic Pump

6-1 Auxiliary and Function Pump...................................................................... 4 - 30

B Manifolds

7-1 Function Manifold Components .................................................................. 4 - 32

7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 36

7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components ............... 4 - 39

7-4 Valve Coils ................................................................................................. 4 - 41

A Turntable Rotation Components

8-1 Turntable Rotation Hydraulic Motor ............................................................. 4 - 43

A Steer Axle Components

9-1 Hub and Bearings ....................................................................................... 4 - 44

A Motor Controller

10-1 Motor Controller .......................................................................................... 4 - 45

Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1

B Fault Code Chart .................................................................................................... 5 - 3

TABLE OF CONTENTS


September 2013

TABLE OF CONTENTS

Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1

A Electrical Symbols Legend .................................................................................... 6 - 2

A Hydraulic Symbols Legend .................................................................................... 6 - 3

A Limit switch Location Legend ................................................................................. 6 - 4

B Electrical Schematic, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ........ 6 - 6

B Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ...... 6 - 10

B Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ...... 6 - 11

B Platform Control Box Wiring Diagram, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ...... 6 - 13

B Electrical Schematic (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ...... 6 - 16

B Ground Control Box Terminal Strip Wiring Diagram, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ...... 6 - 20

B Ground Control Box Switch Panel Wiring Diagram, (CE) (before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ..... 6 - 21

B Platform Control Box Wiring Diagram, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ...... 6 - 23

A Electrical Schematic, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ......... 6 - 26

A Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ......... 6 - 30

A Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ......... 6 - 31

A Platform Control Box Wiring Diagram, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ......... 6 - 33

xi


September 2013

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Section 6 Rev Schematics, continued

B Electrical Schematic (AS / CE)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ......... 6 - 36

A Ground Control Box Terminal Strip Wiring Diagram, (AS / CE)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ......... 6 - 40

A Ground Control Box Switch Panel Wiring Diagram, (AS / CE) (from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ........ 6 - 41

A Platform Control Box Wiring Diagram, (AS / CE)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774) ......... 6 - 44

A Power Cable Wiring Diagram ................................................................................ 6 - 45

B Drive Contactor Panel Wiring Diagram ................................................................. 6 - 48

B Manifold and Limit Switch Wiring Diagram ........................................................... 6 - 49

A LVI/BCI Option Wiring Diagram ............................................................................ 6 - 52

A Charger Interlock option ....................................................................................... 6 - 53

A CTE Option, (CE Models) .................................................................................... 6 - 56

B Hydraulic Schematic ............................................................................................ 6 - 57

TABLE OF CONTENTS

Part No. 139378 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N 2 - 1

Section 2 • SpecificationsJune 2011

REV C Specifications

Machine Specifications

Tires and wheels,Z-30/20N, Z-30/20N RJ and Z-34/22N

Tire size (solid rubber) 22 x 7 x 17.5 in56 x 18 x 44 cm

Load range 7600 lbs3447 kg

Overall tire diameter 22 in56 cm

Wheel diameter 17.5 in44 cm

Wheel width 7 in18 cm

Tires and wheels, Z-34/22

Tire size 9-14.5 LT

Tire ply rating 12

Tire weight, new foam-filled (minimum) 175 lbs79 kg

Overall tire diameter 28 in71 cm

Wheel diameter 14.5 in37 cm

Wheel width 7 in18 cm

Wheel lugs

Front 8 @ 5/8 -18Rear 9 @ 5/8 -18

Lug nut torque, dry 125 ft-lbs169.5 Nm

Lug nut torque, lubricated 95 ft-lbs129 Nm

Fluid Capacities

Hydraulic tank capacity 4 gallons15.1 liters

Hydraulic system capacity 6 gallons(including tank) 22.7 liters

Drive hubs48:1 24.5 ounces 0.72 liter57:1 24.5 ounces 0.72 liter

Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5

For operational specifications, refer to theOperator's Manual.

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

2 - 2 Z-30/20N • Z-30/20N RJ • Z-34/22 • Z-34/22N Part No. 139378

Section 2 • Specifications June 2011

REV CSPECIFICATIONS

Performance Specifications,Z-30/20N and Z-30/20N RJ

Drive speed, maximum

Stowed position 4.5 mph7.2 km/h

40 ft / 6.0 sec12.2 m / 6.0 sec

Boom raised or extended 0.6 mph1 km/h

40 ft / 42 sec12.2 m / 42 sec

Braking distance, maximum

High range on paved surface 2 to 4 ft0.6 to 1.2m

Gradeability See Operator's Manual

Boom function speeds, maximum from platformcontrols (with rated load secured to platform)

Jib boom up 19 to 23 seconds

Jib boom down 17 to 21 seconds

Jib boom rotate, 180° 13 to 17 seconds

Primary boom up 14 to 22 seconds

Primary boom down 12 to 20 seconds

Primary boom extend 15 to 19 seconds

Primary boom retract 10 to 14 seconds

Secondary boom up 11 to 18 seconds

Secondary boom down 7 to 15 seconds

Turntable rotate, 355° 62 to 68 seconds

Platform rotate, 180° 5 to 11 seconds

Platform level up 14 to 19 seconds

Platform level down 13 to 18 seconds

Performance Specifications,Z-34/22 and Z-34/22N

Drive speed, maximum

Stowed position 4.5 mph7.2 km/h

40 ft / 6.0 sec12.2 m / 6.0 sec

Boom raised or extended 0.6 mph1 km/h

40 ft / 42 sec12.2 m / 42 sec

Braking distance, maximum

High range on paved surface 2 to 4 ft0.6 to 1.2m

Gradeability See Operator's Manual

Boom function speeds, maximum from platformcontrols (with rated load secured to platform)

Jib boom up 20 to 24 seconds

Jib boom down 18 to 22 seconds

Primary boom up 16 to 22 seconds

Primary boom down 13 to 20 seconds

Primary boom extend 11 to 15 seconds

Primary boom retract 13 to 17 seconds

Secondary boom up 15 to 22 seconds

Secondary boom down 11 to 18 seconds

Turntable rotate, 355° 62 to 68 seconds

Platform rotate, 180° 5 to 11 seconds

Platform level up 14 to 19 seconds

Platform level down 13 to 18 seconds




REV C

Hydraulic Oil Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rando HD equivalentViscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rando HD oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Continued use of ChevronAviation A hydraulic fluid whenambient temperatures areconsistently above 32°F / 0°C mayresult in component damage.

Note: Use Chevron Aviation A hydraulic fluid whenambient temperatures are consistently below0°F / -18°C.

Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.


SPECIFICATIONS

Hydraulic ComponentSpecifications

Function pump

Type: Fixed displacement gear pump

Displacement 0.183 cu in3 cc

Flow rate @ 2.1 gpm2800 psi / 172 bar 7.9 L/min

Hydraulic tank 10 micron withreturn filter 25 psi / 1.7 bar bypass

Function manifold

System relief valve pressure, 2800 psiZ-30/20N and Z-30/20N RJ 193 bar

System relief valve pressure, 3200 psiZ-34/22 and Z-34/22N 221 bar

Primary boom down relief pressure 1600 psi110 bar

Secondary boom down relief pressure 1600 psi110 bar

Primary boom extend relief pressure 1800 psiModels with rotating jib 124 bar

Turntable rotate relief pressure 1100 psi76 bar

Auxiliary pump

Type: Fixed displacement gear pump

Displacement 0.3 gpm1.14 L/min



REV C

Machine Torque Specifications

Platform rotator and jib boom rotator (Z-30/20N RJ)

1-8 center bolt, GR 5, lubricated 480 ft-lbs(Jib boom rotator) 650 Nm

3/4 -10 bolt, GR 8, lubricated 280 ft-lbs(Platform rotator) 379 Nm

3/8 -16 bolts, GR 8, lubricated 23 ft-lbs(Platform rotator) 31 Nm

1/2 -13 bolts, GR 5, lubricated 57 ft-lbs(Jib boom rotator) 77 Nm

Platform rotator (Z-30/20N, Z-34/22 and Z-34/22N)

3/4 -10 bolt, GR 8, lubricated 280 ft-lbs379 Nm

3/8 -16 bolts, GR 8, lubricated 23 ft-lbs31 Nm

Turntable rotate bearing

Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm

Drive hubs, brakes and motors

Drive hub mounting bolts, lubricated 180 ft-lbs244 Nm

Brake mounting bolts, lubricated 93 ft-lbs126 Nm

Drive motor mounting bolts 31 ft-lbs42 Nm

SPECIFICATIONS

Manifold ComponentSpecifications

Plug torque

SAE No. 2 36 in-lbs / 4 Nm

SAE No. 4 10 ft-lbs / 13 Nm





Valve Coil Resistance

Note: The following coil resistance specifications are atan ambient temperature of 68°F / 20°C. As valve coilresistance is sensitive to changes in air temperature,the coil resistance will typically increase or decrease by4% for each 18°F / 10°C that your air temperatureincreases or decreases from 68°F / 20°C.

Valve Coil Resistance Specification

Description Specification

Solenoid valve, 3 position 4 way, 20V DC 22 Ω(schematic items A, J, K, U, V, Y, AA, AB and CC)

Proportional solenoid valve, 24V DC 19.5 Ω(schematic item H)

Solenoid valve, N.C. poppet, 20V DC 23.5 Ω(schematic item M)

Solenoid valve, N.O. poppet, 20V DC 23.5 Ω(schematic item P)




REV C SPECIFICATIONS

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be replacedanytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end hasbeen tightened beyond finger tight.

Note: The O-rings used in the Parker Seal Lok®fittings and hose ends are custom-size O-rings.They are not standard SAE size O-rings. They areavailable in the O-ring field service kit (Genie partnumber 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

SAE O-ring Boss Port(tube fitting - installed into Aluminum)

SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

Seal-Lok® Fittings(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 27 ft-lbs / 36.6 Nm

-8 40 ft-lbs / 54.2 Nm

-10 63 ft-lbs / 85.4 Nm

-12 90 ft-lbs / 122 Nm

-16 120 ft-lbs / 162.7 Nm

-20 140 ft-lbs / 190 Nm

-24 165 ft-lbs / 223.7 Nm



REV CSPECIFICATIONS

SIZE THREAD

in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

f t - lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

5/16

3/8

7/16

1/2

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

LUBED

1/4

LUBED DRY LUBED DRY

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

Size(mm)

in- lbs N m in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

f t - lbs N m ft-lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6

10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8DRY

10.9 12.98.84.6


Section 3 • Scheduled Maintenance ProceduresJune 2011

Scheduled Maintenance Procedures

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend






Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every 2 years as specified on theMaintenance Inspection Report.

Failure to properly complete eachinspection when required couldresult in death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating machine.

Use only Genie approved replacement parts.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

• Machine parked on a firm, level surface

• Boom in the stowed position

• Turntable rotated with the boom between thenon-steer wheels

• Key switch in the off position with thekey removed

• Wheels chocked

• All external AC power supply disconnectedfrom the machine


Section 3 • Scheduled Maintenance Procedures June 2011

Maintenance Symbols Legend

The following symbols have been used in thismanual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold motor or pump willbe required to perform this procedure.

Indicates that dealer service will berequired to perform this procedure.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two year.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Six months or every 500 hours A + B + C

Annual or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of 4 years or in compliancewith employer, jobsite and governmental regulationsand requirements.

SCHEDULED MAINTENANCE PROCEDURES



Terex South Dakota, Inc USA500 Oak Wood RoadPO Box 1150Watertown, SD 57201-6150(605) 882-4000

Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex SouthDakota, Inc. 133192 Rev D

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompleted

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.

Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machinefrom service, repair and reinspect it. After repair, placea check in the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover ifanything is apparently wrong with a machine before itis put into service.

A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.

Scheduled maintenance inspections shall beperformed by qualified service technicians, accordingto the manufacturer's specifications and therequirements listed in the responsibilities manual.






Checklist A - Rev A Y N R

A-1 Manuals and decals

A-2 Pre-operationinspection

A-3 Function tests

Perform after 40 hours:

A-4 30 Day Service

Perform every 100 hours:

A-5 Grease rotationbearing

Perform after 150 hours:

A-6 Replace drive hub oil

Checklist B - Rev A Y N R

B-1 Batteries

B-2 Electrical wiring

B-3 Key switch

B-4 Tires and Wheels

B-5 Brake configuration

B-6 Drive hub oil level

B-7 Ground controloverride

B-8 Platform leveling

B-9 Drive brakes

B-10 Drive speed-stowed

B-11 Drive speed-raised

B-12 Alarm package(if equipped)

B-13 Turntable rotation stop

B-14 Electrical contactors

B-15 Hydraulic oil analysis

Checklist C - Rev A Y N R

C-1 Grease platformoverload (if equipped)

C-2 Test platformoverload (if equipped)

Checklist D - Rev A Y N R

D-1 Boom wear pads

D-2 Free-wheelconfiguration

D-3 Turntable bearing bolts

D-4 Drive hub oil

D-5 Hydraulic return filter

D-6 Turntable bearingwear

Checklist E - Rev A Y N R

E-1 Hydraulic oil

E-2 Wheel bearings

Instructions• Make copies of this page to use for

each inspection.

• Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hourInspection: A

Quarterly or 250 hourInspection: A+B

Six Month or 500 hourInspection: A+B+C

Annual or 1000 hoursInspection: A+B+C+D

2 Year or 2000 hourInspection: A+B+C+D+E

• Place a check in the appropriate boxafter each inspection procedure iscompleted.

• Use the step-by-step procedures inthis section to learn how to performthese inspections.

• If any inspection receives an “N”, tagand remove the machine fromservice, repair and reinspect it. Afterrepair, place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Comments



REV AChecklist A Procedures

A-1Inspect the Manuals and DecalsNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.

Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or are illegible. Removethe machine from service until the manual isreplaced.

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.



REV A

A-2Perform Pre-operationInspectionNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.

Completing a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The pre-operation inspectionalso serves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the Operator's Manual located on yourmachine.

CHECKLIST A PROCEDURES

A-3Perform Function TestsNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.

Completing the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the Operator's Manual located on yourmachine.



REV A

A-4Perform 30 Day Service

The 30 day maintenance procedure is a one-timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage. After thisinterval, refer to the maintenance checklists forcontinued scheduled maintenance.

1 Perform the following maintenance procedures:

• A-5 Grease the Turntable RotationBearing and Worm Drive Gear

• B-4 Inspect the Tires, Wheels and Lug NutTorque

• D-3 Check the Turnable RotationBearing Bolts

• D-5 Replace the Hydraulic TankReturn Filter Element

A-5Grease the Turntable RotationBearing and Worm Drive Gear

Note: Genie specifications require that thisprocedure be performed every 100 hours.

Frequent application of lubrication to the turntablebearing and worm drive gear is essential to goodmachine performance and service life. Continueduse of an insufficiently greased gear will result incomponent damage.

1 Locate the grease fitting on the tank sideturntable cover bulkhead.

2 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches / 10 to 13 cm at a time and repeat thisstep until the entire bearing has been greased.

3 Locate the 2 grease fittings on top of the wormdrive housing.

a grease fittings

4 Pump grease into the gear until you see itcoming out of the side of the gear housing.

5 Grease each tooth on the outside of theturntable rotation bearing.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent


a



REV A

A-6Replace the Drive Hub Oil

Note: Manufacturer drive hub specifications requirethat this one-time procedure be performed after thefirst 150 hours.

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil after the first 150 hours ofuse may cause the machine to perform poorly andcontinued use may cause component damage.

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

a drive hub plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Refer to Section 2, Specifications.

5 Install the plugs into the drive hub.

6 Repeat this procedure for the other drive hub.


a



REV BChecklist B Procedures

B-1Inspect the Battery

Genie requires that this procedure be performedevery 250 hours or quarterly, whichever comesfirst.

Proper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damage andhazardous conditions.

Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosion onthe battery terminals and cables.

3 Be sure that the battery retainers and cableconnections are tight.

5 Be sure that the battery retainers and cableconnections are tight.

4 Fully charge the battery. Allow the battery torest 24 hours before performing this procedureto allow the battery cells to equalize.

5 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

6 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 +/- 0.007. The batteryis fully charged. Proceed to step 10.

Result: One or more battery cells display aspecific gravity of 1.269 or below. Proceed tostep 7.

7 Perform an equalizing charge OR fully chargethe batteries and allow the battery to rest atleast 6 hours.

8 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.



REV B CHECKLIST B PROCEDURES

9 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specificgravity of 1.277 +/- 0.007. The battery is fullycharged. Proceed to step 10.

Result: One or more battery cells display aspecific gravity from 1.269 to 1.218. The batteryis still usable, but at a lower performance so willneed to be recharged more often. Proceed tostep 11.

Result: One or more battery cells display aspecific gravity from 1.217 to 1.173. The batteryis approaching the end of its life. Proceed tostep 11.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is 1.172or less. Replace the battery.

10 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

11 Install the vent caps and neutralize anyelectrolyte that may have spilled.

B-2Inspect the Electrical Wiring

Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

1 Remove the drive chassis cover from thenon-steer end of the machine.

2 Inspect the following areas for burnt, chafed,corroded and loose wires:

• Electrical power panel

• Electrical relay panel

• Ground control panel

• Function manifold wiring



REV BCHECKLIST B PROCEDURES

3 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

4 Raise the secondary boom until the mid-pivot isapproximately 10 feet / 3 m off the ground.

5 Inspect the turntable center area for burnt,chafed and pinched cables.

6 Lower the boom to the stowed position and turnthe machine off.

7 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

• Cable track on the primary boom

• Primary boom to platform cable harness

• Inside of the platform control box

8 Inspect for a liberal coating of dielectric greaseat the following location:

• All wire harness connectors to the platformcontrol box

• All wire harness connectors located under theground control side turntable cover

• Harness connector to the drive motorcontroller located in the non-steer end of thedrive chassis

B-3Test the Key SwitchNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

Proper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could resultin a hazardous operating situation.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Turn the key switch to platform controls.

3 Check the machine functions from the groundcontrols.

Result: The machine functions should notoperate.

4 Turn the key switch to ground controls.

5 Check the machine functions from the platformcontrols.

Result: The machine functions should notoperate.

6 Turn the key switch to the off position.

Result: No function should operate.



REV B

B-4Inspect the Tires, Wheels andLug Nut Torque


Maintaining the tires and wheels, including properwheel fastener torque, is essential to safeoperation and good performance. Tire and/orwheel failure could result in a machine tip-over.Component damage may also result if problemsare not discovered and repaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts,cracks and unusual wear.

2 Check each wheel for damage, bends andcracks.

3 Check each lug nut for proper torque. Refer toSection 2, Specifications.

B-5Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydraulically-released, spring-applied individualwheel brakes can appear to operate normally whenthey are actually not fully operational.

1 Check each drive hub disconnect cap to besure it is in the engaged position.

CHECKLIST B PROCEDURES

disengaged position

engaged position



REV B

B-6Check the Oil Level in the DriveHubs and Mounting Bolt Torque


Failure to maintain proper drive hub oil levels,including proper drive hub fastener torque, maycause the machine to perform poorly andcontinued use may cause component damage.

1 Drive the machine to rotate the hub until one ofthe plugs is located on top and the other is at90 degrees.

a drive hub plugs

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the side plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole. Refer to Section 2,Specifications.


5 Check the torque of the drive hub bolts.Refer to Section 2, Specifications.

6 Repeat this procedure for each drive hub.

B-7Test the Ground ControlOverrideNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether the red Emergency Stopbutton on the platform controls is in the on or offposition. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.

1 Push in the red Emergency Stop button at theplatform controls to the off position.

2 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition.

3 Operate each boom function through apartial cycle at the ground controls.

Result: All boom functions should operate.

CHECKLIST B PROCEDURES

a




B-8Test the Platform Self-leveling


Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained level by the platform levelingslave cylinder which is controlled by the platformleveling master cylinder located at the base of theprimary boom. A platform self-leveling failurecreates an unsafe working condition for platformand ground personnel.

1 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Lower the boom to the stowed position.

3 Adjust the platform to a level position using theplatform leveling toggle switch.

4 Raise and lower the primary boom througha full cycle.

Result: The platform should remain level atall times to within ±5 degrees.

B-9Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-5, Confirm the ProperBrake Configuration.

1 Select a test area that is firm, level and free ofobstructions.

2 Mark a test line on the ground for reference.

3 Lower the boom to the stowed position.

4 Turn the key switch to platform controls.

5 Choose a reference point on the machine; i.e.,contact patch of a tire, as a visual reference foruse when crossing the test line.

6 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.

7 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.

Note: The brakes must be able to hold the machineon any slope it is able to climb.




B-10Test the Drive Speed -Stowed Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


2 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.

3 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

4 Choose a reference point on the machine; i.e.,contact patch of a tire, as a visual reference foruse when crossing the start and finish lines.

5 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

6 Continue at full speed and note the time whenyour machine reference point passes over thefinish line. Refer to Section 2, Specifications.

B-11Test the Drive Speed -Raised or Extended Position


Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


2 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.

3 Raise the primary boom more than5 feet / 1.5 m.

4 Choose a reference point on the machine; i.e.,contact patch of a tire, as a visual reference foruse when crossing the start and finish lines.

5 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

6 Continue at full speed and note the time whenyour machine reference point passes over thefinish line. Refer to Section 2, Specifications.




B-12Test the Alarm Package(if equipped)Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

The alarm package includes:

• Travel alarm

• Descent alarm

• Flashing beacon

Alarms and a beacon are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theground controls side turntable cover.

1 At the ground controls, pull out the redEmergency Stop button to the on position andturn the key switch to ground control.

Result: The flashing beacon should be on andflashing.

2 Move the primary boom switch to the downposition, hold for a moment and then release it.Move the secondary boom switch to the downposition, hold for a moment and then release it.Move the jib boom switch to the down position,hold for a moment and then release it.

Result: The descent alarm should sound wheneach switch is held down.

3 Turn the key switch to platform control.

4 At the platform controls pull out the redEmergency Stop button to the on position.

Result: The flashing beacon should be onand flashing.

5 Press down the foot switch. Move the primaryboom switch to the down position, hold for amoment and then release it. Move thesecondary boom switch to the down position,hold for a moment and then release it. Move thejib boom switch to the down position, hold for amoment and then release it.

Result: The descent alarm should sound wheneach control switch is held down.

6 Press down the foot switch. Move the drivecontrol handle off center, hold for a moment andthen release it. Move the drive control handle offcenter in the opposite direction, hold for amoment and then release it.

Result: The travel alarm should sound when thedrive control handle is moved off center in eitherdirection.




B-13Test the Turntable Rotation StopNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.

The turntable is capable of rotating the boom 359degrees and is stopped midpoint between the steerwheels by the rotation stop. Detecting a rotationstop malfunction is essential to safe operation andgood machine performance. If the turntable rotatespast the rotation stop, component damage mayresult.

1 Turn the key switch to platform controls and pullout the red Emergency Stop buttons to the onposition at both ground and platform controls.

2 Rotate the turntable to the left as far as itwill go.

Result: Movement should stop when theprimary boom reaches midpoint between thesteer tires.

3 Rotate the turntable to the right as far as itwill go.

Result: Movement should stop when theprimary boom reaches midpoint between thesteer tires.

B-14Check the Electrical Contactors


Maintaining the electrical contactors in goodcondition is essential to safe machine operation.Failure to locate a worn or damaged contactorcould result in an unsafe working condition andcomponent damage.

1 Remove the drive chassis cover from the non-steer end of the machine and locate theelectrical contactors mounted on the electricalcomponent mounting panel.

2 Visually inspect the contact points of eachcontactor for the following items:

• Excessive burns

• Excessive arcs

• Excessive pitting

Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

Note: Replace the contactors if any damage isfound.




B-15Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test. See E-1,Test or Replace the Hydraulic Oil.



REV AChecklist C Procedures

C-1Grease the Platform OverloadMechanism (if equipped)

Note: Genie specifications require that thisprocedure be performed every 500 hours or 6months, whichever comes first. Perform thisprocedure more often if dusty conditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each greasefitting using a multipurpose grease.



C-2Test the Platform OverloadSystem (if equipped)

Note: Genie specifications require that thisprocedure be performed every 500 hours or sixmonths, whichever comes first.

Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stabilitycould be compromised resulting in the machinetipping over.

The platform overload system is designed to detectan overloaded platform and prevent machineoperation anytime the machine is turned on. Whenactivated, the system halts all normal boomoperation, giving visual and audible warning to theoperator.

Models equipped with the platform overload optionare provided with additional machine components:an adjustable spring-loaded platform supportsubassembly, a limit switch, an electronic modulewhich receives the overload signal and interruptspower, and an audio/visual warning indication toalert the operator of the overload.



REV A CHECKLIST C PROCEDURES

The platform support subassembly utilizes two loadsupport arms that are opposed in a fullparallelogram link. This isolates platform loads intoa shear or vertical state, which translates into acompressive load. A spring in the parallelogramlink supports this purely compressive loadregardless of where the load is placed in theplatform.

As weight is added to the platform, the spring willcompress until, when the platform is overloaded,the lower arm contacts a limit switch and therebyactivating the overload signal. When adjustedcorrectly, the platform overload system willdeactivate normal boom operation at platformcapacity.

Note: Perform this procedure with the machine ona firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in aninaccurate test.

4 Using a suitable lifting device, place a testweight equal to that of the available capacityone of the locations shown.Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-3, How to Calibrate the PlatformOverload System (if equipped).

5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lightsare on and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-3, How to Calibrate the PlatformOverload System (if equipped).

Illustration 1

6 Using a suitable lifting device, place anadditional 10 lbs / 4.5 kg of weight onto theplatform.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-3,How to Calibrate the Platform Overload System(if equipped).

Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.



REV A

7 Carefully move the test weights to eachremaining location on the platform.Refer to Illustration 1.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-3,How to Calibrate the Platform OverloadSystem (if equipped).

Note: There may be a 2 second delay before theoverload indicator lights flash and the alarmsounds.

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.

9 Turn the key switch to ground control.

10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Using auxiliary power, test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate.

CHECKLIST C PROCEDURES

12 Using a suitable lifting device, lift the additionaltest weight from the platform.

Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be an 2 second delay before theoverload indicator lights and alarm turn off.

13 Start the engine and test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate normally.



Result: All platform control functions shouldoperate.

Note: If the platform overload system is notoperating properly, Refer to Repair Procedure 2-3,How to Calibrate the Platform Overload System(if equipped).

16 Using a suitable lifting device, remove theremaining test weights from the platform.



REV AChecklist D Procedures

D-1Check the Primary BoomWear Pads

Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.

Maintaining the primary boom wear pads in goodcondition is essential to safe machine operation.Wear pads are placed on boom tube surfaces toprovide a low friction, replaceable wear padbetween moving parts. Improperly shimmed wearpads or continued use of worn out wear pads mayresult in component damage and unsafe operatingconditions.

1 Measure each wear pad. Replace the wear padonce it reaches the minimum allowablethickness. If the wear pad is still withinspecifications, shim as necessary to obtainminimum clearance with zero binding.

2 Extend and retract the primary boom throughthe entire range of motion to check for tightspots that could cause binding or scraping.

Note: Always maintain squareness between theprimary boom outer and inner tubes.

Models without rotating jib boom:

Primary boom wearpad specifications Minimum

Top and side wear pads 5/8 inch(extension end of boom) 15.9 mm

Bottom wear pads 5/8 inch(extension end of boom) 15.9 mm

Bottom and side wear pads 5/8 inch(pivot end of boom) 15.9 mm

Top wear pads 3/8 inch(pivot end of boom) 9.5 mm

Models with rotating jib boom:

Primary boom wearpad specifications Minimum

All wear pads 3/8 inch9.5 mm



REV ACHECKLIST D PROCEDURES

D-2Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheelwithout operator knowledge may cause death orserious injury and property damage.

Collision hazard. Select a worksite that is firm and level.

Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(15,000 lbs / 7000 kg) under the drive chassisbetween the non-steer wheels.

3 Lift the wheels off the ground and then placeblocks under the drive chassis for support.

4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.

5 Manually rotate each non-steer wheel.

Result: Each non-steer wheel should rotate withminimum effort.

6 Engage the drive hubs by turning overthe drive hub disconnect caps.

7 Carefully remove the blocks, lower the machineand remove the jack.

Collision hazard. Failure to engagethe drive hubs could result indeath or serious injury andproperty damage.

disengaged position

engaged position



REV A

D-3Check the Turntable RotationBearing Bolts


Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.

1 Raise the secondary boom and place a safetychock on the secondary boom lift cylinder.Carefully lower the secondary boom onto the liftcylinder safety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering thesecondary boom.

Note: A lift cylinder safety chock is availablethrough Genie Service Parts (Genie part no.36555).

2 Confirm that each turntable mounting bolt istorqued in sequence to specification. Refer toSection 2, Specifications.

Bolt torque sequence

CHECKLIST D PROCEDURES

3 Raise the secondary boom and remove thesafety chock. Lower the secondary boom to thestowed position.

4 Open the latch on the battery packs and swingthem out to expose the turntable bearing boltaccess hole.

5 Confirm that each turntable bearing mountingbolt is torqued in sequence to specification.Refer to Section 2, Specifications.

Bolt torque sequence

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REV A

D-4Replace the Drive Hub Oil


Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.

1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

3 Drive the machine until one plug is at the topand the other is at 90 degrees.

a drive hub plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Refer to Section 2, Specifications.


6 Repeat this procedure for the other drive hub.


D-5Replace the Hydraulic TankReturn Filter Element

Note: Genie specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first. Perform thisprocedure more often if dusty conditions exist.

Replacement of the hydraulic return filter element isessential for good machine performance andservice life. A dirty or clogged filter element maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require that thefilter element be replaced more often.

Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.

1 Locate the hydraulic return filter housing on topof the hydraulic tank.

2 Clean the area around the oil filter housing caplocated on top of the reservoir.

3 Remove the cap from the housing.

4 Lift the handle on the filter element and rotatethe element counterclockwise to release theelement from the housing.

5 Remove the filter element from the filterhousing.

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REV A

6 Install the new oil filter element into the filterhousing.

7 Push the filter element down to be sure the o-ring on the element is fully seated into thehousing.

8 Rotate the filter element clockwise to lock it inplace.

9 Install the filter housing cap.

10 Clean up any oil that may have spilled duringthe replacement procedure.

11 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housing.

12 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition.

13 Move and hold the function enable toggle switchto either side and move and hold the primaryboom toggle switch in the up direction.

14 Inspect the filter housing and relatedcomponents to be sure that there are no leaks.


D-6Inspect for Turntable BearingWear

Note: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.

Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.

1 Grease the turntable bearing. See A-5, Greasethe Turntable Bearing and Rotate Gear.

2 Torque the turntable bearing bolts tospecification. See D-3, Check the TurntableRotation Bearing Bolts.

3 Raise the primary and secondary booms to fullheight using the ground controls. Do not extendthe primary boom.



REV ACHECKLIST D PROCEDURES

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or in line with, the boom and no morethan 1 inch / 2.5 cm from the bearing.

Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch / 2.5 cm fromthe turntable rotation bearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 Adjust the dial indicator to "0".

6 Lower the secondary boom to the stowedposition and lower the primary boom to ahorizontal position. Fully extend the primaryboom.

7 Note the reading on the dial indicator.

Result: The measurement is less than0.055 inch / 1.4 mm. The bearing is good.

Result: The measurement is more than0.055 inch / 1.4 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the primary boom. Raise theprimary and secondary booms to full height.Visually inspect the dial indicator to be sure theneedle returns to the "0" position.

9 Remove the dial indicator and rotate theturntable 90°.

10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.

11 Lower the primary and secondary booms to thestowed position and turn the machine off.

12 Remove the dial indicator from the machine.

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REV A

E-1Test or Replace the Hydraulic Oil

Note: Genie specifications require that thisprocedure be performed every 2000 hours or everytwo years, whichever comes first. Perform thisprocedure more often if dusty conditions exist.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require that the oilbe changed more often.

Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

Note: Perform this procedure with the boom in thestowed position.

1 Close the hydraulic shutoff valve located at thehydraulic tank.

Component damage hazard. Themachine must not be operatedwith the hydraulic tank shutoffvalve in the closed position orcomponent damage will occur. Ifthe tank valve is closed, removethe key from the key switch andtag the machine to informpersonnel of the condition.

2 Place a suitable container under the hydraulictank. Refer to Section 2, Specifications.

3 Tag, disconnect and plug the hydraulic hosefrom the hydraulic tank shutoff valve.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

4 Open the valve on the hydraulic tank andcompletely drain the oil into a suitablecontainer.


Checklist E Procedures



REV A

5 Tag, disconnect and plug the hydraulic hosesfrom the hydraulic tank return filter housing.Cap the fittings on the filter housing.



6 Remove the hydraulic tank mounting fasteners.Remove the hydraulic tank from the machine.

7 Remove the tank lid retaining fasteners andremove the lid and return filter assembly fromthe tank.

8 Remove the suction strainer from the hydraulictank and clean it using a mild solvent.

9 Rinse out the inside of the tank with a mildsolvent.

10 Install the suction strainer into the tank.

11 Install the lid and return filer assembly onto thehydraulic tank.

12 Install the hydraulic tank on the machine. Installthe hydraulic tank mounting fasteners andtorque them to 8 ft-lbs / 10.8 Nm.

Component damage hazard. Thehydraulic tank is plastic and maybecome damaged if the tankmounting fasteners are overtightened.

13 Install the hydraulic hoses.

14 Fill the tank with hydraulic oil until the fluid iswithin the FULL and ADD marks on the hydraulictank. Do not overfill. Refer to Section 2,Specifications.

15 Clean up any oil that may have spilled. Properlydiscard of used oil.

16 Open the hydraulic tank shutoff valve.

Component damage hazard. Besure to open the hydraulic tankshutoff valve after installing thehydraulic tank.

CHECKLIST E PROCEDURES



REV A

E-2Grease the Steer AxleWheel Bearings

Note: Genie requires that this procedure beperformed every 2000 hours or every two years,whichever comes first.

Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not removethem.

2 Block the non-steer wheels and center a liftingjack under the steer axle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the drive chassis for support.

4 Remove the lug nuts. Remove the tire andwheel assembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.

Note: Rotate the hub by hand while torquing thecastle nut to make sure the bearings seat properly.

8 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is no side to side or up anddown movement, continue with step 10 togrease the wheel bearings.

Result: If there is side to side or up and downmovement, continue to step 10 and replace thewheel bearings with new ones.

Note: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.

10 Remove the castle nut.

11 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

12 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

13 Pack both bearings with clean, fresh grease.



CHECKLIST E PROCEDURES



REV ACHECKLIST E PROCEDURES

14 Place the large inner bearing into the rear of thehub.

15 Install a new bearing grease seal into the hub bypressing it evenly into the hub until it is flush.

Note: Always replace the bearing grease sealwhen the hub has been removed.

16 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

17 Fill the hub cavity with clean, fresh grease.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

20 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.



22 Install a new cotter pin. Bend the cotter pinto lock it in.

Note: Always use a new cotter pin when installinga castle nut.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.


June 2011 Section 4 • Repair Procedures

Repair Procedures

Observe and Obey:

Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.


Repair any machine damage or malfunctionbefore operating the machine.

Before Repairs Start:

Read, understand and obey the safety rules andoperating instructions in the appropriateoperator's manual on your machine beforeattempting any maintenance or repair procedure.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:


• Boom in stowed position

• Turntable rotated with the boom betweenthe non-steer wheels


• Wheels chocked


About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then toreassemble, perform the disassembly steps inreverse order.

Symbols Legend






Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.


June 2011Section 4 • Repair Procedures

REV A

1-1Controllers

The drive joystick is connected to the drive motorcontroller, located under the drive chassis cover atthe non-steer end of the machine. Maintaining theboom function speed controller at the propersettings is essential to safe machine operation.The boom function speed controller should operatesmoothly and provide proportional speed controlthrough its entire range of motion. For furtherinformation or assistance, contact the GenieIndustries Service Department.

a boom function speed controllerb drive and brake printed circuit boardc drive joystick

Boom Function SpeedController Adjustments


Note: Do not adjust the boom function speedcontroller unless the static battery supply voltage isabove 24V DC.

1 Turn the key switch to platform controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Open the platform control box lid and locate theboom function speed controller.

a black/red wireb diodec white/red wired boom function speed controllere ramp rate trimpotf threshold trimpotg max out trimpot

Platform Controls

a

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REV A PLATFORM CONTROLS

3 Locate the diode between the black/red wirefrom the boom function speed controller and thewhite/red wire. Disconnect the white/red wirefrom the diode on the black/red wire.

4 Connect the negative lead from a multimeter setto measure amperage to the wire connector ofthe white/red wire. Connect the positive lead ofthe multimeter to the diode on the black/redwire.

5 Turn the boom function speed controller to theCREEP position.

6 Set the threshold: Press down the foot switchand move the primary boom toggle switch tothe up position. Adjust the amperage to 0.28A.Turn the threshold trimpot adjustment screwclockwise to increase the amperage orcounterclockwise to decrease the amperage.

7 Turn the boom function speed controller tothe 9 position.

8 Set the max out: Press down the foot switchand move the primary boom toggle switch tothe down position. Adjust the amperageto 0.65A. Turn the max out trimpot adjustmentscrew clockwise to increase the amperage orcounterclockwise to decrease the amperage.

9 Start a timer and simultaneously press downthe foot switch and move the primary boomtoggle switch in the down direction. Note howlong it takes to reach 0.65A.

10 Set the ramp rate: Turn the ramp rate trimpot toobtain a 2 second delay from 0 to 0.65A. Turnthe trimpot clockwise to increase the time orcounterclockwise to decrease the time.

11 Disconnect the leads from the multimeter andconnect the white/red wire to the diode on theblack/red wire.

Boom function speedcontroller specifications

Threshold 0.28A(controller turned to CREEP)

Max out 0.65A(controller turned to 9)

Ramp rate 2 seconds



REV A

2-1Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of primary boom motion. It operates ina closed loop hydraulic circuit with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent platformmovement in the event of a hydraulic line failure.

How to Remove the SlaveCylinderNote: Before cylinder removal is considered, bleedthe slave cylinder to be sure there is noair in the closed loop hydraulic circuit.


1 Extend the boom until the slave cylinderbarrel-end pivot pin is accessible.

2 Raise the boom slightly and place blocks underthe platform for support. Lower the boom untilthe platform is resting on the blocks.

3 Tag and disconnect the hydraulic hoses to theslave cylinder at the union and connect themtogether with a connector. Cap the fittings onthe cylinder hoses.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

4 Remove the external snap rings from therod-end pivot pin. Do not remove the pin.

5 Remove the external snap rings from thebarrel-end pivot pin.

6 Place a block of wood under the barrel of theslave cylinder for support.

7 Use a soft metal drift to remove the rod-endpivot pin.

Crushing hazard. The platformcould fall if not properly supported.

8 Use a soft metal drift to remove the barrel-endpivot pin.

9 Carefully pull the cylinder with hydraulic hosesout of the boom.

Crushing hazard. The slavecylinder could fall if not properlysupported.

How to Bleed the Slave Cylinder1 Raise the jib boom to a horizontal position.

2 Move the platform level toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.

Platform Components



REV A PLATFORM COMPONENTS

2-2Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform180 degrees.

How to Remove thePlatform RotatorNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Remove the platform.

2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotate manifold.


3 Support the platform mounting weldment. Donot apply any lifting pressure.

4 Remove the six mounting bolts from theplatform mounting weldment. Remove thecenter bolt and slide the platform mountingweldment off of the platform rotator.

5 Support the platform rotator with a suitable liftingdevice. Do not apply any lifting pressure.

6 Remove the pin retaining fasteners from the jibboom and leveling links to platform rotator pivotpins. Do not remove the pins.

7 Support the jib boom, jib boom cylinder andleveling links with an overhead crane.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

Crushing hazard. The platformrotator may fall when the pins areremoved if not properly supported.

Note: When installing the platform rotator, be sureto torque the fasteners to specification. Refer toSection 2, Specifications.

How to Bleed the PlatformRotator Note: This procedure will require two people.

1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right and then to the left throughtwo platform rotation cycles. Then hold theswitch to the right position until the platform isfully rotated to the right.



REV APLATFORM COMPONENTS

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a containerto collect any drainage. Secure the container tothe boom.

3 Open the top bleed valve on the rotator, but donot remove it.

a clear hoseb top bleed valvec bottom bleed valved container

4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

5 Connect the clear hose to the bottom bleedvalve and open the valve. Do not remove thebleed valve.

6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedvalve. Close the bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

7 Remove the hose from the bleed valve andclean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions andinspect the bleed valves for leaks.

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REV A PLATFORM COMPONENTS

2-3Platform Overload System(if equipped)

How to Calibrate the PlatformOverload SystemCalibration of the platform overload system isessential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.

Note: Perform this procedure with the machine ona firm, level surface.


2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Note: Failure to remove all weight, tools andaccessories from the platform will result in anincorrect calibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.

5 Move the platform up and down by hand, so itbounces approximately 2.5 to 5 cm / 1 to 2inches. Allow the platform to settle.

Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Slowly tighten theload spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator light and alarmresponds.


Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds.Proceed to step 7.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.

Note: The platform will need to be moved up anddown and allowed to settle between eachadjustment.

Note: There may be a 2 second delay before theplatform overload indicator lights and alarmresponds.



REV APLATFORM COMPONENTS


Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.

Result: The overload indicator lights areflashing at the platform and ground controls,and the alarm is sounding. Repeat thisprocedure beginning with step 5.


8 Add an additional 10 lb / 4.5 kg test weight tothe platform.

Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.

Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.



Result: All platform control functions should notoperate.

10 Turn the key switch to ground control.


Result: All ground control functions should notoperate.

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

Note: There may be a 2 second delay before theoverload indicator lights and alarm turn off.


Result: All ground control functions shouldoperate normally.



Result: All platform control functions shouldoperate normally.



REV A

3-1Jib Boom

How to Remove the Jib BoomNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.


2 Remove the platform mounting weldmentand the platform rotator. See 2-2, How toRemove the Platform Rotator.

3 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thejib boom lift cylinder.


4 Remove the cable cover from the side of thejib boom.

5 Remove the mounting fasteners from the jibboom/platform rotate manifold and lay themanifold to the side. Do not remove the hosesor disconnect the wiring.

Component damage hazard.Hoses and cables can bedamaged if they are kinked orpinched.

6 Models with rotating jib boom: Tag,disconnect and plug the hydraulic hoses fromthe jib boom rotator. Cap the fittings on therotator manifold.


7 Attach a lifting strap from an overhead crane tothe jib boom.

8 Models without rotating jib boom: Removethe pin retaining fastener from the jib boompivot pin at the jib boom bellcrank. Use a softmetal drift to remove the pin, then remove thejib boom from the jib boom bellcrank.

Crushing hazard. The jib boomcould fall when the pin is removedif not properly supported by theoverhead crane.

Models with rotating jib boom: Remove thepin retaining fastener from the jib boom pivotpin at the jib boom rotator. Use a soft metal driftto remove the pin, then remove the jib boomfrom the jib boom rotator.

Crushing hazard. The jib boomcould fall when the pin is removedif not properly supported by theoverhead crane.

Jib Boom Components



REV A

9 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

10 Models without rotating jib boom: Removeboth of the jib boom leveling links from the bellcrank.

Models with rotating jib boom: Remove bothof the jib boom leveling links from the jib boomrotator.

11 Attach a lifting strap from an overhead crane tothe rod-end of the jib boom lift cylinder.

12 Models without rotating jib boom: Use a softmetal drift to remove the jib boom lift cylinderrod-end pivot pin. Remove the jib boom liftcylinder from the bell crank.

Models with rotating jib boom: Use a softmetal drift to remove the jib boom lift cylinderrod-end pivot pin. Remove the jib boom liftcylinder from the jib boom rotator.

Crushing hazard. The jib boomlift cylinder could fall when the pinis removed if not properlysupported by the overhead crane.

JIB BOOM COMPONENTS

3-2Jib Boom Bell Crank(models without rotatingjib boom)

How to Remove the Jib BoomBell CrankNote: Perform this procedure with the boom in thestowed position.


1 Remove the Jib Boom, See 3-1, How toRemove the Jib Boom.

2 Support and secure the jib boom bell crank toan appropriate lifting device.

3 Remove the pin retaining fasteners from theslave cylinder rod-end pivot pin. Do not removethe pin.

4 Place a block of wood under the platformleveling slave cylinder for support. Protect thecylinder rod from damage.

5 Remove the pin retaining fasteners from the jibboom bell crank at the extension boom. Use asoft metal drift to remove the pin.

6 Use a soft metal drift to remove the slavecylinder rod-end pivot pin.

7 Remove the jib boom bell crank from theextension boom.

Crushing hazard. The jib boombell crank could becomeunbalanced and fall when the pinsare removed if not properlysupported and secured to thelifting device.



REV A

7 Place a block of wood under the platformleveling slave cylinder for support. Protect thecylinder rod from damage.

8 Remove the pin retaining fasteners from the jibboom bell crank at the extension boom. Use asoft metal drift to remove the pin.

9 Use a soft metal drift to remove the slavecylinder rod-end pivot pin.

10 Remove the jib boom bell crank from theextension boom.

Crushing hazard. The jib boombell crank could becomeunbalanced and fall when the pinsare removed if not properlysupported and secured to thelifting device.

3-3Jib Boom Rotator(models with rotating jib boom)

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the jib boom160 degrees.

How to Remove the Jib BoomRotatorNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Remove the jib boom, See 3-1, How to Removethe Jib Boom.

2 Support and secure the jib boom rotator to anappropriate lifting device.

3 Remove the eight mounting bolts from the jibboom rotator mount.

4 Remove the center bolt. Carefully remove thejib boom rotator from the machine.

Crushing hazard. The jib boomrotator could become unbalancedand fall when removed from themachine if not properly supportedand secured to the lifting device.

Note: When installing the jib boom rotator, be sureto torque the fasteners to specification. Refer toSection 2, Specifications.

5 Support and secure the jib boom bell crank toan appropriate lifting device.

6 Remove the pin retaining fasteners from theslave cylinder rod-end pivot pin. Do not removethe pin.

JIB BOOM COMPONENTS



REV A

How to Bleed the Jib BoomRotatorNote: This procedure will require two people.

1 Turn the key switch to ground controls and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.

2 Connect a clear hose to the top bleed valve.Place the other end of the hose in a containerto collect any drainage. Open the top bleedvalve, but do not remove it.

a top bleed valveb clear hosec containerd bottom bleed valve

3 Move and hold the function enable toggle switchto either side and move and hold the jib boomrotate toggle switch to the right forapproximately 5 seconds, then release it.Repeat three times.

Crushing hazard. Keep hands andhead clear of the platform pivotweldment during rotation.

4 Move and hold the function enable switch toeither side and move and hold the jib boomrotate toggle switch to the left for approximately5 seconds, then release it. Repeat three times.

5 Fully rotate the jib boom to the left and continueholding the jib boom rotate toggle switch untilair stops coming out of the bleed valve.Immediately release the platform rotate toggleswitch and close the bleed valve.


6 Rotate the jib boom to the right until the jibboom is centered.

7 Connect the clear hose to the bottom bleedvalve and open the valve.

8 Rotate the jib boom to the right and continueholding the platform rotate toggle switch until airstops coming out of the bleed valve.

Crushing hazard. Keep hands andhead clear of the jib boom duringrotation.

9 Close the bleed valve and remove the hose.

10 Rotate the jib boom full left and right andinspect the bleed valves for leaks.


11 Turn the key switch to the off position and cleanup any hydraulic oil that may have spilled.

JIB BOOM COMPONENTS

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REV A

3-4Jib Boom Lift Cylinder

How to Remove the Jib BoomLift Cylinder

Note: When removing a hose assembly orfitting, the O-ring on the fitting and/or hose endmust be replaced and then torqued tospecification during installation. Refer toSection 2, Hydraulic Hose and Fitting TorqueSpecifications.

1 Raise the jib boom slightly and place blocksunder the platform mounting weldment forsupport. Lower the jib boom until the platform isresting on the blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the rod-end pivotpin half way out and lower one of the levelinglinks to the ground. Tap the pin the otherdirection and lower the opposite leveling link.Do not remove the pin.

5 Attach a lifting strap from an overhead crane tothe rod end of the jib boom lift cylinder.

6 Remove the pin retaining fasteners from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pivotpin.

7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin. Remove the jib boomlift cylinder from the machine.

Crushing hazard. The jib boom liftcylinder could fall when the pinsare removed if not properlysupported by the overhead crane.

JIB BOOM COMPONENTS



REV A

4-1Cable Track

The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.

How to Repair the Plastic CableTrack

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

1 Use a slotted screwdriver to pry down on thelower clip.

a link separation pointb lower clip

2 Repeat step 1 for each link.

3 To remove a single link, open the lower clip.Use a screwdriver to pry the link to the side.

4-2Primary Boom

How to Shim the Primary Boom1 Extend the boom until the wear pads are

accessible.

2 Loosen the wear pad mounting fasteners.

3 Install the new shims under the wear pad toobtain zero clearance and zero drag.

4 Tighten the mounting fasteners.

5 Extend and retract the boom through an entirecycle. Check for tight spots that could causescraping or binding.

Note: Always maintain squareness between theouter and inner boom tubes.

Primary Boom Components

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REV A PRIMARY BOOM COMPONENTS

How to Remove thePrimary Boom

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Note: Perform this procedure with the boom in thestowed position.



2 Remove the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 Remove the jib boom. See 3-1,How to Remove the Jib Boom.

4 Models without rotating jib boom: Removethe jib boom bellcrank. See 3-2, How toRemove the Jib Boom Bellcrank.

Models with rotating jib boom: Remove thejib boom rotator. See 3-3, How to Remove theJib Boom Rotator.

5 Tag, disconnect and cap the slave cylinderhydraulic hoses at the union. Plug the hosesfrom the slave cylinder.


6 Remove the upper cable track mountingfasteners from the platform end of the boom.

7 Remove the cable track mounting fasteners,then remove the cable track from the boom andlay it flat on the ground.

Component damage hazard. Thecable track can be damaged if it istwisted.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

8 Raise the secondary boom until the primaryboom lift cylinder rod-end pivot pin is accessibleabove the mid-pivot weldment. Turn themachine off.

9 Disconnect the battery packs from the machine.

10 Remove all the hose and cable clamps from theunderside of the primary boom and at the pivotend of the primary boom.



REV A

11 Attach a lifting strap of ample capacity from anoverhead 5 ton / 5000 kg crane to the primaryboom for support.

12 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

13 Open the platform control box.

14 Tag and disconnect each wire from the cables inthe platform control box.

15 Pull all the cables out of the platform controlbox.

16 Remove the front counterweight cover.

17 Remove the extension boom drive limit switchfrom the side of the primary boom at the pivotend. Do not disconnect the wiring.

18 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate manifold.

19 Pull all the electrical cables and hydraulic hosesout of the plastic cable track. Then pull all theelectrical cables and hydraulic hoses outthrough the boom rest pad.


20 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Use a softmetal drift to remove the pivot pin. Pull thecylinder back and secure it from moving.

21 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


22 Attach a lifting strap from an overhead crane tothe primary boom lift cylinder.

23 Place 2 x 4 x 18 inch / 5 x 10 x 46 cm supportblocks under the cylinder, across the secondaryboom.

24 Remove the pin retaining fastener from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

Crushing hazard. The primaryboom lift cylinder could fall when itis removed from the machine if notproperly supported.

25 Lower the rod end of the primary boom liftcylinder onto support blocks. Protect thecylinder rod from damage.

26 Remove the pin retaining fastener from theprimary boom pivot pin.

27 Remove the primary boom pivot pin with a softmetal drift. Carefully remove the primary boomassembly from the machine.

Crushing hazard. The primaryboom assembly could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

PRIMARY BOOM COMPONENTS




How to Disassemblethe Primary BoomNote: Complete disassembly of the boom is onlynecessary if the outer or inner boom tubes mustbe replaced. The extension cylinder can beremoved without completely disassembling theboom. See 4-4, How to Remove the ExtensionCylinder.

1 Remove the primary boom. See 4-2,How to Remove the Primary Boom.

2 Place blocks under the extension cylinder forsupport.

3 Remove the retaining fasteners from theextension cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

4 Remove and label the location of the wear padsfrom the top side of the boom tube at theplatform end of the boom.

Note: Pay careful attention to the location andamount of shims used with each wear pad.

5 Support the extension tube with an overheadcrane at the platform end of the boom.

Crushing hazard. The boomextension tube could fall whenremoved from the boom if notproperly supported.

6 Support and slide the extension tube out of theprimary boom tube. Place the extension tubeon blocks for support.

Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.

7 Remove the external snap rings from the slavecylinder barrel-end pivot pin.

8 Use a soft metal drift and drive the slavecylinder barrel-end pivot pin out.

9 Remove the slave cylinder from the primaryextension boom tube.

10 Remove the external snap rings from theextension cylinder rod-end pivot pins at theplatform end of the extension tube. Use a softmetal drift to remove the pins.

11 Support and slide the extension cylinder out ofthe pivot end of the boom extension tube. Placethe extension cylinder on blocks for support.




REV APRIMARY BOOM COMPONENTS

4-3Primary Boom Lift Cylinder

The primary boom lift cylinder raises and lowersthe primary boom. The primary boom lift cylinder isequipped with counterbalance valves to preventmovement in the event of a hydraulic line failure.

How to Remove the PrimaryBoom Lift Cylinder



1 Raise the secondary boom enough to accessthe primary boom lift cylinder barrel-endpivot pin.

2 Raise the primary boom enough to access theprimary boom lift cylinder rod-end pivot pin.

3 Support the primary boom lift cylinder with asuitable lifting device. Place a block of woodacross the upper secondary boom to supportthe cylinder when the rod-end pin is removed.

4 Attach an overhead crane to the primary boomat the platform end for support. Raise theprimary boom using the overhead crane justenough to relieve the pressure on the primaryboom lift cylinder rod-end pivot pin.

5 Remove the counterweight cover fasteners.Remove the counterweight cover from themachine.

6 Place a block of wood between thecounterweight plate on the leveling link and thecross member of the upper secondary boom.Carefully lower the secondary boom onto theblock.

Crushing hazard. Keep handsaway from the block and allmoving parts when lowering thesecondary boom onto the block.

7 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.

Crushing hazard. The primaryboom lift cylinder may fall if notproperly supported when therod-end pivot pin is removed.

8 Lower the rod end of the cylinder onto theblocks that were placed on the uppersecondary boom.

9 Remove the pin retaining fastener from theground control side upper secondary levelinglink pivot pin at the upper pivot (same side ofmachine as the primary boom lift cylinderbarrel-end pivot pin retainer).

10 Place a rod through the upper secondaryleveling link pivot pin at the upper pivot andtwist to remove the pin.



REV A

11 Swing the leveling link up out of the way andsecure it from moving.

12 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


13 Support the barrel end of the primary boom liftcylinder with straps or ropes to restrict it fromswinging freely.

14 Remove the pin retaining fastener from theprimary boom lift cylinder barrel-end pivot pin.Do not remove the pivot pin.

15 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

Crushing hazard. The primaryboom lift cylinder may fall whenthe barrel-end pivot pin is removedif not properly supported.

16 Attach an overhead crane or similar liftingdevice to the lug on the rod-end of the primaryboom lift cylinder. Carefully loosen the strapsand allow the primary boom lift cylinder toslowly swing down.

17 Carefully remove the cylinder from the machine.

Crushing hazard. The primaryboom lift cylinder will fall if notproperly supported when it isremoved from the machine.

PRIMARY BOOM COMPONENTS

4-4Extension Cylinder

The extension cylinder extends and retracts theprimary boom extension tube. The extensioncylinder is equipped with counterbalance valves toprevent movement in the event of a hydraulic linefailure.

How to Remove theExtension Cylinder



1 Raise the primary boom to the horizontalposition. Extend the boom 3 to 4 feet / 1 m untilthe extension cylinder rod-end pivot pins areaccessible.

2 Remove the external snap rings from theextension cylinder rod-end pivot pins. Use asoft metal drift to remove the pins.

3 Remove the counterweight cover fasteners.Remove the counterweight cover from themachine.

4 Raise the secondary boom until the mastercylinder rod-end pivot pin is accessible.



REV APRIMARY BOOM COMPONENTS

5 Remove the primary boom extend drive limitswitch from the pivot end of the primary boom.Do not disconnect the wiring.

6 Remove the retaining fastener from the mastercylinder rod-end pivot pin. Use a soft metal driftto remove the pin.

7 Manually retract the master cylinder and push ittoward the platform end of the boom to obtainenough clearance for extension cylinderremoval.

8 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


9 Remove the retaining fastener from theextension cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

10 Carefully pull out and properly support theextension cylinder from the primary boom witha lifting strap from an overhead crane.

Crushing hazard. The cylindercould fall if not properly supportedwhen it is pulled out of theextension tube.

Note: To make installation of the extension cylindereasier, be sure that the cylinder rod is extended3 to 4 feet / 1 m.

Note: During removal, the overhead crane strap willneed to be carefully adjusted for proper balancing.

4-5Platform Leveling MasterCylinder

The platform leveling master cylinder acts as apump for the slave cylinder. It is part of the closed-loop hydraulic circuit that keeps the platform levelthrough the entire range of primary boom motion.The platform leveling master cylinder is locatedinside the upper mid-pivot at the pivot end of theprimary boom.

How to Remove the PlatformLeveling Master Cylinder



Note: Before cylinder removal is considered, bleedthe cylinder to be sure that there is no air in theclosed loop. See 2-1, How to Bleed the SlaveCylinder.




1 Remove the counterweight cover.

2 Raise the secondary boom until the mastercylinder barrel-end pivot pin is above theturntable counterweights.

3 Raise the primary boom until the mastercylinder rod-end pivot pin is accessible.

4 Attach an overhead crane to the pivot end of theprimary boom for support. Do not lift it.

5 Secure the upper secondary boom to the pivotend of the primary boom with a strap (this willprevent the upper secondary boom from fallingwhen the master cylinder barrel-end pivot pin isremoved from the cylinder).

6 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


7 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder,then secure the strap to the primary boom (usethis strap to lower the master cylinder out of theupper pivot).

8 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

9 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin. Use a softmetal drift to remove the pin from the cylinder.Do not remove the pin from the upper pivot.Push the pin to one side, only far enough toremove the cylinder. The pin should remain inone side of the upper secondary boom andupper pivot.

Crushing hazard. The uppersecondary boom and the upperpivot could fall if the pivot pin iscompletely removed.

10 Use the strap around the rod-end lug to lowerthe cylinder out of the machine.



REV ASecondary Boom Components

Secondary Booma upper pivotb upper compression armc mid-pivotd compression linke lower secondary boomf lower compression armg turntable pivoth counterweight (Z-30N / Z-30N RJ)i upper secondary boom

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REV A SECONDARY BOOM COMPONENTS

5-1Secondary Boom

How to Disassemble theSecondary Boom

Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.


1 Remove the counterweight cover.

2 Place a suitable lifting device under the platformfor support.


4 Remove the cable cover from the side of the jibboom.

5 Remove the wire loom from the cables at theplatform control box.

6 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.

7 Open the platform control box.

8 Tag and disconnect each wire from the cablesin the platform control box.


9 Pull the cables out of the platform control box.

10 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.

11 Remove the hose clamps from the bottom sideof the primary boom.

12 Tag, disconnect and plug the hydraulic hosesfrom the "P" and "T" ports at the jib boom/rotatemanifold. Cap the fittings on the manifold.


13 Remove the hose clamp from the side of theprimary boom at the pivot end.

14 Remove the primary boom extend drive speedlimit switch (LS1) mounted on the side of theprimary boom at the pivot end. Do notdisconnect the wiring.



REV ASECONDARY BOOM COMPONENTS

15 Attach a lifting strap from an overhead crane tothe pivot end of the primary boom.

16 Carefully lift the secondary and primary boomassembly with the overhead crane until themaster cylinder and primary boom lift cylinderhydraulic hoses are accessible.

17 Remove the cable covers from the top of theupper secondary boom.

18 Tag, disconnect and plug the primary boom liftcylinder and master cylinder hydraulic hoses.Cap the fittings on the cylinders.


19 Lower the secondary boom to the fully stowedposition.

20 Pull all the cables and hoses through the upperpivot.


21 Position a lifting strap from the overhead craneapproximately 2 feet / 60 cm from the platformend of the primary boom. Measure from theplatform end of the primary boom tube.

22 Remove the pin retaining fasteners from theupper pivot to upper secondary compressionarm pivot pins. Use a soft metal drift to removethe pins.

23 Swing the compression arms down and out ofthe way. Secure them from moving.

24 Remove the pin retaining fasteners from theupper pivot to the upper secondary boom pivotpin. Use a soft metal drift to remove the pin.

25 Carefully remove the entire primary boomassembly from the machine (primary boomassembly, jib boom assembly, platform, mastercylinder, primary lift cylinder and upper pivot).

Crushing hazard. The primaryboom assembly could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane. Do not removethe assembly from the machineuntil it is properly balanced.


26 Place the entire assembly onto a structurecapable of supporting it.

27 Remove the pin retaining fasteners from theupper secondary compression arm pivot pins.Do not remove the pins.




28 Position a lifting strap from an overhead crane atthe center of the control box side uppersecondary compression arm.

29 Use a soft metal drift to remove the uppersecondary boom compression arm pivot pinsand remove the compression arm from themachine. Repeat this step for the hydraulic tankside upper secondary compression arm.

Crushing hazard. The uppersecondary compression arm couldbecome unbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

30 Close the hydraulic tank shutoff valve. Tag,disconnect and plug the hydraulic hose fromthe hydraulic tank shutoff valve.


31 Open the valve on the hydraulic tank and drainthe oil into a container of suitable capacity.Refer to Section 2, Specifications.


32 Tag, disconnect and plug the hydraulic hosefrom the hydraulic tank return filter housing.Cap the fitting on the filter housing.




34 Open the ground controls side turntable cover.

35 Remove the terminal strip cover retainingfasteners. Remove the cover.

36 Remove the terminal strip retaining fasteners.Do not disconnect the wiring.

37 Remove the plastic plug in the bulkhead toaccess the secondary boom lift cylinder rod-endpivot pin.

38 Remove the pin retaining fastener from the rodend of the secondary boom lift cylinder. Use asoft metal drift to remove the pin through theaccess holes in the bulkheads. Secure thecylinder from moving.

39 Remove the pin retaining fastener from thelower pivot pin on the compression link. Use asoft metal drift to remove the pin.



REV ASECONDARY BOOM COMPONENTS

40 Attach a lifting strap from an overhead crane tothe upper secondary boom.

41 Remove the pin retaining fastener from themid-pivot to upper secondary boom pivot pin.Use a soft metal drift to remove the pin.

42 Remove the upper secondary boom withcompression link from the machine.

Crushing hazard. The uppersecondary boom withcompression link could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.

43 Z-30N and Z-30N RJ: Remove the mountingfasteners from the counterweight attached tothe lower leveling link.

44 Z-30N and Z-30N RJ: Attach a lifting strap froman overhead crane to the counterweight.Remove the counterweight from the lowerleveling link.

Tip-over hazard. The counterweightis critical to machine stability. Ifthe counterweight is not installedduring reassembly of the machine,the machine will become unstableand tip over.

Crushing hazard. Thecounterweight could becomeunbalanced and fall whenremoved from the machine if notproperly supported by the overheadcrane.

45 Remove the mounting fasteners from thefunction manifold and slide the function manifoldto the side. This will allow access to thesecondary boom lift cylinder barrel-end pivotpin.

46 Remove the mounting fasteners from theauxiliary power unit. Do not disconnect theelectrical cables or hydraulic hoses.

47 Slide the auxiliary power unit to the side toaccess the other secondary boom lift cylinderbarrel-end pivot pin.

48 Remove the retaining fasteners from thesecondary boom lift cylinder barrel-end pivotpins.

49 Attach a lifting strap from an overhead crane tothe lug on the rod end of the secondary boomlift cylinder.

50 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder. Cap thefittings on the cylinder.


51 Use a slide hammer to remove the barrel-endpivot pins (access the pins from the accessholes in the bulkheads, one on each side).Remove the secondary boom lift cylinder fromthe machine.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall whenremoved from the machine if notproperly supported by the overheadcrane.




52 Attach a lifting strap from an overhead crane tothe mid-pivot for support.

53 Remove the pin retaining fasteners from themid-pivot to the lower secondary compressionarm pivot pins. Use a slide hammer andremove the pins. Lower the compression armsdown.

54 Remove the pin retaining fasteners from themid-pivot to the lower secondary boom pivotpin. Use a soft metal drift to remove the pins.

55 Remove the mid-pivot from the machine.

Crushing hazard. The mid-pivotcould become unbalanced and fallwhen removed from the machine ifnot properly supported by theoverhead crane.

56 Remove the secondary boom drive speed limitswitch (LS4) mounted to the turntable riser onthe ground controls side. Do not disconnect thewiring.

57 Attach a lifting strap from an overhead crane tothe ground control side lower secondary boomcompression arm.

58 Remove the pin retaining fastener from thelower secondary boom compression arm toturntable riser pivot pin.

59 Use a slide hammer and remove the pin.Remove the compression arm from themachine. Repeat for the hydraulic tank sidelower secondary boom compression arm.

Crushing hazard. The lowersecondary compression arm couldbecome unbalanced and fall whenremoved from the machine if notproperly supported by the overheadcrane.

60 Attach a lifting strap from an overhead crane tothe lower secondary boom.

61 Remove the pin retaining fastener from the lowersecondary boom to turntable riser pivot pin. Usea soft metal drift to remove the pin.

62 Remove the lower secondary boom from themachine.

Crushing hazard. The lowersecondary boom could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.



REV A

5-2Secondary Boom Lift Cylinder

The secondary boom lift cylinder raises andlowers the secondary boom. The secondaryboom lift cylinder is equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure.

How to Remove the SecondaryBoom Lift Cylinder



1 Rotate the turntable to either side until the boomis centered between the steer and non-steertires.

2 Raise the primary boom to full height. Do notextend it.

3 Swing out the battery pack that is directly belowthe secondary boom lift cylinder.


SECONDARY BOOM COMPONENTS

5 Open the hydraulic tank side turntable cover.

6 Tag and disconnect the power cables on theauxiliary power unit.


7 Close the hydraulic tank shutoff valve. Tag anddisconnect and plug the hydraulic hose fromthe hydraulic tank shutoff valve.


8 Open the valve on the hydraulic tank and drainthe oil into a container of suitable capacity.Refer to Section 2, Specifications.


9 Tag, disconnect and plug the hydraulic hosefrom the hydraulic tank return filter housing.Cap the fitting on the filter housing.





REV A


11 Open the ground controls side turntable cover.

12 Remove the terminal strip cover retainingfasteners. Remove the cover.

13 Remove the terminal strip retaining fasteners.Do not disconnect the wiring.

14 Remove the plastic plug in the bulkhead toaccess the secondary boom lift cylinder rod-endpivot pin.

15 Remove the mounting fasteners from thefunction manifold and slide the manifold to theside This will allow access to the hydraulic tankside barrel-end pivot pin.

16 Attach a lifting strap from an overhead crane tothe lug on the rod end of the secondary boomlift cylinder.

17 From the bottom side of the cylinder, removethe retaining fasteners from the secondaryboom lift cylinder barrel-end pivot pins.

18 Remove the hose clamp under the lowersecondary boom.

19 Use a slide hammer to remove both barrel-endpivot pins (access the pins from the accessholes in the bulkheads, one on each side).

20 Remove the pin retaining fastener from thesecondary boom lift cylinder rod-end pivot pin.

SECONDARY BOOM COMPONENTS

21 Use a soft metal drift to remove the secondaryboom rod-end pivot pin.

Crushing hazard. The secondaryboom lift cylinder may fall whenthe rod-end pivot pin is removed ifnot properly supported by theoverhead crane.

22 Carefully lower the cylinder down through thesecondary boom, enough to access thehydraulic hoses. Do not pinch the hoses.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

23 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder. Cap thefittings on the cylinder.


24 Remove the cylinder through the top of thesecondary boom.

Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall whenremoved from the machine if notproperly supported by theoverhead crane.



REV AHydraulic Pumps

6-1Auxiliary and Function Pump

How to Remove the AuxiliaryPump or Function PumpNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Tag and disconnect the cables from the auxiliarypump.


2 Close the hydraulic shutoff valve located at thehydraulic tank.

Component damage hazard. Themachine must not be operatedwith the hydraulic tank shutoffvalve in the closed position orcomponent damage will occur. Ifthe tank valve is closed, removethe key from the key switch andtag the machine to informpersonnel of the condition.

3 Tag, disconnect and plug the hydraulic hosesfrom the pump. Cap the fittings on the pump.


4 Remove the pump mounting bolts from thepump. Carefully remove the pump from theelectric motor.



REV A




REV B

7-1Function Manifold Components

The function manifold is locate behind the ground controls turntable cover.

Index SchematicNo. Description Item Function Torque

1 Solenoid valve, 3 position 4 way ......A ........... Platform level up/down ..................... 20-25 ft-lbs / 27-34 Nm

2 Counterbalance valve .......................B ........... Platform level down .......................... 20-25 ft-lbs / 27-34 Nm

3 Counterbalance valve ...................... C ........... Platform level up ............................... 20-25 ft-lbs / 27-34 Nm

4 Relief valve, 1100 psi / 75.8 bar ...... D ........... Turntable rotate left/right .................. 30-35 ft-lbs / 41-47 Nm

5 Relief valve, 1600 psi / 110 bar ........E ........... Secondary boom down .................... 20-25 ft-lbs / 27-34 Nm

6 Relief valve, 1600 psi / 110 bar ........ F ........... Primary boom down ......................... 20-25 ft-lbs / 27-34 Nm

7 Relief Valve, 1800 psi / 124 bar

(Z-30 N RJ) ....................................... G ........... Primary boom extend ....................... 20-25 ft-lbs / 27-34 Nm

8 Proportional solenoid valve ............. H ........... System flow regulating circuit ........... 30-35 ft-lbs / 41-47 Nm

9 Check valve ....................................... I ............ Brake circuit ...................................... 10-12 ft-lbs / 14-16 Nm

10 Solenoid valve, 3 position 4 way ...... J ............ Steer left/right .................................... 20-25 ft-lbs / 27-34 Nm

11 Solenoid valve, 3 position 4 way ......K ........... Primary boom extend/retract ............ 20-25 ft-lbs / 27-34 Nm

12 Pressure switch ................................. L ........... Brake circuit

13 Solenoid valve, N.C. poppet ............ M ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm

14 Orifice, 0.045 inch / 1.14 mm ........... N ........... Brake circuit

This list continues. Please turn the page.

Manifolds



REV B MANIFOLDS

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REV BMANIFOLDS

Function Manifold Components, continued

The function manifold is locate behind the ground controls turntable cover.


15 Orifice, 0.045 inch / 1.14 mm ........... O ........... Brake and steer circuit

16 Solenoid valve, N.O. poppet .............P ........... Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm

17 Differential sensing valve ................. Q ........... Differential sensing circuit ................ 30-35 ft-lbs / 41-47 Nm

18 Relief valve,2800 psi / 193 bar(Z-30N and Z-30N RJ)

3200 psi / 221 bar(Z-34N and Z-34DC) ........................ R ........... System relief ..................................... 20-25 ft-lbs / 27-34 Nm

19 Orifice, 0.035 inch / 0.89 mm ............S ........... Tank return circuit

20 Diagnostic fitting ................................ T ........... Testing

21 Solenoid valve, 3 position 4 way ..... U ........... Secondary boom up/down ............... 20-25 ft-lbs / 27-34 Nm

22 Solenoid valve, 3 position 4 way ......V ........... Primary boom up/down .................... 20-25 ft-lbs / 27-34 Nm

23 Flow regulator valve,1.5 gpm / 5.7 L/min(before serial number 10808)

Flow regulator valve,1.8 gpm / 6.8 L/min(after serial number 10807) ............. W ........... Turntable rotate circuit ...................... 20-25 ft-lbs / 27-34 Nm

24 Flow regulator valve,0.8 gpm / 3 L/min ...............................X ........... Jib boom/platform rotate circuit ........ 20-25 ft-lbs / 27-34 Nm

25 Solenoid valve, 3 position 4 way ......Y ........... Turntable rotate left/right .................. 20-25 ft-lbs / 27-34 Nm



REV B MANIFOLDS

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REV B

7-2Valve Adjustments -Function Manifold

How to Adjust the System ReliefValve1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port on the function manifold.

2 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition.

3 Move and hold the function enable toggle switchto either side and move and hold the primaryboom extend/retract toggle switch in the retractdirection with the primary boom fully retracted.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the system reliefvalve with a wrench and remove the cap(item R).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

6 Repeat steps 2 and 3 to confirm the relief valvepressure setting.

How to Adjust the Primary BoomDown Relief Valve1 Connect a 0 to 3000 psi / 0 to 200 bar pressure



3 Move and hold the function enable toggle switchto either side and move and hold the primaryboom up/down toggle switch in the downdirection with the primary boom fully lowered.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the primary downrelief valve with a wrench and remove the cap(item F).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.



MANIFOLDS



REV B

How to Adjust the SecondaryBoom Down Relief Valve1 Connect a 0 to 3000 psi / 0 to 200 bar pressure



3 Move and hold the function enable toggle switchto either side and move and hold the secondaryboom up/down toggle switch in the downdirection with the secondary boom fullylowered. Observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.

4 Turn the machine off. Hold the secondary boomdown relief valve with a wrench and remove thecap (item E).




How to Adjust the Primary BoomExtend Relief Valve1 Connect a 0 to 3000 psi / 0 to 200 bar pressure



3 Move and hold the function enable toggle switchto either side and move and hold the primaryboom extend/retract toggle switch in the extenddirection with the primary boom fully extended.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the primary boomextend relief valve with a wrench and removethe cap (item G).


Tip-over hazard. Do not adjustthe relief valves higher thanspecified.


MANIFOLDS



REV B

How to Adjust the TurntableRotate Relief Valve1 Connect a 0 to 3000 psi / 0 to 200 bar pressure



3 Move and hold the function enable toggle switchto either side and move and hold the turntablerotate toggle switch in the right direction (untilturntable stops against the rotation stop).Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.

4 Turn the machine off. Hold the turntable reliefvalve(s) with a wrench and remove the cap(item D).




MANIFOLDS



REV B MANIFOLDS

7-3Jib Boom and Platform / Jib Boom Rotate Manifold Components(before serial numbers Z30N10-12102, Z30N10 (RJ)-12197, Z34N10-8838and Z3410-7720)

The jib boom/platform rotate manifold is mounted to the jib boom.


1 Solenoid valve, 3 position 4 way .... AA .......... Jib boom up/down ............................ 20-25 ft-lbs / 27-34 Nm

2 Solenoid valve, 3 position 4 way .... AB .......... Platform rotate left/right ..................... 20-25 ft-lbs / 27-34 Nm

3 Solenoid valve, 3 position 4 way .... AC .......... Jib boom rotate left/right ................... 20-25 ft-lbs / 27-34 Nm

4 Flow regulator valve,0.3 gpm / 1.14 L/min ........................ AD .......... Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm

5 Orifice plug, 0.025 inch / 0.64 mm .. AE .......... Jib boom rotate circuit(located under plug)

4

5

1 2 31

2

4

Models withoutrotating jib boom

Models withrotating jib boom

AA AB AC AD AA

AB

AE

AD



REV B MANIFOLDS

Jib Boom and Platform / Jib Boom Rotate Manifold Components(from serial numbers Z30N10-12102, Z30N10 (RJ)-12197, Z34N10-8838and Z3410-7720)

The jib boom/platform rotate manifold is mounted to the jib boom.


1 Solenoid valve, 3 position 4 way .... AA .......... Jib boom up/down ............................ 20-25 ft-lbs / 27-34 Nm

2 Solenoid valve, 3 position 4 way .... AB .......... Platform rotate left/right ..................... 20-25 ft-lbs / 27-34 Nm

3 Solenoid valve, 3 position 4 way .... AC .......... Jib boom rotate left/right ................... 20-25 ft-lbs / 27-34 Nm

4 Flow regulator valve,0.3 gpm / 1.14 L/min ........................ AD .......... Platform rotate circuit ........................ 20-25 ft-lbs / 27-34 Nm

5 Orifice plug, 0.025 inch / 0.64 mm .. AE .......... Jib boom rotate circuit(located under plug)

Models withoutrotating jib boom

Models withrotating jib boom

1AA

2AB

1 2 3

AA AB AC

4

AD

4AD

5AE



REV B

7-4Valve Coils

How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.


1 Tag and disconnect the wiring from the coil tobe tested.

2 Test the coil resistance.

Coils with 2 terminals: Connect the leads fromthe ohmmeter to the valve coil terminals.

Coils with 1 terminal: Connect the positivelead from the ohmmeter to the valve coilterminal, then connect the negative lead fromthe ohmmeter to the internal ring of the valvecoil.

Result: The resistance should be withinspecification, plus or minus 30%.

Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.

Valve Coil ResistanceSpecificationNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / 10°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Valve Coil Resistance Specification

Description Specification

Solenoid valve, 3 position 4 way, 20V DC 22 Ω(schematic items A, J, K, U, V, Y, AA, BB and CC)

Proportional solenoid valve, 24V DC 19.5 Ω(schematic item H)

Solenoid valve, N.C. poppet, 20V DC 23.5 Ω(schematic item M)

Solenoid valve, N.O. poppet, 20V DC 23.5 Ω(schematic item P)

MANIFOLDS



REV BMANIFOLDS

9V

BATTERY

10

RESISTOR

�

MULTI

METER

COIL

+

-

+

-

d

b

b

a

c

c

How to Test a Coil DiodeGenie incorporates spike suppressing diodes in allof its valve coils. Properly functioning coil diodesprotect the electrical circuit by suppressing voltagespikes. Voltage spikes naturally occur within afunction circuit following the interruption ofelectrical current to a coil. Faulty diodes can fail toprotect the electrical system, resulting in a trippedcircuit breaker or component damage.


1 Test the coil for resistance. See How to Test aCoil.

2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

Note: The battery should read 9V DC or morewhen measured across the terminals.

Resistor, 10ΩΩΩΩΩGenie part number 27287

a multimeterb 9V DC batteryc 10Ω resistord coil

Note: Dotted lines in illustration indicate areversed connection as specified instep 6

3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DCcurrent, should be capable of reading up to 800mA.

4 Connect the negative lead to the other terminalon the coil.

Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the amperage reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.



REV A

8-1Turntable Rotation HydraulicMotor

The turntable rotation hydraulic motor is the onlyserviceable component of the turntable rotationassembly. The worm gear must not be removedfrom the housing. In order to remove the housing,the turntable has to be removed.

How to Remove the TurntableRotation MotorNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor. Cap thefittings on the motor.


2 Remove the turntable rotation motor mountingbolts. Remove the motor from the machine.

Turntable Rotation Components



REV ASteer Axle Components

9-1Hub and Bearings

How to Remove theHub and Bearings1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steer wheels and place a liftingjack under the steer axle.

3 Raise the machine. Place blocks underthe drive chassis for support.

4 Remove the lug nuts. Remove the tireand wheel assembly.

5 Remove the dust cap, cotter pin andcastle nut.

Note: Always use a new cotter pin when installing acastle nut.

6 Pull the hub off the yoke spindle. The washerand outer bearing should fall loose from thehub.

7 Place the hub on a flat surface and gently prythe grease seal out of the hub. Remove theinner bearing.

Note: When removing a bearing, always use a newinner bearing seal.

How to Install the Huband BearingsNote: When replacing a wheel bearing, both theinner and outer bearings, including the pressed-inraces, must be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rear of thehub.

3 Install a new bearing grease seal into the hubby pressing it evenly into the hub until it is flush.

Note: Always replace the bearing grease sealwhen removing the hub.

4 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

5 Fill the hub cavity with clean, fresh grease.

6 Place the outer bearing into the hub.

7 Install the washer and castle nut.

8 Tighten the castle nut to 158 ft-lbs / 214 Nmto seat the bearings.



10 Install a new cotter pin. Bend the cotter pin tolock it in place.

Note: Always use a new cotter pin when installing acastle nut.

11 Install the dust cap, then the tire and wheelassembly.

12 Lower the machine and remove the blocks.

13 Torque the wheel lug nuts to specification. Referto Section 2, Specifications.



REV A

10-1Motor Controller

The drive motor controller is located under the non-steer end drive chassis cover. The drive motorcontroller can recognize machine drivemalfunctions and display controller fault codes byflashing a LED at the ground controls and on themotor controller. See the Fault Code section of thismanual for a list of fault codes and additionalinformation. There are no adjustments needed onthe drive joystick controller. For further informationor assistance, consult the Genie Industries ServiceDepartment.

How to Test the Motor ControllerNote: Use the following procedure to test the motorcontroller. If the motor controller is found to befaulty, note which test failed and which fault code(if any) was present at the time of failure.

1 Turn the key switch to the off position anddisconnect the battery packs from the machine.

2 Tag and disconnect all power cables from themotor controller.


3 Press the release tab on the motor controllerharness connector and remove the motorcontroller harness connector from the motorcontroller.

4 Set an ohmmeter to diode test mode.

5 Connect the leads from an ohmmeter to testeach motor controller terminal combinationlisted below and check the forward / reversebias (diode test).

Result: All desired results must be within thespecified range. If any test has a result notwithin the specified range, replace the motorcontroller.

Forward Bias:

Test Desired result

Positive Lead Negative Lead

M- B+ 0.4 to 0.45

B- M- 0.4 to 0.45

F1 B+ 0.45 to 0.5

F2 B+ 0.45 to 0.5

B- F1 0.45 to 0.5

B- F2 0.45 to 0.5

Reverse Bias:

Test Desired result

Positive Lead Negative Lead

B+ M- Rises to .0L V

M- B- Rises to .0L V

B+ F1 Rises to .0L V

B+ F2 Rises to .0L V

F1 B- Rises to .0L V

F2 B- Rises to .0L V

Motor Controller





June 2011 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions in the appropriateoperator's manual on your machine beforeattempting any maintenance or repair procedure.

Be sure that all necessary tools and testequipment are available and ready for use.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.



Note: Two persons will be required to safelyperform some troubleshooting procedures.

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:


• Boom in stowed position

• Turntable rotated with the boom betweenthe non-steer wheels


• Wheels chocked



June 2011Section 5 • Fault Codes

REV BFAULT CODES

Tip-over hazard. When adjustingthe raised drive speed settings,the maximum raised drive speedmust not exceed 0.6 mph / 1Km/hor 40 feet / 45 seconds /12.2 meters / 45 seconds. If themachine is allowed to drive fasterthan specification, the machinecould become unstable and will tipover.

Note: Additional troubleshooting of the fault codesmay by accomplished by using the hand-heldpendant motor controller programmer (Genie partnumber 128551).

Note: When using the hand-held pendant motorcontroller programmer, the M1 MAX SPEED needsto be set to 33. If needed, adjust the M1 MAXSPEED higher or lower to achieve the maximumraised drive speed of 0.6 mph / 1Km/h or 40 feet /45 seconds / 12.2 meters / 45 seconds.

The controller status indicator light will flash a faultcode to aid in troubleshooting. This indicator lightis mounted on the tilt level sensor mountingbracket, located behind the cover on the groundcontrols side.

Fault codes are two digits. The controller statusindicator light will blink the first digit of a two digitcode, pause for 1 second, and then blink thesecond digit. There will be a 2 second pausebetween codes.

For example: the indicator light blinks 4consecutive times, pauses for 1 second, and thenblinks 1 time. That would indicate Fault Code 41.



REV BFault Code Chart

Fault Code Programmer Diagnostic Display Condition Possible Causes Solution

Fault code LED is off or is on,

but not blinking

COMMUNICATION ERROR Machine will not drive.

The key switch or Emergency Stop button(s) was cycled on and off faster than 5 seconds OR controller sensed an internal error during start up.

Push in the ground control red Emergency Stop button to the off position and wait for 5 seconds. Pull out the ground control red Emergency Stop button to the on position. If problem persists, replace the motor controller.

01 Normal operation.

12 HW FAILSAFE 1-2-3 Machine will not drive. The motor controller failed self test.

Replace the motor controller.

13 M- SHORTED Machine will not drive.

The motor controller has a internal short between M- and B- terminals.

Test the motor controller. See Repair Section.

FIELD OPEN Machine will not drive.

Motor wiring is loose OR motor is defective OR motor controller has an internal short.

Check for loose or open connections at the drive motors and motor controller OR replace the defective drive motor OR test the motor controller. See Repair Section.

ARM SENSOR Machine will not drive. Defective motor controller.


FLD SENSOR Machine will not drive. Defective motor controller.




REV BFAULT CODE CHART


21 THROTTLE FAULT 1 Machine will not drive.

Open in wht/red wire #32 at pin 14 or red/wht wire #29 at pin 16 on the motor controller going from drive joystick to pins 14 and 16 at the motor controller OR pin 14 is internally shorted to power or ground OR the potentiometer on the drive joystick is defective.

Consult Genie Industries Service Department.

THROTTLE FAULT 2 Machine will not drive.

Pin 14 (wht/red #32) is shorted to power or ground OR the potentiometer on the drive joystick is defective.


31 CONT DRVR OC Machine will not drive.

Main contactor (PR1) coil defective OR brake release relay CR5 defective.

Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller.

32 MAIN CONT WELDED Machine will not drive.

Main contactor (PR1) contacts stuck closed OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring OR motor controller has an internal short to ground.


33 PRECHARGE FAULT Machine will not drive.

External short between B+ terminal on motor controller and ground OR motor controller is defective.

Repair short between B+ terminal on motor controller and ground OR replace motor controller. Note: Short can be on any part of circuit connected to the B+ terminal on the motor controller.



REV B FAULT CODE CHART


34 MISSING CONTACTOR Machine will not drive.

Motor controller does not detect the main contactor PR1 or brake release relay CR5.


MAIN CONT DNC Machine will not drive.

Main contactor PR1 or brake release relay CR5 did not close OR open in org/red wire to PR1 and/or CR5 OR main contactor and/or brake release relay is defective.


41 LOW BATTERY VOLTAGE Machine will not drive.

Battery supply voltage to motor controller less than 32V DC.

Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller.

42 OVERVOLTAGE Machine will not drive.

Battery supply voltage to motor controller more than 55V DC OR machine is being operated with the battery charger plugged in.

Be sure the battery charger is disconnected OR check for loose battery cables or poor connections.

43 THERMAL CUTBACK Machine will not drive.

Machine being operated outside of temperature range of -13°F to 185°F / -25°C to 85°C OR machine being driven under excessive load OR motor controller is not being cooled sufficently.

Operate machine within specified temperature limits OR check for debris around motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine.





June 2011 Section 6 • Schematics

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine beforeattempting any maintenance or repair procedure.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test


June 2011Section 6 • Schematics

REV A

Electrical Symbols Legend

+

-

6V DCBattery

OR

G/B

LK-1

numbercablewithcolorWire

Connectionno terminal

P1

EmergencyStop button

normaly closed

PR4

Relay panelcontactor

Solenoid orrelay coil

Horn

Tilt sensor

NOHCLS1

Limit switchnormally open

held closed

P3HORN

Horn buttonnormally open

T-circuitconnected

LED

AP1

Quick disconnectterminal

Diode

BLK

FS1

Foot switch

Relay contactnormaly open

Relay contactnormally closed

TS3

EN

GIN

ES

TAR

T

Toggle switchSPDT

Circuits crossingno connection

Auxiliary / Primarylift pump

PUMP

Boom functionspeed controller

WH

T

GRNRED

BP1 BL

K/R

ED

Pressureswitch

PS

ITerminal

TB20

T-circuitconnects at terminal

BLK #21TB21

Circuit breaker

Drive motor

A2

A1 S1

S2

FB

Flashingbeacon

Hour meter

Fuse

Limit switch

NO

LS3

NC

Toggle switchDPDT

TS6

RIG

HT

LEFT

GR

N/B

LK

TB17

Groundsupression

circuit _

HM

+

PLATFORM

GROUND

KS1

Key switch

CR2

30

8785

86

CR2

30

8785

86



REV A

Hydraulic Symbols Legend

Fixed displacementpump

M

Pump prime mover(motor)

Check valve

Differentialsensing valve

Solenoid operatedproportional valve

Solenoid operated 3 position,4 way, directional valve

Pressure switch

N.C.COM

N.O.

Brake

Double actingcylinder

Orifice

0.045 /1.14 mm

Relief valve

Hydraulic filter

Counterbalance valve(dual)

Normally openpoppet valve

Normally closedpoppet valve

Filter with by-passcheck valve

Dual relief valve

Flow regulator valve

Counterbalance valve(single)

Bi-directional motor

Regen circuit

Shutoff valve


June 2011Section 6 • Schematics

REV A

Limit Switch Location Legend

Z-30/20NZ-30/20N RJ

Z-34/22Z-34/22N

LS1

LS2

LS4

LS2

LS4

LS1

6 - 5

Section 6 • Schematics June 2011

Electrical Schematic, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

6 - 6


1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N


REV BElectrical Schematic, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

LS

4-S

EC

. UP

/DW

N

LS

2-P

RI. U

P/D

WN

LS

1-E

XT

/RE

T

C48-3TB52

C9

HR

N B

K/R

D

C19LPE GR/WHP42BAT OR/RD

85

86

PR

IMA

RY

LIF

TP

UM

PP

R2

33�

R4

2B

AT

GR

/WH

PR2

CR20

30

87

AU

XIL

IAR

YL

IFT

PU

MP

PR

3

PR

IMA

RY

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

Y

33�

PR3

C4

9-1

1 C

19

LP

E G

R/W

H

C4

9-1

R2

7A

UX

RD

87a

CR3

87

30

P42BAT OR/RD C48-2

C7

B-2

P2

3B

AT

WH

C7

P-2

C4

8-1

P1

82

BA

TR

D

P2

2B

AT

BK

RD

P134BAT RD TB134

R42BAT OR/RD

C12FTS

10A

CB3

C1

33

PL

AB

L/R

DC

2P

-1C

2B

-1

C32

U6AMOTOR CONTROLLER

F4500A

C3

B-9

C1

B-1

2

H2

GR/BK

RD

TB134

C1P-12C132PLI BL/WH

C7

B-1

1 3

4

6 7

5

12 8

C40LS

C4

9-9

OR

C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

BK 2 GA

CH

AS

SIS

GR

OU

ND

J2

-BK

RD

P26BAT

13LS1

(EXT)

14 2

P2

2B

AT

BK

C7P-1

HO

RN

B

A C

P42BAT OR/RD

C4

9-7

C1

78

CS

LB

K

C49-10

C4

9-8

BK

C11

-3 B

K-6

C11

-4 W

H-6

C1

0-2

WH

-7

C1

0-1

BK

-7P

22

LS

BK

C5

2-1

BK

-8

C5

2-2

WH

-8

J1-WH

C4

9-3

C4

9-6

C4

9-5

C4

9-4

C2

B-4

C3

B-3

C1

B-2

C1

B-3

C1

B-4

C1

B-5

C1

B-6

C9P-2

C9P-3

R4

2B

AT

OR

/RD

C2

P-4

C3

BA

TR

D/W

HC

3P

-3

C2

8T

TA

RD

/BK

C1

P-2

C9

HR

N B

K/R

DC

3P

-9

C2

9JS

H R

D/W

HC

1P

-3

C3

2JS

LW

H/R

DC

1P

-6

C3

1R

EV

WH

/BK

C1

P-5

CR5

P182BAT BK

C19LPE GR/WH

R42BAT OR/RD

P24BAT WH

RD

C12DRE BL/WH

CR3

GND BR

TILTALARM

RD

WH-(FS)

FS1

H1

RD-(FS)

PLATFORM

GROUND

P1KS1

TB22

P3HORN

P2

RD

C9P-1 BK

+

RD

P182BAT RD

BK-(FS)

OR

/RD

CR1

CR2

TB42

RD

/WH

30

8785

86

87

3086

85

BR

N

BR

N

PR

1

OF

F-L

IMT

SP

D IN

P

INT

ER

LO

CK

L3

53 17

C1

82

PW

R G

R LS4(SEC)

OR

/RD

LS2(PRI)

RD

/BK

OR

/RD

C4

9-2

C4

8B

RK

RD

/BK

OR

/RD

20

CR

5

22

21

22

21

86

85

CB2

10 A

C1

P-4

RD

20

AP2

24V

FO

RW

AR

D

PO

T. L

OW

DIO

DE

RE

TU

RN

+4

8V

INP

UT

PO

T. H

I

RE

VE

RS

E

10

1 9 11

16

14

PR1

AP2 48V

R4

2B

AT

OR

/RD

WH

WH

/BK

WH

/RD

RD

/WH

F3100A

F510A

F2100A

++

+

+

LEFTBOX

--

-

-

48V

C3

0F

WD

WH

2

48

V P

OW

ER

RE

LA

YC

R1

FL

AS

HIN

G B

EA

CO

NO

PT

ION

48

V P

OW

ER

RE

LA

YC

R2

FB

+

HO

RN

RE

LA

Y

BA

SE

CO

NT

RO

LB

OX

GR

OU

ND

CR4

TIL

TS

EN

SO

RR

D

WH

BK

BR

N

F1

+

86

85

30

87

BR

N

BR

AK

E R

EL

EA

SE

RE

LA

YC

R5

PR

1 D

RIV

EC

ON

TA

CT

OR

AP1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

PR3 PR2

WH

BK

AC POWER

F2 F1

A2

A1

A2

A1+

-

PUMP

+

++

+

CHARGER

LEFTMOTOR

RIGHTBOX

-

--

-

GROUND

24V

SWITCH SHOWN WITH BOOM EXTENDED.

NOTES:

1. ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED.

SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL.

4. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

F2

F2F1 B+M-AP1 B-

PUMP

RIGHTMOTOR

2

3

BL

/WH

L48

ES34DCT

SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.5

OR

TS48DRIVELIGHTS

TS49WORKLIGHTS

CR45N.O.

87

30 86

85

L30

+

L30

+

PLATFORM BOXGROUND

C1

B-9

R4

2B

AT

OR

/RD

P4

8L

PS

WH

/RD

C1

P-9

F187A

WH

/RD

C2

B-9

WH

(16

/2)

WH

C1

B-8

DL

ITE

BK

/WH

C1

P-8

F197A

BK

/WH

C2

B-1

2W

H (1

6/2

)

CR23N.O.

87

30 86

85

L29

+

L29

+

WH

WH

WH

BK

BK

L3

0 W

OR

K L

IGH

TS

(OP

TIO

N)

L2

9 D

RIV

E L

IGH

T(O

PT

ION

)


1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A


REV B Electrical Schematic, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

JIB ROTATE OPTION(Z30N RJ ONLY)

JIBROTATE

RE

TR

AC

T

(GND)

CR3

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

DE

SC

EN

TA

LA

RM

SE

CO

ND

AR

YB

OO

M D

OW

N

SE

CO

ND

AR

YB

OO

M U

P

H4

+

WH

/BK

WH

TB4

BL

/BK

BL

TB5 TB11 TB10

OR

/BK

OR

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BK

/WH

BK

RD

/BK

RD

TB2 TB1 TB8 TB7 TB15 TB14

JIB

BO

OM

DO

WN

JIB

BO

OM

UP

PRIMARYBOOM

C19LPE GR/WH

TS55

C12DRE BL/WH

RD

CR5

RD

C2

PB

D R

D/B

K

C1

0S

BU

BL

C11

SB

D B

L/B

K

C5

TR

R W

H/B

K

C4

TR

LW

H

RIG

HT

TURNTABLEROTATE

FUNCTIONENABLE

LE

FT

TS62

RD

C3

B-4

C3

B-5

SECONDARYBOOM

TS60

DO

WN

UP

C3

B-1

1

C3

B-1

0

C3

B-1

C3

B-2

C3

P-4

C3

P-5

LE

FT

TS12

RIG

HT

TURNTABLEROTATE

C3

P-1

0

C3

P-1

1

C1

PB

U R

D

C3

P-2

C3

P-1

SECONDARYBOOM

DO

WN

2

6

CR19

UP

TS10

DO

WN

CR19

1

5

TS11

UP

C30FWD WH

C29JSH RD/WH

C31REV WH/BK

C32JSL WH/RD

R42BAT OR/RD

P24BAT WH

C1

8P

RR

BL

PLATFORMROTATE

PLATFORMROTATE

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C7

PB

E B

K

C8

PB

R B

K/W

H

DO

WN

TS61

UP

PRIMARYBOOM

TS63

EX

TE

ND

PRIMARYBOOM

C3

B-7

C3

B-8

PLATFORMLEVEL

DO

WN

TS59

C4

B-6

C4

B-5

C4

B-3

C4

B-2

C3

P-7

C3

P-8

EX

TE

ND

PRIMARYBOOM

RE

TR

AC

T

TS13

DO

WN

TS9

C4

P-3

C4

P-2

C4

P-5

C4

P-6

PLATFORMLEVEL

UP

RIG

HT

LE

FT

TS7

C4

7JR

R R

D

C4

6JR

LY

L

C4

7JR

R O

R/B

K

C4

6JR

LO

R

C4

4JD

WH

C4

3JU

BK

C1

7P

RL

OR

C4

3JU

GR

C4

4JD

GR

/BK

RIG

HT

LE

FT

TS57

C2

B-6

C2

B-5

JIB MANIFOLD

DO

WN

TS58

UP

JIBBOOM

C2

B-2

C2

B-3

C2

P-5

C2

P-6

DO

WN

TS8

UP

JIBBOOM

C2

P-3

C2

P-2

RIG

HT

LE

FT

TS16

C7

P-3

BA

TG

ND

BR

N

C8

-4

C8

-3

C1

6D

E O

R/R

D

PS

1

GR/WHP

RO

PO

RT

ION

AL

CO

NT

RO

LV

ALV

E

AU

XIL

IAR

YP

UM

P

TB6

WH

/RD

GR/WH

CR3

TB19

86

85

C19LPE

C2

7A

UX

RD

HO

UR

ME

TE

R

_

BR

AK

E R

EL

EA

SE

N.C

. VA

LV

E

ST

EE

R R

IGH

T

ST

EE

R L

EF

T

BR

AK

EP

RE

SS

UR

ES

WIT

CH

+

WH

/BK

HM

+

TB19

R48BRK

GR/WH

BL

BL

/BK

R4

8B

RK

RD

/WH

TB48

C8

-1

C7

B-3

BA

TG

ND

BR

N

C8

-2

TR

AV

EL

AL

AR

M

H3

TB52

13

RD

-5

RD

/WH

14

BR

N-5

22

LS321

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

BK

-5

TB16

WH

-5

TS15DRIVEENABLE

DP1

C6

MF

V W

H/R

D

C1

9L

PE

GR

/WH

C1

9L

PE

GR

/WH

LE

FT

TS66

RIG

HT

JIBROTATE

C3

B-6

C4

B-7

TB27C27AUX RD

RD

TS51AUXILIARYPUMP

ROTARYOEMFLOWCONTROL

BP1

C3

P-6

BK/RD

RD

GR

C4

P-7

+

BCIOPTION

E

F

C3

7S

CW

BL

/BK

C1

B-1

TB37

TB3687

30

CR5

C1

B-1

1

C1

B-1

0TS1AUXILIARYPUMP

C2

7A

UX

RD

C1

P-1

STEER

L R 10

9

LIFT

DRIVE

FWD

RD

-AU

X

REV

20K

4

8

7

6

5

3

2

1

C1

P-1

1

C1

P-1

0C

36

SC

C B

LR

D

P24BAT WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

C29JSH RD/WH

C1

3D

EL

BL

/RD

C1

2F

TS

BL

/WH

C1

2F

TS

BL

/WH

OR

/RD

C1

3D

EL

BL

/RD

BR

N

C3

B-1

2

TB12

C4

B-4

C4

B-1

C3

P-1

2

C1

6D

E O

R/R

DC

4P

-4

C4

P-1

L1

OR

/RD4

8

2 3

76

1

5

LVI/BCI(OPTION)

BK

7

8

CR19

BRN

WH

WH/RD

WH

UP

UP

5

C4

7-2

C4

7-1

C4

7-3

C4

7-4

C2

P-5

C2

P-5

3

OR

BR

AK

E R

EL

EA

SE

N.O

. VA

LV

E

PLATFORM CONTROLBOX GROUND

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

D29

D30

D50

C47-8 GRN

D72

D74

D4

D75

D71

D73

D66

D77

D78

D59

D60

D76

D87

D86

C4

9-1

6 - 8


6 - 7

Electrical Schematic, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-88577 and Z3410-7774)

6 - 9


Ground Control Box Terminal Strip Wiring Diagram,(ANSI / CSA / AS), (before serial numbers Z30N10-12119,Z34N10-8857 and Z3410-7774)

6 - 10


1

2

3

4

5

6

7

8



REV BGround Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

RD-C32-1 DESCRIPTIONTOFROMCIRCUIT#WIRES

C1B-5

C1B-4

C1B-3

C4B-6

C4B-5

C3B-9

C8-4

TILT-C

C52-2

C3B-3

C2B-5

C2B-6

C10-2

C11-3

C1B-6

C2B-3

C2B-2

WIRES FROM CONNECTOR TO CONNECTORTERMINAL BASE (TB)

TO TERMINAL BASEAND RELAY BLOCK

C49

C48

CHASSISHARNESS(CH)

MANIFOLDHARNESS(MH)

C1B

C2B

C4B

C3B

CABLE#3

CABLE#1

CABLE#2 C7B

C11

C8

C52

C10

LS4 - SECONDARYUP/DOWN

LS3 - DRIVE ENABLE

LS2 - PRIMARYUP/DOWN

LS1 - PRIMARYEXTEND/RETRACT

RD/WH-TILT WH C7B-2 134

134

RD-KSI-4

RD/WH (FLASH. BEACON OPT.)

JIB ROTATE LEFT (Z30NRJ ONLY)

JIB ROTATE RIGHT (Z30NRJ ONLY)

TS-66 (SP)C46JRLOR

OR/BK C47JRR TS-66 (SP)

BR- MH

RD/WH-MHWH/BK-SP

WH/BK-SP

OR/RD-CR5

BL-19D

BL/BK-19D

RD/WH-CR5

OR/RD-16A

RD/BK-C49-2

BK-22A

BK/RD-MH-HORN

BK/RD-C3B-9

CR5 - BRAKE RELEASE

RD-27D

CR1 - SECONDARY 48V POWER

CR3 - AUXILIARY PUMP

CR2 - PRIMARY 48V POWER

CR4 - HORN

CONTROL RELAY I.D.

WH C10-1

OR/RD-CR1

JOYSTICK POT. LOWWH/RD C32JSL C49-6 (CH)

CR1, #86, CR2, #86

RD-C49-1

LS1-LS2 JUNCTION

LS2-LS4 JUNCTION

OR/BK-MH

OR/RD C8-1

BR-CB2

BRBK

BK (FLASH. BEACON OPT.)

BR-SP

BR-CR4

RD/WH-SP

52

52J2

48

C52-1BR C7B-3BR C8-2

OR/RD-L3OR/RD C49-10

C49-4 (CH)

RD-CR3

TB36/TB37 GR/WH-CR3

GR/WH-SP

48V RELAY COIL POWER

GR/WH-19C

BR-52A

BL-MH

BL/BK-MH

C49-9 (CH)

CR4

GR/WH-C49-11

CR3CR2CR1

CR5

RD/WH-48D

OR/RD-42D

OR/RD-C48-2

RD/WH-C3B-3

WH J1 C11-4

TS-58 (SP)

TS-58 (SP)GR/BK

C43JU

C44JD

JIB UP

JIB DOWN

GR

C40LS

42

36

37

BK-CR4

RD-SP

C28TTA

27

C31REV

C30FWD

C29JSH

22

TILT ALARM

REVERSE

FORWARD

2-WIRE POT.

OFF-LIMIT SPEED

TS-57 (SP)

TS-57 (SP)

GR/WH-MH

BK C8-3

OR/BK-SP

OR-SPC17PRL

C18PRR

19

19

C13DEL12

14

15

16

BK/WH-SP

BK-SP

BL-SP

WH/BK-SP

RD/WH

RD/BK-SP

WH-SP

WH/RD-SP

8

C9HRN

7

10C3BAT

4

5

2

6

11 BL/BK-SP

DRIVE ENABLE LIGHT

PLATFORM ROTATE RIGHT

PLATFORM ROTATE LEFT

HORN

ORBL-MH

BL/BK-MH

RD/BK

C49-3 (CH)

C49-5 (CH)BK-SP

BL/RDBL/WH-CH

OR-MH

BK-MH

BK/RD

BK/WH-MH

WH-MH

RD/BK-MH

WH/BK-MH

WH/RD-MHWH/RD C3B-6

RD/BK C3B-2

WH/BK C3B-5

WH C3B-4

C4B-1

CR4, #86

BK/WH C3B-8

BK C3B-7

BL/WH C3B-12

BL/BK C3B-11

BL C3B-10

GR

OR/BK C4B-3

OR C4B-2

OR/RD C4B-4

GR/BK

GR/WH C4B-7

C1B-2

BK-C32-4

RD C1B-1

RD/WH

WH

WH/BK

BL C1B-10

BL/BK C1B-11

OR/RD C2B-4

ABCD

RD-MHRD C3B-1 1 RD-SP C1PBU

C12FTS

C6MFV

C7PBE

C11SBD

C10SBU

C19LPE

C8PBR

C14PLU

C15PLD

C2PBD

C4TRL

C5TRR

C37SCW

C27AUX

P22BAT

C36SCC

C16DE

C19LPE

R42BAT

R48BRK

BATGND

BATGND

P134BAT

P134BAT

CIRCUIT #DESCRIPTION

KEYSWITCH POWER

KEYSWITCH POWER

GROUND

GROUND

BRAKE RELEASE

SWITCHED 48V

LIFT PUMP

DRIVE ENABLE

STEER LEFT

+24V TO PLATFORM

AUXILIARY PUMP

STEER RIGHT

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

PRIMARY BOOM DOWN

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

PRIMARY BOOM RETRACT

LIFT PUMP

SECONDARY BOOM UP

SECONDARY BOOM DOWN

PRIMARY BOOM EXTEND

FUNCTION SPEED CONTROL

FOOTSWITCH

PRIMARY BOOM UP

30

8586

87A

87

REF.

(RELAY SOCKET SHOWN)

ES34DCT

OR/RD P42BAT CR2, #30 C48-2 48V POWER

RD/BK C48BRK CR5, #85 C49-2 BRAKE RELEASE

RD

L29

BR

CR23

F197A

WH

C2B-12WH

GND

AP2+48V DC

CR23 - DRIVE LIGHTS (OPTION)

DRIVE LIGHTS (OPTION)


1

2

3

4

5

6

7

8



REV B Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA / AS)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

KS1

TS51

TS57

TS55

P1

LABEL

TS61

TS63

TS62

CB2

TS59

PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH

CIRCUIT BREAKER, CONTROLS, 10A

PRIMARY BOOM UP/DOWN TOGGLE SWITCH

PLATFORM ROTATE TOGGLE SWITCH

TURNTABLE ROTATE TOGGLE SWITCH

PLATFORM LEVEL TOGGLE SWITCH

DESCRIPTION

AUXILIARY TOGGLE SWITCH

KEY SWITCH

EMERGENCY STOP BUTTON

TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

TS58 JIB BOOM UP/DOWN TOGGLE SWITCH

HOURMETERHM

CHASSIS HARNESSCH

FUNCTION ENABLE TOGGLE SWITCH

MANIFOLD HARNESSMH

SP SWITCH PANEL

CR CONTROL RELAY

SWITCH PANEL

DESCENT ALARM (OPTION)

TRAVEL ALARM

H4

H3

L3

CB3BK-C49-7

OR/RD-42A

BR-52D

BR-C48-3

TS58

TS66

TS60

TS62

TS61

TS63

TS51

HM

H3RD/WH-48A

TS60

TS58 TS61

TS62TS55

TS66 TS63

CB2

TS51

HM

H3

P1

OR

NC

NC

BR-52AH4

OR

DESCENT ALARM WIRING

TILT SENSOR

RD/BK-C1B-2

RD/WH-134D

BK BR-CB2

U

D

U

D D

U

L R R E

L R

CONTROLLER STATUS LEDL3

TS66 JIB ROTATE TOGGLE SWITCH (Z30NRJ ONLY)

TS57

TS59

OR

CB2

P1

NC

NC

TS55

TS59

TS57

BK-22A

RD-27A

OR/BK-15A

OR/BK-C2-3

WH/RD-6A

BK-7A

BK/WH-8A

WH-4A

WH/BK-5A

GN-17A

RD-1A

GN-43A

RD/BK-2A

OR-14A

GN/BK-18A

GN/WH-19A

WH/BK-19C/48C

RD-C48-1

BL/BK-11A

BL-10A

L R

D

U

OR-C2-2

GN/BK-44A

JIB ROTATE(Z30N RJ MODELS)

KS1

CB3 CIRCUIT BREAKER, CONTROLS RETURN, 10A

WH

RDA

C

B

12876543

BL

/WH

C1

32

PL

I

BK

22

C

BK

P2

2B

AT

BR

/GN

D

1

C32

RD/134A

RD-C23-6

RD-C32-7

BR HM(-)

BK C7-1

BK 22C

BL/WH C1-12

TO TERMINAL BASEAND CONNECTORS

BR-52A

BR C32-12

RD

-C2

3-6

KS1

ES34DCT

6 - 12


6 - 11

Ground Control Box Switch Panel Wiring Diagram,(ANSI / CSA / AS), (before serial numbers Z30N10-12119,

Z34N10-8857 and Z3410-7774)

Section 6 • SchematicsJune 2011

1

2

3

4

5

6

7

8



REV B Platform Control Box Wiring Diagram, (ANSI / CSA / AS),(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

Y

Y

JIB

H1

BR

N-J

IBB

RN

-2

F.S.

C2P

C9

C7B

C1P

C47

C4POPTION

C3P

PL

AT

FO

RM

CO

NT

RO

LB

OX

RD/BK

RD

C1

32

PL

I BL

/WH

C1

P-1

2

C2

8T

TA

RD

/BK

C1

P-2

TURNTABLE TILT ALARM LED (CSA OPTION)

L48


P2

3B

AT

WH

C7

P-2

C1

2F

TS

BL

/WH

C3

P-1

2

C1

6D

RE

OR

/RD

C4

P-4

C5

TR

R W

H/B

K C

3P

-5

C4

TR

LW

H C

3P

-4

C11

SB

D B

L/B

K C

3P

-11

C1

0S

BU

BL

C3

P-1

0

C6

MF

V W

H/R

D C

3P

-6

C1

8P

RR

GR

/BK

C4

P-6

C1

7P

RL

GR

C4

P-5

C4

3JU

GR

C2

P-5

C1

9L

PE

GR

/WH

C4

P-7

C4

4JD

GR

/BK

C2

P-6

C2

PB

D R

D/B

K C

3P

-2

C1

PB

U R

D C

3P

-1

C1

4P

LU

OR

C4

P-2

C4

7JR

R O

R/B

K C

2P

-3

C4

6JR

LO

R C

2P

-2

C4

7JR

R R

D C

47

-6

C4

6JR

LY

LC

47

-5

C1

5P

LD

OR

/BK

C4

P-3

DRIVE ENABLE TOGGLE SWITCHTS15

TS9

UD

TS7

L

R

RE

R

L

R

L

D

D

DU

U

U

WH

BRN

RD

RD

C2

9JS

H R

D/W

H C

1P

-3

109876

BP1

BCI

OR

G/R

D

C3

BA

TR

D/W

H C

3P

-3

BATTERY CHARGE INDICATOR (OPTION)BCI

TILT ALARMH1

R4

2B

AT

OR

/RD

C2

P-4

P2

4B

AT

WH

C9

P-2

C1

3D

EL

BL

/RD

C4

P-1

BK

/RD

RD

GR

N

C3

7S

CW

BL

/BK

C1

P-1

1

C3

2JS

LW

H/R

D C

1P

-6

L1 DRIVE ENABLE LED

HORN BUTTONP3



DRIVE CONTROLLER

BOOM FUNCTION SPEED CONTROLLER


JIB ROTATE TOGGLE SWITCH (Z30NRJ ONLY)

JIB BOOM UP/DOWN TOGGLE SWITCH


SECONDARY BOOM UP/DOWN TOGGLE SWITCH

EXTEND/RETRACT TOGGLE SWITCH



TS8

TS7

TS9

TS13

TS11

TS12

TS10

P2

TS1

BP1

DP1

TS16

L1

P2

DP1

TS8TS16

TS13

TS11

TS10

TS12

TS15

TS1

P3

53 41 2

C1

8P

RL

OR

C4

7-1

C1

7P

RR

BL

C4

7-2

C4

4JD

WH

C4

7-3

C4

3JU

BK

C4

7-4

C8

PB

R B

K/W

H C

3P

-8

C7

PB

E B

K C

3P

-7

C2

7A

UX

RD

C1

P-1

C3

1R

EV

WH

/BK

C1

P-5

C3

0F

WD

WH

C1

P-4

C3

6S

CC

BL

C1

P-1

0

C9

HR

N B

K/R

D C

3P

-9

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

NC

NC

NO

1

L48

D73

D71

D40D66

ES34DCT

D77

OPTION

P4

8L

PS

WH

/RD

C1

P-9

L3

0

BR

CR

45

WH W

OR

K L

IGH

TS

(OP

TIO

N)WH/RD TS49

85

86

873

0NOTES:

1 TURNTABLE TILT ALARM LED (OPTION).

2ON Z-34/22 MODELS, THIS LOCATION IS USED FORTS49, WORK LIGHT OPTION.

TS49

P2

6B

AT

RD

P2

WH

/RD

CR

45

#8

6

WORK LIGHTS OPTION(Z30N (RJ) MODELS)

2

RELAY, N.O., WORK LIGHTS (OPTION)

DESCRIPTIONLABEL

CR45

6 - 14


Platform Control Box Wiring Diagram, (ANSI / CSA / AS),(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

6 - 13

6 - 15


6 - 16

Electrical Schematic, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)


1

2

3

4

5

6

7

8




REV B

LS

4-S

EC

. UP

/DW

N

LS

2-P

RI. U

P/D

WN

LS

1-E

XT

/RE

T

C48-3TB52

C9

HR

N B

K/R

D


85

86

PR

IMA

RY

LIF

TP

UM

PP

R2

33�

R1

9L

PE

GR

/WH

PR2

CR2030

87

AU

XIL

IAR

YL

IFT

PU

MP

PR

3

PR

IMA

RY

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

Y

33�

PR3

C4

9-1

1 C

19

LP

E G

R/W

H

C4

9-1

R2

7A

UX

RD

87a

CR3

87

30

P42BAT OR/RD C48-2

C7

B-2

P2

3B

AT

WH

C7

P-2

C4

8-1

P1

82

BA

TR

D

P2

2B

AT

BK

RD

C134BAT RD TB134

R42BAT OR/RD

C12FTS

10A

CB3

C1

33

PL

AB

L/R

DC

2P

-1C

2B

-1

D39

L4

H6 L45

U33

U6AMOTOR CONTROLLER

F4500A

ADD D40 ONLY IF UNIT HAS L4 AND L48.

C3

B-9

C1

B-1

2

H2

GR/BK

RD

TB134

C1P-12C132PLI BL/WH

C7

B-1

LS18

D40

1 3

4

6 7

5

12 8

C40LS

C4

9-9

C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

BK 2 GA

CH

AS

SIS

GR

OU

ND

J2

-BK

RD

P26BAT

13LS1

(EXT)

14

2

P2

2B

AT

BK

C7P-1

HO

RN

B

A C

P42BAT OR/RD

C4

9-7

C1

78

CS

LB

K

C49-10

C4

9-8

BK

C11

-3 B

K-6

C11

-4 W

H-6

C1

0-2

WH

-7

C1

0-1

BK

-7P

22

LS

BK

C5

2-1

BK

-8

C5

2-2

WH

-8

J1-WH

C4

9-3

C4

9-6

C4

9-5

C4

9-4

C2

B-4

C3

B-3

C1

B-2

C1

B-3

C1

B-4

C1

B-5

C1

B-6

C9P-2

C9P-3

R4

2B

AT

OR

/RD

C2

P-4

C3

BA

TR

D/W

HC

3P

-3

C2

8T

TA

RD

/BK

C1

P-2

C9

HR

N B

K/R

DC

3P

-9

C2

9JS

H R

D/W

HC

1P

-3

C3

2JS

LW

H/R

DC

1P

-6

C3

1R

EV

WH

/BK

C1

P-5

CR5

P182BAT BK

C19LPE GR/WH

R42BAT OR/RD

P24BAT WH

RD

C12DRE BL/WH

CR3

GND BR

TILTALARM

RD

WH-(FS)

FS1

H1

RD-(FS)

PLATFORM

GROUND

P1

KS1

TB22

P3HORN

P2

RD

C9P-1 BK

+

RD

P182BAT RD

BK-(FS)

OR

/RDCR1

CR2

TB42

RD

/WH

30

8785

86

87

3086

85

BR

N

BR

N

PR

1

OF

F-L

IMT

SP

D IN

P

INT

ER

LO

CK

L3

53 17

C1

82

PW

R G

R

LS4(SEC)

OR

/RD

LS2(PRI)

RD

/BK

OR

/RD

C4

9-2

C4

8B

RK

RD

/BK

OR

/RD

20

CR

5

22

21

22

21

86

85

CB2

10 A

C1

P-4

RD

20

AP2

24 V

FO

RW

AR

D

PO

T. L

OW

DIO

DE

RE

TU

RN

+4

8V

INP

UT

PO

T. H

I

RE

VE

RS

E

10

1 9 11

16

14

PR1

AP2 48V

R4

2B

AT

OR

/RD

WH

WH

/BK

WH

/RD

RD

/WH

F3100A

F510A

F2100A

+

++

+

LEFTBOX

-

--

-

48V

C3

0F

WD

WH

2

48

V P

OW

ER

RE

LA

YC

R1

FL

AS

HIN

G B

EA

CO

NO

PT

ION

48

V P

OW

ER

RE

LA

YC

R2

FB

+

HO

RN

RE

LA

Y

BA

SE

CO

NT

RO

LB

OX

GR

OU

ND

CR4

TIL

TS

EN

SO

RR

D

WH

BK

BR

N

F1

+

86

85

30

87

BR

N

BR

AK

E R

EL

EA

SE

RE

LA

YC

R5

PR

1 D

RIV

EC

ON

TA

CT

OR

AP1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

PR3 PR2

WH

BK

AC POWER

F2 F1

A2

A1

A2

A1+

-

PUMP

+

++

+

CHARGER

LEFTMOTORRIGHT

BOX

-

--

-

GROUND

24V


NOTES:




F2

F2F1 B+M-AP1 B-

PUMP

RIGHTMOTOR

2

3

5

5

BL

/WH

L48

ES34DCT

OR

OR

TS48DRIVELIGHTS

TS49WORKLIGHTS

CR45N.O.

87

30 86

85

L30

+

L30

+

PLATFORM BOXGROUND

C1

B-9

R4

2B

AT

OR

/RD

P4

8L

PS

WH

/RD

C1

P-9

F187A

WH

/RD

C2

B-9

WH

(16

/2)

C1

B-8

DL

ITE

BK

/WH

C1

P-8

F197A

BK

/WH

C2

B-1

2W

H (1

6/2

)

CR23N.O.

87

30 86

85

L29

+

L29

+

WH

WH

WH

BK

BK

L3

0 W

OR

K L

IGH

TS

(OP

TIO

N)

L2

9 D

RIV

E L

IGH

T(O

PT

ION

)

WH


1

2

3

4

5

6

7

8




REV B


JIBROTATE

RE

TR

AC

T

(GND)

CR3

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

DE

SC

EN

TA

LA

RM

SE

CO

ND

AR

YB

OO

M D

OW

N

SE

CO

ND

AR

YB

OO

M U

P

H4

+

WH

/BK

WH

TB4

BL

/BK

BL

TB5 TB11 TB10

OR

/BK

OR

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

DO

WN

BO

OM

RE

TR

AC

T

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

DO

WN

CO

IL

PL

AT

FO

RM

LE

VE

LU

PC

OIL

BK

/WH

BK

RD

/BK

RD


PL

AT

FO

RM

RO

TA

TE

LE

FT

/JIB

BO

OM

DO

WN

PL

AT

FO

RM

RO

TA

TE

RIG

HT

/JIB

BO

OM

UP

PRIMARYBOOM

C19LPE GR/WH

TS55

C12DRE BL/WH

RD

CR5

RD

C2

PB

D R

D/B

K

C1

0S

BU

BL

C11

SB

D B

L/B

K

C5

TR

R W

H/B

K

C4

TR

LW

H

RIG

HT

TURNTABLEROTATE

FUNCTIONENABLE

LE

FT

TS62

RD

C3

B-4

C3

B-5

SECONDARYBOOM

TS60

DO

WN

UP

C3

B-1

1

C3

B-1

0

C3

B-1

C3

B-2

C3

P-4

C3

P-5

LE

FT

TS12

RIG

HT

TURNTABLEROTATE

C3

P-1

0

C3

P-1

1

C1

PB

U R

D

C3

P-2

C3

P-1

SECONDARYBOOM

DO

WN

2

6

CR19

UP

TS10

DO

WN

CR19

1

5

TS11

UP

C30FWD WH

C29JSH RD/WH

C31REV WH/BK

C32JSL WH/RD

R42BAT OR/RD

P24BAT WH

C1

8P

RR

BL

PLATFORMROTATE

PLATFORMROTATE

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C7

PB

E B

K

C8

PB

R B

K/W

H

DO

WN

TS61

UP

PRIMARYBOOM

TS63

EX

TE

ND

PRIMARYBOOM

C3

B-7

C3

B-8

PLATFORMLEVEL

DO

WN

TS59

C4

B-6

C4

B-5

C4

B-3

C4

B-2

C3

P-7

C3

P-8

EX

TE

ND

PRIMARYBOOM

RE

TR

AC

T

TS13

DO

WN

TS9

C4

P-3

C4

P-2

C4

P-5

C4

P-6

PLATFORMLEVEL

UP

RIG

HT

LE

FT

TS7

C4

7JR

R R

D

C4

6JR

LY

L

C4

7JR

R O

R/B

K

C4

6JR

LO

R

C4

4JD

WH

C4

3JU

BK

C1

7P

RL

OR

C4

3JU

GR

C4

4JD

GR

/BK

RIG

HT

LE

FT

TS57

C2

B-6

C2

B-5JIB MANIFOLD

DO

WN

TS58

UP

JIBBOOM

C2

B-2

C2

B-3

C2

P-5

C2

P-6

DO

WN

TS8

UP

JIBBOOM

C2

P-3

C2

P-2

RIG

HT

LE

FT

TS16

C7

P-3

BA

TG

ND

BR

N

C8

-4

C8

-3

C1

6D

E O

R/R

D

PS

1

GR/WHP

RO

PO

RT

ION

AL

CO

NT

RO

LV

ALV

E

AU

XIL

IAR

YC

ON

TR

OL

RE

LA

Y

TB6

WH

/RD

GR/WH

CR3

TB19

86

85

C19LPE

HO

UR

ME

TE

R

_

BR

AK

E R

EL

EA

SE

NC

CO

IL

ST

EE

R R

IGH

T

ST

EE

R L

EF

T

BR

AK

E R

EL

EA

SE

PR

ES

SU

RE

SW

ITC

H

+

WH

/BK

HM

+

TB19

R48BRK

GR/WH

BL

BL

/BK

R4

8B

RK

RD

/WH

TB48

C8

-1

C7

B-3

BA

TG

ND

BR

N

C8

-2

TR

AV

EL

AL

AR

M

H3

TB52

13

RD

-5

RD

/WH

14

BR

N-5

22

LS321

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

BK

-5

TB16

WH

-5

TS15DRIVEENABLE

DP1

C6

MF

V W

H/R

D

C1

9L

PE

GR

/WH

C1

9L

PE

GR

/WH

LE

FT

TS66

RIG

HT

JIBROTATE

C3

B-6

C4

B-7

TB27C27AUX RD

RD

TS51AUXILIARYPUMP


BP1

C3

P-6

BK/RD

RD

GR

C4

P-7

+

BCIE

F

C3

7S

CW

BL

/BK

C1

B-1

TB37

TB3687

30

CR5

C1

B-1

1

C1

B-1

0

TS1AUXILIARYPUMP

C2

7A

UX

RD

C1

P-1

STEER

L R 10

9

LIFT

DRIVE

FWD

RD

-AU

X

REV

20K

4

8

7

6

5

3

2

1

C1

P-1

1

C1

P-1

0C

36

SC

C B

LR

D

P24BAT WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

C29JSH RD/WH

C1

3D

EL

BL

/RD

C1

2F

TS

BL

/WH

C1

2F

TS

BL

/WH

OR

/RD

C1

3D

EL

BL

/RD

BR

N

C3

B-1

2

TB12

C4

B-4

C4

B-1

C3

P-1

2

C1

6D

E O

R/R

DC

4P

-4

C4

P-1

L1

OR

/RD4

8

2 3

76

1

5

LVI/BCI(OPTION)

BK

7

8

CR19

BRN

WH

WH/RD

WH

UP

UP

5

C4

7-2

C4

7-1

C4

7-3

C4

7-4

C2

P-5

C2

P-5

3

OR

BR

AK

E R

EL

EA

SE

NO

CO

IL

D29

D30

D50

C47-8 GRN

D73

D71

D66

D75

D4

D74

D72

D59

D60

D76

D86

D87

D77

D78

C4

9-1

C2

7A

UX

RD

6 - 18



6 - 17

6 - 19


6 - 20

Ground Control Box Terminal Strip Wiring Diagram, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)


1

2

3

4

5

6

7

8



REV BGround Control Box Terminal Strip Wiring Diagram, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

RD-C32-1

C32-3BL/WH PLATFORM OVERLOAD INPUT

C133PLA

C132PLI

GR/BK PLATFORM OVERLOAD ALARMH6(-), L45(-)C2B-1

C1B-12

DESCRIPTIONTOFROMCIRCUIT#WIRES

C1B-5

C1B-4

C1B-3

C4B-6

C4B-5

C3B-9

C8-4

TILT-C

C52-2

C3B-3

C2B-5

C2B-6

C10-2

C11-3

C1B-6

C2B-3

C2B-2



C49

C48

CHASSISHARNESS(CH)

MANIFOLDHARNESS(MH)

C1B

C2B

C4B

C3B

CABLE#3

CABLE#1

CABLE#2 C7B

C11

C8

C52

C10


LS3 - DRIVE ENABLE




134

RD-KSI-4RD-H6


JIB ROTATE LEFT (Z30N RJ ONLY)

JIB ROTATE RIGHT (Z30N RJ ONLY)

TS-66 (SP)C46JRLOR


BR- MH

RD/WH-MHWH/BK-SP

WH/BK-SP

OR/RD-CR5

BL-19D

BL/BK-19D

RD/WH-CR5

OR/RD-16A

RD/BK-C49-2

BK-22A

BK/RD-MH-HORN

BK/RD-C3B-9

RD-27D

WH C10-1

OR/RD-CR1


CR1, #86, CR2, #86

RD-C49-1

LS1-LS2 JUNCTION

LS2-LS4 JUNCTION

OR/BK-MH

OR/RD C8-1

BR-CB2

BRBK


BR-SP

BR-CR4

RD/WH-SP

52

52J2

48



C49-4 (CH)

RD-CR3

TB36/TB37 GR/WH-CR3

GR/WH-SP


GR/WH-19C

BR-52A

BL-MH

BL/BK-MH

C49-9 (CH)

CR4

GR/WH-C49-11

CR3CR2CR1

CR5

RD/WH-48D

OR/RD-42D

OR/RD-C48-2

RD/WH-C3B-3

WH J1 C11-4

TS-58 (SP)

TS-58 (SP)GR/BK

C43JU

C44JD

JIB UP

JIB DOWN

GR

C40LS

42

36

37

BK-CR4

RD-SP

C28TTA

27

C31REV

C30FWD

C29JSH

22

TILT ALARM

REVERSE

FORWARD

2-WIRE POT.

OFF-LIMIT SPEED

TS-57 (SP)

TS-57 (SP)

GR/WH-MH

BK C8-3

OR/BK-SP

OR-SPC17PRL

C18PRR

19

19

C13DEL12

14

15

16

BK/WH-SP

BK-SP

BL-SP

WH/BK-SP

RD/WH

RD/BK-SP

WH-SP

WH/RD-SP

8

C9HRN

7

10C3BAT

4

5

2

6

11 BL/BK-SP

DRIVE ENABLE LIGHT



HORN

ORBL-MH

BL/BK-MH

RD/BK

C49-3 (CH)

C49-5 (CH)BK-SP

BL/RDBL/WH-CH

OR-MH

BK-MH

BK/RD

BK/WH-MH

WH-MH

RD/BK-MH

WH/BK-MH

WH/RD-MHWH/RD C3B-6

RD/BK C3B-2

WH/BK C3B-5

WH C3B-4

C4B-1

CR4, #86

BK/WH C3B-8

BK C3B-7

BL/WH C3B-12

BL/BK C3B-11

BL C3B-10

GR

OR/BK C4B-3

OR C4B-2

OR/RD C4B-4

GR/BK

GR/WH C4B-7

C1B-2

BK-C32-4

RD C1B-1

RD/WH

WH

WH/BK

BL C1B-10

BL/BK C1B-11

OR/RD C2B-4

ABCD


C12FTS

C6MFV

C7PBE

C11SBD

C10SBU

C19LPE

C8PBR

C14PLU

C15PLD

C2PBD

C4TRL

C5TRR

C37SCW

C27AUX

P22BAT

C36SCC

C16DE

C19LPE

R42BAT

R48BRK

BATGND

BATGND

P134BAT

P134BAT


KEYSWITCH POWER

KEYSWITCH POWER

GROUND

GROUND

BRAKE RELEASE

SWITCHED 48V

LIFT PUMP

DRIVE ENABLE

STEER LEFT

+24V TO PLATFORM

AUXILIARY PUMP

STEER RIGHT



PRIMARY BOOM DOWN

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP


LIFT PUMP

SECONDARY BOOM UP

SECONDARY BOOM DOWN

PRIMARY BOOM EXTEND


FOOTSWITCH

PRIMARY BOOM UP

ES34DCT



RD CE C11-1 CR10A #86, CR10B #86 PLATFORM LEVEL CUT-OUT

CR5 - BRAKE RELEASE




CR4 - HORN

CONTROL RELAY I.D.

30

8586

87A

87

REF.


RD

L29

BR

CR23

F197A

WH

C2B-12WH

GND

AP2+48V DC




1

2

3

4

5

6

7

8



REV B Ground Control Box Switch Panel Wiring Diagram, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

KS1

TS51

TS57

TS55

P1

LABEL

TS61

TS63

TS62

CB2

TS59







DESCRIPTION


KEY SWITCH




HOURMETERHM

CHASSIS HARNESSCH


MANIFOLD HARNESSMH

SP SWITCH PANEL

CR CONTROL RELAY

SWITCH PANEL

DESCENT ALARM

TRAVEL ALARM

H4

H3

L3

CB3BK-C49-7

OR/RD-42A

BR-52D

BR-C48-3

TS58

TS66

TS60

TS62

TS61

TS63

TS51

HM

H3RD/WH-48A

TS60

TS58 TS61

TS62TS55

TS66 TS63

CB2

L45

TS51

HM

H3

P1

OR

NC

NC

BR-52AH4

OR


TILT SENSOR

RD/BK-C1B-2

RD/WH-134D

BK BR-CB2

U

D

U

D D

U

L R R E

L R


TS66 JIB ROTATE TOGGLE SWITCH (Z30N RJ ONLY)

TS57

TS59

OR

L45

CB2

P1

NC

NC

TS55

TS59

TS57

BK-22A

RD-27A

OR/BK-15A

OR/BK-C2-3

WH/RD-6A

BK-7A

BK/WH-8A

WH-4A

WH/BK-5A

GN-17A

RD-1A

GN-43A

RD/BK-2A

OR-14A

GN/BK-18A

GN/WH-19A

WH/BK-19C/48C

RD-C48-1

BL/BK-11A

BL-10A

L R

D

U

OR-C2-2

GN/BK-44A

JIB ROTATE(Z30N RJ ONLY)

KS1


WH

RDA

C

B

L45 PLATFORM OVERLOAD LED

12876543

RD

A6

GN

/BK

A6

BL

/WH

C1

32

PL

I

BK

22

C

BK

P2

2B

AT

BR

/GN

D

U33

1

C32

RD/134A

RD-C23-6

RD-C32-7

H6

RD C32-1

GN/BK

BR HM(-)

BK C7-1

BK 22C

BL/WH C1-12


RD 134B

BL/RD C2B-1

BR-52A

BR C32-12

RD

-C2

3-6

H6 PLATFORM OVERLOAD

KS1

ES34DCT

6 - 22


6 - 21

Ground Control Box Switch Panel Wiring Diagram, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)


1

2

3

4

5

6

7

8



REV B Platform Control Box Wiring Diagram, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

Y

Y

JIB

H1

BR

N-J

IBB

RN

-2

F.S.

C2P

C9

C7B

C1P

C47

C4POPTION

C3P

PL

AT

FO

RM

CO

NT

RO

LB

OX

RD/BK

RD

C1

32

PL

I BL

/WH

C1

P-1

2

C1

33

PL

AB

L/R

D C

2P

-1

C2

8T

TA

RD

/BK

C1

P-2

TURNTABLE TILT ALARM LED (OPTION)

L4

L48

LS18


P2

3B

AT

WH

C7

P-2

C1

2F

TS

BL

/WH

C3

P-1

2

C1

6D

RE

OR

/RD

C4

P-4

C5

TR

R W

H/B

K C

3P

-5

C4

TR

LW

H C

3P

-4

C11

SB

D B

L/B

K C

3P

-11

C1

0S

BU

BL

C3

P-1

0

C6

MF

V W

H/R

D C

3P

-6

C1

8P

RR

GR

/BK

C4

P-6

C1

7P

RL

GR

C4

P-5

C4

3JU

GR

C2

P-5

C1

9L

PE

GR

/WH

C4

P-7

C4

4JD

GR

/BK

C2

P-6

C2

PB

D R

D/B

K C

3P

-2

C1

PB

U R

D C

3P

-1

C1

4P

LU

OR

C4

P-2

C4

7JR

R O

R/B

K C

2P

-3

C4

6JR

LO

R C

2P

-2

C4

7JR

R R

D C

47

-6

C4

6JR

LY

LC

47

-5

C1

5P

LD

OR

/BK

C4

P-3


TS9

UD

TS7

L

R

RE

R

L

R

L

D

D

DU

U

U

WH

BRN

RD

RD

C2

9JS

H R

D/W

H C

1P

-3

109876

BP1

BCI

OR

G/R

D

C3

BA

TR

D/W

H C

3P

-3


TILT ALARMH1

R4

2B

AT

OR

/RD

C2

P-4

P2

4B

AT

WH

C9

P-2

C1

3D

EL

BL

/RD

C4

P-1

BK

/RD

RD

GR

N

C3

7S

CW

BL

/BK

C1

P-1

1

C3

2JS

LW

H/R

D C

1P

-6

NOTES:

L1 DRIVE ENABLE LED

HORN BUTTONP3



DRIVE CONTROLLER


DESCRIPTION


JIB ROTATE TOGGLE SWITCH (Z30N RJ ONLY)







TS8

TS7

TS9

TS13

TS11

TS12

TS10

LABEL

P2

TS1

BP1

DP1

TS16

L1

P2

DP1

TS8TS16

TS13

TS11

TS10

TS12

TS15

TS1

P3

53 41 2

C1

8P

RL

OR

C4

7-1

C1

7P

RR

BL

C4

7-2

C4

4JD

WH

C4

7-3

C4

3JU

BK

C4

7-4

C8

PB

R B

K/W

H C

3P

-8

C7

PB

E B

K C

3P

-7

C2

7A

UX

RD

C1

P-1

C3

1R

EV

WH

/BK

C1

P-5

C3

0F

WD

WH

C1

P-4

C3

6S

CC

BL

C1

P-1

0

C9

HR

N B

K/R

D C

3P

-9

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

NC

NC

NO

L4

1


PLATFORM OVERLOAD LED

L48

D73

D71

D40

D39

D66

ES34DCT

D77

P4

8L

PS

WH

/RD

C1

P-9

L3

0

BR

CR

45

WH W

OR

K L

IGH

TS

(OP

TIO

N)WH/RD TS49

85

86

873

0

2


TS49

P2

6B

AT

RD

P2

WH

/RD

CR

45

#8

6


RELAY, N.O., WORK LIGHTS (OPTION)CR45

6 - 24


Platform Control Box Wiring Diagram, (CE)(before serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

6 - 23

6 - 25


6 - 26

Electrical Schematic, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)


1

2

3

4

5

6

7

8



REV AElectrical Schematic, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

LS

4-S

EC

. UP

/DW

N

LS

2-P

RI. U

P/D

WN

LS

1-E

XT

/RE

T

C48-3TB52

C9

HR

N B

K/R

D


85

86

PR

IMA

RY

LIF

TP

UM

PP

R2

33�

R4

2B

AT

GR

/WH

PR2

CR20

30

87

AU

XIL

IAR

YL

IFT

PU

MP

PR

3

PR

IMA

RY

LIF

TP

UM

PC

ON

TA

CT

OR

RE

LA

Y

33�

PR3

C4

9-1

1 C

19

LP

E G

R/W

H

C4

9-1

R2

7A

UX

RD

87a

CR3

87

30

P42BAT OR/RD C48-2

C7

B-2

P2

3B

AT

WH

C7

P-2

C4

8-1

P1

82

BA

TR

D

P2

2B

AT

BK

RD

P134BAT RD TB134

R42BAT OR/RD

C12FTS

10A

CB3

C1

33

PL

AB

L/R

DC

2P

-1C

2B

-1

C32

U6AMOTOR CONTROLLER

F4500A

C3

B-9

C1

B-1

2

H2

GR/BK

RD

TB134

C1P-12C132PLI BL/WH

C7

B-1

1 3

4

6 7

5

12 8

C40LS

C4

9-9

OR

C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

BK 2 GA

CH

AS

SIS

GR

OU

ND

J2

-BK

RD

P26BAT

13LS1

(EXT)

14 2

P2

2B

AT

BK

C7P-1

HO

RN

B

A C

P42BAT OR/RD

C4

9-7

C1

78

CS

LB

K

C49-10

C4

9-8

BK

C11

-3 B

K-6

C11

-4 W

H-6

C1

0-2

WH

-7

C1

0-1

BK

-7P

22

LS

BK

C5

2-1

BK

-8

C5

2-2

WH

-8

J1-WH

C4

9-3

C4

9-6

C4

9-5

C4

9-4

C2

B-4

C3

B-3

C1

B-2

C1

B-3

C1

B-4

C1

B-5

C1

B-6

C9P-2

C9P-3

R4

2B

AT

OR

/RD

C2

P-4

C3

BA

TR

D/W

HC

3P

-3

C2

8T

TA

RD

/BK

C1

P-2

C9

HR

N B

K/R

DC

3P

-9

C2

9JS

H R

D/W

HC

1P

-3

C3

2JS

LW

H/R

DC

1P

-6

C3

1R

EV

WH

/BK

C1

P-5

CR5

C108LPR

C19LPE GR/WH

R42BAT OR/RD

P24BAT WH

RD

C12DRE BL/WH

CR3

GND BR

TILTALARM

RD

WH-(FS)

FS1

H1

RD-(FS)

PLATFORM

GROUND

P1KS1

TB22

P3HORN

P2

RD

C9P-1 BK

+

RD

P182BAT RD

BK-(FS)

OR

/RD

CR1

CR2

TB42

RD

/WH

30

8785

86

87

3086

85

BR

N

BR

N

PR

1

OF

F-L

IMT

SP

D IN

P

INT

ER

LO

CK

L3

53 17

C1

82

PW

R G

R LS4(SEC)

OR

/RD

LS2(PRI)

RD

/BK

OR

/RD

C4

9-2

C4

8B

RK

RD

/BK

OR

/RD

20

CR

5

22

21

22

21

86

85

CB2

10 A

C1

P-4

RD

20

AP2

24V

FO

RW

AR

D

PO

T. L

OW

DIO

DE

RE

TU

RN

+4

8V

INP

UT

PO

T. H

I

RE

VE

RS

E

10

1 9 11

16

14

PR1

AP2 48V

R4

2B

AT

OR

/RD

WH

WH

/BK

WH

/RD

RD

/WH

F3100A

F510A

F2100A

++

+

+

LEFTBOX

--

-

-

48V

C3

0F

WD

WH

2

48

V P

OW

ER

RE

LA

YC

R1

FL

AS

HIN

G B

EA

CO

NO

PT

ION

48

V P

OW

ER

RE

LA

YC

R2

FB

+

HO

RN

RE

LA

Y

BA

SE

CO

NT

RO

LB

OX

GR

OU

ND

CR4

TIL

TS

EN

SO

RR

D

WH

BK

BR

N

F1

+

86

85

30

87

BR

N

BR

AK

E R

EL

EA

SE

RE

LA

YC

R5

PR

1 D

RIV

EC

ON

TA

CT

OR

AP1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

PR3 PR2

WH

BK

AC POWER

F2 F1

A2

A1

A2

A1+

-

PUMP

+

++

+

CHARGER

LEFTMOTOR

RIGHTBOX

-

--

-

GROUND

24V


NOTES:




F2

F2F1 B+M-AP1 B-

PUMP

RIGHTMOTOR

2

3

BL

/WH

L48

ES34DCU

SETUP ENABLE: USE TO SET THE BATTERY INDICATOR PROFILES.5

OR

TS48DRIVELIGHTS

TS49WORKLIGHTS

CR45N.O.

87

30 86

85

L30

+

L30

+

PLATFORM BOXGROUND

P4

8L

PS

WH

/RD

C2

P-1

0

F187A

WH

C2

P-1

2

F197A

RD

(16

/4)

CR23N.O.

87

30 86

85

L29

+

L29

+

WH

WH

WH

BK

BK

L3

0 W

OR

K L

IGH

TS

(OP

TIO

N)

L2

9 D

RIV

E L

IGH

T(O

PT

ION

)

C2

P-1

1B

R (1

6/4

)

WH

(16

/4)


1

2

3

4

5

6

7

8



REV A Electrical Schematic, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)


JIBROTATE

RE

TR

AC

T

(GND)

CR3

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

DE

SC

EN

TA

LA

RM

SE

CO

ND

AR

YB

OO

M D

OW

N

SE

CO

ND

AR

YB

OO

M U

P

H4

+

WH

/BK

WH

TB4

BL

/BK

BL

TB5 TB11 TB10

OR

/BK

OR

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BK

/WH

BK

RD

/BK

RD


JIB

BO

OM

DO

WN

JIB

BO

OM

UP

PRIMARYBOOM

C19LPE GR/WH

TS55

C12DRE BL/WH

RD

CR5

RD

C2

PB

D R

D/B

K

C1

0S

BU

BL

C11

SB

D B

L/B

K

C5

TR

R W

H/B

K

C4

TR

LW

H

RIG

HT

TURNTABLEROTATE

FUNCTIONENABLE

LE

FT

TS62

RD

C3

B-4

C3

B-5

SECONDARYBOOM

TS60

DO

WN

UP

C3

B-1

1

C3

B-1

0

C3

B-1

C3

B-2

C3

P-4

C3

P-5

LE

FT

TS12

RIG

HT

TURNTABLEROTATE

C3

P-1

0

C3

P-1

1

C1

PB

U R

D

C3

P-2

C3

P-1

SECONDARYBOOM

DO

WN

2

6

CR19

UP

TS10

DO

WN

CR19

1

5

TS11

UP

C30FWD WH

C29JSH RD/WH

C31REV WH/BK

C32JSL WH/RD

R42BAT OR/RD

P24BAT WH

C1

8P

RR

BL

PLATFORMROTATE

PLATFORMROTATE

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C7

PB

E B

K

C8

PB

R B

K/W

H

DO

WN

TS61

UP

PRIMARYBOOM

TS63

EX

TE

ND

PRIMARYBOOM

C3

B-7

C3

B-8

PLATFORMLEVEL

DO

WN

TS59

C4

B-6

C4

B-5

C4

B-3

C4

B-2

C3

P-7

C3

P-8

EX

TE

ND

PRIMARYBOOM

RE

TR

AC

T

TS13

DO

WN

TS9

C4

P-3

C4

P-2

C4

P-5

C4

P-6

PLATFORMLEVEL

UP

RIG

HT

LE

FT

TS7

C4

7JR

R R

D

C4

6JR

LY

L

C4

7JR

R O

R/B

K

C4

6JR

LO

R

C4

4JD

WH

C4

3JU

BK

C1

7P

RL

OR

C4

3JU

GR

C4

4JD

GR

/BK

RIG

HT

LE

FT

TS57

C2

B-6

C2

B-5

JIB MANIFOLD

DO

WN

TS58

UP

JIBBOOM

C2

B-2

C2

B-3

C2

P-5

C2

P-6

DO

WN

TS8

UP

JIBBOOM

C2

P-3

C2

P-2

RIG

HT

LE

FT

TS16

C7

P-3

BA

TG

ND

BR

N

C8

-4

C8

-3

C1

6D

E O

R/R

D

PS

1

GR/WHP

RO

PO

RT

ION

AL

CO

NT

RO

LV

ALV

E

AU

XIL

IAR

YP

UM

P

TB6

WH

/RD

GR/WH

CR3

TB19

86

85

C19LPE

C2

7A

UX

RD

HO

UR

ME

TE

R

_

BR

AK

E R

EL

EA

SE

N.C

. VA

LV

E

ST

EE

R R

IGH

T

ST

EE

R L

EF

T

BR

AK

EP

RE

SS

UR

ES

WIT

CH

+

WH

/BK

HM

+

TB19

R48BRK

GR/WH

BL

BL

/BK

R4

8B

RK

RD

/WH

TB48

C8

-1

C7

B-3

BA

TG

ND

BR

N

C8

-2

TR

AV

EL

AL

AR

M

H3

TB52

13

RD

-5

RD

/WH

14

BR

N-5

22

LS321

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

BK

-5

TB16

WH

-5

TS15DRIVEENABLE

DP1

C6

MF

V W

H/R

D

C1

9L

PE

GR

/WH

C1

9L

PE

GR

/WH

LE

FT

TS66

RIG

HT

JIBROTATE

C3

B-6

C4

B-7

TB27C27AUX RD

RD

TS51AUXILIARYPUMP


BP1

C3

P-6

BK/RD

RD

GR

C4

P-7

+

BCIOPTION

E

F

C3

7S

CW

BL

/BK

C1

B-1

TB37

TB3687

30

CR5

C1

B-1

1

C1

B-1

0

TS1AUXILIARYPUMP

C2

7A

UX

RD

C1

P-1

STEER

L R 10

9

LIFT

DRIVE

FWD

RD

-AU

X

REV

20K

4

8

7

6

5

3

2

1

C1

P-1

1

C1

P-1

0C

36

SC

C B

LR

D

P24BAT WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

C29JSH RD/WH

C1

3D

EL

BL

/RD

C1

2F

TS

BL

/WH

C1

2F

TS

BL

/WH

OR

/RD

C1

3D

EL

BL

/RD

BR

N

C3

B-1

2

TB12

C4

B-4

C4

B-1

C3

P-1

2

C1

6D

E O

R/R

DC

4P

-4

C4

P-1

L1

OR

/RD4

8

2 3

76

1

5

LVI/BCI(OPTION)

BK

7

8

CR19

BRN

WH

WH/RD

WH

UP

UP

5

C4

7-2

C4

7-1

C4

7-3

C4

7-4

C2

P-5

C2

P-5

3

OR

BR

AK

E R

EL

EA

SE

N.O

. VA

LV

E

PLATFORM CONTROLBOX GROUND

PL

AT

FO

RM

RO

TA

TE

LE

FT

PL

AT

FO

RM

RO

TA

TE

RIG

HT

D29

D30

D50

C47-8 GRN

D72

D74

D4

D75

D71

D73

D66

D77

D78

D59

D60

D76

D87

D86

C4

9-1

6 - 28


6 - 27

Electrical Schematic, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

6 - 29


6 - 30

Ground Control Box Terminal Strip Wiring Diagram,(ANSI / CSA), (from serial numbers Z30N10-12119, Z34N10-8857and Z3410-7774)


1

2

3

4

5

6

7

8



REV AGround Control Box Terminal Strip Wiring Diagram, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

RD-C32-1 DESCRIPTIONTOFROMCIRCUIT#WIRES

C1B-5

C1B-4

C1B-3

C4B-6

C4B-5

C3B-9

C8-4

TILT-C

C52-2

C3B-3

C2B-5

C2B-6

C10-2

C11-3

C1B-6

C2B-3

C2B-2



C49

C48

CHASSISHARNESS(CH)

MANIFOLDHARNESS(MH)

C1B

C2B

C4B

C3B

CABLE#3

CABLE#1

CABLE#2 C7B

C11

C8

C52

C10


LS3 - DRIVE ENABLE




134

RD-KSI-4


JIB ROTATE LEFT (Z30NRJ ONLY)

JIB ROTATE RIGHT (Z30NRJ ONLY)

TS-66 (SP)C46JRLOR


BR- MH

RD/WH-MHWH/BK-SP

WH/BK-SP

OR/RD-CR5

BL-19D

BL/BK-19D

RD/WH-CR5

OR/RD-16A

RD/BK-C49-2

BK-22A

BK/RD-MH-HORN

BK/RD-C3B-9

CR5 - BRAKE RELEASE

RD-27D




CR4 - HORN

CONTROL RELAY I.D.

WH C10-2

OR/RD-CR1


CR1, #86, CR2, #86

RD-C49-1

LS1-LS2 JUNCTION

LS2-LS4 JUNCTION

OR/BK-MH

OR/RD C8-1

BR-CB2

BRBK


BR-SP

BR-CR4

RD/WH-SP

52

52J2

48



C49-4 (CH)

RD-CR3

TB36/TB37 GR/WH-CR3

GR/WH-SP


GR/WH-19C

BR-52A

BL-MH

BL/BK-MH

C49-9 (CH)

CR4

GR/WH-C49-11

CR3CR2CR1

CR5

RD/WH-48D

OR/RD-42D

OR/RD-C48-2

RD/WH-C3B-3

WH J1 C11-4

TS-58 (SP)

TS-58 (SP)GR/BK

C43JU

C44JD

JIB UP

JIB DOWN

GR

C40LS

42

36

37

BK-CR4

RD-SP

C28TTA

27

C31REV

C30FWD

C29JSH

22

TILT ALARM

REVERSE

FORWARD

2-WIRE POT.

OFF-LIMIT SPEED

TS-57 (SP)

TS-57 (SP)

GR/WH-MH

BK C8-3

OR/BK-SP

OR-SPC17PRL

C18PRR

19

19

C13DEL12

14

15

16

BK/WH-SP

BK-SP

BL-SP

WH/BK-SP

RD/WH

RD/BK-SP

WH-SP

WH/RD-SP

8

C9HRN

7

10C3BAT

4

5

2

6

11 BL/BK-SP

DRIVE ENABLE LIGHT



HORN

ORBL-MH

BL/BK-MH

RD/BK

C49-3 (CH)

C49-5 (CH)BK-SP

BL/RDBL/WH-CH

OR-MH

BK-MH

BK/RD

BK/WH-MH

WH-MH

RD/BK-MH

WH/BK-MH

WH/RD-MHWH/RD C3B-6

RD/BK C3B-2

WH/BK C3B-5

WH C3B-4

C4B-1

CR4, #86

BK/WH C3B-8

BK C3B-7

BL/WH C3B-12

BL/BK C3B-11

BL C3B-10

GR

OR/BK C4B-3

OR C4B-2

OR/RD C4B-4

GR/BK

GR/WH C4B-7

C1B-2

BK-C23-4

RD C1B-1

RD/WH

WH

WH/BK

BL C1B-10

BL/BK C1B-11

OR/RD C2B-4

ABCD


C12FTS

C6MFV

C7PBE

C11SBD

C10SBU

C19LPE

C8PBR

C14PLU

C15PLD

C2PBD

C4TRL

C5TRR

C37SCW

C27AUX

P22BAT

C36SCC

C16DE

C19LPE

R42BAT

R48BRK

BATGND

BATGND

P134BAT

P134BAT


KEYSWITCH POWER

KEYSWITCH POWER

GROUND

GROUND

BRAKE RELEASE

SWITCHED 48V

LIFT PUMP

DRIVE ENABLE

STEER LEFT

+24V TO PLATFORM

AUXILIARY PUMP

STEER RIGHT



PRIMARY BOOM DOWN

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP


LIFT PUMP

SECONDARY BOOM UP

SECONDARY BOOM DOWN

PRIMARY BOOM EXTEND


FOOTSWITCH

PRIMARY BOOM UP

30

8586

87A

87

REF.


ES34DCU



RD

L29

BR

CR23

F197A

WH

C2B-12WH

GND

AP2+48V DC




1

2

3

4

5

6

7

8



REV A Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

KS1

TS51

TS57

TS55

P1

LABEL

TS61

TS63

TS62

CB2

TS59







DESCRIPTION


KEY SWITCH




HOURMETERHM

CHASSIS HARNESSCH


MANIFOLD HARNESSMH

SP SWITCH PANEL

CR CONTROL RELAY

SWITCH PANEL

DESCENT ALARM (OPTION)

TRAVEL ALARM

H4

H3

L3

CB3BK-C49-7

OR/RD-42A

BR-52D

BR-C48-3

TS58

TS66

TS60

TS62

TS61

TS63

TS51

HM

H3RD/WH-48A

TS60

TS58 TS61

TS62TS55

TS66 TS63

CB2

TS51

HM

H3

P1

OR

NC

NC

BR-52AH4

OR


TILT SENSOR

RD/BK-C1B-2

RD/WH-134D

BK BR-CB2

U

D

U

D D

U

L R R E

L R


TS66 JIB ROTATE TOGGLE SWITCH (Z30NRJ ONLY)

TS57

TS59

OR

CB2

P1

NC

NC

TS55

TS59

TS57

BK-22A

RD-27A

OR/BK-15A

OR/BK-C2-3

WH/RD-6A

BK-7A

BK/WH-8A

WH-4A

WH/BK-5A

GN-17A

RD-1A

GN-43A

RD/BK-2A

OR-14A

GN/BK-18A

GN/WH-19A

WH/BK-19C/48C

RD-C48-1

BL/BK-11A

BL-10A

L R

D

U

OR-C2-2

GN/BK-44A


KS1


WH

RDA

C

B

RD

A6

GN

/BK

A6

BL

/WH

C1

32

PL

I

BK

22

C

BK

P2

2B

AT

BR

/GN

D

RD/134A

RD-C23-6

RD-C32-7

GN/BK

BR HM(-)

BK C7-1

BK 22C

BL/WH C1-12


BR-52A

BR C32-12

RD

-C2

3-6

KS1

ES34DCU

128765431

C32

6 - 32


6 - 31

Ground Control Box Switch Panel Wiring Diagram,(ANSI / CSA), (from serial numbers Z30N10-12119, Z34N10-8857

and Z3410-7774)


1

2

3

4

5

6

7

8



REV A Platform Control Box Wiring Diagram, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

Y

Y

JIB

H1

BR

N-J

IBB

RN

-2

F.S.

C2P

C9

C7B

C1P

C47

C4POPTION

C3P

PL

AT

FO

RM

CO

NT

RO

LB

OX

RD/BK

RD

C1

32

PL

I BL

/WH

C1

P-1

2

C2

8T

TA

RD

/BK

C1

P-2 TURNTABLE TILT ALARM LED (CSA OPTION)

L48


P2

3B

AT

WH

C7

P-2

C1

2F

TS

BL

/WH

C3

P-1

2

C1

6D

RE

OR

/RD

C4

P-4

C5

TR

R W

H/B

K C

3P

-5

C4

TR

LW

H C

3P

-4

C11

SB

D B

L/B

K C

3P

-11

C1

0S

BU

BL

C3

P-1

0

C6

MF

V W

H/R

D C

3P

-6

C1

8P

RR

GR

/BK

C4

P-6

C1

7P

RL

GR

C4

P-5

C4

3JU

GR

C2

P-5

C1

9L

PE

GR

/WH

C4

P-7

C4

4JD

GR

/BK

C2

P-6

C2

PB

D R

D/B

K C

3P

-2

C1

PB

U R

D C

3P

-1

C1

4P

LU

OR

C4

P-2

C4

7JR

R O

R/B

K C

2P

-3

C4

6JR

LO

R C

2P

-2

C4

7JR

R R

D C

47

-6

C4

6JR

LY

LC

47

-5

C1

5P

LD

OR

/BK

C4

P-3


TS9

UD

TS7

L

R

RE

R

L

R

L

D

D

DU

U

U

WH

BRN

RD

RD

C2

9JS

H R

D/W

H C

1P

-3

109876

BP1

BCI

OR

G/R

D

C3

BA

TR

D/W

H C

3P

-3


TILT ALARMH1

R4

2B

AT

OR

/RD

C2

P-4

P2

4B

AT

WH

C9

P-2

C1

3D

EL

BL

/RD

C4

P-1

BK

/RD

RD

GR

N

C3

7S

CW

BL

/BK

C1

P-1

1

C3

2JS

LW

H/R

D C

1P

-6

L1 DRIVE ENABLE LED

HORN BUTTONP3



DRIVE CONTROLLER










TS8

TS7

TS9

TS13

TS11

TS12

TS10

P2

TS1

BP1

DP1

TS16

L1

P2

DP1

TS8TS16

TS13

TS11

TS10

TS12

TS15

TS1

P3

53 41 2

C1

8P

RL

OR

C4

7-1

C1

7P

RR

BL

C4

7-2

C4

4JD

WH

C4

7-3

C4

3JU

BK

C4

7-4

C8

PB

R B

K/W

H C

3P

-8

C7

PB

E B

K C

3P

-7

C2

7A

UX

RD

C1

P-1

C3

1R

EV

WH

/BK

C1

P-5

C3

0F

WD

WH

C1

P-4

C3

6S

CC

BL

C1

P-1

0

C9

HR

N B

K/R

D C

3P

-9

P2

2B

AT

BK

C7

P-1

P2

6B

AT

BK

C9

P-1

NC

NC

NO

1

L48

D73

D71

D40D66

ES34DCU

D77

P4

8L

PS

WH

C2

P-1

0

L3

0

BR

CR

45

WH W

OR

K L

IGH

TS

(OP

TIO

N)WH/RD TS49

85

86

873

0

OPTION

TS49

P2

6B

AT

RD

P2

WH

/RD

CR

45

#8

6


2

NOTES:




DESCRIPTIONLABEL

CR45

6 - 34


Platform Control Box Wiring Diagram, (ANSI / CSA)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

6 - 33

6 - 35

Section 6 • Schematics September 2013

6 - 36

Electrical Schematic, (AS / CE)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

Section 6 • Schematics September 2013

1

2

3

4

5

6

7

8




LS

4 - S

EC

ON

DA

RY

LIM

ITS

WIT

CH

LS

2 - P

RIM

AR

YL

IMIT

SW

ITC

H

LS

1-E

XT

/RE

TL

IMIT

SW

ITC

H

C48-3 TB52

C9

HR

N B

K/R

D


85

86

33 �

R1

9L

PE

GR

/WH

PR2

CR20

30

87

PR

3 - A

UX

ILIA

RY

LIF

TP

UM

P

CR

-20

- RE

LA

YP

RIM

AR

YL

IFT

PU

MP

CO

NTA

CT

OR

PR

2 - P

RIM

AR

YL

IFT

PU

MP

CO

IL

33 �PR3

C4

9-1

1 C

19

LP

E G

R/W

H

C4

9-1

R2

7A

UX

RD

87A

CR3

87

30

P42BAT OR/RD C48-2

C7

B-2

P2

3B

AT

WH

C7

P-2

C4

8-1

P1

82

BA

TR

D

P2

2B

AT

BK

RD

C134PWR RD

TB134

R42PWR

C12DE

10A

CB3

C1

33

PL

AB

L/R

DC

2P

-1C

2B

-1

D39

L4

H6 L45

U33

U6AMOTOR CONTROLLER

F4500A

C3

B-9

C1

B-1

2

H2

GR/BK

RD

TB134

C7

B-1

1 3

4

6 7

5

12 8

C40LS

C4

9-9

C29JSH RD/WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

BK

2 G

AG

RO

UN

D - C

HA

SS

IS

J2

-BK

RD

RD

/BK

BK P26BAT

13

LS1

14

P2

2B

AT

C7P-1

HO

RN

B

A C

P42BAT OR/RD

C4

9-7

C1

78

CS

LB

K

C49-10

C4

9-8

BK

C11

-3 B

K-6

C11

-4 W

H-6

C1

0-2

WH

-7

C1

0-1

BK

-7P

22

LS

BK

C5

2-1

BK

-8

C5

2-2

WH

-8

J1-WH

C4

9-3

C4

9-6

C4

9-5

C4

9-4

C2

B-4

C3

B-3

C1

B-2

C1

B-3

C1

B-4

C1

B-5

C1

B-6

R4

2P

WR

OR

/RD

C2

P-4

C3

BA

TR

D/W

HC

3P

-3

C2

8T

TA

RD

/BK

C1

P-2

C9

HR

N B

K/R

DC

3P

-9

C2

9JS

H R

D/W

HC

1P

-3

C3

2JS

LW

H/R

DC

1P

-6

C3

1R

EV

WH

/BK

C1

P-5

CR5

PR3

PR2

C180LPR BK

C19LPE GR/WH

RD

C12DE BL/WH

CR3

01GND BR

RD

H1

PLATFORM

GROUND

P1 KS1

TB22

P3

RD

+

RD

P182BAT RD

OR/RD

CR1

CR2

TB42

RD

/WH

30

8785

86

87

3086

85

BR

N

BR

N

PR1

OF

F-L

MT

SP

D IN

P

INT

ER

LO

CK

L3

53 17

LS4

BL

/WH

OR

/RD

LS2

RD

/BK

OR

/RD

C4

9-2

C4

8B

RK

RD

/BK

OR

/RD

20

CR5

22

21

22

21

86

85

CB2

10A

C1

P-4

RD

20

AP2

24 V

FO

RW

AR

D

PO

T. L

OW

DIO

DE

RE

TU

RN

+4

8V

INP

UT

PO

T. H

I

RE

VE

RS

E

101 9 11 1614

PR1AP2

48V

R4

2P

WR

OR

/RD

WH

WH

/BK

WH

/RD

RD

/WH

F3100A

F510A

F2100A

+

LEFTSIDE

_

+48 V

C3

0F

WD

WH

2

CR

1 - R

EL

AY

48

V D

C P

OW

ER

FL

AS

HIN

G B

EA

CO

N(O

PT

ION

)

FB

+

CR

4 - R

EL

AY

HO

RN

GR

OU

ND

- BA

SE

CO

NT

RO

LB

OX

CR4

TIL

TS

EN

SO

RR

D

WH

BK

BR

N

F1

+

86

85

30

87

RIGHTMOTOR

BR

N

CR

5 - R

EL

AY

BR

AK

E R

EL

EA

SE

PR

1 - M

AIN

PU

MP

CO

NTA

CT

OR

AP1

AU

XIL

IAR

YL

IFT

PU

MP

PR

IMA

RY

LIF

TP

UM

P

PR3 PR2

WH

BK AC POWER

F2 F1

A2

A1

A2

A1+

-

M2

BA

TT

ER

YC

HA

RG

ER

LEFTMOTOR

RIGHTSIDE

+24 V

F2

F2F1 B+M-AP1 B-

R42PWR OR/RD

P26BAT RD

D79

1

C1

79

DP

R G

R

LS18A

BK

RD

BK

RD

C1P-12 BL/WHC132PLI1 GR

LS18

WH

OR

D88

R20

4.7k �

NO

U3530A

2 SEC

5

2

COM

3

+

-

D90

P2BK-(FS)C9P-1 BK

RD-(FS)FS1

WH-(FS) P24BAT WH

C9P-3

C9P-2

P26BAT

U3

5 - T

IME

DE

LA

Y

LS

18

-OV

ER

LO

AD

LIM

ITS

WIT

CH

+ _

+ _

+ _

+ _

+ _

+ _

M5

8

9

ES34DCU

S7

CR

2 - R

EL

AY

48

V D

C P

OW

ER

FS

1 - F

OO

TS

WIT

CH

ADD D40 ONLY IF UNIT HAS L4 AND L48.


NOTES:




2

3

5

REV B

September 2013 Section 6 • Schematics

1

2

3

4

5

6

7

8





RE

TR

AC

T

(GND)

CR3

TU

RN

TA

BL

ER

OTA

TE

LE

FT

TU

RN

TA

BL

ER

OTA

TE

RIG

HT

DE

SC

EN

TA

LA

RM

SE

CO

ND

AR

YB

OO

M D

OW

N

SE

CO

ND

AR

YB

OO

M U

P

H4

+

WH

/BK

WH

TB4

BL

/BK

BL

TB5 TB11 TB10

OR

/BK

OR

PR

IMA

RY

BO

OM

UP

PR

IMA

RY

BO

OM

DO

WN

BO

OM

RE

TR

AC

T

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

BK

/WH

BK

RD

/BK

RD


PL

AT

FO

RM

RO

TA

TE

RIG

HT

JIB

BO

OM

UP

C19LPE GR/WH

TS55FUNCTIONENABLE

C12DE BL/WH

RD

CR5

RD

C2

PB

D R

D/B

K

C1

0S

BU

BL

C11

SB

D B

L/B

K

C5

TR

R W

H/B

K

C4

TR

LW

H

RIG

HT

TURNTABLEROTATE

LE

FT

TS62

RD

C3

B-4

C3

B-5

SECONDARYBOOM

TS60

DO

WN

UP

C3

B-1

1

C3

B-1

0

C3

B-1

C3

B-2

C3

P-4

C3

P-5

LE

FT

TS12TURNTABLEROTATE

RIG

HT

C3

P-1

0

C3

P-1

1

C1

PB

U R

D

C3

P-2

C3

P-1

DO

WN

2

6

CR19

UP

TS10SEC.BOOM

DO

WN

CR19

1

5

TS11PRIMARYBOOM

UP

C30FWD WH

C29JSH RD/WH

C31REV WH/BK

C32JSL WH/RD

R42PWR OR/RD

P26BAT RD

C4

7-2

C1

8P

RR

BL

PLATFORMROTATE

C1

8P

RR

GR

/BK

C1

7P

RL

GR

C1

5P

LD

OR

/BK

C1

4P

LU

OR

C7

PB

E B

K

C8

PB

R B

K/W

H

DO

WN

TS61

UP

PRIMARYBOOM

TS63

EX

TE

ND

PRIMARYBOOM

C3

B-7

C3

B-8

PLATFORMLEVEL

DO

WN

TS59

C4

B-6

C4

B-5

C4

B-3

C4

B-2

C3

P-7

C3

P-8

EX

T.

RE

T.

TS13PRIMARYBOOM

DO

WN

TS9PLATFORMLEVEL

C4

P-3

C4

P-2 C

4P

-5

C4

P-6

UP

RIG

HT

LE

FT

TS7PLATFORMROTATE

C4

7-6

C4

7JR

R R

D

C4

7-5

C4

6JR

LY

L

C4

7JR

R O

R/B

K

C4

6JR

LO

R

C4

7-4

C4

4JD

WH

C4

7-3

C4

3JU

BK

C4

7-1

C1

7P

RL

OR

C4

3JU

GR

C4

4JD

GR

/BK

RIG

HT

LE

FT

TS57

C2

B-6

GR

/BK

C2

B-5

GR

JIB MANIFOLD

DO

WN

TS58

UP

JIBBOOM

C2

B-2

OR

C2

B-3

OR

/BK

C2

P-5

C2

P-6

DO

WN

TS8JIBBOOM

UP

C2

P-3

C2

P-2

RIG

HT

LE

FT

TS16JIBROTATE

C7

P-3

BA

TG

ND

BR

N

C8

-4

C8

-3

C1

6D

E O

R/R

D

PS

1

PR

OP

OR

TIO

NA

LC

ON

TR

OL

VA

LV

E

AU

XIL

IAR

YC

ON

TR

OL

RE

LA

Y

TB6

WH

/RD

TB46 TB47

GR/WH

CR3

TB19

86

85

C19LPE GR/WH

RD

HO

UR

ME

TE

R

_

BR

AK

E R

EL

EA

SE

(NO

)

ST

EE

R R

IGH

T

ST

EE

R L

EF

T

BR

AK

E R

EL

EA

SE

PR

ES

SU

RE

SW

ITC

H

+

WH

/BK

HM

+

TB19

R48BRK

GR/WH

BL

BL

/BK

R4

8B

RK

RD

/WH

TB48

C8

-1

C7

B-3

BA

TG

ND

BR

N

C8

-2

TR

AV

EL

AL

AR

M

H3

TB52

13

RD

-5

RD

/WH

14

BR

N-5

22

LS321

BK

-5TB16

WH

-5

DP1

C6

MF

V W

H/R

D

C1

9L

PE

GR

/WH

C1

9L

PE

GR

/WH

LE

FT

TS66

RIG

HT

JIBROTATE

C3

B-6

WH

/RD

TS51AUXILIARYPUMP

C4

B-7

GR

/WH

TB27

C27AUX RD

RD

BP1ROTARYFLOWCONTROL

C3

P-6

C4

P-7

+

BCI(OPTION)

E

F

C3

7S

CC

BL

/BK

C1

B-1

TB37

TB3687

30CR5

CR5

C1

B-1

1

C1

B-1

0

C2

7A

UX

RD

C1

P-1

STEER

L R10

9

LIFT

DRIVE

TS1AUXILIARYPUMP

FWD

WH

-AU

X REV

20K

4OR/BK-R6

8

7

6

5

3

2

1C

1P

-11

C1

P-1

0C

36

SC

W B

LW

HTS15DRIVEENABLE

LVI/BCI OPTION

P24BAT WH

C32JSL WH/RD

C30FWD WH

C31REV WH/BK

C29JSH RD/WH

C1

3D

EL

BL

/RD

C1

2D

E B

L/W

HC

12

DE

BL

/WH

OR

/RD

C1

3D

EL

BL

/RD

BR

N

C3

B-1

2

TB12

BRN

C4

B-4

C4

B-1

C3

P-1

2

C1

6D

E O

R/R

DC

4P

-4

C4

P-1

L1

3

OR

/RD

48

2 376

15

LVI/BCI

BK

7

8

CR19

WH

2

WH

OR

BR

BR

AK

E R

EL

EA

SE

(NC

)

C2

P-1

0

BK

CR45NO

BR

WH

WH

TS48DRIVELIGHT

WO

RK

LIG

HT

S(O

PT

ION

)

DR

IVE

LIG

HT

S(O

PT

ION

)

CR23NO

L29

L30

(AP2)

48VWH

WH

F187A

P4

8L

PS

WH

P24BAT WH

D30

D50

D29

D71

D69

D77

D78

D4

D75

D59

D60

D76

D73

D74

D72

C2

P-1

2

C2

P-1

1

UP

TS49WORKLIGHT

L30

WH

BR

F197A

WH

L29

BK

GND BR

C47-8

WH/RD

BRN

RD

BK/RD

C47-8

PL

AT

FO

RM

RO

TA

TE

LE

FT

JIB

BO

OM

DO

WN

JIB

BO

OM

RO

TA

TE

RIG

HT

JIB

BO

OM

RO

TA

TE

LE

FT

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

DR

IVE

EN

AB

LE

LE

D

REV B

6 - 38

September 2013 Section 6 • Schematics


6 - 37

6 - 39


6 - 40

Ground Control Box Terminal Strip Wiring Diagram,(AS / CE), (from serial numbers Z30N10-12119, Z34N10-8857and Z3410-7774)


1

2

3

4

5

6

7

8



Ground Control Box Terminal Strip Wiring Diagram, (AS / CE)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

REV A

RD-C32-1

C32-3BL/WH PLATFORM OVERLOAD INPUT

C133PLA

C132PLI

BL/RD PLATFORM OVERLOAD ALARMH6(-), L45(-)C2B-1

C1B-12

DESCRIPTIONTOFROMCIRCUIT#WIRES

C1B-5

C1B-4

C1B-3

C4B-6

C4B-5

C3B-9

C8-4

TILT-C

C52-2

C3B-3

C2B-5

C2B-6

C11-3

C11-4

C1B-6

C2B-3

C2B-2



C49

C48

CHASSISHARNESS(CH)

MANIFOLDHARNESS(MH)

C1B

C2B

C4B

C3B

CABLE#3

CABLE#1

CABLE#2 C7B

C11

C8

C52

C10


LS3 - DRIVE ENABLE




134

RD-KSI-4RD-H6


JIB ROTATE LEFT (Z30N RJ ONLY)

JIB ROTATE RIGHT (Z30N RJ ONLY)

TS-66 (SP)C46JRLOR


BR- MH

RD/WH-MHWH/BK-SP

WH/BK-SP

OR/RD-CR5

BL-19D

BL/BK-19D

RD/WH-CR5

OR/RD-16A

RD/BK-C49-2

BK-22A

BK/RD-MH-HORN

BK/RD-C3B-9

RD-27D

BK C10-1

OR/RD-CR1


CR1, #86, CR2, #86

RD-C49-1

LS1-LS2 JUNCTION

LS2-LS4 JUNCTION

OR/BK-MH

OR/RD C8-1

BR-CB2

BRWH


BR-SP

BR-CR4

RD/WH-SP

52

52J2

48



C49-4 (CH)

RD-CR3

TB36/TB37 GR/WH-CR3

GR/WH-MH


GR/WH-19C

BR-52A

BL-MH

BL/BK-MH

C49-9 (CH)

CR4

GR/WH-C49-11

CR3CR2CR1

CR5

RD/WH-48D

OR/RD-42D

OR/RD-C48-2

RD/WH-C3B-3

BK J1 C52-1

TS-58 (SP)

TS-58 (SP)GR/BK

C43JU

C44JD

JIB UP

JIB DOWN

GR

C40LS

42

36

37

BK-CR4

RD-SP

C28TTA

27

C31REV

C30FWD

C29JSH

22

TILT ALARM

REVERSE

FORWARD

2-WIRE POT.

OFF-LIMIT SPEED

TS-57 (SP)

TS-57 (SP)

GR/WH-SP

BK C8-3

OR/BK-SP

OR-SPC17PRL

C18PRR

19

19

C13DEL12

14

15

16

BK/WH-SP

BK-SP

BL-SP

WH/BK-SP

RD/WH

RD/BK-SP

WH-SP

WH/RD-SP

8

C9HRN

7

10C3BAT

4

5

2

6

11 BL/BK-SP

DRIVE ENABLE LIGHT



HORN

ORBL-MH

BL/BK-MH

RD/BK

C49-3 (CH)

C49-5 (CH)BK-SP

BL/RDBL/WH-CH

OR-MH

BK-MH

BK/RD

BK/WH-MH

WH-MH

RD/BK-MH

WH/BK-MH

WH/RD-MHWH/RD C3B-6

RD/BK C3B-2

WH/BK C3B-5

WH C3B-4

C4B-1

CR4, #86

BK/WH C3B-8

BK C3B-7

BL/WH C3B-12

BL/BK C3B-11

BL C3B-10

GR

OR/BK C4B-3

OR C4B-2

OR/RD C4B-4

GR/BK

GR/WH C4B-7

C1B-2

BK-C32-4

RD C1B-1

RD/WH

WH

WH/BK

BL C1B-10

BL/BK C1B-11

OR/RD C2B-4

ABCD


C12FTS

C6MFV

C7PBE

C11SBD

C10SBU

C19LPE

C8PBR

C14PLU

C15PLD

C2PBD

C4TRL

C5TRR

C37SCW

C27AUX

P22BAT

C36SCC

C16DE

C19LPE

R42BAT

R48BRK

BATGND

BATGND

P134BAT

P134BAT


KEYSWITCH POWER

KEYSWITCH POWER

GROUND

GROUND

BRAKE RELEASE

SWITCHED 48V

LIFT PUMP

DRIVE ENABLE

STEER LEFT

+24V TO PLATFORM

AUXILIARY PUMP

STEER RIGHT



PRIMARY BOOM DOWN

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP


LIFT PUMP

SECONDARY BOOM UP

SECONDARY BOOM DOWN

PRIMARY BOOM EXTEND


FOOTSWITCH

PRIMARY BOOM UP

ES34DCU



CR5 - BRAKE RELEASE




CR4 - HORN

CONTROL RELAY I.D.

30

8586

87A

87

REF.


RD

L29

BR

CR23

F197A

WH

C2B-12WH

GND

AP2+48V DC




1

2

3

4

5

6

7

8



Ground Control Box Switch Panel Wiring Diagram, (AS / CE)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

REV A

KS1

TS51

TS57

TS55

P1

LABEL

TS61

TS63

TS62

CB2

TS59







DESCRIPTION


KEY SWITCH




HOURMETERHM

CHASSIS HARNESSCH


MANIFOLD HARNESSMH

SP SWITCH PANEL

CR CONTROL RELAY

SWITCH PANEL

DESCENT ALARM

TRAVEL ALARM

H4

H3

L3

CB3BK-C49-7

OR/RD-42A

BR-52D

BR-C48-3

TS58

TS66

TS60

TS62

TS61

TS63

TS51

HM

H3RD/WH-48A

TS60

TS58 TS61

TS62TS55

TS66 TS63

CB2

L45

TS51

HM

H3

P1

OR

NC

NC

BR-52AH4

OR


TILT SENSOR

RD/BK-C1B-2

RD/WH-134D

BK BR-CB2

U

D

U

D D

U

L R R E

L R


TS66 JIB ROTATE TOGGLE SWITCH (Z30N RJ ONLY)

TS57

TS59

OR

L45

CB2

P1

NC

NC

TS55

TS59

TS57

BK-22A

RD-27A

OR/BK-15A

OR/BK-C2-3

WH/RD-6A

BK-7A

BK/WH-8A

WH-4A

WH/BK-5A

GN-17A

RD-1A

GN-43A

RD/BK-2A

OR-14A

GN/BK-18A

GN/WH-19A

WH/BK-19D/48C

RD-C48-1

BL/BK-11A

BL-10A

L R

D

U

OR-C2-2

GN/BK-44A


KS1


WH

RDA

C

B

L45 PLATFORM OVERLOAD LED

12876543

RD

A6

GN

/BK

H6

BL

/WH

C1

32

PL

I

BK

22

C

BK

P2

2B

AT

BR

/GN

D

U33

1

C32

RD/134A

RD-C23-6

RD-C32-7

H6

RD C32-1

GN/BK

BR HM(-)

BK C7-1

BK 22C

BL/WH C1-12


RD 134B

BL/RD C2B-1

BR-52A

BR C32-12

RD

-C2

3-6

H6 PLATFORM OVERLOAD ALARM

KS1

ES34DCU

6 - 42


Ground Control Box Switch Panel Wiring Diagram,(AS / CE), (from serial numbers Z30N10-12119, Z34N10-8857

and Z3410-7774)

6 - 41

6 - 43


6 - 44

Platform Control Box Wiring Diagram, (AS / CE)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)


1

2

3

4

5

6

7

8



Platform Control Box Wiring Diagram, (AS / CE)(from serial numbers Z30N10-12119, Z34N10-8857 and Z3410-7774)

1 D39NO

NC

NC

P2

2B

AT

BK

C7

P-1

C9

HR

N B

K/R

D C

3P

-9

C3

6S

CW

BL

C1

P-1

0

C3

0F

WD

WH

C1

P-4

C3

1R

EV

WH

/BK

C1

P-5

C2

7A

UX

RD

C1

P-1

C7

PB

E B

K C

3P

-7

C8

PB

R B

K/W

H C

3P

-8

C4

3JU

BK

C4

7-3

C4

4JD

WH

C4

7-4

C1

8P

RR

BL

C4

7-2

C1

7P

RL

OR

C4

7-1

21 43 5

P3

TS1

TS15

TS12

TS10

TS11

TS13

TS16 TS8

DP1

P2

L1

C3

2JS

LW

H/R

D C

1P

-6

C3

7S

CC

BL

/BK

C1

P-1

1

GR

RD

BK

/RD

P2

4B

AT

WH

C9

P-2

R4

2P

WR

OR

/RD

C2

P-4

OR

/RD

BCI(OPTION)

BP1

6 7 8 9 10

C2

9JS

H R

D/W

H C

1P

-3

RD

WH

RD

BR

WH

U

U

U D

D

D

L

R

L

R

E R

R

L

TS7

D U

TS9

C1

5P

LD

OR

/BK

C4

P-3

C4

6JR

LY

LC

47

-5

C4

7JR

R R

D C

47

-6

C4

6JR

LO

R C

2P

-2

C4

7JR

R O

R/B

K C

2P

-3

C1

4P

LU

OR

C4

P-2

C1

PB

U R

D C

3P

-1

C2

PB

D R

D/B

K C

3P

-2

C4

4JD

GR

/BK

C2

P-6

C1

9L

PE

GR

/WH

C4

P-7

C4

3JU

GR

C2

P-5

C1

7P

RL

GR

C4

P-5

C1

8P

RR

GR

/BK

C4

P-6

C6

MF

V W

H/R

D C

3P

-6

C1

0S

BU

BL

C3

P-1

0

C11

SB

D B

L/B

K C

3P

-11

C4

TR

LW

H C

3P

-4

C5

TR

R W

H/B

K C

3P

-5

C1

6D

RE

OR

/RD

C4

P-4

C1

2F

TS

BL

/WH

C3

P-1

2

P2

3B

AT

WH

C7

P-2


LS18LS18A

L48

L4

C2

8T

TA

RD

/BK

C1

P-2

C1

33

PL

AB

L/R

D C

2P

-1

C1

32

PL

I1 B

L/W

H C

1P

-12

RD

RD

RD/BK

GR/BK

PL

AT

FO

RM

CO

NT

RO

LB

OX

C3P

OPTIONC4P

C47JIB

C1P

C7P

C9F.S.

C2P

BR

N-2

BR

N-J

IB

H1

R2

0

D88

D90

P2

6B

AT

BK

P2

C3

BA

TR

D/W

H C

3P

-3

R2

6B

AT

BK

C9

P-1

D40

RDBK

WH

OR

D77

D71

D73

C1

3D

EL

BL

/RD

C4

P-1

U352 +

3 -

5

1

TURNTABLE TILT ALARM LED (OPTION)

L4



TILT ALARMH1

L1 DRIVE ENABLE LED

HORN BUTTONP3



DRIVE CONTROLLER










TS8

TS7

TS9

TS13

TS11

TS12

TS10

P2

TS1

BP1

DP1

TS16

PLATFORM OVERLOAD LED

L48

TIME DELAY RELAY - 2 SECONDS, 30AU35ES34DCU

RESISTOR, 4.7k �R20

TS49

P2

6B

AT

RD

P2

WH

/RD

CR

45

#8

6


P4

8L

PS

WH

C2

P-1

0

L3

0

BR

CR

45

WH W

OR

K L

IGH

TS

(OP

TIO

N)WH/RD TS49

85

86

873

0

NOTES:



2


DESCRIPTIONLABEL

CR45

REV A


1

2

3

4

5

6

7

8



REV A Power Cable Wiring Diagram

LEFT SIDEBATTERY PACK

+

+

+

+

A1 D1

A2

F2 A2

F1

A1 A2

F2

F1A1

48V

D1

+ +

++

AP2 AP1

+

WH (10)

BK (10)

ACBATTERYCHARGER

+

+

+

+

RIGHT SIDEBATTERY PACK

24V

AUXILIARYLIFT PUMP

BK (4)

PRIMARYLIFT PUMP

BK

(4)

BK (2)

BK (2)

WH

(10

)

BK

(10

)

RD (2)

RIGHT SIDEDRIVE MOTOR

LEFT SIDEDRIVE MOTOR

RD (10)

RD (10) RD (10)

BK (2)

PRIMARY LIFTPUMP CONTACTOR

(PR2)

AUXILIARY LIFTPUMP CONTACTOR

(PR3)

BK (2)

BK (2)

RD

(4)

BK

(2)

RD

(2)

RD

(2)

BK

(2)

AMMETER

DRIVE CONTACTOR(PR1)

RD (2)

NOTE: WIRE GAUGE NOTED IN PAENTHESES AFTER WIRE COLOR.

F2100A

F1500A

F3100A

BK (2)

B+M-B-

F1 F2

RD

(4)

CURTIS / SEPEXMOTOR CONTROLLER

BATTERY

CONTROLLER 3 DIODES

_

_

_ _

_ _

_

_

_

_ _

_

_

ES34DCN

6 - 46


6 - 45

Power Cable Wiring Diagram

6 - 47


6 - 48

Drive Contactor Panel Wiring Diagram


1

2

3

4

5

6

7

8



Drive Contactor Panel Wiring Diagram REV B

C48

C49

SEEDETAIL-A

OR

/RD

#C

R2

0

C48-2 P42BAT OR/RD

P182BAT BK / P180LPR BK

BR

1316 1519 18 17 14212224 23 20

23456789101112

C49-6 C32JSL WH/RD

C49-2 C48BRK RD/BK

OR

/RD

#C

R2

P4

2B

AT

GR/WH #PR2 R42BAT

GR/WH #CR3 C19LPE BR

DETAIL-A

CR20RELAY SOCKET WIRING

(WIRE INSERTION SIDE SHOWN)

C49-11 C19LPE GR/WH

CR20LIFT PUMP

CONTACTORRELAY

C48-3 01GND BR

MOTOR CONTROLLER

CURTIS SEPEX

PR3AUXILIARYLIFT PUMP

CONTACTOR

PR1DRIVE

CONTACTOR

PR2

PRIMARYLIFT PUMP

CONTACTOR

C49-5 C31REV WH/BK

C49-4 C30FWD WH

C49-7 C178CSL BK

24V

F410A

48V

BR

OR/RD

OR/RD

GR

C49-1 R27AUX RD

C48-1 P182BAT RD

C49-9 C4OLS OR

C49-8 C12FTS BL/WH

C49-10 R42BAT OR/RD

OR/RD #CR20

R42BAT GR/WH #PR2

C49-3 C29JSH RD/WH

1

ES34DCU

30

8586

87

87A

CIRCUIT CHANGE:P182BAT BEFORE SERIAL NUMBERS:Z30N (RJ), Z30N10-12120Z34 (DC), Z3410-7774Z34N, Z34N10-8858

C180LPR AFTER SERIAL NUMBERS:Z30N (RJ), Z30N10-12119Z34 (DC), Z3410-7773Z34N, Z34N10-8857

1

1


1

2

3

4

5

6

7

8



REV B Manifold and Limit Switch Wiring Diagram

H2

PIN# WIRES

1 BK

C52

WH2

3 BK

WH4

2 BR

C8

RD1

WIRESPIN#

PIN# WIRES

1 RD

C11

BR2

4 WH

BK3

2 WH

C10

BK1

WIRESPIN#

C47

PIN# WIRES CIRCUIT#

1 OR C17PRL

C47

BL2 C18PRR

C43JU

4

BK

C44JDWH

3

GNDBR

NC

8

5 ----

----

----

NC

NC

7

6

RD

#1

34

RD

/BK

C2

8T

TA

BR

A B C

WH

RD

BK

TILT SENSOR

P

T

JIB CABLE TO PLATFORM BOX

BL-JIB

(PLATFORMROTATE RIGHT)

OR-JIB

(PLATFORMROTATE LEFT)

JIB / PLATFORM ROTATE MANIFOLD(TOP VIEW)

WH-JIB

(JIB DOWN)

BK-JIB

(JIB UP)

BR-JIB

(GROUND)

1413

2221

21 22

1413

21 22

1413

21

13

BRAKE RELEASE N.O. VALVE

GR

/WH

C1

9L

PE

RD

/WH

C4

8B

RK

BL

C3

6S

CC

(L

EF

T)

BL

/BK

C3

7S

CW

(R

IGH

T)

BRAKE RELEASE N.C. VALVE

BRAKE PRESSURE SWITCH

MANIFOLD HARNESS (MH) TO GROUND CONTROL BOX

SERVICE HORN

BL

K/R

ED

#C

R4

BR

ST

EE

R R

IGH

T/ L

EF

T

PR

OP

OR

TIO

NA

LF

LO

W C

ON

TR

OL

PR

IMA

RY

BO

OM

EX

TE

ND

/ R

ET

RA

CT

PR

IMA

RY

BO

OM

UP

/ D

OW

N

SE

CO

ND

AR

YB

OO

MU

P/ D

OW

N

TU

RN

TA

BL

E R

OTA

TE

RIG

HT

/ L

EF

T

PL

AT

FO

RM

LE

VE

LU

P/ D

OW

N

(SHOWN WITH BOOM ROTATEDPAST EITHER NON-STEER WHEEL)

BR

NOTE:ALL LIMIT SWITCHES SHOWN WITH THE BOOM INTHE STOWED POSITION EXCEPT WHERE NOTED.

(SHOWN WITH BOOM EXTENDED)

CABLE 7

CABLE 6

CABLE 5

CABLE 8

OR

C1

4P

LU

(U

P)

OR

/BK

C1

5P

LD

(D

OW

N)

WH

/BK

C5

TR

R (

RIG

HT

)

WH

C4

TR

L(L

EF

T)

BL

C1

0S

BU

(U

P)

BL

/BK

C11

SB

D (

DO

WN

)

RD

/BK

C2

PB

D (

DO

WN

)

RD

C1

PB

U (

UP

)

LS1EXTEND/RETRACT

LIMIT SWITCH

14

22

WH-7BK-7

LS2PRIMARY BOOMLIMIT SWITCH

WH-6

LS3DRIVE ENABLELIMIT SWITCH

BK-6

RD-6

BR-5

RD-5

WH-5

BK-5

LS4SECONDARY BOOM

LIMIT SWITCH

BK-8WH-8

BR-6

BR

N

WH

/RD

C6

MF

V

BK

C7

PB

E (

EX

TE

ND

)

BK

/WH

C7

PB

R (

RE

TR

AC

T)

6

7

RD

NC

C47JRR

-----

C47

C46JRL5

8

YL

BR GND

3 BK C43JU

WH4 C44JD

C18PRR2 BL

C47

C17PRLOR1

CKT#WIRESPIN#

JR1

JR2

P

T

BR-JIB

(JIB L)

(GROUND)

RD-JIB

(JIB R)

YL-JIB

(JIB DOWN)(PLAT L)

WH-JIB

BK-JIB

(JIB UP)(PLAT R)

BL-JIB

OR-JIB

JIB MANIFOLD WITH JIB ROTATE OPTION(Z30N RJ ONLY)

(TOP VIEW) JIB CABLE TO PLATFORM BOX

ES34DCU

6 - 50


Manifold and Limit Switch Wiring Diagram

6 - 49

6 - 51


6 - 52

LVI/BCI Option Wiring Diagram


1

2

3

4

5

6

7

8



LVI/BCI Option Wiring Diagram

C3P

C4P

C1P

C2P

LS18

OPTION

C47 JIB

C7B

C9 F.S.

TS2

TS4TS6

RD

BL

CR

19

LV

I BK

GN

D B

RN

P2

4B

AT

WH

TS7TS9

TS1 L1

R4

2B

AT

OR

/RD

10986 75431 2

DP1

C3

P-1

C1

PB

U R

D

C3

P-1

0 C

10

SB

U B

L

C2

P-4

R4

2B

AT

OR

/RD

CR19

BP1

LVI/BCI

21

2

6

4

3

1

5

3

4

7

7

5

8

8

6

BK/RD

RD

GR

LIFT LOCKOUTRELAY

P2

TS8

TS13 TS11 TS10

TS12

TS15

P3

NC

NC

NO

15

48

GN

D B

RN

CR

19

LV

I BK

SETUP ENABLE (+) WIREENABLE WHEN IT IS TEMPORARILY CONNECTED TO 24VDC

WH/RD

WH

BK

BRN

P2

4B

AT

WH

1

1

ES34DCN

REV A


1

2

3

4

5

6

7

8



Charger Interlock OptionREV A

R42BAT RD

R42BAT RD R42BAT RD

WH

BK

LEDCHARGERINDICATOR

SEPEX CONTROLLER

18 B-M- B+F1 F2

2

R4

2P

WR

OR

/RD

14 161191 10

RE

VE

RS

E

PO

T. H

I

+4

8V

INP

UT

DIO

DE

RE

TU

RN

PO

T. L

OW

FO

RW

AR

D

20

OR

/RD

GR

173 5

INT

ER

LO

CK

OF

F-L

MT

SP

D IN

P

PR1COIL

U6ASEPEX CONTROLLER

ACBATTERYCHARGER

C56-1 BK (N.O.)

C56-2 WH (COM)

87

85

30

86

CR24

P42BAT OR/RD

R42BAT OR/RD

C1

08

PL

PG

R/B

K

GR

/BK

PR1 - DRIVE CONTACTOR(TOP VIEW)

CONTROLLER

BATTERY

23

12

24

4 3 1267 511 10 9 8

C1

79

DP

R G

R

CR

5 R

D/B

K

2022 21 19 18

C2

9JS

H R

D/W

H

C3

2JS

LW

H/R

D

1617 15 1314

PR-1

DIODE

ACBATTERYCHARGER

C56-1 BK (NO)C56-2 WH (COM)

BATTERY INDICATOR LED1. LED IS RED DURING PHASES I1 AND P (BULK CHARGE). (20% BATTERY CHARGED)2. LED IS YELLOW DURING PHASES U AND I2. (80% BATTERY CHARGED)3. LED IS GREEN AT THE END OF CHARGE. (100% BATTERY CHARGED)4. LED FLASHES GREEN DURING CYCLE EQUALIZATION.5. LED IS OFF WHEN THE CHARGER IS NOT POWERED.6. LED FLASHES RED, INDICATES DEFECT / FAULT.

INTERLOCK RELAY (N.O.), 10A CONTACT1. CHARGER NOT CONNECTED TO BATTERY OR MAIN SUPPLY, CONTACT OPEN.2. CHARGER CONNECTED TO BATTERY, CONTACT CLOSED.3. CHARGER CONNECTED TO BATTERY AND MAIN SUPPLY, CONTACT OPEN.

48V DCOUTPUT

SCHEMATIC

C49-10

WIRING DIAGRAM

CHARGER ECU

SUPPLY BATTERY CONTACT

OPENNCNC

CLOSEDCONNECTNC

OPENCONNECTCONNECT

OPENNCCONNECT

87

30

86

85

ES34BEAB

6 - 54


6 - 53

Charger Interlock Option

6 - 55


6 - 56

CTE Option, (CE Models)


1

2

3

4

5

6

7

8



CTE Option, (CE Models) REV A

ES0276N

C21-1

SCHEMATIC - PLATFORM LEVEL CUTOUT

PL

AT

FO

RM

LE

VE

LD

OW

N

GROUND BR

BR

C1

5P

LD

OR

/BK

CR18B

C1

5P

LD

OR

/BK

TB15

P22LS BK

LIM

ITS

WIT

CH

ES

TB14

C1

4P

LU

OR

CR18A

C1

4P

LU

OR

C52-2 WH-8

LOAD WEIGHING LIM. SW. +12V (2)

LOAD WEIGHING LIM. SW. +12V (1)

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

WIRING DIAGRAM

CR18APLATFORM LEVEL UP

OR-TS59

OR/BK-TS59

14

15

P134FB WH-FH

RD-KS1

134

134

GROUND BOLT

C15PLD OR/BK C21-1

C14PLU OR C20-1

BR

CR18BPLATFORM LEVEL DOWN

C15PLD OR/BK CR18B#86

C14PLU OR CR18A#86

C15PLD OR/BK C4B-3

C14PLU OR C4B-2

14

15

P134BAT BK-LS5 C37-3

P134TTS RD A

P134BAT RD-LS17 C38-1

134

134

FU

NC

TIO

N H

AR

NE

SS

C21-2

C20-1

C20-2

PL

AT

FO

RM

LE

VE

LU

P

C40LS OR

C10-1 BK-7

C40LS1 OR CR18A#30

+24V TO PLATFORMP22LS BK C10-1

22 22

P22BAT BK C32-4 P22BAT BK KSI

P22BAT BK CR4-30


1

2

3

4

5

6

7

8



REV B Hydraulic Schematic

L2

(Z30N, Z30NRJ) 2800 psi / 193 bar(Z34N, Z34DC) 3200 psi / 221 bar

AUXILIARYPUMP0.5 gpm1.89 L/min

100 MESH10 MICRON

HYDRAULIC RESERVOIR

M

PRIMARYPUMP2.1 gpm7.95 L/min

T1

M

COM

0.045 inch1.14 mm

0.090 inch /2.29 mm

0.045 inch1.14 mm

P1 G1 BRAKE

BRAKES

M M

S2

0.8 gpm3 L/min

3000 psi207 bar

3:1

3200 psi221 bar

3:13000 psi207 bar

1.5:1

N.O.

N.C.

PS S1

STEERCYLINDER

MASTERCYLINDER

L1P2

3000 psi207 bar

4.5:1

PLATFORM LEVELINGSLAVE CYLINDER

1600 psi110 bar

1600 psi110 bar

1100 psi75.8 bar

TURNTABLE ROTATEMOTOR

TR1 TR2 SC1 SC2 PC1 PC2

0.035 inch0.89 mm

T2

JIB BOOM

SECONDARY BOOMCYLINDER

3000 psi207 bar

1.5:1

P

0.025 inch0.635 mm

JR1 JR2 J1

3300 psi227.5 bar

3:13300 psi227.5 bar

3:1

JIB BOOM ROTATE(Z30NRJ)

PRIMARY BOOMCYLINDER

J2

0.3 gpm1.14 L/min

PR1

T

PR2

PLATFORM ROTATE

JIB BOOM MANIFOLD

ROTATE MANIFOLD(PLATFORM)

ROTATE MANIFOLD(JIB BOOM)

1800 psi124 bar

2500 psi172 bar

3:1

2500 psi172 bar

3:1

EXT RET

EXTENSION CYLINDER(Z30N, Z34N, Z34DC)

EXTENSION CYLINDER(Z30NRJ)

0.032 inch0.81 mm

FUNCTION MANIFOLD

AB

BJ

AD

AEAC

AX

W

Y

B

D

E

U V

F G

K

S

C

H

OQ

R

P I J

L

M

N

T

7.6 cu in/rev124.5 cc/rev

1.86.8

gpmL/min

1

1

HS0079C

RATIO PRESSURE

2500 PSI

3000 PSI

3200 PSI

3:1

3300 PSI

3:1

3:1

3:1

4.5:1 3000 PSI

1.5:1 3000 PSI

COUNTERBALANCE VALVES

BF

BD BE

BC

BA BB

BK BL

BI BJ

B C

SCHEMATIC ITEM

BA BB

BC

BD BE

BG BH

BI BK BL BM BN

AA

BF

BG BH

BM BN

CA

CB

CHECK VALVES

DESCRIPTION

CA

SCHEMATIC ITEM

CB

PILOT CHECK VALVE

CHECK VALVE

K

6 - 58


Hydraulic Schematic

6 - 57

Dis

trib

ute

d B

y:

Genie North America

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Brasil

Genie Holland

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Phone +86 21 53852570

Fax +86 21 53852569

Phone +65 98 480 775

Fax +65 67 533 544

Phone +81 3 3453 6082

Fax +81 3 3453 6083

Phone +82 25 587 267

Fax +82 25 583 910

Phone +55 11 41 665 755

Fax +55 11 41 665 754

Phone +31 183 581 102

Fax +31 183 581 566

Genie Scandinavia

Genie France

Genie Iberica

Genie Germany

Genie U.K.

Genie Mexico City

Phone +46 31 575100

Fax +

Phone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Phone +34 93 579 5042

Fax +34 93 579 5059

Phone 0800 180 9017

Fax +49 422 149 1820

Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Phone +52 55 5666 5242

Fax +52 55 5666 3241

46 31 579020

Phone +49 422 149 1818

Documents

257_Service Manual.pdf - mateco