88619 Z-80/60 Service Manual

Part No. 88619

Rev B1

September 2006

Service Manual

(from serial number 101)

Z-80/60 Part No. 88619

September 2006

ii

Important

Read, understand and obey the safety rules andoperating instructions in the Genie Z-80/60 Operator'sManual before attempting any maintenance or repairprocedure.

This manual provides detailed scheduled maintenanceinformation for the machine owner and user. It alsoprovides troubleshooting fault codes and repairprocedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However, severalprocedures require specialized skills, tools, liftingequipment and a suitable workshop. In these instances,we strongly recommend that maintenance and repair beperformed at an authorized Genie dealer service center.

Technical Publications

Genie Industries has endeavored to deliver the highestdegree of accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject to changewithout notice.

Readers are encouraged to notify Genie of errors andsend in suggestions for improvement. Allcommunications will be carefully considered for futureprintings of this and all other manuals.

Contact Us:

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

Copyright © 2003 by Genie Industries

88619 Rev B July 2006First Edition, Second Printing

"Genie" and "Z" are registered trademarks ofGenie Industries in the USA and many othercountries.

Printed on recycled paper

Printed in U.S.A.

Introduction

Part No. 88619 Z-80/60

September 2006

iii

Serial Number Legend

Z80 06 - 12345

Model

Model year

Sequencenumber

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5CAN B.354.4

Model: Z-80/60

Serial number: Z8006-12345

Electrical schematic number: ES0188

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : 150 lb / 670 N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/062006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 86 ft/ 26.38 m

Maximum platform reach : 60 ft/ 18.28 m

Serial number(stamped on chassis)

Serial label(located under cover)

INTRODUCTION

Z-80/60 Part No. 88619

September 2006

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iv

Part No. 88619 Z-80/60

September 2006

v

Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual, and the Operator's Manual will resultin death or serious injury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are 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.

Section 1 • Safety Rules

Z-80/60 Part No. 88619

September 2006

SAFETY RULES

vi

Section 1 • Safety Rules

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 machineuse 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.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Used to indicate operation ormaintenance information.

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.

Part No. 88619 Z-80/60

September 2006

Table of Contents

vii

Introduction

Important 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

Function Speeds Specifications ............................................................................ 2 - 3

Hydraulic Specifications ........................................................................................ 2 - 4

Manifold Component Specifications ...................................................................... 2 - 6

GM 3.0L EFI Engine .............................................................................................. 2 - 7

Ford LRG-425 Engine ........................................................................................... 2 - 8

Deutz F4L-913 Engine ......................................................................................... 2 - 10

Deutz BF4L-2011 Engine .................................................................................... 2 - 11

Perkins 704-30 Engine ........................................................................................ 2 - 13

Perkins 804C-33 Engine ...................................................................................... 2 - 14

Machine Torque Specifications............................................................................ 2 - 15

Manifold Component Specifications .................................................................... 2 - 15

Hydraulic Hose and Fitting Torque Specifications ............................................... 2 - 16

SAE and Metric Fasteners Torque Charts ........................................................... 2 - 17

Section 3 Rev Scheduled Maintenance Procedures

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

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

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

C Checklist A Procedures

A-1 Inspect the Manuals and Decals .................................................................. 3 - 7

A-2 Perform Pre-operation Inspection ................................................................ 3 - 8

A-3 Perform Function Tests ............................................................................... 3 - 8

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viii

Section 3 Rev Scheduled Maintenance Procedures, continued

A-4 Perform Engine Maintenance ...................................................................... 3 - 9

A-5 Check the Hydraulic Filter Condition Indicators ......................................... 3 - 10

A-6 Perform 30 Day Service ............................................................................. 3 - 11

A-7 Perform Engine Maintenance .................................................................... 3 - 12

A-8 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 13

A-9 Inspect the Fuel Filter/Water Separator - Diesel Models ............................ 3 - 13

A-10 Perform Engine Maintenance - Deutz Models ............................................ 3 - 15

A-11 Replace the Drive Hub Oil ......................................................................... 3 - 15

A-12 Perform Engine Maintenance - Gasoline/LPG Models ............................... 3 - 17

B Checklist B Procedures

B-1 Inspect the Batteries .................................................................................. 3 - 18

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 19

B-3 Test the Key Switch ................................................................................... 3 - 21

B-4 Check the Exhaust System........................................................................ 3 - 21

B-5 Inspect the Engine Air Filter ....................................................................... 3 - 22

B-6 Engine Maintenance - Deutz Models ......................................................... 3 - 23

B-7 Check the Tires, Wheels and Lug Nut Torque ........................................... 3 - 24

B-8 Confirm the Proper Brake Configuration .................................................... 3 - 24

B-9 Check the Drive Hub Oil Level and Fastener Torque ................................. 3 - 25

B-10 Test the Ground Control Override .............................................................. 3 - 26

B-11 Test the Platform Self-leveling ................................................................... 3 - 27

B-12 Test the Engine Idle Select Operation ....................................................... 3 - 28

B-13 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 29

B-14 Test the Drive Brakes ................................................................................ 3 - 30

B-15 Test the Drive Speed - Stowed Position .................................................... 3 - 30

B-16 Test the Drive Speed - Raised or Extended Position ................................. 3 - 31

B-17 Test the Alarm and Optional Flashing Beacon ........................................... 3 - 32

B-18 Perform Hydraulic Oil Analysis .................................................................. 3 - 32

B-19 Check and Adjust the Engine RPM ............................................................ 3 - 33

B-20 Test the Safety Envelope and Safety Circuits ............................................ 3 - 36

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Section 3 Rev Scheduled Maintenance Procedures, continued

B-21 Test the Primary Boom Self-leveling .......................................................... 3 - 38

B-22 Test the Primary Boom Angle Sensor ........................................................ 3 - 39

B-23 Inspect the Fuel Tank Cap Venting Systems ............................................. 3 - 40

B-24 Perform Engine Maintenance .................................................................... 3 - 41

B-25 Perform Engine Maintenance - Gasoline/LPG Models ............................... 3 - 42

B Checklist C Procedures

C-1 Perform Engine Maintenance - Diesel Models ........................................... 3 - 43

C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 44

C-3 Test the Platform Overload System (if equipped) ...................................... 3 - 44

C-4 Replace the Engine Air Filter ..................................................................... 3 - 46

C-5 Replace the Fuel Filter/Water Separator - Diesel Models .......................... 3 - 47

C-6 Perform Engine Maintenance - Gasoline/LPG Models ............................... 3 - 49

B Checklist D Procedures

D-1 Check the Boom Wear Pads ..................................................................... 3 - 50

D-2 Check the Free-wheel Configuration .......................................................... 3 - 50

D-3 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 52

D-4 Inspect for Turntable Bearing Wear ........................................................... 3 - 53

D-5 Replace the Drive Hub Oil ......................................................................... 3 - 55

D-6 Perform Engine Maintenance - Diesel Models ........................................... 3 - 57

D-7 Replace the Hydraulic Filter Elements ....................................................... 3 - 58

B Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 60

E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ............................... 3 - 62

E-3 Perform Engine Maintenance - Perkins and Ford Models .......................... 3 - 63

E-4 Perform Engine Maintenance - Ford Models .............................................. 3 - 64

E-5 Perform Engine Maintenance - Diesel Models ........................................... 3 - 65

E-6 Perform Engine Maintenance - Deutz Models ............................................ 3 - 66



Z-80/60 Part No. 88619

September 2006

Section 4 Rev Repair Procedures

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

B Display Module ...................................................................................................... 4 - 2

B Platform Controls

1-1 ALC-1000 Circuit Board ............................................................................... 4 - 9

1-2 Membrane Decal ....................................................................................... 4 - 10

1-3 Joysticks .................................................................................................... 4 - 11

B Platform Components

2-1 Platform ..................................................................................................... 4 - 18

2-2 Platform Leveling Cylinder ......................................................................... 4 - 18

2-3 Platform Rotator ......................................................................................... 4 - 20

2-4 Calibrate the Platform Overload System (if equipped) ............................... 4 - 22

B Jib Boom Components

3-1 Jib Boom.................................................................................................... 4 - 25

3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 27

C Boom Components

4-1 Primary Boom Cable Track ........................................................................ 4 - 29

4-2 Primary Boom ............................................................................................ 4 - 32

4-3 Primary Boom Lift Cylinder ........................................................................ 4 - 36

4-4 Primary Boom Extension Cylinder ............................................................. 4 - 37

4-5 Primary Boom Angle Sensor ..................................................................... 4 - 39

4-6 Secondary Boom ....................................................................................... 4 - 42

4-7 Secondary Boom Lift Cylinder ................................................................... 4 - 44

B Engines

5-1 RPM Adjustment ........................................................................................ 4 - 47

5-2 Flex Plate ................................................................................................... 4 - 47

5-3 Engine Fault Codes - Gasoline/LPG Models .............................................. 4 - 54

A Ground Controls

6-1 Circuit Boards ............................................................................................ 4 - 55

6-2 Membrane Decal ....................................................................................... 4 - 56

x

TABLE OF CONTENTS

Part No. 88619 Z-80/60

September 2006

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Section 4 Rev Repair Procedures, continued

B Hydraulic Pumps

7-1 Function Pump .......................................................................................... 4 - 57

7-2 Drive Pump ................................................................................................ 4 - 58

C Manifolds

8-1 Function Manifold - View 1 ......................................................................... 4 - 60

8-2 Function Manifold - View 2 ......................................................................... 4 - 62

8-3 Valve Adjustments - Function Manifold ...................................................... 4 - 64

8-4 Platform Manifold ....................................................................................... 4 - 70

8-5 Turntable Rotation Manifold ....................................................................... 4 - 72

8-6 Platform Rotate Manifold ........................................................................... 4 - 73

8-7 2 Wheel Steer and Oscillate Manifold ........................................................ 4 - 74

8-8 4 Wheel Steer and Oscillate Manifold ........................................................ 4 - 80

8-9 Oil Diverter Manifold (welder option) .......................................................... 4 - 85

8-10 Traction Manifold, 2WD ............................................................................. 4 - 86

8-11 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 88

8-12 Traction Manifold, 4WD ............................................................................. 4 - 90

8-13 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 92

8-14 Valve Coils ................................................................................................. 4 - 94

B Turntable Rotation Components

9-1 Turntable Rotation Assembly ..................................................................... 4 - 95

A Axle Components

10-1 Hub and Bearings, 2WD Models ................................................................ 4 - 97

10-2 Oscillating Axle Cylinders .......................................................................... 4 - 99

Section 5 Rev Fault Codes

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

A Control System Fault Codes .................................................................................. 5 - 2

A Ford Engine ECM Fault Code Chart ...................................................................... 5 - 9

Z-80/60 Part No. 88619

September 2006

xii

TABLE OF CONTENTS

Section 6 Rev Schematics

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

B Wire Circuit Legend ............................................................................................... 6 - 2

B Limit Switches and Angle Sensors ........................................................................ 6 - 8

B Drive Chassis and Platform Controller Pin Legend .............................................. 6 - 10

B Engine Relay and Fuse Panel Legend ................................................................ 6 - 11

B Turntable Controller Pin Legend .......................................................................... 6 - 13

B Electrical Symbols Legend .................................................................................. 6 - 14

B Hydraulic Symbols Legend .................................................................................. 6 - 15

B Electrical Schematic Legend ............................................................................... 6 - 17

B Electrical Schematic - View 1, Drive Chassis Controller (DCON) ........................ 6 - 18

B Electrical Schematic - View 2, Platform Controls (PCON) ................................... 6 - 19

B Electrical Schematic - View 3, Ground Controls (TCON) ..................................... 6 - 20

B Electrical Schematic - View 4 .............................................................................. 6 - 21






B Electrical Schematic - View 10, Limit Switches .................................................... 6 - 27

B Electrical Schematic - View 11, Deutz F4L-913 Engine(before serial number 339) .................................................................................. 6 - 28

A Electrical Schematic - View 11, Deutz BF4L-2011(after serial number 338) ..................................................................................... 6 - 29

B Electrical Schematic - View 12 ............................................................................ 6 - 30

B Electrical Schematic - View 13, GM 3.0L Engine ................................................. 6 - 31

B Electrical Schematic - View 14, Perkins 704-30 Engine(before serial number 329) .................................................................................. 6 - 32

A Electrical Schematic - View 14, Perkins 804C-33 Engine(after serial number 328) ..................................................................................... 6 - 33

A Electrical Schematic - View 15, Ford LRG 425 Engine ........................................ 6 - 34

A Electrical Schematic - View 16, Hydraulic Generator Option ............................... 6 - 35

Part No. 88619 Z-80/60

September 2006

Section 6 Rev Schematics, continued

B Electrical Schematic - View 17, Safety Circuits ................................................... 6 - 36

B Hydraulic Schematic, 2 Wheel Drive with 2 Wheel Steer - View 1 ....................... 6 - 37








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xiii

Z-80/60 Part No. 88619

September 2006


xiv

Part No. 88619 Z-80/60 2 - 1

Section 2 • SpecificationsSeptember 2006

REV C Specifications

Machine Specifications

Tires and wheels

Tire size(foam filled, and non-marking) 18-625 FF

Tire size(Hi-flotation) 445D50/70

Tire ply rating(foam filled, and non-marking) 16

Tire ply rating(Hi-flotation) 14

Overall tire diameter 40.7 in(foam filled, and non-marking) 103.3 cm

Overall tire diameter 45.47 in(Hi-flotation) 115.5 cm

Wheel diameter 24.5 in(foam filled, and non-marking) 62.2 cm

Wheel diameter 28 in(Hi-flotation) 71.1 cm

Wheel width 15 in(foam filled, non-marking and Hi-flotation) 38.1 cm

Wheel lugs 10 @ 3/4 -16

Lug nut torque, dry 420 ft-lbs570 Nm

Lug nut torque, lubricated 320 ft-lbs434 Nm

Fluid capacities

Fuel tank 40 gallons151.4 liters

LPG tank 33.5 lbs15.2 kg

Hydraulic tank 45 gallons170 liters

Hydraulic system 55 gallons(including tank) 208 liters

Drive hubs 50.7 fl oz1.5 liters

Turntable rotation drive hub 17 fl oz0.5 liters

Drive hub oil type: EP 80-90W gear oilAPI Service Classification GL5

For operational specification, refer to theOperator's Manual.

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

2 - 2 Z-80/60 Part No. 88619

Section 2 • Specifications September 2006

REV CSPECIFICATIONS

Performance Specifications

Drive speed, maximum(models with rough terrain tires)

Stowed position 3 mph4.8 km/h

40 ft / 9.1 sec12.2 m / 9.1 sec

Raised or extended position 0.7 mph1.1 km/h

40 ft / 40 sec12.2 m / 40 sec

Drive speed, maximum(models with Hi-flotation tires)

Stowed position 2 mph3.1 km/h

40 ft / 14 sec12.2 m / 14 sec

Raised or extended position 0.4 mph0.7 km/h

40 ft / 66 sec12.2 m / 66 sec

Gradeability - Refer to Operator's Manual

Braking distance, maximum

High range on paved surface 3 ft90 cm


Part No. 88619 Z-80/60 2 - 3


REV C SPECIFICATIONS

Function SpeedsSpecifications

Function speeds (factory settings)

Primary boom up, stowed(retracted -35° to 65°) 57 to 63 seconds

Primary boom down, stowed(retracted -35° to 65°) 50 to 56 seconds

Secondary boom up, stowed 60 to 70 seconds

Secondary boom down, stowed 60 to 70 seconds

Primary boom up, unstowed(-35° to 65°) 80 to 96 seconds

Primary boom down, unstowed(-35° to 65°) 80 to 96 seconds

Boom extend, stowed 48 to 52 seconds

Boom retract, stowed 38 to 42 seconds

Turntable rotate, 360°boom fully stowed 114 to 126 seconds

Turntable rotate, 360°boom unstowed 200 to 240 seconds


Boom function speeds, maximumfrom platform controls

Jib boom up 40 to 55 seconds

Jib boom down 40 to 55 seconds

Primary boom up 75 to 120 seconds

Primary boom down 75 to 120 seconds

Secondary boom up 120 to 180 seconds

Secondary boom down 120 to 180 seconds

Secondary boom extend 25 to 40 seconds

Secondary boom retract 25 to 40 seconds

Primary boom extend 32 to 45 seconds

Primary boom retract 32 to 45 seconds

Turntable rotate, 360° 78 to 86 secondsboom fully stowed

Turntable rotate, 360° 165 to 185 secondsboom raised or extended

Platform rotate, 160° 10 to 16 seconds

2 - 4 Z-80/60 Part No. 88619


REV C

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentviscosity grade Multi-viscosityViscosity index rating 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV 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 have a minimum viscosity indexrating greater than 140. They should provide excellentantiwear, oxidation, corrosion inhibition, sealconditioning, and foam and aeration suppressionproperties.

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 5606A

Use Chevron Aviation A hydraulicoil when in ambient temperaturesconsistently below 0°F / -17°C

Use Shell Tellus T46 hydraulic oilwhen in ambient temperaturesconsistently exceed 205°F / 96°C

Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.


SPECIFICATIONS

Part No. 88619 Z-80/60 2 - 5


REV C

Drive pump

Type: bi-directional variable displacement piston pump

Displacement 2.81 cu in46 cc

Flow rate @ 2300 rpm 28 gpm106 L/min

Drive pressure, maximum 3625 psi250 bar

Charge pump

Type: gerotor

Displacement 0.85 cu in13.9 cc


Charge pressure @ 2300 rpm 320 psiNeutral position 22 bar

Function pumps

Type: two-section tandem gear pump

Displacement - Pump 1 (inner) 1.94 cu in31.8 cc

Flow rate @ 2300 rpm 17 gpm64.4 L/min

Displacement - Pump 2 (outer) 0.58 cu in9.5 cc


Auxiliary pump

Type: two-section fixed displacement gear pump

Displacement - Section 1 (inner) 0.159 cu in2.61 cc

Flow rate @ 2687 rpm 1.7 gpm6.4 L/min

Displacement - Section 2 (outer) 0.051 cu in0.84 cc

Flow rate @ 2687 rpm 0.3 gpm1.1 L/min

Function manifold

System relief pressure 3200 psi(measured at PTEST port) 220.6 bar

Primary boom down relief pressure 1300 psi(measured at PTEST port) 89.6 bar

Secondary boom down relief pressure 2500 psi(measured at PTEST port) 172 bar

Secondary boom up relief pressure 2500 psi(measured at PTEST port) 172 bar

Primary boom extend relief pressure 1300 psi(measured at PTEST port) 89.6 bar

Secondary boom extend relief pressure 2600 psi(measured at PTEST port) 179 bar

Platform manifold relief pressure 3000 psi207 bar

Platform manifold flow regulator 3 gpm11.4 L/min


SPECIFICATIONS

2 - 6 Z-80/60 Part No. 88619


REV CSPECIFICATIONS

Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 14 ft-lbs / 18.9 Nm




SAE No. 12 84 ft-lbs / 113.9 Nm

Valve coil resistance specifications

Proportional solenoid valve, 12V DC 4 to 6Ω(schematic items G, R and BB)

3 position 4 way solenoid valve, 12V DC 4.5 to 6.5Ω(schematic items GB, GP and GQ)

3 position 4 way solenoid valve, 10V DC 5 to 7Ω(schematic items O, S, BA, BB, CA, CB,CP and CQ)

2 position 2 way solenoid valve, 10V DC 5.5 to 7.5Ω(schematic items C and P)

2 position 3 way solenoid valve, 10V DC 4.5 to 6.5Ω(schematic items H, J, V, X, Z, AA, BC,BD, CE, CF, EE, EF, FB and FC)


Oscillate manifold

Oscillate relief pressure (item GG) 800 psi55.1 bar

Platform manifold

Platform level flow regulator (item CH) 1 gpm0.38 L/min

Drive manifold

Hot oil relief pressure 280 psi19.3 bar

Brakes

Brake release pressure 215 psi14.8 bar

Drive motors

Displacement per revolution, variable 0.9 to 2.7 cu in(2 speed motor) 14.7 to 45 cc

Hydraulic tank return filter

High pressure filter Beta 3 ≥ 200

High pressure filter 102 psibypass pressure 7 bar

Medium pressure filter Beta 3 ≥ 200

Medium pressure filter 51 psibypass pressure 3.5 bar

Hydraulic tank return filter 10 micron with 25 psi / 1.7 bar bypass

Part No. 88619 Z-80/60 2 - 7



Starter motor

Normal engine cranking speed 350 rpm

Current draw, normal load 400A

Current draw, maximum load 600A

Current draw, minimum 100A

Batteries

Type 12V DC

Group 31

Quantity 2

Cold cranking ampere 1000A

Reserve capacity @ 25A rate 200 minutes

Electronic fuel pump

Fuel pressure, static 9 to 11 psi0.6 to 0.76 bar

Fuel flow rate 0.3 gpm1.14 L/min

Fuel Requirement

For fuel requirements, refer to the engine Operator'sManual on your machine.

Ignition system

Spark plug type AC ACMR-43-LTS

Spark plug gap 0.040 inch1.01 mm

Engine coolant

Capacity 12 quarts11.4 liters

Alternator

Output 66A, 12V DC

Fan belt deflection 0.5 inch12 mm

GM 3.0L EFI Engine

Displacement 181 cu in3 liters

Number of cylinders 4

Bore & stroke 4 x 3.6 inches101.6 x 91.44 mm

Horsepower

Intermittent 67 @ 2300 rpm49 kW @ 2300 rpm

Continuous 60 @ 2300 rpm45 kW @ 2300 rpm

Firing order 1 - 3 - 4 - 2

Low idle 1650 rpmFrequency 386.1 Hz

High idle 2300 rpmFrequency 538.2 Hz

Compression ratio 9.25:1

Compression pressure - minimum 100 psiPressure (psi or bar) of lowest cylinder 6.9 barmust be at least 75% of highest cylinder

Valve clearances Zero lash + 1 full turn

Lubrication system

Oil pressure - minimum 18 psi(operating temp. @ 2000 rpm) 1.24 bar

Oil capacity 5 quarts(including filter) 4.7 liters

Oil viscosity requirements

Extreme operating temperatures my require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.


2 - 8 Z-80/60 Part No. 88619


REV C

Oil pressure switch specifications

Torque 8-18 ft-lbs11-24 Nm

Oil pressure switch point 3-5 psi0.21-0.34 bar

Starter motor

Normal engine cranking speed 200 to 250 rpm

Current draw, normal load 140-200A

Current draw, maximum load 800A

Current draw, no load 70A

Maximum circuit voltage drop 0.5V DCwhile starting (normal temperature)

Battery

Type 12V DC

Group 34/78

Quantity 1



Electronic fuel pump

Fuel pressure, static 64 psi4.4 bar

Fuel flow rate 0.58 gpm2.18 L/min

Fuel requirement


Ignition system

Spark plug type Motorcraft AWSF-52C

Spark plug gap 0.042 to 0.046 in1.07 to 1.18 mm

Spark plug torque 5 to 10 ft-lbs7 to 14 Nm

Ford LRG-425 EFI Engine

Displacement 153 cu in2.5 liters


Bore & stroke 3.78 x 3.4 in96.01 x 86.36 mm

Horsepower

Continuous 60 @ 2500 rpm44.7 kW @ 2500 rpm

Intermittent 70 @ 2500 rpm52 kW @ 2500 rpm



High idle 2500 rpmFrequency 620 Hz


Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must beat least 75% of highest cylinder.

Valve clearances - 0.035 to 0.055 incollapsed tappet 0.889 to 1.397 mm

Lubrication system

Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar



Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.


SPECIFICATIONS

Part No. 88619 Z-80/60 2 - 9



Engine coolant

Capacity 11.5 quarts10.9 liters

Coolant temperature switch


Temperature switch point 230° F112° C

Alternator

Output 95A, 13.8V DC


2 - 10 Z-80/60 Part No. 88619


REV CSPECIFICATIONS

Injection system

Injection pump make IMSA

Injection pump pressure 8702 psi600 bar

Injector opening pressure 3626 psi250 bar

Fuel Requirement


Batteries

Type 12V DC

Group 31

Quantity 2



Alternator output 55A, 12V DC

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Deutz F4L- 913 Engine

Displacement 249.3 cu in4.085 liters


Bore and stroke 4.02 x 4.92 inches102.1 x 125 mm

Horsepower 76 @ 2300 rpm56.6 kW @ 2300 rpm


Compression ratio 18:1

Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.

Low idle - no load 1300 rpmFrequency 385.7 Hz

High idle - no load 2300 rpmFrequency 570.4 Hz

Valve clearance, cold

Intake 0.006 in0.15 mm

Exhaust 0.006 in0.15 mm

Lubrication system

Oil pressure 40 to 60 psi2.75 to 4.14 bar

Oil capacity 14.3 quarts(including filter) 13.5 liters


Units ship with 15W-40.Extreme operating temperatures my require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.


Part No. 88619 Z-80/60 2 - 11


REV C

Lubrication system

Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar




Oil temperature switch


Oil temperature switch point 275°F135°C

Oil pressure switch


Oil pressure switch point 7 psi0.48 bar

Deutz BF4L-2011 Engine

Displacement 189.6 cu in3.1 liters


Bore and stroke 3.7 x 4.409 inches94 x 112 mm

Horsepower

Continuous 69.1 @ 2500 rpm51.5 kW @ 2500 rpm

Net intermittent 72.8 @ 2500 rpm54.3 kW @ 2500 rpm


Low idle 1500 rpmFrequency 372 Hz



Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.

Governor centrifugal mechanical





SPECIFICATIONS

2 - 12 Z-80/60 Part No. 88619


REV CSPECIFICATIONS

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum 15,000 psi1034 bar


Fuel Requirement


Starter motor

Current draw, normal load 140-200A

Cranking speed 200-250 rpm

Battery - Engine starting and control system

Type 12V DC, Group 31Quantity 2Cold cranking ampere 1000Reserve capacity @ 25A rate 200 minutes

Alternator output 80A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch9 to 12 mm


Part No. 88619 Z-80/60 2 - 13



Perkins 704-30 Engine

Displacement 183 cu in3 liters



Horsepower 61 @ 2300 rpm 45.5 kW @ 2500 rpm



Compression pressure 300 to 500 psi20.7 to 34.5 bar

Pressure (psi or bar) of lowest cylinder must be within50 psi / 3.45 bar of highest cylinder



Governor centrifugal mechanical




Lubrication system

Oil pressure @ 2300 rpm 41 psi2.8 bar

Oil capacity 7.4 quarts(including filter) 7 liters



Injection system

Injection pump make Zexel PFR-KX

Injection pump pressure 2755 psi190 bar


Fuel Requirement


Engine coolant


Batteries

Type 12V DC

Group 31

Quantity 2




Fan belt deflection 3/8 in10 mm


2 - 14 Z-80/60 Part No. 88619


REV C

Perkins 804C-33 Engine

Displacement 201 cu in3.3 liters



Horsepower 63 @ 2600 rpm47 kW @ 2600 rpm


Compression ratio 22:1

Compression pressure 300 to 500 psi20.7 to 34.5 bar

Pressure (psi or bar) of lowest cylinder must bewithin 50 psi / 3.45 bar of highest cylinder



Governor mechanical all speed




Lubrication system

Oil pressure @ 2000 rpm 40-60 psi2.8-4.1 bar

Oil capacity 10.6 quarts(including filter) 10 liters



Injection system

Injection pump make Zexel 10641-3932

Injection pump pressure 1707 to 1849 psi117.7 to 127.5 bar

Injector opening pressure ~2000 psi~138 bar

Fuel Requirement


Engine coolant


Batteries

Type 12V DC

Group 31

Quantity 2




Fan belt deflection 3/8 to 1/2 in9 to 12 mm


SPECIFICATIONS

Part No. 88619 Z-80/60 2 - 15



Machine Torque Specifications

Platform rotator

1-8 center bolt, Gr 5, dry 640 ft-lbs867 Nm

3/8 -16 bolts, Gr 8 35 ft-lbs**(use blue thread locking compound) 47.5 Nm*

Turntable rotate assembly

Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm

Rotate drive hub mounting bolts, lubricated 80 ft-lbs108.4 Nm

Backlash plate mounting bolts, lubricated 280 ft-lbs379 Nm

Drive motor and hubs

Drive hub mounting bolts, dry 210 ft-lbs284 Nm

Drive hub mounting bolts, lubricated 160 ft-lbs217 Nm

Drive motor mounting bolts, dry 110 ft-lbs149 Nm

Drive motor mounting bolts, lubricated 80 ft-lbs108.4 Nm


Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm





SAE No. 12 84 ft-lbs / 113.9 Nm

2 - 16 Z-80/60 Part No. 88619


REV CSPECIFICATIONS

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 bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield 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 14 ft-lbs / 18.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 36 ft-lbs / 48.8 Nm

-10 62 ft-lbs / 84.1 Nm

-12 84 ft-lbs / 113.9 Nm

-16 125 ft-lbs / 169.5 Nm

-20 151 ft-lbs / 204.7 Nm

-24 184 ft-lbs / 250 Nm

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


-4 15 ft-lbs / 20.3 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 100 ft-lbs / 135.6 Nm

-12 135 ft-lbs / 183 Nm

-16 200 ft-lbs / 271 Nm

-20 250 ft-lbs / 334 Nm

-24 305 ft-lbs / 414 Nm

Seal-Lok® Fittings(hose end)


-4 18 ft-lbs / 24.4 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

Part No. 88619 Z-80/60 2 - 17



Size

(mm)in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

5 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

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm8 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 42.610 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 4.6

DRYLUBED

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 8.8

DRY

SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 100 11.3 80 9 140 15.8 110 12.4 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm18 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

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

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

Grade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

10.9 12.98.84.6

2 - 18 Z-80/60 Part No. 88619

Section 2 • Specifications July 2006


Part No. 88619 Z-80/60 3 - 1

September 2006 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

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 two years as specified on theMaintenance Inspection Report.

Failure to perform each procedureas presented and scheduled 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.

Keep records on all inspections for three years.

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 betweenthe circle-end (yellow arrow) wheels

· Turntable secured with the turntablerotation lock pin

· Key switch in the off position with thekey removed

· Wheels chocked

· All external AC power supply disconnectedfrom the machine

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




Safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may resultin minor or moderate injury.



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

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

3 - 2 Z-80/60 Part No. 88619

July 2006Section 3 • Scheduled Maintenance Procedures

REV B

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold engine will berequired to perform this procedure.

Indicates that a warm engine will berequired to perform this procedure.

Indicates that dealer service is requiredto perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery Preparation reportto use for each inspection. Store completed formsas required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two years.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 years 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. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES

Part No. 88619 Z-80/60 3 - 3

July 2006 Section 3 • Scheduled Maintenance Procedures

Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev B

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-Delivery Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspection completed

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 completing thePre-operation Inspection, the Maintenance items and theFunction Tests.

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

If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin 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 if anythingis apparently wrong with a machine before it is put intoservice.

A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removedfrom service.

Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.

Scheduled maintenance inspections shall be performed byqualified service technicians, according to themanufacturer's specifications and the requirements listedin the responsibilities manual.

3 - 4 Z-80/60 Part No. 88619

September 2006Section 3 • Scheduled Maintenance Procedures


Part No. 88619 Z-80/60 3 - 5


Checklist A - Rev C Y N R

A-1 Inspect the manualsand decals

A-2 Pre-operationinspection

A-3 Function tests

A-4 Engine maintenance

A-5 Hydraulic filtercondition indicators

Perform after 40 hours:

A-6 30 Day Service

Perform every 100 hours:


A-8 Rotation bearing

A-9 Filter/separator



Perform after 150 hours:

A-11 Replace drive hub oil



Instructions· Make copies of this report to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to be performed.

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 from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Checklist B - Rev B Y N R

B-1 Batteries

B-2 Electrical wiring

B-3 Key switch

B-4 Exhaust system

B-5 Engine Air Filter

B-6 Engine maintenance

B-7 Lug nut torque

B-8 Brake configuration

B-9 Drive hub maintenance

B-10 Ground control override

B-11 Platform self leveling

B-12 Engine idle select

B-13 Fuel select operation

B-14 Drive brakes

B-15 Drive speed - stowed

B-16 Drive speed - raisedor extended

B-17 Alarm and beacon

B-18 Hydraulic oil analysis

B-19 Engine RPM

B-20 Safety envelope andcircuits

B-21 Primary boomself-leveling

B-22 Primary boomangle sensor

B-23 Fuel and hydraulic tankcap venting system




Maintenance Inspection Report

Comments

3 - 6 Z-80/60 Part No. 88619

July 2006Section 3 • Scheduled Maintenance Procedures

MAINTENANCE INSPECTION REPORT

Instructions· Make copies of this report to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to be performed.

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 from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Comments

Checklist C - Rev B Y N R

C-1 Engine maintenance

C-2 Grease platformoverload (if equipped)

C-3 Test the platformoverload (if equipped)

C-4 Engine Air Filter

C-5 Replace filter/separator


C-6 Engine maintenance

Checklist D - Rev B Y N R

D-1 Boom wear pads

D-2 Free-wheelconfiguration

D-3 Turntable rotation bolts

D-4 Turntable bearing wear

D-5 Drive hub oil

D-6 Engine maintenance


D-7 Replace hydraulic filters

Checklist E - Rev B Y N R

E-1 Replace hydraulic oil

E-2 Wheel bearings,2WD models

E-3 Engine maintenance











Part No. 88619 Z-80/60 3 - 7


REV C Checklist A ProceduresA-1Inspect the Manuals and DecalsMaintaining 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 is illegible. Remove themachine 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.

Contact your authorized Geniedistributor or Genie Industries ifreplacement manuals or decalsare needed.

3 - 8 Z-80/60 Part No. 88619


REV CCHECKLIST A PROCEDURES

A-2Perform Pre-operation InspectionCompleting 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 appropriate operator's manual.Refer to the Operator's Manual on your machine.

A-3Perform Function TestsCompleting 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 appropriate operator's manual.Refer to the Operator's Manual on your machine.

Part No. 88619 Z-80/60 3 - 9


REV C

A-4Perform Engine Maintenance

Engine specifications require thatthis procedure be performed dailyor every 8 hours, whichevercomes first.

Deutz Models:

Required maintenance procedures and additionalengine information are available in theDeutz 913 Operation Manual(Deutz part number 0297 7341) OR theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929).

Deutz 913 Operation ManualGenie part number 62446

Deutz BF4L2011 Operation ManualGenie part number 84794

GM Models:

Required maintenance procedures and additionalengine information are available in theGM 3.0L Operator Handbook(GM part number 36100007).

GM 3.0L Operator HandbookGenie part number 77738

Perkins Models:

Required maintenance procedures and additionalengine information are available in thePerkins 704-30 User's Handbook(Perkins part number TPD 1336E) OR thePerkins 804C-33 Operation and MaintenanceManual (Perkins part number SEBU7853-00).

Perkins 704-30 User's HandbookGenie part number 101840

Perkins 804C-33 Operation and Maintenance ManualGenie part number 111332

Ford Models:

Required maintenance procedures and additionalengine information are available in theFord LRG-425 EFI Operator Handbook(Ford part number FPP 194-302).

Ford LRG-425 EFI Operator HandbookGenie part number 84792

To access the engine:

1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.

2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.

Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.

CHECKLIST A PROCEDURES

3 - 10 Z-80/60 Part No. 88619



A-5Check the Hydraulic FilterCondition Indicators

Maintaining the hydraulic filters in good condition isessential to good system performance and safemachine operation. The filter condition indicatorswill show when the hydraulic flow is bypassing aclogged filter. If the filters are not frequentlychecked and replaced, impurities will remain in thehydraulic system and cause component damage.

There are four hydraulic filters onthe machine: one tank return filter,one medium pressure filter andtwo high pressure filters. All thefilters have condition indicators onthem, except the medium pressurefilter.

1 Start the engine from the ground controls.

2 Press and release the engine idle select buttonto change the engine rpm to high idle.

Tank return filter

3 Open the ground control side turntable coverand inspect the filter condition indicator gauge.

Result: The needle on the gauge should beoperating in the green area. If the needle is inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter needs tobe replaced. See D-7, Replace the HydraulicFilter Elements.

a filter condition indicator gauge

a

Part No. 88619 Z-80/60 3 - 11


REV C

A-6Perform 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-8 Grease the Turntable RotationBearing and Rotate Gear

· B-7 Check the Tires, Wheels andLug Nut Torque

· B-9 Check the Drive Hub Oil Level andFastener Torque

· B-24 Perform Engine Maintenance

· C-6 Perform Engine Maintenance -Gasoline/LPG Models

· D-3 Check the Turntable RotationBearing Bolts

· D-6 Perform Engine Maintenance -Diesel Models

· D-7 Replace the HydraulicFilter Elements

Medium and high pressure filters

The medium and high pressurefilters are mounted to the engineside bulkhead.

4 Inspect the filter condition indicators.

a high pressure filtersb filter condition indicatorsc medium pressure filter

Result: The filter condition indicators should beoperating with the plungers in the green area. Ifany of the indicators display the plunger in thered area, this indicates that a hydraulic filter isbeing bypassed and the filter needs to bereplaced. See D-7, Replace the Hydraulic FilterElements.

a

b

c


3 - 12 Z-80/60 Part No. 88619



A-7Perform Engine Maintenance

Engine specifications require thatthis procedure be performed every100 hours.

GM Models:



Perkins Models:

Required maintenance procedures and additionalengine information are available in thePerkins 704-30 User's Handbook(Perkins part number TPD 1336E) OR thePerkins 804C-33 Operation and MaintenanceManual(Perkins part number SEBU7853-00).



Ford Models:







Part No. 88619 Z-80/60 3 - 13


REV C

A-9Inspect the Fuel Filter/WaterSeparator - Diesel Models

Genie specifications require thatthis procedure be performed every100 hours or monthly, whichevercomes first.

Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and/or hardstarting, and continued use may result incomponent damage. Extremely dirty conditionsmay require this procedure be performed moreoften.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Perform this procedure with theengine off.

1 Open the turntable cover at the engine side ofthe machine. Locate the fuel filter/waterseparator.

A-8Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require thatthis procedure be performed every100 hours of operation. Performthis procedure more often if dustyconditions exist.

Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.

1 Locate the grease fitting next to the groundcontrol box.

2 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of4 to 5 inches / 10 to 13 cm at a time and repeatthis step until the entire bearing has beengreased.

3 Apply grease to each tooth of the drive gear,located under the turntable.

Grease Specification

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


3 - 14 Z-80/60 Part No. 88619



2 Inspect the filter bowl for water.

Result: Water is not visible in the filter bowl.

Result: There is water present. Proceed to step3.

3 Loosen the vent plug located on the head of thefuel filter/water separator.

a head boltb vent plugc drain plugd filter bowle separator head

4 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.

5 Clean up any fuel that may have spilled.

If the fuel filter/water separator iscompletely drained, you mustprime the fuel filter/waterseparator before starting theengine.See C-5, Replace The Fuel Filter/Water Separator Element, forinstructions on how to prime thefuel filter/water separator.

6 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.

Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.

d

c

e

b

a

Part No. 88619 Z-80/60 3 - 15


REV C

A-10Perform Engine Maintenance -Deutz Models


Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.

Deutz Models:

Required maintenance procedures and additionalengine information are available in theDeutz 913 Operation Manual(Deutz part number 0297 7341).


A-11Replace the Drive Hub Oil

Manufacturer drive hubspecifications require that thisone-time procedure be performedafter the first 150 hours.

Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil after the first 150 hoursof use may cause the machine to perform poorlyand continued use may cause componentdamage.

Drive Hubs:

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.

models with pipe plugs models with o-ring plugs

a


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REV C

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Apply pipe thread sealant to the plugs. Installthe plugs.

5 Models with pipe plugs: Apply pipe threadsealant to the plugs and install the plugs.

Models with O-ring plugs: Install the plugsinto the drive hub.

6 Repeat steps 1 through 5 for the other drivehub.

Turntable Rotate Drive Hub:

1 Secure the turntable from rotating with theturntable rotation lock pin.

unlocked locked

2 Remove the motor/brake mounting bolts, andthen remove the motor and brake from the drivehub and set them to the side.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

a motorb motor/brake mounting boltsc braked drive hube drive hub mounting bolts

3 Remove the drive hub mounting bolts, and usea lifting device to remove the drive hub from themachine.

4 Remove the plug from the side of the drive hub.Drain the oil from the hub into a container ofadequate capacity. Refer to Section 2,Specifications.

5 Install the drive hub. Torque the drive hubmounting bolts to specification. Refer toSection 2, Specifications.

6 Install the brake and motor onto the drive hub.Torque the motor/brake mounting bolts tospecification. Refer to Section 2, Specifications.

7 Fill the hub with oil from the side hole until theoil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug.

8 Adjust turntable rotation gear backlash. Refer toRepair Procedure 9-1, How to Adjust theTurntable Rotation Gear Backlash.


Part No. 88619 Z-80/60 3 - 17


REV C

A-12Perform Engine Maintenance -Gasoline/LPG Models



GM Models:



Ford Models:








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REV C

B-1Inspect the Batteries

Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions. There are 2batteries on this machine. One is used in startingthe engine and the other is used to power thecontrol system and auxiliary power unit. Bothbatteries are charged by the alternator through abattery separator.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and 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.

Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.

3 Be sure that the battery hold downs and cableconnections are tight.

4 Be sure that the battery separator wireconnections are tight.

5 Fully charge the batteries and allow them to restat least 6 hours.

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

7 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 or higher. The batteryis fully charged. Proceed to step 11.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 8.

8 Perform an equalizing charge, OR fully chargethe batteries and allow them to rest at least 6hours.

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

Checklist B Procedures

Part No. 88619 Z-80/60 3 - 19


REV C

10 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 specific gravityof 1.277 or greater. The battery is fully charged.Proceed to step 13.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.177. Replace the battery.

11 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.

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

B-2Inspect the Electrical Wiring

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 hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

1 Open the engine side turntable cover.

2 Remove the engine tray retaining fastener.Swing the engine tray out away from themachine.

a engine tray anchor holeb engine tray retaining fastener

3 Locate the engine tray anchor hole at the pivotend of the engine tray.

CHECKLIST B PROCEDURES

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REV C

4 Install the bolt that was just removed into theanchor hole to secure the engine tray frommoving.

Crushing hazard. Failure to installthe bolt into the engine tray tosecure it from moving could resultin death or serious injury.

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

· Engine wiring harness

· Battery area wiring

6 Open the ground controls side turntable cover.


· Inside of the ground control box

· Hydraulic manifold wiring

· Hydraulic oil cooler wiring

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

· All wire harness connectors to the groundcontrol box


9 Start the engine from the ground controls andraise the secondary boom above the turntablecovers.

10 Inspect the turntable area for burnt, chafed andpinched cables.

11 Lower the secondary boom to the stowedposition and turn the engine off.


· Cable track on the boom

· Cables on the boom and jib boom

· Jib boom/platform rotate manifold

· Inside of the platform control box

13 Remove the engine tray retaining fastener fromthe engine tray anchor hole at the pivot end ofthe engine tray.

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

· All wire harness connectors to the platformcontrol box


15 Swing the engine tray in towards the machine.

16 Install the bolt that was just removed into theoriginal hole to secure the engine tray.



Part No. 88619 Z-80/60 3 - 21


REV C CHECKLIST B PROCEDURES

B-3Test the Key SwitchProper 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 causea 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 ground control, start theengine and then turn the key switch to platformcontrol.

3 Check all machine function from the groundcontrols.

Result: All machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check all machine function from the platformcontrols.

Result: All machine functions should notoperate.

6 Turn the key switch to the off position.

Result: The engine should stop and nofunctions should operate.

B-4Check the Exhaust System

Maintaining the exhaust system is essential togood engine performance and service life.Operating the engine with a damaged or leakingexhaust system can cause component damageand unsafe operating conditions.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Bodily injury hazard. Beware ofhot engine components. Contactwith hot engine components maycause severe burns.



3 - 22 Z-80/60 Part No. 88619


REV CCHECKLIST B PROCEDURES




4 Be sure that all nuts and bolts are tight.

5 Inspect all welds for cracks.

6 Inspect for exhaust leaks (i.e., carbon buildup)around seams and joints.





a

b

c

B-5Inspect the Engine Air Filter

Genie requires that this procedurebe performed every 250 hours orquarterly, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.


1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.

a retaining clampb canister end capc dust discharge valve

Part No. 88619 Z-80/60 3 - 23



2 Disconnect the retaining clamp from the aircleaner canister.

3 Remove the filter element.

4 Clean the inside of the canister and the gasketwith a damp cloth.

5 Inspect the air filter element. If needed, blowfrom the inside out using low pressure drycompressed air, or carefully tap out dust.

6 Install the filter element.

7 Install the air filter canister end cap and connectthe end cap retaining clamp.

B-6Perform Engine Maintenance -Deutz Models


Deutz Models

Required maintenance procedures and additionalengine information are available in theDeutz 913 Operation Manual(Deutz part number 0297 7341)






3 - 24 Z-80/60 Part No. 88619



B-8Confirm the ProperBrake Configuration

Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.

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

2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

The free-wheel valve is located onthe drive pump.

a drive pumpb screwdriverc lift pumpd free-wheel valve

The free-wheel valve shouldalways remain closed.

B-7Check the Tires, Wheelsand Lug Nut Torque

Maintaining the tires and wheels in goodcondition, including proper wheel fastener torque,is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

The tires on this machine are foamfilled and do not need air added tothem.

1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracked welds.

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

disengaged position

engaged position

a

d

c

b

Part No. 88619 Z-80/60 3 - 25


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B-9Check the Drive Hub Oil Leveland Fastener Torque

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

Drive hubs

1 Drive the machine to rotate the hub until one ofthe plugs is located on top and the other one isat 90 degrees.

a. models with pipe plugs

b. models with o-ring plugs

a

a

b

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.


Models with O-ring plugs: Install the plugsinto the drive hub. Torque to Specification.Refer to Section 2, Specifications.


6 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.


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B-10Test the Ground Control OverrideA 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 or not the EmergencyStop button on the platform controls is in the ON orOFF position. This function is particularly useful ifthe operator at the platform controls cannot returnthe boom to the stowed position.

1 Push in the platform red Emergency Stopbutton to the off position.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.

Turntable rotate drive hub

1 Remove the plug located on the side of the huband check the oil level.

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

a drive hubb plug

2 If necessary, add oil until the oil level is evenwith the bottom of the plug hole opening.

3 Apply pipe thread sealant to the plug, andinstall the plug in the drive hub.

a b

Part No. 88619 Z-80/60 3 - 27


REV C

B-11Test the Platform Self-leveling

Automatic platform self-leveling throughoutthe full cycle of primary boom raising and loweringis essential for safe machine operation. Theplatform is maintained level by the communicationbetween the platform level sensor and theturntable level sensor. If the platform becomes outof level, the computer at the ground controls willopen the appropriate solenoid valve(s) at theplatform manifold to maintain a level platform.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.


2 Press and hold a function enable/speed selectbutton and fully retract the primary boom.

3 Push one of the LCDscreen buttons shown untilplatform angle isdisplayed.

4 Press and hold a function enable/speed selectbutton and adjust the platform to zero degreesusing the platform level up/down buttons.


5 Push and hold a function enable/speed selectbutton and fully raise the primary boom whileobserving the platform angle shown on the LCDdisplay.

Result: The platform should remain level atall times to within ±2 degrees.

If the platform becomes out oflevel, the tilt alarm will sound andthe Platform Not Level Indicatorwill flash at the ground controls.The platform level up/downbuttons will only work in thedirection that will level theplatform. Level the platform untilthe indicator light turns off.

6 Push and hold a function enable/speed selectbutton and fully lower the primary boom.

Result: The platform should remain level atall times to within ±2 degrees.

If the platform becomes out oflevel, the tilt alarm will sound andthe Platform Not Level Indicatorwill flash at the ground controls.The platform level up/downbuttons will only work in thedirection that will level theplatform. Level the platform untilthe indicator light turns off.

3 - 28 Z-80/60 Part No. 88619



6 Turn the key switch to platform controls.

7 At the platform controls, press the engine idleselect button until high idle (rabbit symbol) isselected.

Result: The engine should change to high idle.

a foot switch activated high idleindicator light

b low idle indicator lightc high idle indicator lightd engine rpm select button

8 Press the engine idle select button until low idle(turtle symbol) is selected.

Result: The engine should change to low idle.

9 Press the engine idle select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.

Result: The engine should not change tohigh idle.

10 Press down the foot switch.


B-12Test the Engine Idle SelectOperationA properly operating engine idle select functionis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously, though at reduced speed. Thissetting maintains a consistent low idle.

High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle.

Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This selection activates highidle only when the foot switch is pressed down.

1 Turn the key switch to ground controls.



4 Push and release the rpm select button untilhigh rpm is selected (rabbit symbol).


5 Push and release the rpm select button until lowrpm is selected (turtle symbol).

Result: The engine should return to low idle.

b

d

a c

Part No. 88619 Z-80/60 3 - 29


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B-13Test the Fuel Select Operation -Gasoline/LPG Models

The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade whether the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicatefuel system problems that could develop into ahazardous situation.

Perform this test after checkingthe gasoline and LPG fuel levels,and warming the engine to normaloperating temperature.

1 Turn the key switch to platform controls and pullout the red Emergency Stop buttons out to theon position at both the ground and platformcontrols.

2 Press the fuel select button to gasoline mode.

3 Start the engine from the platform controls andallow the engine to run at low idle.

4 At the platform controls, press the engine idleselect button until foot switch activated high idle(rabbit and foot switch symbol) is selected.


5 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

6 Release the foot switch and shut the engine offby pushing the red Emergency Stop button in tothe off position.

7 Pull the red Emergency Stop button out to theon position at the platform controls.

8 Press the fuel select button to LPG mode.

9 Start the engine and allow it to run at low idle.

10 Press down the foot switch to allow the engineto run at high idle.

Result: The engine should start promptly andoperate smoothly in low and high idle.

The engine may hesitatemomentarily and then continueto run on the selected fuel if thefuel source is switched whilethe engine is running.

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B-14Test 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.See B-8, Confirm the ProperBrake Configuration.

Select a test area that is firm, leveland free of obstructions.

1 Mark a test line on the ground for reference.

2 Start the engine from the platform controls.

3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected, then lower the boom intothe stowed position.

4 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the test line.

5 Bring the machine to top drive speed beforereaching the test line. Release the drivecontroller when your reference point on themachine crosses the test line.

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

The brakes must be able to holdthe machine on any slope it is ableto climb.

B-15Test 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.


Perform this procedure with theboom in the stowed position.

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


3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.

4 Choose a point on the machine; i.e., contactpatch of a tire as a visual reference for usewhen crossing the start and finish lines.

5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

Part No. 88619 Z-80/60 3 - 31



B-16Test 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.


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


3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.

4 Press down the foot switch and raise the boomuntil the engine switches to low idle.

5 Choose a point on the machine; i.e., contactpatch of a tire as a visual reference for usewhen crossing the start and finish lines.


7 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

8 Lower the boom to the stowed position.

9 Extend the boom 4 feet / 1.2 m.

10 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.


12 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.

3 - 32 Z-80/60 Part No. 88619



B-17Test the Alarm and OptionalFlashing BeaconAn alarm and optional flashing beacon are installedto alert operators and ground personnel ofmachine proximity and motion. There are fouralarm option modes that can be activated based onuser preference or requirement. Refer to DisplayModule in the Repair Section for information.

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

Result: The alarm should sound twice. Theflashing beacon (if equipped) should be on andflashing.

B-18Perform Hydraulic Oil Analysis

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

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.See E-1, Test or Replace theHydraulic Oil.

Part No. 88619 Z-80/60 3 - 33



B-19Check and Adjust theEngine RPM

Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.

GM models:

The engine rpm is controlled bythe ECM and can only be adjustedby re-programming the ECM. Ifrpm adjustment or service isrequired, please contact the GenieIndustries Service Department oryour local GM dealer.

Ford models:

The engine rpm is controlled bythe ECM and can only be adjustedby re-programming the ECM. Ifrpm adjustment or service isrequired, please contact GenieIndustries Service Department oryour local Ford dealer.

Deutz 913 models:


2 Push one of the LCDscreen buttons shown untilengine rpm is displayed.Refer to Section 2, Specifications.

Skip to step 11 if the low idle rpm is correct.

3 Remove the secondary idle adjustment screwcap from the secondary idle adjustment screwon the injection pump. Loosen the locknut.

a primary idle adjustment screwb secondary idle adjustment screw

4 Turn the secondary adjustment screwcounterclockwise until the adjustment screw isloose. Tighten the locknut.

Be sure the adjustment screw isloosened until there is no springtension felt.

5 Remove the primary idle adjustment screw capfrom the primary idle adjustment screw on theinjection pump. Loosen the locknut.

6 Adjust the primary idle adjustment screw untillow idle meets specification. Tighten thelocknut.

7 Install the primary idle adjustment screw capand tighten. Do not over tighten.

8 Loosen the secondary idle adjustment screwlocknut.

3 - 34 Z-80/60 Part No. 88619



9 Adjust the secondary adjustment screw until thelow idle meets specification. Tighten thelocknut.

10 Install the secondary idle adjustment screw capand tighten. Do not over tighten.

11 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.Refer to Section 2, Specifications.

If the high idle is correct, disregard adjustmentstep 12.

12 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.

Be sure the solenoid fully retractswhen activating high idle.

Deutz BF4L2011 models:




3 Loosen the locknut on the low idle adjustmentscrew.

a low idle adjustment screwb high idle adjustment screw

4 Adjust the low idle adjustment screw until lowidle meets specification. Tighten the locknut.


If the high idle is correct, disregard adjustmentstep 6.

6 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.


a b

Part No. 88619 Z-80/60 3 - 35



Perkins models:




3 Loosen the low idle lock nut and turn the lowidle adjustment screw clockwise to increase therpm, or counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.

a solenoid bootb high idle adjustment nutc yoke lock nutd yokee low idle adjustment screwf low idle lock nut


If high idle rpm is correct, disregardadjustment step 5.

5 Loosen the yoke lock nut, then turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and confirm the rpm.


f

e

c dba

3 - 36 Z-80/60 Part No. 88619



B-20Test the Safety Envelope andCircuitsTesting the machine safety envelope is critical tosafe machine operation. If the boom is allowed tooperate when a safety switch is not functioningcorrectly, the machine stability is compromised andmay tip over. Refer to Section 6 for limit switch andangle sensor information.

Secondary Boom #1 Angle Safety Limit Switch,LSS2AS

1 Turn the key switch to ground control and pullout the red Emergency Stop buttons out to theon position at both the ground and platformcontrols.


3 Simultaneously push theLCD screen buttonsshown to activate statusmode.

4 Push one of the LCDscreen buttons shownuntil secondary boomstatus is displayed.

5 Fully raise the secondary boom and extend thesecondary boom approximately 2 feet / 61 cm.

6 Remove the fasteners from the turntable risercover at the pivot end of the secondary boom.Remove the cover.

7 Locate secondary boom #1 retract operationallimit switch (LSS1RO) at the end of thesecondary boom.

8 Carefully disconnect the wire harness fromLSS1RO and install a wire jumper between pin1 and pin 2 of the deutsch connector on thewire harness.

9 Install a second wire jumper between pin 3 andpin 4 of the deutsch connector on the wireharness.

Result: The display should show = 0FT.

10 Press and hold the low speed function enablebutton and lower the secondary boom.

Result: The secondary boom should lower to60° and the engine should stop.

Result: If the engine does not stop at 60° andthe secondary boom continues to lower, thesecondary boom #2 angle safety limit switch(LSS2AS) is out of adjustment or the wiringcircuit is faulty and will need to be replaced orrepaired.

Bodily injury hazard. If thesecondary boom lowers to lessthan 60° without stopping theengine, stop immediately andraise the secondary boom above60°. Failure to raise the secondaryboom could result in death orserious injury.

11 Remove the wire jumpers installed in steps 8and 9 and connect the wire harness toLSS1RO.

Part No. 88619 Z-80/60 3 - 37



Secondary Boom #1 Retracted SafetyLimit Switch, LSS1RS

12 Simultaneously push theLCD screen buttonsshown to activate statusmode.

13 Push one of the LCDscreen buttons shownuntil secondary boomstatus is displayed.

14 Raise the secondary boom until the displayshows >35 DEGREES.

15 Locate the secondary boom #2 angleoperational limit switch (LSS2AO) on the insideof the turntable riser.

16 Carefully disconnect the wire harness fromLSS2AO and install a wire jumper between pins1 and 2 of the deutsch connector on the wireharness. Install a second wire jumper betweenpins 3 and 4 of the deutsch connector.

Result: The display should show AT 65 DEGREES.

17 Press and hold the low speed function enablebutton and extend the secondary boom.

Result: The secondary boom should extend12 inches / 30.5 cm and stop. The engineshould stop and the display will show P9B SAFETY

FAULT and P11 SAFETY FAULT.

Result: If the engine does not stop and thesecondary boom continues to extend, thesecondary boom #1 retracted safety limit switch(LSS1RS) is out of adjustment or the wiringcircuit is faulty and will need to be replaced orrepaired.

Bodily injury hazard. If thesecondary boom continues toextend without stopping theengine, stop immediately andretract the secondary boom.Failure to retract the secondaryboom could result in death orserious injury.

18 Remove the wire jumpers installed in step 16and connect the wire harness to LSS2AO.

3 - 38 Z-80/60 Part No. 88619



B-21Test the Primary BoomSelf-leveling

The primary boom self-levelingfunction is adjustable on machineswith software revision 1.03 andlower. This function is notadjustable on machines with asoftware revision higher than 1.03.Refer to Repair Procedure 6-1,How to Determine the RevisionLevel.

Automatic primary boom self-leveling throughoutthe full cycle of secondary boom raising andlowering is essential for safe machine operation.The primary boom is maintained level by thecommunication between the platform level sensorand the turntable level sensor. If the platformbecomes out of level, the computer at the groundcontrols will open the appropriate solenoid valve(s)at the function manifold to maintain a level primaryboom.


2 Push one of the LCDscreen buttons shownuntil primary boom angleis displayed.

3 Start the engine and level the platform until thedisplays shows 0 DEGREES.

4 Fully raise the secondary boom while watchingthe display at the ground controls. Stop whenthe secondary boom just begins to extend.

Result: The primary boom should remain levelat all times to within ±2 degrees.

If the platform becomes out oflevel, the tilt alarm will sound andthe platform not level indicator willturn on. Level the platform until theindicator light turns off.

Part No. 88619 Z-80/60 3 - 39



B-22Test the Primary Boom AngleSensorA properly functioning primary boom angle sensor(PBAS) is essential to safe machine operation. Theprimary boom angle sensor is used to limit theangle of the primary boom relative to the angle ofthe secondary boom and gravity. The ECM at theground controls (TCON) monitors the position andangle of the primary boom using the signal fromPBAS. The PBAS signal is used to control theramping of the primary boom as well as velocitycontrol, limiting the speed of the primary boom to1.3 feet / 0.4 meters per second.

Perform this procedure on a firm,level surface.


2 Push one of the LCDscreen buttons shownuntil primary boom angleis displayed.


4 Raise the primary boom. The display will beginshowing a boom angle of 40°.

5 Continue raising the primary boom until thedisplay shows 65°.

Result: The primary boom should stop.

Result: The primary boom does not stop.Immediately release the function enable buttonand lower the boom. Calibrate the limit switch.Refer to Repair Procedure 4-7 How to Calibratethe Primary Boom Limit Switch.

Crushing hazard. If the boom doesnot stop at 65°, immediatelyrelease the function enable buttonand lower the primary boom.Failure to lower the boom couldcause the machine to tip overresulting in death or serious injury.

3 - 40 Z-80/60 Part No. 88619



B-23Inspect the Fuel and HydraulicTank Cap Venting Systems

Genie requires that this procedurebe performed every 250 hours orquarterly, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.



1 Remove the cap from the fuel tank.

2 Check for proper venting.

Result: Air passes through the fuel tank cap.Proceed to step 4.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.

When checking for positive tankcap venting, air should pass freelythrough the cap.

3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.

4 Install the fuel tank cap onto the fuel tank.

5 Remove the breather cap from the hydraulictank.

6 Check for proper venting.

Result: Air passes through the hydraulic tankcap. Proceed to step 8.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 7.

When checking for positive tankcap venting, air should pass freelythrough the cap.

7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.

8 Install the breather cap onto the hydraulic tank.

Part No. 88619 Z-80/60 3 - 41



B-24Perform Engine Maintenance

Engine specifications require thatthis procedure be performedquarterly or every 250 hours,whichever comes first.

Deutz Models:



Perkins Models:








3 - 42 Z-80/60 Part No. 88619


REV C

B-25Perform Engine Maintenance -Gasoline/LPG Models



GM Models:




Ford Models:







Part No. 88619 Z-80/60 3 - 43


REV C

C-1Perform Engine Maintenance -Diesel Models


Deutz Models:




Checklist C Procedures

Perkins Models:








C-2

3 - 44 Z-80/60 Part No. 88619


REV C

Grease the Platform OverloadMechanism (if equipped)

Genie specifications requirethat this procedure be performedevery 500 hours or 6 months,whichever comes first. Performthis procedure more often if dustyconditions 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 multi-purpose grease.

Grease Specification

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

4 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity in one of thelocations shown.

C-3Test the Platform OverloadSystem (if equipped)

Genie specifications require thatthis procedure be performed every500 hours or 6 months, whichevercomes 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.

Perform this procedure with themachine on a 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.

Failure to remove all weight, toolsand accessories from the platformwill result in an inaccurate test.

CHECKLIST C PROCEDURES

Part No. 88619 Z-80/60 3 - 45


REV C CHECKLIST C PROCEDURES

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 2-4, How to Calibrate the PlatformOverload System (if equipped).

Illustration 1

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 2-4, How to Calibrate the PlatformOverload System (if equipped).

6 Using a suitable lifting device, place anadditional 50 lbs / 23 kg of weight onto theplatform.

Result: The alarm should sound. The platformoverload indicator light should be flashing at theplatform controls and “PLATFORMOVERLOAD” should be displayed on the LCDscreen at the ground controls.

Result: The alarm is not sounding OR theplatform overload indicator light is not flashingOR “PLATFORM OVERLOAD” is not displayedon the LCD screen at the ground controls.Calibrate the platform overload system. Referto Repair Procedure 2-4, How to Calibrate thePlatform Overload System (if equipped).

There may be a 2 second delaybefore the overload indicator lightsflash and the alarm sounds.

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 2-4,How to Calibrate the Platform Overload System(if equipped).

There may be a 2 second delaybefore the overload indicator lightsflash and the alarm sounds.

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.

3 - 46 Z-80/60 Part No. 88619


REV CCHECKLIST C PROCEDURES


10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Press and hold the auxiliary power button.

The engine will turn off when theauxiliary power is activated.

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

Result: All ground control functions shouldoperate.

13 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.

There may be an 2 second delaybefore the overload indicator lightsand alarm turn off.

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

Result: All ground control functions shouldoperate normally.

15 Turn the key switch to platform control.


Result: All platform control functions shouldoperate.

If the platform overload system isnot operating properly, Refer to2-4, How to Calibrate the PlatformOverload System (if equipped).

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

C-4Replace the Engine Air Filter

Engine specifications require thatthis procedure be performed every500 hours or 6 months, whichevercomes first.

Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and componentdamage..


1 Open the engine side cover. Empty the dustdischarge valve by pressing together the sidesof the discharge slot. Clean the discharge slotas needed.

a retaining clampb canister end capc dust discharge valve

a

b

c

Part No. 88619 Z-80/60 3 - 47



Perkins 804C-33:




All Models:

4 Release the clamps from the end cap of the airfilter canister. Remove the end cap.

5 Remove the filter element.

6 Clean the inside of the canister and the gasketwith a damp cloth.

7 Install the new filter element.

8 Install the air filter canister end cap and connectthe end cap retaining clamp.

C-5Replace the Fuel/WaterSeparator - Diesel Models

Genie specifications require thatthis procedure be performed every500 hours or annually, whichevercomes first.

Regular replacement of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and/or hardstarting, and continued use may result incomponent damage. Extremely dirty conditionsmay require this procedure be performed moreoften.



1 Open the engine side turntable cover and locatethe fuel filter/water separator.

The fuel filter/water separator islocated near the hydraulic pump.

3 - 48 Z-80/60 Part No. 88619


REV C

2 Disconnect and plug the fuel supply hose fromthe fuel tank to the fuel filter/water separatorhead.

3 Loosen the vent plug located on the fuel filter/water separator head.

a vent plugb drain plugc filter bowld separator head

4 Place a suitable container under the filter bowl.Loosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel.

5 Rotate the filter bowl counterclockwise andremove it from the element.

6 Rotate the filter element counterclockwise andremove it from the filter head.

7 Install the filter bowl onto the new filter element.

CHECKLIST C PROCEDURES

8 Apply a thin layer of oil onto the element gasket.Install the filter/bowl assembly onto the filterhead. Tighten the drain plug and vent plug.

Component damage hazard. Thedrain plug and vent plug can bedamaged if they areovertightened.

9 Install the fuel supply hose from the fuel tank tothe fuel filter/water separator. Tighten theclamp.

10 Clean up any diesel fuel that may have spilledduring the installation procedure.

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

Bleed the fuel system:

Before bleeding the system, fill thefuel tank.

12 Loosen the vent plug located on thefuel filter/water separator head.

13 Operate the priming lever of the fuel lift pumpuntil fuel, free from air, comes from the ventplug. Tighten the vent plug.

14 Loosen the air vent screw, located on top of thefuel injection pump.

15 Tighten the air vent screw when air stopscoming through the air vent.

16 Clean up any diesel fuel that may have spilledduring the bleeding procedure and dispose ofproperly.

17 Start the engine from ground controls andcheck for leaks.

c

b

d

a

Part No. 88619 Z-80/60 3 - 49



C-6Perform Engine Maintenance -Gasoline/LPG Models



GM Models:



Ford Models:







3 - 50 Z-80/60 Part No. 88619


REV CChecklist D Procedures

D-1Check the Boom Wear Pads

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions. Refer to Section 2, Specifications, forBoom Wear Pad Specifications.


2 Raise the end of the boom to a comfortableworking height (chest high), then extend theboom 1 foot / 30 cm.

3 Measure each wear pad.

Result: Replace the wear pad if it is less thanspecification. If the wear pad is still withinspecification, shim as necessary to obtain zeroclearance and zero drag. Refer to RepairProcedure 4-2, How to Shim the Boom.

4 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.

Always maintain squarenessbetween the outer and innerboom tubes.

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-wheel withoutoperator knowledge may cause death or seriousinjury 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(20,000 lbs / 10,000 kg) under the drive chassisbetween the wheels at the non-steer end of themachine.

3 Lift the wheels off the ground and place blocksunder the drive chassis for support.

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

disengaged position

engaged position

Part No. 88619 Z-80/60 3 - 51


REV C CHECKLIST D PROCEDURES

5 Manually rotate each non-steer wheel.

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

6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the blocks.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.

4WD models:

7 Chock the non-steering wheels to prevent themachine from rolling.

8 Center a lifting jack with a minimum capacity of25,000 lbs / 12000 kg under the drive chassisbetween the steer wheels.

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

10 Disengage the drive hubs by turning over thedrive hub disconnect caps on each steer wheelhub.

11 Manually rotate each steer wheel.

Result: Each steer wheel should rotate withminimum effort.

12 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.

All models:

13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).

The free-wheel valve is located onthe drive pump, and should alwaysremain closed.

a drive pumpb screwdriverc lift pumpd free-wheel valve

disengaged position

engaged position

a

d

c

b

3 - 52 Z-80/60 Part No. 88619


REV CCHECKLIST D PROCEDURES

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 approximately8 feet / 2.4 m.






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

Bolt torque sequence(from above turntable)


7 Confirm that each bearing mounting bolt underthe drive chassis is torqued in sequence tospecification. Refer to Section 2, Specifications.

Bolt torque sequence(from below chassis)

1

2

3

4

5

6

7

8

9

10

11

1213

14 15

1617

18

22

26

30

192327

2024 28

21

25

29

1 15

7

12

4

17

5

14

9216

8

11

3

18

6

13

10

Part No. 88619 Z-80/60 3 - 53



8 Lower the secondary boom to the stowedposition.





D-4Inspect for Turntable BearingWear

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.

Perform this procedure with themachine on a firm, level surfaceand the boom in the stowedposition.

1 Grease the turntable bearing. See A-7, Greasethe Turntable Bearing and Rotate Gear.

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

3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.

3 - 54 Z-80/60 Part No. 88619



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

To obtain an accuratemeasurement, place the dialindicator no more than1 inch / 2.5 cm from the turntablerotation bearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 At the dial indicator, adjust it to "zero" theindicator.

6 Fully extend the boom and lower to a horizontalposition.

7 Note the reading on the dial indicator.

Result: The measurement is less than0.063 inch / 1.6 mm. The bearing is good.

Result: The measurement is more than0.063 inch / 1.6 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the boom and raise the boom to fullheight. Visually inspect the dial indicator to besure the needle returns to the "zero" 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 boom to the stowed position and turnthe machine off.

12 Remove the dial indicator from the machine.

a

b

c

d

Part No. 88619 Z-80/60 3 - 55



D-5Replace 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.

Drive Hubs:

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 models with pipe plugs

b models with o-ring plugs

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Apply pipe thread sealant to the plugs. Installthe plugs.


Models with O-ring plugs: Install the plugsinto the drive hub.


Turntable Rotate Drive Hub:


unlocked locked

b

a

a

3 - 56 Z-80/60 Part No. 88619



2 Remove the motor/brake mounting bolts, andthen remove the motor and brake from the drivehub and set them to the side.

Component damage hazard.Hoses can be damaged if they arekinked or pinched.

a motorb motor/brake mounting boltsc braked drive hube drive hub mounting bolts

3 Remove the drive hub mounting bolts, and usea lifting device to remove the drive hub from themachine.

4 Remove the plug from the side of the drive hub.Drain the oil from the hub into a container ofadequate capacity. Refer to Section 2,Specifications.

5 Install the drive hub. Torque the drive hubmounting bolts to specification. Refer toSection 2, Specifications.

6 Install the brake and motor onto the drive hub.Torque the motor/brake mounting bolts tospecification. Refer to Section 2, Specifications.

7 Fill the hub with oil from the side hole until theoil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug.

8 Adjust turntable rotation gear backlash. Refer toRepair Procedure 9-1, How to Adjust theTurntable Rotation Gear Backlash.

Part No. 88619 Z-80/60 3 - 57



D-6Perform Engine Maintenance -Diesel Models


Deutz Models:




Perkins Models:








3 - 58 Z-80/60 Part No. 88619



D-7Replace the Hydraulic FilterElements

Genie requires that this procedurebe performed annually or every1000 hours, whichever comesfirst. Perform this procedure moreoften if dusty conditions exist.

Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.

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


Hydraulic return filter

1 Open the ground controls side turntable coverand locate the hydraulic return filter mounted onthe hydraulic tank.

2 Place a suitable container under the hydraulictank return filter.

3 Remove the filter with an oil filter wrench.

4 Apply a thin layer of fresh oil to the gasket ofthe new oil filter.

5 Install the new hydraulic return filter elementand tighten it securely by hand. Clean up anyoil that may have spilled during the installationprocedure.

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

Medium and high pressure filters

The medium pressure filter is forthe charge pump. One highpressure filter is for all boom andsteer functions. The other highpressure filter is for the oscillatingaxle circuit and platform manifold.

7 Open the engine side turntable cover and locatethe three filters mounted to the bulkhead.

a high pressure filtersb medium pressure filter

a

b

Part No. 88619 Z-80/60 3 - 59



8 Place a suitable container under the filters.

9 Remove the filter housing by using a wrench onthe nut provided on the bottom of the housing.

10 Remove the filter element from the housing.

11 Inspect the housing seal and replace it ifnecessary.

12 Install the new medium and high pressure filterelements into the housings and tighten themsecurely.

13 Clean up any oil that may have spilled duringthe installation procedure.

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


16 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.

3 - 60 Z-80/60 Part No. 88619


REV CChecklist E Procedures

E-1Test or Replace the Hydraulic Oil

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.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.


1 GM and Ford models: Turn the valve on theLPG tank clockwise to the off position(if equipped). Then slowly disconnect the hosefrom the LPG tank.

2 GM and Ford models: Open the clamps fromthe LPG tank straps and remove the LPG tankfrom the machine (if equipped).

3 Models with hydraulic tank shut-off valves:Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.

4 Place a suitable container underneath thehydraulic tank.

5 Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications.

6 Tag, disconnect and plug the two suction hosesand supply hose for the auxiliary pump from thehydraulic tank. Cap the fittings on the tank.

The hoses can be accessedthrough the access hole under theturntable.

7 Tag, disconnect and plug the return filterhydraulic hose at the return filter. Cap the fittingon the filter housing.

8 Remove the ground controls side turntablecover.

9 Support the hydraulic tank with an appropriatelifting device.

10 Remove the hydraulic tank mounting fasteners.

11 Remove the hydraulic tank from the machine.

Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedwhen removed from the machine.

12 Remove the hydraulic return filter housingmounting fasteners. Remove the hydraulicreturn filter housing from the hydraulic tank.

13 Remove the suction strainers from the tank andclean them using a mild solvent.

Part No. 88619 Z-80/60 3 - 61


REV C CHECKLIST E PROCEDURES

24 Prime the pump. Refer to Repair Procedure7-2, How to Prime the Pump.

Always use pipe thread sealantwhen installing the suction hosefittings and the drain plug.

Component damage hazard. Theengine must not be started withthe hydraulic tank shut-off valvesin the closed position orcomponent damage will occur. Ifthe tank valves are closed,remove the key from the keyswitch and tag the machine toinform personnel of the condition.

14 Rinse out the inside of the tank using a mildsolvent.

15 Install the suction strainers using a threadsealant on the threads.

16 Install the drain plug using a thread sealant onthe threads.

17 Install the hydraulic return filter housing onto thehydraulic tank.

18 Install the hydraulic tank onto the machine.

19 Install the two suction hoses to the suctionstrainers.

20 Install the supply hose for the auxiliary powerunit and the return filter hose.

Models with hydraulic tank shut-off valves:

21 Open the two hydraulic tank valves at thehydraulic tank.

22 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.

23 Clean up any oil that may have spilled.open closed

3 - 62 Z-80/60 Part No. 88619


REV C

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub, thenremove the cotter pin from the castle nut.

7 Tighten the castle nut to 35 ft-lbs / 47 Nm toseat the bearings.

8 Fully loosen the castle nut, then re-tighten to8 ft-lbs / 11 Nm.

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

Result: If there is side to side or up and downmovement, continue to step 11 and replace thewheel bearings with new ones.

When replacing a wheel bearing,both the inner and outer bearings,including the pressed-in races,must be replaced.

Result: If there is no side to side or up anddown movement, continue with step 11 andgrease the wheel bearings.

10 Remove the dust cap from the hub, thenremove the cotter pin from the castle nut.

11 Remove the castle nut.

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

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

14 Pack both bearings with clean, fresh grease.

E-2Grease the Steer AxleWheel Bearings, 2WD Models

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, then center a liftingjack with a minimum capacity of25,000 lbs / 12000 kg under the drive chassisbetween the steer wheels.

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

4 Select a wheel. Remove the lug nuts, andremove the tire and wheel 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.

CHECKLIST E PROCEDURES

Part No. 88619 Z-80/60 3 - 63



E-3Perform Engine Maintenance



Deutz Models:



Perkins Models:




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

16 Install a new bearing grease seal into the hubby pressing it evenly into the hub until it is flush.

Always replace the bearing greaseseal when removing the hub.

17 Slide the hub onto the yoke spindle.

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

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.

20 Tighten the slotted nut to 35 ft-lbs / 47 Nm toseat the bearings.


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

Always replace the cotter pin witha new one when removing thecastle nut or when checking thetorque of the castle nut.

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

24 Repeat this procedure for the other wheelsbeginning with step 4.

3 - 64 Z-80/60 Part No. 88619


REV CCHECKLIST E PROCEDURES

Ford Models







E-4Perform Engine Maintenance -Ford Models



Ford Models







Part No. 88619 Z-80/60 3 - 65



E-5Perform Engine Maintenance -Diesel Models



Deutz Models:




Perkins Models:








3 - 66 Z-80/60 Part No. 88619


REV C

E-6Perform Engine Maintenance -Deutz Models



Deutz Models:

Required maintenance procedures and additionalengine information are available in theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929).







Part No. 88619 Z-80/60 3 - 67


REV C




Deutz Models:










Deutz Models:








3 - 68 Z-80/60 Part No. 88619



Part No. 88619 Z-80/60 4 - 1

July 2006 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 rulesand operating instructions in theOperator’s Manual on your machine.

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 the stowed position

· Turntable rotated with the boom betweenthe circle-end (yellow arrow) wheels

· Turntable secured with the turntablerotation lock pin

· Key switch in the off position with thekey removed

· 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. To re-assemble,perform the disassembly steps in reverse order.

Symbols Legend




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.



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

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

4 - 2 Z-80/60 Part No. 88619

July 2006Section 4 • Repair Procedures

REV BDisplay Module

This table lists the various screens and menu options of the operating software. Some display menus arefor informational purpose only, while others can be used to change the machine operating parameters.

The key switch must be in the off position before entering the programming mode.

Screen or Menu

Procedure Description Range

Operator Default

Hour meter Engine speed Engine oil pressure PSI Engine oil pressure kPa Engine temperature °F Engine temperature °C Primary boom angle sensor Turntable level sensor X° Turntable level sensor Y° Platform angle Battery voltage

Machine Status

With key switch ON, press the

and at the same time.

Hydraulic pressure PSI Hydraulic pressure kPa Primary boom angle Primary boom length Secondary boom angle Secondary boom length

0-4500 PSI 0-31000 kPa 0-65 DEG = 0’, >0’, >22’ = 0 DEG, >0 DEG, = 65 DEG, = 0 FT, > 0 FT

Unit of Measure and Language

With the key switch OFF, press and hold the button and turn the key switch to the ON position. Release the button and press .

Metric/English measurements Language selection

English, German, French, Spanish, Portuguese, Italian, Dutch, and Swedish.

Drive Functions


Forward not stowed drive speed % Forward low drive speed % Forward high drive speed % Reverse not stowed drive speed % Reverse low drive speed % Reverse high drive speed % Drive acceleration % Drive deceleration % Speed limit on steer angle

120% (default) 50% min 120% (default) 50% min 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 100% max and 0% min, 75% (default)

Part No. 88619 Z-80/60 4 - 3


REV B DISPLAY MODULE

Screen or Menu


Boom Function Speeds


Primary boom up speed % (stowed) Primary boom up speed % (raised) Primary boom down speed % (stowed) Primary boom down speed % (raised) Primary boom extend speed % Primary boom retract speed % Secondary boom up speed % (stowed) Secondary boom up speed % (raised) Secondary boom down speed % (stowed) Secondary boom down speed % (raised) Secondary boom extend speed % Secondary boom retract speed % Turntable rotate speed % (retracted) Turntable rotate speed % (extended) Jib boom up/down speed %

120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default) 120% max and 50% min, 100% (default)

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REV BDISPLAY MODULE

Screen or Menu


Lift Function Ramp Settings


Primary boom up/down ramp acceleration % Primary boom up/down ramp deceleration % Primary boom extend/retract ramp acceleration % Primary boom extend/retract ramp deceleration % Secondary boom ramp acceleration % Secondary boom ramp deceleration % Turntable rotate ramp acceleration % Turntable rotate ramp deceleration % Jib boom up/down ramp deceleration %

150% max and 50% min, 100% (default) 150% max and 50% min, 100% (default) 150% max and 50% min, 100% (default) 150% max and 50% min, 100% (default) 150% max and 50% min, 100% (default) 150% max and 50% min, 100% (default) 150% max and 50% min, 100% (default) 150% max and 50% min, 100% (default) 150% max and 50% min, 100% (default)

Part No. 88619 Z-80/60 4 - 5



Screen or Menu


Valve Calibration


Reset drive valve defaults

Reset primary boom up/down valve defaults

Reset primary boom extend/retract valve defaults

Reset secondary boom valve defaults

Reset turntable rotate valve defaults

Allow primary boom up/down speed calibration

Allow primary boom extend/retract speed calibration

Allow secondary boom up/down speed calibration

Allow turntable rotate speed calibration

Reset drive joystick defaults

Reset primary boom up/down joystick defaults

Reset primary boom extend/retract joystick defaults

Reset secondary boom joystick defaults

Reset turntable rotate joystick defaults

Reset steer joystick defaults

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REV BDISPLAY MODULE

Screen or Menu


Sensor Calibration


Set unit levels to gravity Unit level Y-axis millivolts per degree Unit level X-axis millivolts per degree Set platform level to gravity Platform level sensor millivolts per degree Reset blue end blue side steer sensor (YES/NO) Reset yellow end blue side steer sensor (YES/NO) Reset blue end yellow side steer sensor (YES/NO) Reset yellow end yellow side steer sensor (YES/NO) Reset all steer sensors (YES/NO) Reset primary boom angle sensor (YES/NO) Primary boom angle = 35 deg (YES/NO) Primary boom angle = 65 deg (YES/NO)

Default Reset


Reset drive functions Reset boom functions Reset lift function ramps Reset all

Part No. 88619 Z-80/60 4 - 7



Screen or Menu


Options With the key switch OFF, press and hold the button and turn the key switch to the ON position. Release the button and press .

Boom length limit: No limit (NO LT) Secondary boom extend disabled: (EXT LT) Secondary boom function disabled: (SEC LT) AC generator: (NO/BELT/HI_LO/HYDRL) Alarm: NO, Motion (MO AL), Travel (TR AL), Descent (DE AL) Travel and Decent (TD AL) Lift/drive cut outs: No (NO CO) Drive cutout while not stowed (DCONS), Lifting or Driving (LORDR) Auxiliary drive OPT: (YES/NO) Proximity kill switch OR Platform overload sensing: (OVERLOAD/NONE/PROX/PLTFS) Work light: (YES/NO) Flashing beacon: (YES/NO) Drive lights: (YES/NO) Disable steer mode change while driving: (YES/NO) Rocker joystick steering (YES/NO) Chassis Tilt Cutout (YES/NO) Foot Switch Lockout, 0 to 30 minutes Generator Off Delay, 0 to 10 seconds

0 to 30 minutes (holding or button will cause display to

scroll through options or increment number settings).

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REV B

The platform controls contains twoprinted circuit boards:

The LED circuit board is mounted to theunderside of the control box lid which contains theLED's. The LED circuit board sends the input fromthe operator to the platform controls ECM circuitboard (PCON). The ECM circuit board (PCON)sends the data to the turntable control box (TCON)for processing.

The platform controls ECM circuit board(ALC-1000) communicates with the turntablecontrols. The joystick controllers at the platformcontrols utilize Hall Effect technology and requireno adjustment. The operating parameters of thejoysticks are stored in memory at the turntablecontrols. If a joystick controller error occurs or if ajoystick is replaced, it will need to be calibratedbefore that particular machine function will operate.See 1-3, How to Calibrate a Joystick.

Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.

a platform controls ALC-1000circuit board

b primary boom extend/retractjoystick

c secondary boom up/extend anddown/retract joystick

d drive/steer joystick controllere LED circuit boardf primary boom up/down and

turntable rotate left/right joystick

Platform Controls

a

d

e

f

b

c

Part No. 88619 Z-80/60 4 - 9


REV B

7 Attach a grounded wrist strap to the groundscrew inside the platform control box.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

8 Carefully disconnect the wire connectors fromthe circuit board.

9 Remove the ALC-1000 circuit board mountingfasteners.

10 Carefully remove the ALC-1000 circuit boardfrom the platform control box.

How to Remove the LEDCircuit Board1 Push in the red Emergency Stop button to the

off position at both the ground and platformcontrols.

2 Remove the platform control box lid retainingfasteners. Open the control box lid.

1-1

ALC-1000 Circuit Board

When the ALC-1000 circuit boardis replaced, the joystick controllerswill need to be calibrated. See 1-3,How to Calibrate a Joystick.

How to Remove the ALC-1000Circuit Board1 Push in the red Emergency Stop button to the


2 Locate the cables that connect to the bottom ofthe control box. Tag each cable and its locationat the control box.

3 Disconnect the cables from the bottom of theplatform control box.

4 Remove the control cable plug retainingfasteners from the bottom of the platformcontrol box.


6 Locate the ALC-1000 circuit board mounted tothe inside of the platform control box.

PLATFORM CONTROLS

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REV BPLATFORM CONTROLS

3 Locate the LED circuit board mounted to theinside of the platform control box lid.



4 Carefully tag and disconnect the two ribboncables from the membrane circuit board.

5 Remove the LED circuit board retainingfasteners.

6 Carefully remove the LED circuit board from theplatform control box lid.

1-2Membrane Decal

How to Replace the MembraneDecalThe membrane decal is a special decal thatconsists of a decal with an electronic membraneon the backside. The membrane contains touchsensitive areas that, when pushed, activates themachine functions. The membrane buttonsactivate machine functions similar to toggleswitches, but do not have any moving parts.

1 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols.


3 Carefully tag and disconnect the two ribboncables from the membrane circuit board.



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REV B PLATFORM CONTROLS

4 Close the control box lid.

5 Remove the platform controls decal from theplatform control box.

6 Carefully remove the membrane decal from theplatform control box while guiding the ribboncables out of the control box lid.

7 Remove any decal adhesive from the controlbox lid with a mild solvent.

Do not allow any solvent to comein contact with the membranecircuit board.

8 Install the new membrane decal while guidingthe ribbon cables through the control box lid.

Be sure that all LED locations onthe membrane decal align with theLEDs on the membrane circuitboard.

9 Install a new platform controls decal over themembrane decal.

10 Open the control box lid and carefully connectthe ribbon cables from the membrane decal tothe membrane circuit board.

1-3Joysticks

How to Calibrate a JoystickThe joystick controllers on this machine utilizedigital Hall Effect technology for proportionalcontrol. If a joystick controller is disconnected orreplaced, it must be calibrated before thatparticular machine function will operate.

The joystick must be calibratedbefore the threshold, max-out orramping can be set.

After each joystick is calibrated,check the display at the groundcontrol box. There should be nocalibration faults shown on thedisplay. If calibration faults exist,repeat steps 1 through 8 for thatjoystick controlled function.


Drive functions:


2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls.

3 Press the minus button twice, then press the

enter button twice.

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REV BPLATFORM CONTROLS

4 Use the scroll button to scroll through themenu until RESET DRIVE JOYSTICK DEFAULTS is

displayed. Press the button to select YES,

then press the button.

5 Do not start the engine.

6 Locate the drive/steer joystick.

7 Move the drive/steer joystick full stroke in theforward direction and hold for 5 seconds, thenreturn to the center or neutral position.

8 Move the drive/steer joystick full stroke in thereverse direction and hold for 5 seconds, thenreturn to the center or neutral position.

Result: The alarm at the ground controls shouldsound for a successful calibration.

Steer functions:




enter button twice.

4 Use the scroll button to scroll through themenu until RESET STEER JOYSTICK DEFAULTS is

displayed. Press the button to select YES,

then press the button.


6 Locate the drive/steer joystick.

7 Move the drive/steer joystick or thumb rockerswitch (if equipped) full stroke in the leftdirection and hold for 5 seconds, then return tothe center or neutral position.

8 Move the drive/steer joystick or thumb rockerswitch (if equipped) full stroke in the rightdirection and hold for 5 seconds, then return tothe center or neutral position.


Result: If the alarm does not sound, repeatcalibration procedure.

Primary boom extend/retract functions:




enter button twice.

4 Use the scroll button to scroll through themenu until RESET PRIMARY BOOM EXTEND/RETRACT

JOYSTICK DEFAULTS is displayed. Press the

button to select YES, then press the button.


6 Locate the primary boom extend/retractjoystick.

Part No. 88619 Z-80/60 4 - 13


REV B

7 Move the primary boom extend/retract joystickfull stroke in the extend direction and hold for 5seconds, then return to the center or neutralposition.

8 Move the primary boom extend/retract joystickfull stroke in the retract direction and hold for 5seconds, then return to the center or neutralposition.



Secondary boom up/down andextend/retract functions:




enter button twice.

4 Use the scroll button to scroll through themenu until RESET SECONDARY BOOM JOYSTICK

DEFAULTS is displayed. Press the button to

select YES, then press the button.


6 Locate the secondary boom up/down andextend/retract joystick.

7 Move the secondary boom up/down andextend/retract joystick full stroke in the up/extend direction and hold for 5 seconds, thenreturn to the center or neutral position.

8 Move the secondary boom up/down andextend/retract joystick full stroke in the down/retract direction and hold for 5 seconds, thenreturn to the center or neutral position.



Primary boom up/down functions:




enter button twice.

4 Use the scroll button to scroll through themenu until RESET PRIMARY BOOM UP/DOWN JOYSTICK

DEFAULTS is displayed. Press the button to

select YES, then press the button.


6 Locate the primary boom/turntable rotatejoystick.

7 Move the boom/turntable rotate joystick fullstroke in the up direction and hold for 5seconds, then return to the center or neutralposition.

PLATFORM CONTROLS

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REV B

8 Move the boom/turntable rotate joystick fullstroke in the down direction and hold for 5seconds, then return to the center or neutralposition.



Turntable rotate functions:




enter button twice.

4 Use the scroll button to scroll through themenu until RESET TURNTABLE ROTATE LEFT/RIGHT

JOYSTICK DEFAULTS is displayed. Press the

button to select YES, then press the button.


6 Locate the primary boom/turntable rotatejoystick.

7 Move the boom/turntable joystick full stroke inthe left direction and hold for 5 seconds, thenreturn to the center or neutral position.

8 Move the boom/turntable joystick full stroke inthe right direction and hold for 5 seconds, thenreturn to the center or neutral position.



How to Reset a ProportionalValve Coil Default

This procedure only needs to beperformed if a proportional valvehas been replaced.

After the valve coil defaults havebeen set, each machine functionthreshold and default functionspeed must be set. See 1-3, Howto Set the Function Thresholdsand Default Function Speeds.




enter button twice.

4 Use the scroll button to scroll through themenu until the function valve that needs to bereset is displayed. Press the button to select

YES, then press the button.

PLATFORM CONTROLS

Part No. 88619 Z-80/60 4 - 15


REV B PLATFORM CONTROLS

How to Set the FunctionThresholds and DefaultFunctions Speeds

Before the threshold and defaultfunction speeds can be set, theboom function proportional valvecoil defaults must be set first.See 1-3, How to Reset aProportional Valve Coil Default.

If a boom function proportionalvalve coil has not been replacedand just want to reset the functionspeed to original factory settings,begin with step 10.

Perform this procedure with themachine parked on a firm, levelsurface which is free ofobstructions.


2 Press down the foot switch.

Be sure the engine rpm is set tofoot switch activated high idle.

Function threshold:

3 Select a joystick controlled function that needsto have the threshold set.

4 Slowly move the joystick off center in eitherdirection just until the machine function starts tomove, then move the joystick very slowlytowards the neutral or center position justbefore the machine function stops.Do not let go of the joystick.

5 While holding the joystick in position, press theengine start button at the platform controlsto set the joystick controller threshold.

6 Repeat steps 3 through 5 for each joystickcontrolled machine function (primary boom up/down and turntable rotate left/right, primaryboom extend/retract, secondary up/down andextend/retract, drive forward/reverse and steerleft/right).

7 Once the threshold has been set, press andhold the engine start button until the engineshuts off. Do not press the red Emergency Stopbutton.

Approximately 3 seconds after theengine shuts off, the alarm at theground controls will sound toindicate the threshold settings arebeing saved in memory. Releasethe button.

8 At the ground controls, turn the key switch tothe off position, wait a moment and then turnthe key switch to platform controls.

9 Check the display at the ground controls to besure there are no calibration faults.

Result: There should be no calibration faultsshown on the display. If calibration faults exist,repeat this procedure.

Function speeds:

Be sure the machine is in thestowed position and the boom isrotated between the square endtires.

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REV B


11 Select a boom function that needs the functionspeed set.

12 Boom up/down and extend/retractfunctions: Move the joystick full stroke in theup or extend direction. When the alarm sounds,move the joystick in the opposite direction fullstroke until the alarm sounds again. Return thejoystick to center.

Turntable rotate functions: Move the joystickfull stroke in either the left or right direction.When the alarm sounds, move the joystick inthe opposite direction full stroke until the alarmsounds again. Return the joystick to center.

13 Once the function speeds have been set, pressand hold the engine start button until theengine shuts off. Do not press the redEmergency Stop button.

Approximately 3 seconds after theengine shuts off, the alarm at theground controls will sound toindicate the speed settings arebeing saved in memory. Releasethe button.

14 At the ground controls, turn the key switch tothe off position, wait three seconds and thenturn the key switch to platform controls.

15 Inspect the display at the ground controls to besure there are no calibration faults.

There should be no calibrationfaults shown on the display. Ifcalibration faults exist, repeat thisprocedure.

PLATFORM CONTROLS

How to Adjust the FunctionSpeeds

Perform this procedure with theboom in the stowed position.Refer to Section 2, Specifications.


2 Press and hold the enter button on theground control panel while turning the keyswitch to ground controls.

3 Press the plus button twice, then press the

minus button twice.

4 Press the scroll button until the function tobe adjusted is displayed.

5 Press the plus button to increase the speed

or press the minus button to decrease thespeed.

6 Press the enter button to save the setting inmemory.

7 Perform this procedure until the machinefunction speed meets specification.

Part No. 88619 Z-80/60 4 - 17


REV B

How to Adjust the FunctionRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position.The ramp rate settings of a joystick can bechanged to compensate for hydraulic pump wearto maintain peak performance from the machine.Refer to Section 2, Specifications.



2 Press and hold the enter button on theground control panel while turning the keyswitch to ground controls.

3 Press the plus button twice, then press thescroll button twice.

4 Press the scroll button until the function tobe adjusted is displayed.

5 Press the plus button to increase the ramp

rate or press the minus button to decreasethe ramp rate.

6 Press the enter button to save the setting inmemory.

7 Perform this procedure until the machinefunction speed meets specification.

PLATFORM CONTROLS

Ramp RateSpecifications

Ramp rate (factory settings)

Primary boom and turntable rotateaccelerate 4 secondsdecelerate 1 second

Primary boom extend/retractaccelerate 3 secondsdecelerate 0.75 second

Secondary boom up/downaccelerate 7 secondsdecelerate 0.75 second

Secondary boom extend/retractaccelerate 8 secondsdecelerate 1 second

Driveaccelerate 2.5 secondsdecelerate to neutral 0.75 seconddecelerate, change of direction 0.75 seconddecelerate, coasting 1 seconddecelerate, braking 1.5 secondsdecelerate, shift from low to high speed 1 seconddecelerate, shift from high to low speed 4 seconds

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REV BPlatform Components

2-1Platform

How to Remove the Platform1 Separate the foot switch quick disconnect plug.

2 Support the platform with an appropriate liftingdevice.

3 Locate the cables that connect to the bottom ofthe control box. Number each cable and itslocation at the platform control box.

4 Disconnect the cables from the bottom of theplatform control box.

5 Remove the platform control box mountingfasteners. Remove the platform control box andset it aside.

6 Remove the air line to platform bracket retainingfasteners (if equipped).

7 Remove the weld cables from the platform(if equipped).

8 Remove the platform mounting fasteners andremove the platform from the machine.

Crushing hazard. The platformcould become unbalanced and fallwhen it is removed from themachine if it is not properlysupported.

2-2Platform Leveling Cylinder

The platform leveling cylinder maintains platformleveling through the entire range of boom motion.This allows the platform to be level with theturntable. The ECM at the ground controlscompares the difference in readings between theplatform angle sensor and the turntable levelsensor. The ECM at the ground controls sends asignal to the platform controls to open or close theappropriate platform level proportional valve on theplatform manifold to maintain a level platform. Theplatform leveling cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the PlatformLeveling Cylinder

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.

1 Extend the boom until the platform levelingcylinder barrel-end pivot pin is accessible.

2 Raise the jib boom slightly and place blocksunder the platform.

Part No. 88619 Z-80/60 4 - 19


REV B

3 Lower the jib boom until the platform is restingon the blocks just enough to support theplatform.

Do not rest the entire weight of theboom on the blocks.

4 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling cylinder at thebulkhead fittings located inside the boom tubeat the platform end. Cap the bulkhead fittingson the boom tube.

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.

5 Remove the pin retaining fasteners fromthe platform leveling cylinder rod-end pivot pin.Do not remove the pin.

6 Remove the external snap rings from the barrel-end pivot pin. Do not remove the pin.

7 Support and secure the jib boom cylinder to thejib boom with a strap or other suitable device.Protect the cylinder rod from damage.

Crushing hazard. The jib boomcylinder will fall if not properlysupported when the platform levelcylinder rod-end pivot pin isremoved.

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

Crushing hazard. The platformand jib boom will fall when theplatform leveling cylinder barrel-end pivot pin is removed if notproperly supported.

9 Support the rod end of the platform levelcylinder.

10 Use a soft metal drift to tap the platform levelcylinder rod-end pivot pin half way out andlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

11 Use a soft metal drift to remove the platformlevel cylinder rod-end pivot pin.

12 Carefully pull the platform leveling cylinder outof the boom.

Crushing hazard. The jib boomcylinder will fall if not properlysupported when the platform levelcylinder rod-end pivot pin isremoved.

How to Bleed the PlatformLeveling Cylinder

Do not start the engine. Useauxiliary power for all machinefunctions in this procedure.

1 Raise the jib boom to a horizontal position.

2 Push the platform level up and down buttonsthrough two complete platform leveling cyclesto remove any air that might be in the system.

PLATFORM COMPONENTS

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REV BPLATFORM COMPONENTS

2-3Platform Rotator

The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator

Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment allthe way in the left position.


1 Remove the platform. See 2-1,How to Remove the Platform.

2 Disconnect the wire harness from the platformangle sensor.

3 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator manifold. Cap thefittings on the manifold.

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 Remove the hose and cable clamp from theplatform support.

5 Remove the platform manifold mountingfasteners. Lay the platform manifold to the side.

Component damage hazard.Cables can be damaged if theyare kinked or pinched.

6 Remove the power to platform electrical outletbox bracket mounting fasteners.

7 Remove the power to platform electrical outletbox from the platform and lay it to the side.

8 Remove the weld cable from the platform(if equipped).


Part No. 88619 Z-80/60 4 - 21


REV B PLATFORM COMPONENTS

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

10 Remove the eight mounting bolts from theplatform mounting weldment.

11 Remove the center bolt and slide the platformmounting weldment off of the platform rotator.

Crushing hazard. The platformmounting weldment may becomeunbalanced and fall if it is notproperly supported.

12 Support the platform rotator. Do not applyany lifting pressure.

13 Remove the pin retaining fasteners from the jibboom and jib boom leveling arms to platformrotator pivot pins. Do not remove the pins.

14 Support the jib boom leveling arms with asuitable lifting device.

15 Use a soft metal drift to remove both pins andremove the platform rotator from the machine.

Crushing hazard. The jib boomleveling arms may fall if they arenot properly supported when thejib boom leveling arm pivot pin isremoved.

Component damage hazard. Theplatform angle sensor is a verysensitive instrument. It can bedamaged internally if the platformrotator is dropped or sustains anyphysical shock, even if thedamage is not visible.

How to Bleed the PlatformRotatorBefore serial number 229:

Do not start the engine. Useauxiliary power for all machinefunctions in this procedure.

1 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.

a top bleed valveb bottom bleed valvec clear hosed container

2 Move the platform rotate switch to the left andthen to the right through two platform rotationcycles, continue holding the switch to the rightuntil the platform is fully rotated to the right.

a

d c b

4 - 22 Z-80/60 Part No. 88619



3 Open the top bleed valve, but do not remove it.

4 Move the platform rotate switch to the left untilthe platform is fully rotated to the left. Continueholding the switch until air stops coming out ofthe bleed valve. Close the bleed valve.

Crushing hazard. Keep clear ofthe platform during rotation.

5 Connect the clear hose to the bottom bleedvalve. Open the bottom bleed valve, but do notremove it.

6 Hold the platform rotate switch to the right untilthe platform is fully rotated to the right.Continue holding the switch until air stopscoming out of the bleed valve. Close the bleedvalve.


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

8 Rotate the platform full right, then full left andinspect the bleed valves for leaks.

After serial number 228:

1 Rotate the platform full right, then full left untilair is completely out of the rotator. Bleeding thevalve is not necessary.


2-4Platform Overload System

How to Calibrate the PlatformOverload System (if equipped)

Calibration 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.

Perform this procedure with themachine on a 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.

Failure to remove all weight, toolsand accessories from the platformwill result in an incorrectcalibration.

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

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REV B PLATFORM COMPONENTS

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 alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols. Proceed to step 6.

Result: The alarm is sounding. The platformoverload indicator light is flashing at theplatform controls and “PLATFORMOVERLOAD” should is displayed on the LCDscreen at the ground controls. Slowly tightenthe load spring adjustment nut in a clockwisedirection in 10° increments until the overloadindicator light turns off, and the alarm does notsound. Proceed to step 8.

The platform will need to bemoved up and down and allowedto settle between eachadjustment.

There may be a 2 second delaybefore the platform overloadindicator light and alarm responds.


Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols. 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 tostep 7.

Result: The alarm should be sounding.The platform overload indicator light should beflashing at the platform controls and“PLATFORM OVERLOAD” should be displayedon the LCD screen at the ground controls.Repeat this procedure beginning with step 5.

The platform will need to bemoved up and down and allowedto settle between eachadjustment.

There may be a 2 second delaybefore the platform overloadindicator lights and alarmresponds.

4 - 24 Z-80/60 Part No. 88619




Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols. 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 alarm should be sounding.The platform overload indicator light should beflashing at the platform controls and“PLATFORM OVERLOAD” should be displayedon the LCD screen at the ground controls.Proceed to step 9.

Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols. Remove the additional 10 lb / 4.5 kgtest weight. Repeat this procedure beginningwith step 6.



Result: All platform control functions should notoperate.



Result: All ground control functions should notoperate.

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

Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols.

There may be a 2 second delaybefore the overload indicator lightsand alarm turn off.


Result: All ground control functions shouldoperate normally.

14 Turn the key switch to platform control.


Result: Only for software versions 1.03 andlower. All ground control functions should notoperate. Refer to Repair Procedure 6-1, How toDetermine the Revision Level.

Result: Only for software versions 1.04 andhigher. All ground control functions should stilloperate. Refer to Repair Procedure 6-1, How toDetermine the Revision Level.

Part No. 88619 Z-80/60 4 - 25


REV BJib Boom Components

3-1Jib Boom

How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.


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

2 Remove the hose and cable cover retainingfasteners from the jib boom. Remove the hoseand cable cover from the machine.

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

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


a jib boomb platform rotator upper pivot pinc platform rotator lower pivot pind jib boom leveling arme jib cylinder pivot pinf jib boom cylinderg primary boom lower pivot pinh primary boom upper pivot pin

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4 - 26 Z-80/60 Part No. 88619


REV B

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

14 Slide both of the jib boom leveling arms off ofthe jib boom cylinder rod-end pivot pin and laythem off to the side.

15 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.

16 Attach a lifting strap from a second overheadcrane to the jib boom bellcrank.

17 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin. Remove the jib boomlift cylinder and jib boom bellcrank from themachine.

Crushing hazard. The jib boom liftcylinder and jib boom bellcrankcould become unbalanced and fallif not properly supported whenthey are removed from themachine.

Crushing hazard. The platformleveling cylinder may fall if notsupported when the rod-end pivotpin is removed.

5 Support the barrel end of the cylinder withanother suitable lifting device.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin.

7 Use a soft metal drift to remove the pin and letthe cylinder hang down.

Crushing hazard. The jib boomcould become unbalanced and fallif not properly supported when thejib boom lift cylinder barrel-endpivot pin is removed.

8 Secure the jib boom bellcrank to prevent it frommoving.

9 Remove the hose and cable clamp from the jibboom pivot pin.

10 Remove the pin retaining fastener from the jibboom pivot pin. Do not remove the pin.

11 Place blocks under the platform levelingcylinder for support.

12 Use a soft metal drift to remove the pin.Carefully remove the jib boom from the primaryboom.

Crushing hazard. The jib boomcould become unbalanced and fallif not properly supported whenremoved from the machine.

JIB BOOM COMPONENTS

Part No. 88619 Z-80/60 4 - 27


REV B JIB BOOM COMPONENTS

3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift Cylinder



1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Lowerthe jib boom until the platform is resting on theblocks just enough to support the platform.

Do not rest the entire weight of theboom 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 jib boom liftcylinder rod-end pivot pin half way out andlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.

Crushing hazard. The jib boom liftcylinder may fall if not supportedwhen the rod-end pivot pin isremoved.

5 Support the jib boom lift cylinder with a suitablelifting device.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pivotpin and let the cylinder hang down.

Crushing hazard. The platformand jib boom lift cylinder couldbecome unbalanced and fall if notproperly supported when the jibboom lift cylinder barrel-end liftpivot pin is removed.

7 Place blocks under the platform levelingcylinder for support.

8 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 become unbalancedand fall if not properly supportedwhen removed from the machine.

4 - 28 Z-80/60 Part No. 88619

September 2006Section 4 • Repair Procedures

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Boom Components

a primary boom lift cylinder link armb primary boom lift cylinderc primary boomd primary extension boome platform leveling cylinderf upper turntable coverg lower turntable coverh secondary boom lift cylinderi secondary boomj secondary extension boomk secondary boom hose coverl primary boom lift cylinder lever arm

m primary boom hose covern primary boom link arm pivot pino primary lift cylinder pivot pin - rod endp primary lift cylinder pivot pin - barrel endq primary extend cylinder pivot pin - rod endr platform level cylinder pivot pin - barrel ends secondary boom pivot pint secondary lift cylinder pivot pin - barrel endu secondary lift cylinder pivot pin - rod endv secondary extend cylinder pivot pin - rod endw secondary boom lever arm pivot pinx primary boom pivot piny primary extend cylinder pivot pins - barrel end

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Part No. 88619 Z-80/60 4 - 29

September 2006 Section 4 • Repair Procedures

BOOM COMPONENTS

4-1Primary Boom Cable 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 Remove the Cable TrackWhen removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.

1 Tag and disconnect the wire connectors fromthe platform control box.

2 Tag, disconnect and plug the hydraulic hosesfrom the counterbalance valve manifold locatedon the platform rotator. Cap the fittings on themanifold.


3 Remove the mounting fasteners from the outletbox. Remove the outlet box and lay to the side.

4 Remove the hose clamp from the platformsupport.

5 Tag and disconnect the electrical connectorfrom the platform angle sensor.

The platform angle sensor ismounted to the platform rotator.

6 Tag and disconnect the electrical connectors forthe foot switch and jib boom limit switch.

7 Remove the platform manifold mountingfasteners. Remove the manifold and lay to theside.

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

8 Remove the hose and cable cover retainingfasteners from the jib boom. Remove the hoseand cable cover from the machine.

9 Remove the hose and cable clamp from the jibboom pivot pin.

Crushing hazard. The jib boommay fall if not supported when thejib boom pivot pin is removed.

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4 - 30 Z-80/60 Part No. 88619


10 Tag, disconnect and plug the slave cylinderhydraulic hoses from the bulkhead fittings at theplatform end of the primary boom. Cap thebulkhead fittings.


11 Tag, disconnect and plug the jib boom cylinderhydraulic hoses. Cap the fittings.


12 Remove the cotter pin from the platform end ofthe cable track tube.

Always replace the cotter pin witha new one when installing thecable track.

13 Remove the fasteners from the cable trackguide at the platform end of the primary boom.Remove the cable track guide from themachine.

14 Tag and disconnect the electrical connectorfrom the limit switch at the pivot end of theprimary boom.

15 Remove all hose clamps for the primary boomlift cylinder hydraulic hoses.

The primary boom lift cylinderhydraulic hose clamps are locatedbehind the cable track.

16 Support the end cover from the secondaryboom at the pivot end of the primary boom.

17 Remove the cover retaining fasteners andremove the cover from the machine.

Crushing hazard. The secondaryboom hose cover could becomeunbalanced and fall if not properlysupported when removed from themachine.

18 Tag, disconnect and plug each hydraulic hosefrom the bulkhead fittings that lead to the cabletrack. Cap the fittings.


BOOM COMPONENTS REV C

Part No. 88619 Z-80/60 4 - 31


BOOM COMPONENTS

19 Tag and disconnect each electrical connector towiring that leads to the cable track.

20 Pull all hoses and electrical cables through theopening in the primary boom at the pivot end.

21 Secure the upper and lower cable trackstogether.

22 Attach a lifting strap from an overhead crane tothe cable track.

23 Remove all cable track mounting fasteners.

24 Carefully remove the cable track from themachine and lay it on a structure capable ofsupporting it.

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

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

How to Repair the Cable TrackComponent damage hazard.The boom cable track can bedamaged if it is twisted.

A cable track repair kit is availablethrough the Genie IndustriesService Parts Department.

1 Visually inspect the cable track and determinewhich 4-link section needs to be replaced.

2 Carefully remove the snap rings from each endof the damaged section of cable track.

3 Remove the retaining fasteners from the upperblack rollers from the 4-link section of cabletrack to be replaced. Remove the rollers.

4 Lift up the hoses and cables and carefullyremove the damaged 4-link section of cabletrack.

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

5 Remove the upper rollers from the replacementsection of cable track.

6 Lift up the hoses and cables and carefully insertthe new 4-link section of cable track.


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4 - 32 Z-80/60 Part No. 88619


7 Connect the ends of the replacement cabletrack section to the existing cable track usingthe snap rings.

8 Install the rollers onto the new section of cabletrack.

9 Operate the boom extend/retract functionthrough a full cycle to ensure smooth operationof the cable track.

BOOM COMPONENTS

4-2Primary Boom

How to Shim the Boom1 Measure each wear pad.

Result: Each wear pad meets minimumspecification. Proceed to step 2.

Result: Each wear pad does not meet minimumspecification. Replace any wear pad that doesnot meet minimum specification. Proceed tostep 2.

2 Extend the boom until the wear pads areaccessible.

3 Loosen the wear pad mounting fasteners.

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

5 Tighten the mounting fasteners.

6 Extend and retract the boom through an entirecycle. Check for tight spots that could causebinding or scraping.

Always maintain squarenessbetween the outer and innerboom tubes.

REV C

Part No. 88619 Z-80/60 4 - 33


BOOM COMPONENTS

How to Remove the PrimaryBoom

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.



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

2 Remove the fasteners securing the limit switchto the primary boom at the pivot end of theboom. Do not disconnect the wiring. Move thelimit switch to a safe location.

3 Tag and disconnect the wire harness from theprimary boom angle sensor (PBAS).

The primary boom angle sensor islocated inside the primary boom atthe pivot end.

Wear Pad Specifications

Primary boom wearpad specifications Minimum

Top, bottom andside wear pads 5/8 inch(platform end of boom) 15.9 mm

Side and bottom wear pads 1/2 inch(pivot end of boom) 12.7 mm

Top wear pads 5/8 inch(pivot end of boom) 15.9 mm

Secondary boom wearpad specifications Minimum

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

Bottom wear pads 1/2 inch(extension end of boom) 12.7 mm

Top wear pads 1/2 inch(pivot end of boom) 12.7 mm

Bottom and side wear pads 7/8 inch(pivot end of boom) 22.2 mm

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4 - 34 Z-80/60 Part No. 88619


11 Use a soft metal drift to remove the upperprimary boom lift cylinder linkage arm pivot pin.

Crushing hazard. The upperprimary boom lift cylinder linkagearm will fall if not properlysupported when the pivot pin isremoved.

12 Attach a 5 ton / 5000 kg overhead crane to thecenter point of the primary boom.

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

14 Use a soft metal drift to remove the primaryboom pivot pin.

Crushing hazard. The primaryboom could become unbalancedand fall if not properly supportedwhen the pivot pin is removed

15 Carefully remove the primary boom from themachine and place it on a structure capable ofsupporting it.

Crushing hazard. The primaryboom could become unbalancedand fall if not properly supportedwhen removed from the machine.

When the primary boom isinstalled, the primary boom anglesensor will need to be calibrated.

BOOM COMPONENTS

4 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


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

6 Remove the pin retaining fasteners from theprimary boom lift cylinder barrel-end pivot pin.

7 Place blocks under both ends of the primaryboom lift cylinder for support.

8 Use a soft metal drift to remove the barrel-endpivot pin. Rest the barrel end of the primaryboom cylinder on the blocks.


9 Attach a lifting strap from an overhead crane tothe upper primary boom lift cylinder linkagearm. Support the arm.

10 Remove the pin retaining fasteners from theupper primary boom lift cylinder linkage armwhere it connects to the primary boom.

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Part No. 88619 Z-80/60 4 - 35


BOOM COMPONENTS

7 Support and slide the extension boomassembly out of the primary boom tube andplace it on a structure capable of supporting it.

Crushing hazard. The extensionboom tube could becomeunbalanced and fall if not properlysupported when removed from theprimary boom tube.

During removal, the overheadcrane strap will need to beadjusted for proper balancing.

8 Remove the external snap rings from theextension cylinder rod-end pivot pin at theplatform end of the extension tube.

Crushing hazard. The extensioncylinder could become unbalancedand fall if not properly supportedwhen removed from primary boomextension tube.

9 Use a soft metal drift to remove the pin.


10 Attach a lifting strap from an overhead crane tothe extension cylinder.

How to Disassemble thePrimary Boom

Complete disassembly of theprimary boom is only necessaryif the outer or inner primary boomtube must be replaced. Theextension cylinder can beremoved without completelydisassembling the boom. See 4-4,How to Remove the Primary BoomExtension Cylinder.

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

2 Place blocks under the barrel end of the primaryboom extension cylinder for support.

3 Remove the pin retaining fastener from theextension cylinder barrel-end pivot pin at thepivot end of the primary boom.



5 Remove and label the location of the wear padsfrom the platform end of the primary boom.

Pay careful attention to thelocation and number of shimsused with each wear pad.

6 Attach a lifting strap from an overhead crane tothe extension boom assembly.

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4 - 36 Z-80/60 Part No. 88619


BOOM COMPONENTS

4-3Primary Boom Lift Cylinder

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

How to Remove the PrimaryBoom Lift Cylinder


When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer toSection 2, Hydraulic Hose andFitting Torque Specifications.

1 Raise the primary boom to a horizontal position.

2 Raise the secondary boom until the primaryboom lift cylinder rod-end pivot pin is above thecounterweight.

3 Attach a 5 ton / 5000 kg overhead crane to theplatform end of the primary boom. Support theboom. Do not apply any lifting pressure.

11 Working at the end of the extension boom tubeopposite the jib boom mount, support and slidethe extension cylinder out of the extensionboom tube.


During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

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Part No. 88619 Z-80/60 4 - 37


BOOM COMPONENTS

10 Use a soft metal drift to remove the barrel-endpivot pin. Remove the primary boom lift cylinderfrom the machine.

Crushing hazard. The lift cylinderwill become unbalanced and fall ifnot properly supported when thepin is removed.

4 Support both ends of the primary boom liftcylinder with a second overhead crane orsimilar lifting device.

5 Place blocks under the primary boom liftcylinder linkage arms for support.

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


7 Remove the pin retaining fastener from theprimary boom lift cylinder rod-end pivot pin.


Crushing hazard. The primaryboom will fall if not properlysupported when the pivot pin isremoved.

Crushing hazard. The lift cylinderwill fall if not properly supportedwhen the pivot pin is removed.

Crushing hazard. The primaryboom lift cylinder linkage armsmay fall if not properly supportedwhen the pivot pin is removed.

9 Remove the primary boom lift cylinder barrel-end pivot pin retaining fasteners.

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4 - 38 Z-80/60 Part No. 88619


BOOM COMPONENTS

3 Remove the access cover from the pivot end ofthe primary boom.

4 Place blocks under the barrel end of the primaryboom extension cylinder for support.

5 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


6 Working at the platform end of the boom,remove the external snap rings from theextension cylinder rod-end pivot pin.


Crushing hazard. The primaryboom could fall when removedfrom the extension boom if notproperly supported.

8 Remove the barrel-end pivot pin retainingfasteners.

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

4-4Primary Boom ExtensionCylinder

The primary boom extension cylinder extends andretracts the primary boom extension tube. Theprimary boom extension cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the PrimaryBoom Extension Cylinder



1 Raise the primary boom to a horizontal position.

2 Extend the primary boom until the primaryboom extension cylinder rod-end pivot pin isaccessible.

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Part No. 88619 Z-80/60 4 - 39


BOOM COMPONENTS

4-5Primary Boom Angle Sensor

A properly functioning primary boom angle sensor(PBAS) is essential to safe machine operation. Theprimary boom angle sensor is used to limit theangle of the primary boom relative to the angle ofthe secondary boom and gravity. The ECM at theground controls (TCON) monitors the position andangle of the primary boom using the signal fromPBAS. The PBAS signal is used to control theramping of the primary boom as well as velocitycontrol, limiting the speed of the primary boom to1.3 feet / 0.4 meters per second.

How to Replace the PrimaryBoom Angle Sensor

Perform this procedure on a firm,level surface with the boom in thestowed position.

1 Remove the retaining fasteners from the boomend cover at the pivot end of the primary boom.Remove the cover from the machine.

2 Locate the primary boom angle sensor insidethe primary boom at the boom pivot pin.

3 Tag and disconnect the electrical connectorfrom the sensor.

4 Remove the angle sensor mounting bracketretaining fasteners.

5 Remove the wing nut from the threaded rod. Donot disconnect the threaded rod from clevisyoke.

10 Working at the pivot end of the boom, supportand slide the extension cylinder out of the boomextension.

Crushing hazard. The extensioncylinder could fall when removedfrom the extension boom if notproperly supported.

Component damage hazard. Becareful not to damage the primaryboom angle sensor (PBAS) whenremoving the cylinder from theprimary boom.


Note the length of the cylinderafter removal. For ease ofinstallation, the cylinder must be atthe same length for reinstallation.

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4 - 40 Z-80/60 Part No. 88619


How to Calibrate the PrimaryBoom Angle Sensor

Perform this procedure on a firm,level surface with the boom in thestowed position.

A digital level will be required toperform this procedure.


2 Press and hold the enter button until theengine symbol appears the display at theground control box.

3 Enter sensor calibration mode by pressing thebuttons at the ground controls in the following

sequence: .

4 Press the scroll button until PRIMARY BOOM

ANGLE = 70° is shown on the display.

5 Press the plus button to select yes, then

press and hold the enter button to accept.

6 Press the scroll button until EXIT is shown on

the display. Press the plus button to select

yes, then press and hold the enter button toaccept.

Result: The alarm should sound.

Result: The alarm does not sound. Repeat thisprocedure beginning with step 1.

6 Remove the angle sensor and bracketassembly.

7 Remove the sensor retaining fasteners from thesensor bracket. Remove the angle sensor.

8 Install the new angle sensor onto the mountingbracket.

9 Install the angle sensor and bracket assembly.

The sensor should be installedrotated in a fully counter clock-wise position.

10 Insert the threaded rod through the threadedrod adjustment bracket.

11 Move threaded rod to the top of the slotted hole.Tighten the wing nut and hex nut towards eachother.

12 Connect the electrical connector to the anglesensor.

13 Calibrate the primary boom angle sensor. SeeHow to Calibrate the Primary Boom AngleSensor.

Tip-over hazard. Failure tocalibrate the primary boom sensorcould cause the machine to tipover resulting in death or seriousinjury.

BOOM COMPONENTS REV C

Part No. 88619 Z-80/60 4 - 41


16 Press and hold the enter button until theengine symbol appears the display at theground control box.


sequence: .





20 Press the scroll button until EXIT is shown on

the display. Press the plus button to select

yes, then press and hold the enter button toaccept.

21 At the ground controls, use auxiliary power andlower the boom until the faults are no longershown on the display.

Result: The flashing arrow in the display at theground controls will turn off.

Result: The flashing arrow in the display at theground controls does not turn off. Repeat thisprocedure beginning with step 1.

22 Start the engine and activate the primary boomdown function. Release the function enablebutton when the digital level displays 40°. Pushin the red Emergency Stop button to the offposition.

23 Press and hold the enter button and pull outthe red Emergency Stop button to the onposition.

7 Loosen the Primary Boom Angle Sensor(PBAS) assembly bracket fasteners attached tothe primary boom. Loosen the wing nut and hexnut on the threaded rod to allow the threadedrod to move upward. Tighten the fasteners.

8 Set a digital level on top of the mast so it isviewable from the ground controls.

9 Start the engine.

10 Raise the boom until the digital leveldisplays 70°.

11 Loosen the wing nut from threaded rod andmove the threaded rod down until the engineturns off.

12 Screw threaded rod into clevis yoke. Tightenthe wing nut to welded bracket. Tighten the jamnut to welded bracket. Tighten the PBASfasteners to boom.

Result: The ground control box display shouldread P9B & P11 FAULT.

13 Push in the red Emergency Stop button to theoff position. Wait until display turns off beforeproceeding.

14 Press and hold the enter button and pull outthe red Emergency Stop button to the onposition.


BOOM COMPONENTSREV C

4 - 42 Z-80/60 Part No. 88619


BOOM COMPONENTS

24 Press and hold the enter button until theengine symbol appears in the display at theground controls.


sequence: .





Result: The alarm should not sound.

Result: The alarm does sound. Repeat thisprocedure beginning with step 1.

28 Press the scroll button until EXIT is shown on the

display. Press the plus button to select yes,

then press and hold the enter button toaccept.

29 Start the engine.

30 Activate the boom up function until the digitallevel reads 65°.

Result: The primary boom should stop.

Result: The primary boom does not stop.Immediately release the function enable buttonand lower the boom. Repeat this procedurebeginning with step 1.

Tip-over hazard. If the boom doesnot stop at 65°, immediatelyrelease the function enable buttonand lower the primary boom.Failure to lower the boom couldcause the machine to tip overresulting in death or serious injury.

4-6Secondary Boom

How to Remove the SecondaryBoom

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.


Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.

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

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Part No. 88619 Z-80/60 4 - 43


BOOM COMPONENTS

2 Tag, disconnect and plug the hydraulic hoses atthe primary boom lift cylinder. Cap the fittingson the cylinder.







6 Attach a lifting strap from an overhead crane toto the lug on the barrel end of the primary boomlift cylinder. Raise the primary boom lift cylinderto a vertical position.

7 Remove the pin retaining fastener from theprimary boom rod end pivot pin.

8 Use a slide hammer to remove the pin. Removethe primary boom lift cylinder and linkage armsfrom the machine.

Crushing hazard. The primaryboom lift cylinder and linkage armscould become unbalanced and fallif not properly supported when thepin is removed.

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4 - 44 Z-80/60 Part No. 88619


BOOM COMPONENTS

4-7Secondary Boom Lift Cylinder

How to Remove the SecondaryBoom Lift Cylinder



1 Lower the secondary boom to the stowedposition.

2 Tag, disconnect, secure and remove the wireharnesses connecting the batteries. Removebattery fasteners and hooks from battery tray.Remove the batteries and store them in a safeand secure location away from the unit.


3 Remove the retaining fasteners securing theupper and lower turntable covers from theturntable at the platform end. Remove thecovers.






7 Remove the fuel tank filler cap.

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Part No. 88619 Z-80/60 4 - 45


BOOM COMPONENTS

8 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Refer toSection 2, Specifications.


Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

Be sure to only use a hand-operated pump suitable for usewith gasoline and diesel fuels.

9 Tag and disconnect the wire harness from thefuel level sending unit.

10 Tag, disconnect and plug the fuel hoses fromthe fuel tank.

11 Clean up any fuel that may have spilled.

12 Remove the fuel tank mounting fasteners.Carefully remove the fuel tank from themachine.

Component damage hazard. Thefuel tank is plastic and maybecome damaged if allowed to fall.

Clean the fuel tank and inspect forcracks and other damage beforeinstalling it onto the machine.

13 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder.


14 Place blocks under each end of the secondaryboom lift cylinder for support.

15 Remove the pin retaining fasteners from thesecondary boom lift cylinder rod-end pivot pin.


Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall if not properlysupported when removed from themachine.

17 Remove the pin retaining fastener from thesecondary boom lift cylinder barrel-end pivotpin.



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4 - 46 Z-80/60 Part No. 88619


BOOM COMPONENTS

19 Remove the secondary boom lift cylinder fromthe machine by pulling it through the platformend of the secondary boom.


Component damage hazard.When removing the secondaryboom lift cylinder from themachine, be careful not to damagethe counterbalance valves at thebarrel end of the cylinder.

Component damage hazard.Cables and hoses can bedamaged if the cylinder is pulledacross them.

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Part No. 88619 Z-80/60 4 - 47


5-1RPM Adjustment

Refer to Maintenance Procedure B-20, Check andAdjust the Engine RPM.

5-2Flex Plate

The flex plate acts as a coupler between theengine and the pump. It is bolted to the engineflywheel and has a splined center to drive thepump.

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How to Remove the Flex PlatePerform this procedure with theengine off and cool to the touch.


2 Tag and disconnect the battery cables from thebatteries.




4 Tag and disconnect the wiring plug at theelectronic displacement controller (EDC),located on the drive pump.

Engines

a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.185 inch / 4.7 mm gap - Deutz Engines

0.15 inch / 3.8 mm gap - GM Engines0.25 inch / 6.35 mm gap - Ford Engine0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine0.3 inch / 7.6 mm gap - Perkins 704-30 Engine

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4 - 48 Z-80/60 Part No. 88619


REV B

GM models:

5 Remove the fasteners securing the muffler tothe exhaust manifold.

Burn hazard. Hot engine parts cancause severe burns.

6 Remove muffler mounting bracket fasteners.Remove the muffler and bracket assembly fromthe engine.

7 Remove the hose clamp securing the air filterassembly to the air inlet tube.

8 Remove the air cleaner bracket fasteners.Remove the air cleaner and bracket assemblyfrom the engine.

9 Support the drive pump with an appropriatelifting device. Do not apply any lifting pressure.

10 Remove all of the remaining bell housing toengine fasteners. Carefully pull the pump awayfrom the engine and secure it from moving.

Component damage hazard.Hoses can be damaged if they arekinked or pinched

11 Remove the flex plate mounting fasteners,and remove the flex plate from the engineflywheel.

Ford models:

5 Tag and disconnect the wire harness from theoxygen sensor.

6 Remove the exhaust pipe heat shield fastenersfrom the top of the muffler.

Burn Hazard. Hot engine parts cancause severe burns.

7 Remove the muffler retainer bracket fasteners.

8 Remove the muffler fasteners securing themuffler to the exhaust manifold. Remove themuffler from the bracket.

9 Remove the muffler bracket retaining fasteners.Remove the muffler bracket from the engine.

10 Close the shutoff valve on the Liquid PetroleumGas (LPG) tank by turning it clockwise(if equipped).

11 Tag and disconnect the wiring from the LPGsolenoid.

12 Remove the engine starter retaining fastenersand remove the starter from the engine. Do notdisconnect the wiring.

13 Remove the dipstick tube bracket fasteners.

14 Attach a lifting strap from an overhead crane tothe lifting eyes on the engine.

15 Remove the bell housing engine tray fasteners.

16 Raise the engine slightly using the overheadcrane. Do not apply any lifting pressure.

17 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing engine fasteners.

18 Carefully pull the pump and bell housingassembly away from the engine and secure itfrom moving.


19 Remove the flex plate mounting fasteners.Remove the flex plate from the engine flywheel.

ENGINES

Part No. 88619 Z-80/60 4 - 49


REV B

Deutz F4L-913 models:

5 Tag and disconnect the wiring from the bellhousing.

6 Remove the exhaust tailpipe and air inlet tubeU-bolts from the air cleaner mounting bracket.


7 Remove the fuel filter/water separator retainingfasteners. Remove the filter/separator from theengine. Do not disconnect the fuel hoses.

8 Remove the air cleaner mounting bracketfasteners. Remove the air cleaner and bracketassembly from the engine.

9 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing to engine fasteners.




Deutz BF4L-2011 models:


6 Remove the U-bolt from the exhaust flex pipe atthe muffler.


7 Remove the muffler bracket retaining fastenersfrom bell housing. Remove the muffler andbracket assembly from the engine.

8 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing engine fasteners.




ENGINES

4 - 50 Z-80/60 Part No. 88619


REV B

Perkins 704-30 Models:

5 Remove the clamp securing the air intake elbowto the air cleaner assembly. Remove the airintake tube from the engine. Do not remove theelbow from the air intake tube.

6 Support the drive pump with an appropriatelifting device. Remove all of the bell housing toengine fasteners.




Perkins 804C-33 Models:


6 Remove the exhaust pipe clamp at the muffler.


7 Remove the muffler mounting bracketfasteners. Remove the muffler and bracketassembly from the engine.

8 Remove the hose clamps from the air cleanerelbow and the engine intake manifold.

9 Remove the air cleaner mounting bracketfasteners. Remove the air cleaner and bracketassembly from the engine.

10 Support the drive pump with an appropriatelifting device. Remove all of the remaining bellhousing to engine fasteners.




ENGINES

Part No. 88619 Z-80/60 4 - 51


REV B

How to Install the Flex Plate1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.

2 Ford models: Torque the flex plate mountingbolts in sequence to 14 ft-lbs / 19 Nm. Thentorque the flex plate mounting bolts in sequenceto 20 ft-lbs / 27 Nm.GM models: Torque the flex plate mountingbolts in sequence to 22 ft-lbs / 30 Nm. Thentorque the flex plate mounting bolts in sequenceto 31 ft-lbs / 42 Nm.Deutz models: Torque the flex plate mountingbolts in sequence to 26 ft-lbs / 35 Nm. Thentorque the flex plate mounting bolts in sequenceto 37 ft-lbs / 51 Nm.Perkins models: Torque the flex platemounting bolts in sequence to 13 ft-lbs / 18 Nm.Then torque the flex plate mounting bolts insequence to 19 ft-lbs / 26 Nm.

3 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.

4 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque set screw to61 ft-lbs / 83 Nm.

5 Install the pump onto the bell housing/mountingplate and torque the pump retaining fastenersto specification. Refer to Section 2,Specifications for torque specifications.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

ENGINES

a b c d e

fa pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.185 inch / 4.7 mm gap - Deutz Engines

0.15 inch / 3.8 mm gap - GM Engines0.25 inch / 6.35 mm gap - Ford Engine0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine0.3 inch / 7.6 mm gap - Perkins 704-30 Engine

4 - 52 Z-80/60 Part No. 88619


REV BENGINES

Ford, Perkins andDeutz BF4L-2011 models

Deutz F4L-913 models

GM models

6 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pumpend plate for your engine.

7 Install the pump and bellhousing assembly ontothe engine. Torque the bellhousing mountingbolts in sequence to 28 ft-lbs / 38 Nm. Refer tothe illustrations on the next page.

Component damage hazard.When installing the pump, do notforce the pump coupler into theflexplate or damage to the pumpshaft seal may occur.

Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.

1

2

3

4 5

6 1

2

34

5

1

2

3

4 5

6

1

2

3

4

56

7

8

Part No. 88619 Z-80/60 4 - 53


REV B ENGINES

8 Torque the bellhousing mounting bolts insequence to 40 ft-lbs / 54 Nm.

Deutz F4L-913 andPerkins 704-30 models

Ford models

10

6 1

8

4

11

7 5

92

12

3

Deutz BF4L-2011 models

Perkins 804C-33 andGM models

10

6 1

8

4

11

7 5

92

12

3

10

6 1

8

4

11

7 5

92

12

3

1 6

5 2

34

7 8

9

4 - 54 Z-80/60 Part No. 88619


REV BENGINES

5-3Engine Fault Codes -Gasoline/LPG Models

How to Retrieve Engine FaultCodesWhen an engine malfunction is detected by theElectronic Control Module (ECM), a fault code isrecorded and the check engine light will turn on atthe platform controls. Use the following procedureto retrieve the engine fault code to determine theengine malfunction.

Perform this procedure with thekey switch in the off position


2 Locate the run/test toggle switch located on therelay box cover.

3 Pull out the red Emergency Stop button to theon position at the ground controls.

4 Hold the run/test toggle switch to the testposition and turn the key switch to the groundcontrols position.

Result: The check engine light should turn on.The check engine light should begin to blink.

The check engine light will blink a"123" code three times beforeblinking a fault code if one ispresent.

5 Continue to hold the run/test toggle switch in thetest position and count the blinks.

If any fault codes are present, theECM will blink a three digit code. Itwill blink the first digit of a threedigit code, pause, blink the seconddigit, pause, and then blink thethird digit. For example: the checkengine light blinks 5 consecutivetimes, blinks 3 times and then 1time. That would indicate code531.

Before the fault codes aredisplayed, the check engine lightwill blink a code 123 times. Afterthe fault codes, the check enginelight will blink a code 123 threetimes again indicating the end ofthe stored codes.

6 Refer to Section 5, Fault Codes for definition ofengine fault codes.

How to Clear Engine Fault Codesfrom the ECM

Perform this procedure with theengine off and the key switch inthe off position.

1 Open the engine side turntable cover and locatethe battery.

2 Disconnect the negative battery cable from thebattery for a minimum of 5 minutes.


3 Connect the negative battery cable to thebattery.

Part No. 88619 Z-80/60 4 - 55


REV AGround Controls

6-1Circuit Boards

The ground control box (TCON) is thecommunication and operations center for themachine. The ground control box contains two keyswitches. The key switch towards the top of thecontrol box is for selection of ground or platformcontrols. The key switch at the bottom of thecontrol box is the Service Bypass key switch. It isused to correct an out-of-level platform. If themachine trips an envelope safety switch, theoperator at the ground controls can turn and holdthe Service Bypass key switch in the RECOVER

position, which will automatically retract the boomand lower the platform to the ground.

The ground control box contains a replaceablemembrane decal with touch sensitive buttons forvarious machine functions. The ground control boxalso contains two printed circuit boards:

The LCD (Liquid Crystal Display) circuit boardis mounted to the inside of the control box lid whichcontrols the LCD display screen.

The ECM circuit board is the main circuit boardfor the machine. There are relays on the ECMcircuit board that can be replaced. All operatingparameters and configuration of options for themachine are stored in the ECM memory.

The ECM circuit board inside theground control box (TCON) cannotbe replaced by itself. If the ECMcircuit board is faulty and needs tobe replaced, contact the GenieIndustries Service Department.

When an ECM circuit board isreplaced, the proportional valveswill need to be calibrated.See 1-3, How to Calibrate aJoystick.

How to Determine the RevisionLevel1 Turn the key switch to ground controls and pull

out the red Emergency Stop buttons to the onposition at both platform and ground controls.

Result: The revision level of the ECM willappear in the LED display window.

How to Remove the LCD DisplayScreen Circuit Board1 Push in the red Emergency Stop button to the


2 Remove the ground control box lid fasteners.Open the control box lid.



3 Carefully disconnect the ribbon cable from theLCD display circuit board.

4 Remove the LCD display circuit board retainingfasteners.

5 Carefully remove the LCD display circuit boardfrom the ground control box lid.

4 - 56 Z-80/60 Part No. 88619


REV A

6-2Membrane Decal

The membrane decal is a special decal thatconsists of a decal with an electronic membraneon the backside. The membrane contains touchsensitive areas that, when pushed, activates themachine functions. The membrane buttonsactivate machine functions similar to toggleswitches, but do not have any moving parts.

How to Replace the MembraneDecal1 Turn the key switch at to the off position.

2 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols.

3 Remove the ground control box lid fasteners.Open the control box lid.

4 Tag and disconnect the two ribbon cables fromthe membrane decal at the ECM circuit board.



5 Carefully remove the membrane decal from thecontrol box lid while guiding the ribbon cablesout of the control box lid.

6 Remove any decal adhesive from the controlbox lid with a mild solvent.

Component damage hazard.Certain solvents can damage LCDdisplay. Do not allow any solventto come in contact with the LCDdisplay screen.

7 Install the new membrane decal onto the controlbox lid while guiding the ribbon cables throughthe control box lid.

8 Connect the ribbon cables to the ECM circuitboard.

9 Close the control box lid and install the retainingfasteners.

GROUND CONTROLS

Part No. 88619 Z-80/60 4 - 57


REV BHydraulic Pumps

7-1Function Pump

How to Remove the FunctionPump


1 Models without hydraulic tank shutoffvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. Refer to Section 2,Specifications.

Models with hydraulic tank shutoff valves:Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

2 Tag, disconnect and plug the hydraulic hoses atthe function pump. Cap the fittings on thepump.


3 Remove the pump mounting fasteners.Carefully remove the pump.

Component damage hazard.Be sure to open the two hydraulictank valves (if equipped) andprime the pump after installing thepump. See 7-2, How to Prime thePump.

open closed

4 - 58 Z-80/60 Part No. 88619


REV B

7-2Drive Pump

The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. Any internal serviceto the pump should only be performed at anauthorized Sauer-Danfoss service center. Contactthe Genie Industries Service Department to locateyour local authorized service center.

How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.


1 Disconnect the wire harness at the electronicdisplacement controller (EDC), located on thedrive pump.

2 Models without hydraulic tank shutoffvalves: Remove the drain plug from thehydraulic tank and completely drain the tankinto a suitable container. Refer to Section 2,Specifications.

Models with hydraulic tank shutoff valves:Close the two hydraulic tank valves located atthe hydraulic tank.

Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

3 Tag, disconnect and plug the hydraulic hoses atthe drive and function pumps. Cap the fittingson the pumps.


open closed

HYDRAULIC PUMPS

Part No. 88619 Z-80/60 4 - 59


REV B HYDRAULIC PUMPS

4 Support the pumps with a suitable lifting deviceand remove the two drive pump mountingfasteners.

5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.

6 Remove the drive pump assembly from themachine.

Component damage hazard.Be sure to open the two hydraulictank valves and prime the pumpafter installing the pump.

Before installing the pump, verifyproper pump coupler spacing. See5-2, Flex Plate.

How to Prime the Pump1 Connect a 0 to 600 psi / 0 to 50 bar pressure

gauge to the test port on the drive pump.

2 Remove the safety pin (if equipped) from theengine tray latch.

The engine tray latch is locatedunder the engine tray at thecounterweight end of the machine.




5 Install the bolt removed in step 4 into the anchorhole to secure the engine tray from moving.


6 Deutz and Perkins models: Tag anddisconnect the engine wiring harness from thefuel shutoff solenoid at the injector pump.

GM and Ford models: Close the valve on theLPG tank. Disconnect the hose from the tank.Move the fuel select switch to the LPG position.

7 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches 320 psi / 22 bar.

8 Deutz and Perkins models: Connect theengine wiring harness to the fuel solenoid.

GM and Ford models: Connect the LPG hoseto the LPG tank and open the valve on the tank.

9 Start the engine from the ground controls andcheck for hydraulic leaks.

4 - 60 Z-80/60 Part No. 88619


REV CManifolds

8-1Function Manifold - View 1

The function manifold is located next to the ground control box.

Index SchematicNo. Description Item Function Torque

1 Differential sensing valve .................. A ........... Secondary boomup/extend and down/retract .............. 30-35 ft-lbs / 41-47 Nm

2 Relief valve, 2500 psi / 172 bar ......... B ........... Secondary boom up .......................... 20-25 ft-lbs / 27-34 Nm

3 Solenoid valve, 2 position 2 way ....... C ........... Secondary boom up circuit ............... 20-25 ft-lbs / 27-34 Nm

4 Relief valve, 2500 psi / 172 bar ......... D ........... Secondary boom down ..................... 20-25 ft-lbs / 27-34 Nm

5 Relief valve, 1300 psi / 89.6 bar ........ E ........... Primary boom down .......................... 20-25 ft-lbs / 27-34 Nm

6 Flow regulator valve,0.1 gpm / 0.38 L/min .......................... F ........... Bleeds off check valves in

differential sensing circuits to tank .... 20-25 ft-lbs / 27-34 Nm

7 Proportional solenoid valve ............... G ........... Primary boom up/down ..................... 30-35 ft-lbs / 41-47 Nm

8 Solenoid valve, 2 position 3 way ....... H ........... Primary boom retract ........................ 33-37 ft-lbs / 45-50 Nm

9 Check valve ....................................... I ............ Differential sensing circuit,primary boom extend/retract ............... 8-10 ft-lbs / 11-14 Nm

10 Solenoid valve, 2 position 3 way ....... J ............ Primary boom extend ........................ 50-55 ft-lbs / 68-75 Nm

11 Differential sensing valve .................. K ........... Turntable rotate left/right ................... 30-35 ft-lbs / 41-47 Nm

12 Differential sensing valve .................. L ........... Primary boom extend/retract ............ 30-35 ft-lbs / 41-47 Nm

13 Differential sensing valve .................. M .......... Primary boom up/down ..................... 30-35 ft-lbs / 41-47 Nm

14 Priority flow regulator valve,3 gpm / 11.4 L/min ............................. N ........... Controls flow to the oscillate

and platform manifolds ..................... 30-35 ft-lbs / 41-47 Nm

15 Solenoid valve, 3 position 4 way ....... O ........... Secondary boom extend/retract ........ 33-37 ft-lbs / 45-50 Nm

Part No. 88619 Z-80/60 4 - 61


REV C MANIFOLDS

A B

O

N

C D E F G H I J

L

M

K

1 2 3 4 5 6 108 9 117

15

14

12

13

4 - 62 Z-80/60 Part No. 88619


REV CMANIFOLDS

8-2Function Manifold - View 2


1 Solenoid valve, 2 position 2 way ....... P ........... Secondary boom extend circuit ........ 20-25 ft-lbs / 27-34 Nm

2 Relief valve, 2600 psi / 179 bar ......... Q ........... Secondary boom extend ................... 20-25 ft-lbs / 27-34 Nm

3 Proportional solenoid valve ............... R ........... Turntable rotate left/right ................... 20-25 ft-lbs / 27-34 Nm

4 Solenoid valve, 3 position 4 way ....... S ........... Turntable rotate left/right ................... 26-30 ft-lbs / 35-41 Nm

5 Check valve ....................................... T ........... Differential sensing circuit,turntable rotate .................................... 8-10 ft-lbs / 11-14 Nm

6 Relief valve, 1300 psi / 89.6 bar ........ U ........... Primary boom extend ........................ 30-35 ft-lbs / 41-47 Nm

7 Solenoid valve, 2 position 3 way ....... V ........... Primary boom up ............................... 33-37 ft-lbs / 45-50 Nm

8 Proportional solenoid valve ............... W .......... Primary boom extend/retract ............ 30-35 ft-lbs / 41-47 Nm

9 Solenoid valve, 2 position 3 way ....... X ........... Primary boom down .......................... 33-37 ft-lbs / 45-50 Nm

10 Check valve ....................................... Y ........... Differential sensing circuit,primary boom up/down ....................... 8-10 ft-lbs / 11-14 Nm

11 Solenoid valve, 2 position 3 way ....... Z ........... Secondary boom up .......................... 33-37 ft-lbs / 45-50 Nm

12 Solenoid valve, 2 position 3 way ....... AA ......... Secondary boom down ..................... 33-37 ft-lbs / 45-50 Nm

13 Proportional solenoid valve ............... AB ......... Secondary boom extend/retract ........ 30-35 ft-lbs / 41-47 Nm

14 Check valve ....................................... AC ........ Differential sensing circuit,secondary boom extend/retract .......... 8-10 ft-lbs / 11-14 Nm

15 Check valve, 5 psi / 0.34 bar ............. AD ........ Blocks flow from auxiliarypump #1 to function pump #1 ........... 30-35 ft-lbs / 41-47 Nm

16 Check valve, 5 psi / 0.34 bar ............. AE ......... Blocks flow from function pump #1to auxiliary pump #1 .......................... 20-25 ft-lbs / 27-34 Nm

17 Check valve, 5 psi / 0.34 bar ............. AF ......... Blocks flow from auxiliarypump #2 to function pump #2 ........... 20-25 ft-lbs / 27-34 Nm

18 Relief valve, 3000 psi / 207 bar ......... AG ........ Oscillate and platform manifoldsystem relief ...................................... 20-25 ft-lbs / 27-34 Nm

19 Check valve, 5 psi / 0.34 bar ............. AH ........ Blocks flow from function pump #2to auxiliary pump #2 .......................... 20-25 ft-lbs / 27-34 Nm

20 Differential sensing valve,150 psi / 10.3 bar ............................... AI .......... Meters flow to functions ....................30-35 ft-lbs / 41-47 Nm

21 Relief valve, 3200 psi / 220.6 bar ...... AJ ......... Boom functions system relief ............ 30-35 ft-lbs / 41-47 Nm

Part No. 88619 Z-80/60 4 - 63


REV C MANIFOLDS

P Q

R

S

T

U

V

W

X

Z

Y

AA

AB

ACADAEAFAGAHAJ AI

1415161718192021

21

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7

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8

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6

4 - 64 Z-80/60 Part No. 88619


REV C

8-3Valve Adjustments -Function Manifold

How to Adjust the SystemRelief Valve


1 Locate the boom retracted limit switch(LSP1RO) limit switch on the outside of theprimary boom at the pivot end of the primaryboom.

2 Tag and disconnect the wire harness from thelimit switch, and install a wire jumper betweenpins 1 and 2 of the limit switch connector. Placeanother wire jumper between pins 3 and 4 ofthe limit switch connector.

3 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the PTEST port on the functionmanifold.


5 Press and release the rpm select button untilthe engine changes to high idle.

6 Simultaneously push and hold the functionenable/high speed button and the primary boomretract button with the primary boom fullyretracted. Observe the reading on the pressuregauge. Refer to Section 2, Specifications.

MANIFOLDS

7 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item AJ).

8 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.

9 Repeat steps 4 through 8 confirm the reliefvalve pressure.

10 Remove the pressure gauge.

11 Remove the wire jumpers from the limit switchconnector.

12 Securely install the LSP1RO pig tail into thewire harness.

How to Adjust the Primary BoomDown Relief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the LS port on the function manifold.



4 Raise the primary boom approximately5 feet / 1.5 m.

Part No. 88619 Z-80/60 4 - 65


REV C

5 Place a 4 x 4 inch / 10 x 10 cm block on theprimary boom rest pad. Lower the primaryboom onto the block.

Crushing hazard. Keep handsclear of the block when loweringthe primary boom.

6 Simultaneously push and hold the functionenable/high speed button and the primary boomdown button. Observe the pressure reading onthe pressure gauge. Refer to Section 2,Specifications.

7 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item E).



9 Start the engine and repeat steps 6 through 8 toconfirm the relief valve pressure.

10 Start the engine and raise the primary boomapproximately 12 inches / 30 cm. Remove theblock and lower the primary boom to thestowed position.

11 Turn the engine off and remove the pressuregauge.

How to Adjust the Primary BoomExtend Relief Valve1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the LS port on the function manifold.


3 Raise the boom to a horizontal position. Turnthe engine off.

4 Locate the boom extended limit switch(LSP1EO) on the outside of the primary boom.

5 Remove the limit switch mounting bracketretaining fasteners.

6 Pull the limit switch and bracket assembly out ofthe boom tube and let it hang down.

7 Start the engine from the ground controls andpress and release the rpm select button untilthe engine changes to high idle.

8 Simultaneously push and hold the functionenable/high speed button and the primary boomextend button with the primary boom fullyextended. Observe the reading on the pressuregauge. Refer to Section 2, Specifications.

9 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item U).

MANIFOLDS

4 - 66 Z-80/60 Part No. 88619


REV C



11 Repeat steps 7 through 8 to confirm relief valvepressure.

12 Start the engine and fully retract the primaryboom. Turn the engine off.

13 Install the limit switch and bracket assembly tothe primary boom.


How to Adjust the SecondaryBoom Up Relief Valve1 Remove the cover retaining fasteners from the

secondary boom end cover. Remove the coverfrom the machine.

2 Locate the wire connector for secondary boomlimit switch LSS2AO. Disconnect the connector.

The secondary boom limit switchLSS2AO is the upper limit switchlocated on the inside of the riserplate at the engine side of themachine.

3 Install a jumper wire between pins 3 and 4 ofthe LSS2AO Deutsch connector on the wireharness end.



6 Simultaneously push and hold the functionenable/high speed button and the secondaryboom up/extend button and fully raise thesecondary boom.

7 Continue holding the function enable/highspeed button and the secondary boom up/extend button while observing the reading onthe pressure gauge. Refer to Section 2,Specifications.

8 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item B).





12 Remove the jumper wire from LSS2AO limitswitch connector. Connect the limit switch tothe wire harness.

13 Install the secondary boom end cover andtighten the retaining fasteners.

MANIFOLDS

Part No. 88619 Z-80/60 4 - 67


REV C

How to Adjust the SecondaryBoom Down Relief Valve1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the LS port on the function manifold.



4 Raise the secondary boom approximately12 inches / 30 cm.

5 Place a 4 x 4 inch / 10 x 10 cm block on thesecondary boom rest pad. Lower the secondaryboom onto the block.

Crushing hazard. Keep handsclear of the block when loweringthe secondary boom.

6 Simultaneously push and hold the functionenable/high speed button and the secondaryboom down button. Observe the reading on thepressure gauge. Refer to Section 2,Specifications.

7 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item D).

MANIFOLDS



9 Start the engine and repeat step to confirmrelief valve pressure.

10 Start the engine and raise the secondary boomapproximately 12 inches / 30 cm. Remove theblock and lower the secondary boom to thestowed position.


How to Adjust the SecondaryBoom Extend Relief Valve

Perform this procedure with thesecondary boom fully raised.



3 Simultaneously push and hold the functionenable/high speed button and the secondaryboom up/extend button with the secondaryboom fully raised and extended. Observe thepressure reading on the pressure gauge. Referto Section 2, Specifications.

4 - 68 Z-80/60 Part No. 88619


REV C

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item Q).





How to Adjust the PlatformManifold Relief Valve


1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the PTEST 2 port on the functionmanifold.


3 Simultaneously push and hold the functionenable/high speed button and the jib boomdown button with the jib boom fully lowered.Observe the reading on the pressure gauge.Refer to Section 2, Specifications.

MANIFOLDS

4 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item AG).





Part No. 88619 Z-80/60 4 - 69


REV C MANIFOLDS


4 - 70 Z-80/60 Part No. 88619


REV CMANIFOLDS

8-4Platform Manifold

The platform Manifold is mounted to the platform mounting weldment.


1 Check valve ....................................... GA ........ Platform level circuit

2 Proportional solenoid valve,3 position 4 way ................................. GB ........ Jib boom up/down

— Core Tube, Top ............................................................................................................7.5-9 ft-lbs / 10-12 Nm— Core Tube, Bottom .......................................................................................................3.7-4.5 ft-lbs / 5-6 Nm— Coil Nut .........................................................................................................................3.7-4.5 ft-lbs / 5-6 Nm

(Hand Tighten Only)

3 Check valve ....................................... GC ........ Jib boom circuit

4 Accumulator, 500 psi / 34.5 bar ......... GD ........ Hydraulic dampening ........................23 ft-lbs / 31 Nm

5 Differential sensing valve, N.O. ......... GE ........ Jib boom differentialsensing circuit ...................................23-25 ft-lbs / 31-34 Nm

6 Differential sensing valve, N.O. ......... GF ........ Platform level differentialsensing circuit ...................................23-25 ft-lbs / 31-34 Nm

7 Differential sensing valve, N.O. ......... GH ........ Platform rotate differentialsensing circuit ...................................23-25 ft-lbs / 31-34 Nm

8 Shuttle valve ...................................... GI .......... Jib boom load sense circuit ..............7.5-9 ft-lbs / 10-12 Nm

9 Orifice plug, 0.030 inch / 0.762 mm... GJ ......... Platform rotate left circuit

10 Orifice plug, 0.030 inch / 0.762 mm... GK ........ Platform rotate right circuit

11 Shuttle valve ...................................... GL ......... Platform level load sense circuit .......7.5-9 ft-lbs / 10-12 Nm

12 Diagnostic nipple ............................... GM ........ Testing

13 Shuttle valve ...................................... GN ........ Platform rotate load sense circuit .....7.5-9 ft-lbs / 10-12 Nm

14 Differential sensing valve, N.C. ......... GO ........ Directs flow to functions ....................23-25 ft-lbs / 31-34 Nm

15 Proportional solenoid valve,3 position 4 way ................................. GP ........ Platform rotate left/right


(Hand Tighten Only)

16 Proportional solenoid valve,3 position 4 way ................................. GQ ........ Platform level up/down


(Hand Tighten Only)

17 Check valve ....................................... GR ........ Platform rotate circuit

Part No. 88619 Z-80/60 4 - 71


REV C MANIFOLDS

GP

GO

GQ

GB

GR

GA GC GD

GE

GF

GH

GJ

GK

GI

GLGM

GN

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14

13

15

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17

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4 - 72 Z-80/60 Part No. 88619


REV CMANIFOLDS

8-5Turntable Rotation Manifold

The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.


1 Shuttle valve, 2 position 3 way ....... KK ........... Turntable rotation brake release ...... 10-13 ft-lbs / 14-18 Nm

2 Counterbalance valve ...................... LL ........... Turntable rotate right ....................... 35-40 ft-lbs / 47-54 Nm

3 Counterbalance valve ..................... MM .......... Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm

LLKK MM

1 2 3

Part No. 88619 Z-80/60 4 - 73


REV C MANIFOLDS

8-6Platform Rotate Manifold

The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.


1 Counterbalance valve ..................... HA ........... Turntable rotation brake release ...... 35-40 ft-lbs / 47-54 Nm

2 Counterbalance valve ..................... HB ........... Turntable rotate left .......................... 35-40 ft-lbs / 47-54 Nm

HA

HB2

1

4 - 74 Z-80/60 Part No. 88619


REV CMANIFOLDS

8-7Two Wheel Steer and Oscillate Manifold

The Two Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of themachine.


1 Solenoid valve, 3 position 4 way ....... BA ......... Steer left/right,right side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm

2 Solenoid valve, 3 position 4 way ....... BB ......... Steer left/right,left side steer cylinder ....................... 26-30 ft-lbs / 35-41 Nm

3 Solenoid valve, 2 position 3 way ....... BC ........ Oscillate cylinder, left side ................ 26-30 ft-lbs / 35-41 Nm

4 Solenoid valve, 2 position 3 way ....... BD ........ Oscillate cylinder, right side .............. 26-30 ft-lbs / 35-41 Nm

5 Relief valve,750 to 860 psi / 51.71 to 59.3 bar ..... BE ......... Oscillate circuit .................................. 20-25 ft-lbs / 27-34 Nm

6 Flow regulator valve,2.3 gpm / 8.7 L/min ............................ BF ......... Left side steer cylinder

extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm

7 Flow regulator valve,1.2 gpm / 4.5 L/min(before software revision 1.04)1.5 gpm / 5.7 L/min(after software revision 1.03) ............. BG ........ Left side steer cylinder

retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm

8 Check valve ....................................... BH ........ Load sensing circuit,left side steer cylinder retract .............. 8-10 ft-lbs / 11-14 Nm

9 Check valve ....................................... BI .......... Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

10 Check valve ....................................... BJ ......... Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

11 Flow regulator valve,2.3 gpm / 8.7 L/min ............................ BK ......... Right side steer cylinder

extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm

12 Flow regulator valve,1.2 gpm / 4.5 L/min(before software revision 1.04)1.5 gpm / 5.7 L/min(after software revision 1.03) ............. BL ......... Right side steer cylinder

retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm

13 Check valve, 65 psi / 4.5 bar ............. BM ........ Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

14 Check valve, 65 psi / 4.5 bar ............. BN ........ Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

This list continues on the next page.

Part No. 88619 Z-80/60 4 - 75


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BA BB BC BD

BE

BF

BG

BK

BL

BI

BH

BJ

BM

BN

BP

BO

BQ

14

13

10 9

1 2 3 4

17

16

15

11

12

5

8

7

6

4 - 76 Z-80/60 Part No. 88619


REV CMANIFOLDS

Two Wheel Steer and Oscillate Manifold, continued


15 Check valve ....................................... BO ........ Load sensing circuit,right side steer cylinder retract ........... 8-10 ft-lbs / 11-14 Nm

16 Check valve ....................................... BP ......... Load sensing circuit,right side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm

17 Check valve ....................................... BQ ........ Load sensing circuit,left side steer cylinder extend ............. 8-10 ft-lbs / 11-14 Nm

Part No. 88619 Z-80/60 4 - 77


REV C

BA BB BC BD

BE

BF

BG

BK

BL

BI

BH

BJ

BM

BN

BP

BO

BQ

14

13

10 9

1 2 3 4

17

16

15

11

12

5

8

7

6

MANIFOLDS

4 - 78 Z-80/60 Part No. 88619


REV CMANIFOLDS

How to Adjust the OscillateRelief Valve


Perform this procedure with theengine running at high RPM.

This procedure will require twopeople.

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

2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port on the two wheel steerand oscillate manifold.


4 Press down the foot switch and manuallyactivate one of the oscillate limit switches. Holdthe switch in the activated position and observethe reading on the pressure gauge. Refer toSection 2, Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BE).





9 Install the drive chassis cover.

Part No. 88619 Z-80/60 4 - 79


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4 - 80 Z-80/60 Part No. 88619


REV C

8-8Four Wheel Steer and Oscillate Manifold

The Four Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of themachine.


1 Solenoid valve, 3 position 4 way ....... CA ........ Steer left/right, square endright side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm

2 Solenoid valve, 3 position 4 way ....... CB ........ Steer left/right, square endleft side steer cylinder ....................... 26-30 ft-lbs / 35-41 Nm

3 Check valve ....................................... CC ........ Load sensing circuit, circle endright side steer cylinder retract ........... 8-10 ft-lbs / 11-14 Nm

4 Check valve, 65 psi / 4.5 bar ............. CD ........ Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

5 Solenoid valve, 2 position 3 way ....... CE ........ Oscillate cylinder, left side ................ 26-30 ft-lbs / 35-41 Nm

6 Solenoid valve, 2 position 3 way ....... CF ......... Oscillate cylinder, right side .............. 26-30 ft-lbs / 35-41 Nm

7 Check valve, 65 psi / 4.5 bar ............. CG ........ Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

8 Relief valve,750 to 860 psi / 51.71 to 59.3 bar ..... CH ........ Oscillate circuit .................................. 20-25 ft-lbs / 27-34 Nm

9 Flow regulator valve,2.3 gpm / 8.7 L/min ............................ CI .......... Circle end, left side steer

cylinder extend circuit ....................... 20-25 ft-lbs / 27-34 Nm10 Flow regulator valve,

1.2 gpm / 4.5 L/min(before software revision 1.04)1.5 gpm / 5.7 L/min(after software revision 1.03) ............. CJ ......... Circle end, left side steer

cylinder retract circuit ........................ 20-25 ft-lbs / 27-34 Nm

11 Flow regulator valve,1.2 gpm / 4.5 L/min(before software revision 1.04)1.5 gpm / 5.7 L/min(after software revision 1.03) ............. CK ........ Circle end, right side steer


12 Flow regulator valve,2.3 gpm / 8.7 L/min ............................ CL ......... Circle end, right side steer

cylinder extend circuit ....................... 20-25 ft-lbs / 27-34 Nm

13 Check valve ....................................... CM ........ Load sensing circuit, circle endleft side steer cylinder retract .............. 8-10 ft-lbs / 11-14 Nm

14 Check valve ....................................... CN ........ Load sensing circuit, circle endleft side steer cylinder extend ............. 8-10 ft-lbs / 11-14 Nm

This list continues on the next page.

MANIFOLDS

Part No. 88619 Z-80/60 4 - 81


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CA CB CC CECD CF

CH

CG

CI

CJ

CK

CL

CPCQ

CN

CM

CO

CX

CR

CW

CV

CT

CS

CU

CZ

CAA

CAD

CAB

CAC

CY

CAE

26

27

30

31

1618 17

1 2 543 6

7

8

9

10

12

11

14

13

15

28

29

23

25

24

22

21

20

19

4 - 82 Z-80/60 Part No. 88619


REV CMANIFOLDS

Four Wheel Steer and Oscillate Manifold, continued


15 Check valve ....................................... CO ........ Load sensing circuit, circle endright side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm

16 Solenoid valve, 3 position 4 way ....... CP ........ Steer left/right, circle endleft side steer cylinder ....................... 26-30 ft-lbs / 35-41 Nm

17 Solenoid valve, 3 position 4 way ....... CQ ........ Steer left/right, circle endright side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm

18 Flow regulator valve,1.2 gpm / 4.5 L/min ............................ CR ........ Square end, left side steer


19 Check valve ....................................... CS ........ Load sensing circuit, square endleft side steer cylinder retract ............ 20-25 ft-lbs / 27-34 Nm

20 Check valve, 65 psi / 4.5 bar ............. CT ......... Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

21 Check valve, 65 psi / 4.5 bar ............. CU ........ Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

22 Flow regulator valve,2.3 gpm / 8.7 L/min ............................ CV ........ Square end, right side steer


23 Flow regulator valve,1.2 gpm / 4.5 L/min(before software revision 1.04)1.5 gpm / 5.7 L/min(after software revision 1.03) ............. CW ....... Square end, right side steer


24 Flow regulator valve,2.3 gpm / 8.7 L/min ............................ CX ........ Square end, left side steer


25 Check valve ....................................... CY ........ Load sensing circuit, square endright side steer cylinder retract ........... 8-10 ft-lbs / 11-14 Nm

26 Check valve, 65 psi / 4.5 bar ............. CZ ......... Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

27 Check valve, 65 psi / 4.5 bar ............. CAA ...... Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

28 Check valve ....................................... CAB ...... Load sensing circuit, square endright side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm

29 Check valve ....................................... CAC ...... Load sensing circuit, square endleft side steer cylinder extend ............. 8-10 ft-lbs / 11-14 Nm

30 Check valve, 65 psi / 4.5 bar ............. CAD ...... Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

31 Check valve, 65 psi / 4.5 bar ............. CAE ...... Prevents steer cylinder frommoving when not steering ................. 20-25 ft-lbs / 27-34 Nm

Part No. 88619 Z-80/60 4 - 83


REV C MANIFOLDS

CA CB CC CECD CF

CH

CG

CI

CJ

CK

CL

CPCQ

CN

CM

CO

CX

CR

CW

CV

CT

CS

CU

CZ

CAA

CAD

CAB

CAC

CY

CAE

26

27

30

31

1618 17

1 2 543 6

7

8

9

10

12

11

14

13

15

28

29

23

25

24

22

21

20

19

4 - 84 Z-80/60 Part No. 88619


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How to Adjust the OscillateRelief Valve



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

2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port on the steer/oscillatemanifold.


4 Press down the foot switch and manuallyactivate one of the oscillate limit switches. Holdthe switch in the activated position and observethe reading on the pressure gauge. Refer toSection 2, Specifications.

5 Turn the engine off. Use a wrench to hold therelief valve and loosen the jam nut. (item CH).

6 Adjust the stud with a hex wrench. Turn itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the relief valve cap.




9 Install the drive chassis cover.

MANIFOLDS

Part No. 88619 Z-80/60 4 - 85


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8-9Oil Diverter Manifold Components (welder option)

The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.


1 Pilot Operated Directional valve,2 position 3 way ............................. CBA .......... Activates generator ...................... 80-90 ft-lbs / 108-122 Nm

2 Solenoid valve, 2 position 3 way ... CBB .......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm

3 Orifice disc,0.031 inch / 0.79 mm ..................... CBC .......... Delays shift to drive ......................... 35-40 ft-lbs / 47-54 Nm

4 Relief valve,270 psi @ 3.5 gpm / 18.6 bar @13.2 L/min ...................................... CBD .......... Charge pressure circuit .................... 35-40 ft-lbs / 47-54 Nm

5 Check valve ................................... CBE .......... Prevents oil flowing into generator .. 35-40 ft-lbs / 47-54 Nm

CBA

CBD CBC CBB

CBE

24

5

1

3

4 - 86 Z-80/60 Part No. 88619


REV C

8-10Traction Manifold, 2WD

The 2WD traction manifold is mounted inside the drive chassis at the circle-end of the machine.


1 Check valve, 5 psi / 0.34 bar ............ EA ......... Drive motor anti-cavitation ................ 30-35 ft-lbs / 41-47 Nm

2 Check valve, 5 psi / 0.34 bar ............ EB ......... Drive motor anti-cavitation ................ 30-35 ft-lbs / 41-47 Nm

3 Orifice, 0.031 in / 0.79 mm ............... EC ......... Brake and 2-speed circuit

4 Check valve ...................................... ED ......... Keeps brakes released in case oftemporary loss of charge pressure ... 20-25 ft-lbs / 27-34 Nm

5 Solenoid valve, 2 position 3 way ...... EE ......... Brake release .................................... 26-30 ft-lbs / 35-41 Nm

6 Solenoid valve, 2 position 3 way ...... EF .......... 2-speed drive motor shift .................. 26-30 ft-lbs / 35-41 Nm

7 Relief valve, 250 psi / 17.2 bar ......... EG ......... Charge pressure circuit ..................... 20-25 ft-lbs / 27-34 Nm

8 Shuttle valve, 3 position 3 way ......... EH ......... Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump ............................ 30-35 ft-lbs / 41-47 Nm

9 Bi-directional flow control valve,4.5 gpm / 17 L/min ............................. EI .......... Equalizes pressure on both sides

of divider/combiner valve EJ ............. 30-35 ft-lbs / 41-47 Nm

10 Flow divider/combiner valve ............. EJ .......... Controls flow to drive motorsin forward and reverse ................ 90-100 ft-lbs / 122-136 Nm

MANIFOLDS

Part No. 88619 Z-80/60 4 - 87


REV C MANIFOLDS

EA EB EC

ED

EE

EF

EG

EH

EI

EJ

2

7

2 31

4

5

6

8

9

10

4 - 88 Z-80/60 Part No. 88619


REV C

8-11Valve Adjustments, 2WDTraction Manifold

How to Adjust the ChargePressure Relief Valve

Perform this procedure with thehydraulic oil temperature from100°F to 150°F / 38°C to 65.5°C.

1 Connect a 0 to 600 psi / 0 to 50 bar pressuregauge to the test port on the drive pump.

2 Use a wrench to hold the charge pressure reliefvalve and remove the cap (item EG).

3 Turn the internal hex socket fully in a clockwisedirection until it stops. Install the cap.


5 Press and hold the function enable/high rpmselect button (rabbit symbol) position. Note thereading on the pressure gauge.

6 Turn the engine off.

7 Remove the pressure gauge from the drivepump. Connect the gauge to the test portlocated on the drive manifold.

8 Use a wrench to hold the charge pressure reliefvalve and remove the cap from the valve(item EG).


MANIFOLDS

10 Press and hold the function enable/high rpmselect button (rabbit symbol) position.

11 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading taken in step 5. Turnit clockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the valve cap.


Part No. 88619 Z-80/60 4 - 89


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4 - 90 Z-80/60 Part No. 88619


REV C

8-12Traction Manifold, 4WD

The 4WD traction manifold is mounted inside the drive chassis at the circle-end of the machine.


1 Check valve, 5 psi / 0.34 bar ............. FA ......... Drive motor anti-cavitation ................ 30-35 ft-lbs / 41-47 Nm

2 Solenoid valve, 2 position 3 way ....... FB ......... 2-speed drive motor shift .................. 26-30 ft-lbs / 35-41 Nm

3 Solenoid valve, 2 position 3 way ....... FC ......... Brake release .................................... 26-30 ft-lbs / 35-41 Nm

4 Check valve ....................................... FD ......... Keeps brakes released in case oftemporary loss of charge pressure ... 20-25 ft-lbs / 27-34 Nm

5 Shuttle valve, 3 position 3 way .......... FE ......... Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump ............................30-35 ft-lbs / 41-47 Nm

6 Relief valve, 250 psi / 17.2 bar .......... FF ......... Charge pressure circuit ..................... 20-25 ft-lbs / 27-34 Nm

7 Orifice, 0.030 in / 0.76 mm ................ FG ........ Brake and 2-speed circuit

8 Check valve ....................................... FH ......... Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm

9 Check valve ....................................... FI .......... Drive motor anti-cavitation ................ 30-35 ft-lbs / 41-47 Nm

10 Flow divider/combiner valve .............. FJ ......... Controls flow to square enddrive motors in forwardand reverse ................................. 90-100 ft-lbs / 122-136 Nm

11 Check valve, 5 psi / 0.34 bar ............. FK ......... Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm

12 Bi-directional flow control valve,2 gpm / 7.6 L/min ............................... FL ......... Equalizes pressure on both sides

of divider/combiner valve FJ ............. 30-35 ft-lbs / 41-47 Nm

13 Bi-directional flow control valve,2 gpm / 7.6 L/min ............................... FM ........ Equalizes pressure on both sides

of divider/combiner valve FQ ............ 30-35 ft-lbs / 41-47 Nm

14 Bi-directional flow control valve,2 gpm / 7.6 L/min ............................... FN ......... Equalizes pressure on both sides

of divider/combiner valve FP ............ 30-35 ft-lbs / 41-47 Nm

15 Check valve ....................................... FO ........ Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm

16 Flow divider/combiner valve .............. FP ......... Controls flow to circle enddrive motors in forwardand reverse ................................. 90-100 ft-lbs / 122-136 Nm

17 Flow divider/combiner valve .............. FQ ........ Controls flow to divider/combiner valves FJ and FP ........ 90-100 ft-lbs / 122-136 Nm

18 Check valve ....................................... FR ......... Drive motor anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm

MANIFOLDS

Part No. 88619 Z-80/60 4 - 91


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FQ

FB

FR

FA FC FD FE

FF

FH

FG

FI

FKFL

FJ

FP

FM

FN

FO

1

1112

1 2 3 4 5

16

18

17

14

13

15

9

10

6

7

8

4 - 92 Z-80/60 Part No. 88619


REV CMANIFOLDS

B-13Valve Adjustments, 4WDTraction Manifold

How to Adjust the ChargePressure Relief Valve

Perform this procedure with thehydraulic oil temperature must be100°F to 150°F / 38°C to 65.5°C.

1 Connect a 0 to 600 psi / 0 to 50 bar pressuregauge to the test port on the drive pump.

2 Use a wrench to hold the charge pressure reliefvalve and remove the cap (item FF).

3 Turn the internal hex socket fully in a clockwisedirection until it stops. Install the cap.


5 Press and hold the function enable/high rpmselect button (rabbit symbol) position. Note thereading on the pressure gauge.

6 Turn the engine off.

7 Remove the pressure gauge from the drivepump. Connect the gauge to the test portlocated on the drive manifold.

8 Use a wrench to hold the charge pressure reliefvalve and remove the cap from the valve(item FF).


10 Press and hold the function enable/high rpmselect button (rabbit symbol).

11 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading taken in step 5. Turnit clockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the valve cap.


Part No. 88619 Z-80/60 4 - 93


REV C

8-14Valve 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.

Result: The resistance should be withinspecification, plus or minus 30%.

Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.

How to Test a Coil DiodeProperly functioning coil diodes protect theelectrical circuit by suppressing voltage spikes.Voltage spikes naturally occur within a functioncircuit following the interruption of electrical currentto a coil. Faulty diodes can fail to protect theelectrical system, resulting in a tripped circuitbreaker or component damage.


1 Test the coil for resistance. See 8-14, How toTest a Coil.

MANIFOLDS

Valve coil resistance specifications

Proportional solenoid valve, 12V DC 4 to 6Ω(schematic items G, R and BB)

3 position 4 way solenoid valve, 12V DC 4.5 to 6.5Ω(schematic items GB, GP and GQ)

3 position 4 way solenoid valve, 10V DC 5 to 7Ω(schematic items O, S, BA, BB, CA, CB,CP and CQ)

2 position 2 way solenoid valve, 10V DC 5.5 to 7.5Ω(schematic items C and P)

2 position 3 way solenoid valve, 10V DC 4.5 to 6.5Ω(schematic items H, J, V, X, Z, AA, BC,BD, CE, CF, EE, EF, FB and FC)


REV C

4 - 94 Z-80/60 Part No. 88619

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.

Resistor, 10ΩΩΩΩΩGenie part number 27287

The battery should read 9V DC ormore when measured across theterminals.

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.

The multimeter, when set to readDC current, should be capable ofreading up to 800 mA.

4 Connect the negative lead to the other terminalon the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current 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.

9VBATTERY

10

RESISTOR

�

MULTIMETER

COIL

+

-

+

-

d

b

b

a

c

c

MANIFOLDS


REV B

Part No. 88619 Z-80/60 4 - 95

3 Tag, disconnect the hydraulic hoses from theturntable rotation motor. Cap the fittings on themotor.

4 Attach a lifting strap from an overhead crane orother suitable lifting device to the lifting eye onthe turntable rotation assembly.

5 Remove the turntable rotator mounting boltsand remove the turntable rotation assemblyfrom the machine.

6 Repeat steps 3 through 5 for the other turntablerotation assembly.

Tip-over hazard. If the turntablerotation lock pin is not properlyinstalled, machine stability iscompromised and the machinecould tip over when the drive hubis removed from the machine,which could result in death orserious injury.

Crushing hazard. The drive hubcould become unbalanced and fallif not properly supported by theoverhead crane or lifting devicewhen removed from the machine.

When installing a turntable rotationassembly, the rotation gearbacklash must be adjusted.See 9-1, Adjust the TurntableRotation Gear Backlash.

Turntable Rotation Components

9-1Turntable Rotation Assembly

How to Remove a TurntableRotation Assembly


Perform this procedure with theplatform between the circle-endtires and with the machine on afirm, level surface.


unlocked locked

2 Remove the ground controls side fixed turntablecover.

4 - 96 Z-80/60 Part No. 88619


TURNTABLE ROTATION COMPONENTS

How to Adjust the TurntableRotation Gear BacklashThe turntable rotation drive hub is mounted on anadjustable plate that controls the gap between therotation motor pinion gear and the turntablebearing ring gear.

Perform this procedure with theplatform between the circle-endtires and with the machine on afirm, level surface.


2 Loosen the backlash pivot plate mountingfasteners.

3 Push the backlash pivot plate towards theturntable as far as possible (this will push therotation gear into the turntable bearing ringgear).

4 Loosen the lock nut on the adjustment bolt.

5 Turn the adjustment bolt clockwise until itcontacts the backlash pivot plate.

6 Turn the adjustment bolt 1/2 turncounterclockwise. Tighten the lock nut on theadjustment bolt.

7 Rotate the backlash pivot plate away from theturntable until it contacts the adjustment bolt.Torque the mounting fasteners on the backlashpivot plate to specification. Refer to Section 2,Specifications.

8 Rotate the turntable through an entire rotation.Check for tight spots that could cause binding.Readjust if necessary.

REV B

Part No. 88619 Z-80/60 4 - 97


How to Install the Hub andBearings, 2WD Models

When replacing a wheel bearing,both the inner and outer bearingsincluding the pressed-in racesmust be replaced.

1 Be sure that both bearings are packedwith clean, fresh grease.

2 Place the large inner bearing into the rearof the hub.

3 Press the bearing seal evenly into the hubuntil it is flush.

4 Slide the hub onto the yoke spindle.

Component damage. Do notapply excessive force or damageto the lip of the seal may occur.

5 Place the outer bearing into the hub.

6 Install the washer and castle nut.

7 Tighten the castle nut to 35 ft-lbs / 47 Nm toseat the bearing.


9 Install a new cotter pin. Bend the cotter pinto secure the castle nut.

Always use a new cotter pin wheninstalling a castle nut.

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

Axle Components

10-1Hub and Bearings, 2WD Models

How to Remove theHub and Bearings, 2WD Models1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steer wheels.

3 Center a lifting jack with a minimum capacity of25,000 lbs / 12000 kg under the drive chassisbetween the steer wheels.

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

Crushing hazard. The machinemay fall if not properly supported.

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

6 Remove the dust cap, cotter pin andcastle nut.

Always use a new cotter pin wheninstalling a castle nut.

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

8 Place the hub on a flat surface and gently prythe bearing seal out of the hub.

9 Remove the rear bearing.

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4 - 98 Z-80/60 Part No. 88619


AXLE COMPONENTS

How to Adjust the Oscillate LimitSwitches

Tip-over hazard. Failure toperform this procedure on a firm,level surface will compromise thestability of the machine and couldcause the machine to tip overwhich could result in death orserious injury.

Perform this procedure with themachine on a firm, level surfacethat is free of obstructions. Use adigital level to confirm.



2 Remove the drive chassis cover from thecircle-end of the machine.

3 Remove the oscillate axle limit switch mountingfasteners. Remove the limit switches.

The oscillate axle limit switchesare located inside the drivechassis above the axle.

4 Place a digital level on the turntable rotatebearing plate.

5 Start the engine and level the drive chassis.Press down the foot switch and manuallyactivate the oscillate limit switches until themachine is completely level.

6 Loosely install the limit switches. Using a feelergauge, establish a gap of 0.015 - 0.030 inches/ 0.381 - 0.762 mm between the limit switchplunger and the top of the axle.

7 Carefully hold the position of each limit switchand tighten the limit switch mounting fasteners.

8 Verify the gap is 0.015 - 0.030 inches / 0.381 -0.762 mm between the limit switch plunger andthe top of the axle.

9 Measure the distance between the drivechassis and the axle on both sides (from theinside of the drive chassis).

Result: The measurements should be equal.

If the distance is not equal and theadjustment to the limit switcheswas completed with the groundand drive chassis level, consultGenie Industries ServiceDepartment.

REV C

Part No. 88619 Z-80/60 4 - 99


AXLE COMPONENTS

10-2Oscillating Axle Cylinders

The oscillating axle cylinders extend and retractbetween the drive chassis and the oscillating axle.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure. The valves are notadjustable.

How to Remove an OscillatingAxle Cylinder

Perform this procedure on a firm,level surface with the boom inthe stowed position.


1 Rotate the boom until the turntablecounterweight is between the circle-end andsquare-end tires.

2 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on theoscillate cylinder.


3 Remove the pin retaining fasteners from theoscillate cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

4 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.

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

Crushing hazard. The oscillatecylinder may become unbalancedand fall if not properly supportedwhen removed from the machine.

6 Remove the oscillate cylinder from the machine.

REV C

4 - 100 Z-80/60 Part No. 88619



Part No. 88619 Z-80/60 5 - 1

July 2006 Section 5 • Fault Codes

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theOperator's Manual on your machine.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropriate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.

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.

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


Two persons will be required tosafely perform sometroubleshooting 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 between the circle-end (yellow arrow) wheels.

· Turntable secured with the turntable rotation lock pin

· Key switch in the off position with the key removed

· Welder disconnected from the machine (if equipped with the weld cable to platform option)

· Wheels chocked


5 - 2 Z-80/60 Part No. 88619

July 2006Section 5 • Fault Codes

REV AControl System Fault Codes

Error Source Error Type Effects Recovery Actions

Not calibrated Normal function except threshold for

one or the other direction is zero. Display message on LCD.

Calibrate thresholds.

Just calibratedInitiate one second beep of audible

warning device.Self-clearing (transient)

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

PRI BOOM EXT VALVE

PRI BOOM RET VALVE

PRI BOOM UP VALVE

PRI BOOM DOWN VALVE

SEC BOOM LENGTHFault check

(unknown length)

Stop all secondary boom functions, allow only secondary boom retract.

Display message on LCD.

Power up controller with the problem corrected.

SEC BOOM ANGLEFault check

(unknown angle)

Stop all secondary boom functions, allow only secondary boom retract. Once the boom is retracted allow secondary boom down. Display

message on LCD.


SEC BOOM UP/DOWN SPEED

Not calibratedDisplay message on LCD and allow

operation at default speed.Perform auto calibrate procedure.






Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

SEC BOOM EXT VALVE

SEC BOOM RET VALVE

SEC BOOM UP VALVE

SEC BOOM DOWN VALVE

SEC EXT SEQ VALVE

SEC DWN SEQ VALVE

Fault check

PRIMARY BOOM EXT/RET FLOW VALVE

Limited speed and direction frozen at zero and neutral, alarm sounds..


SEC BOOM UP/DOWN/EXT/RET

FLOW VALVE





Fault check



Part No. 88619 Z-80/60 5 - 3


REV A CONTROL SYSTEM FAULT CODES

Continued on nextpage

Error Source Error Type Effects Recovery ActionsENGINE SPEED

Range check (underspeed)

OIL PRESSURERange check (low oil

pressure)

WATER/OIL TEMPRange check (high

temperature)

OIL PRESSURE SENSOR

WATER/OIL TEMP SENSOR

AXLE EXT/RET BUTTONSAxle extend/retract disabled, display

message on LCD.Power up controller with the problem

corrected.

CAN BUS Fault check Display message on LCD.Power up controller with the problem

corrected.

Value at 5.0 V

Value too high

Value too low

Value at 0 V

Not calibratedJoystick Speed and Direction frozen at

zero and neutralCalibrate joystick.



Value at 5.0 V

Value too high

Value too low

Value at 0 V

Not calibratedJoystick speed and direction frozen at

zero and neutral.Calibrate joystick.



Value at 5.0 V

Value too high

Value too low

Value at 0 V





Limited speed and direction frozen at zero and neutral, alarm sounds.

Power up controller with problem corrected.


SECONDARY BOOM JOYSTICK



PRIMARY EXTEND/RETRACT

JOYSTICK

Display message on LCD.

PRIMARY BOOM UP/DOWN JOYSTICK



Fault check Display message on LCD.Power up controller with the problem

corrected.

5 - 4 Z-80/60 Part No. 88619


REV ACONTROL SYSTEM FAULT CODES

Error Source Error Type Effects Recovery ActionsValue at 5.0 V

Value too high

Value too low

Value at 0 V





PRIMARY BOOM UP/DOWN SWITCHES ON TCON

Fault Check, (both buttons pressed)

Primary boom up/down disabled, display message on LCD.


SEC BOOM UP/EXT/DWN/RET

SWITCHES ON TCON


Secondary boom up/extend and down/retract disabled, display message

on LCD.

Power up controller with the problem corrected

PRIMARY BOOM EXT/RET SWITCHES ON TCON


Primary boom extend/retract disabled, display message on LCD.


PRIMARY BOOM LENGTHFault check

(unknown length)Display message on LCD.


PRIMARY BOOM ANGLEFault check

(unknown angle)Allow only primary boom retract and

down. Display message on LCD.Power up controller with the problem

corrected.

PRIMARY UP/DOWN SPEED Not calibratedDisplay message on LCD and allow


PRIMARY EXTEND/RETRACT SPEED








Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

STEER JOYSTICK



PRIMARY BOOM UP/DOWN FLOW VALVE



Part No. 88619 Z-80/60 5 - 5




Error Source Error Type Effects Recovery ActionsSAFETY SWITCH P3

Display message on LCD. P3 SAFETY SWITCH FAULT

SAFETY SWITCH P6R1Display message on LCD.

P6R1 SAFETY SWITCH FAULT

SAFETY SWITCH P6R2Display message on LCD.

P6R2 SAFETY SWITCH FAULT

SAFETY SWITCH P7Display message on LCD.

P7 SAFETY SWITCH FAULT

SAFETY SWITCH P7RDisplay message on LCD.

P7R SAFETY SWITCH FAULT

SAFETY SWITCH P9ADisplay message on LCD.

P9A SAFETY SWITCH FAULT

SAFETY SWITCH P9BDisplay message on LCD.

P9B SAFETY SWITCH FAULT













SAFETY SWITCH P22RDisplay message on LCD.

P22R SAFETY SWITCH FAULT


P30 SAFETY SWITCH FAULTPLATFORM OVERLOAD

SENSORBOOM UP OVERLOAD

BOOM DOWN OVERLOAD

SHUT DOWN MODE

Fault checkPower up controller with the problem

corrected.

Fault check (if active) Display message on LCD. Power up controller with the problem

corrected.

5 - 6 Z-80/60 Part No. 88619



Error Source Error Type Effects Recovery ActionsValue at 5.0 V

Value too high

Value too low

Value at 0 V





TURNTABLE ROTATE BUTTONS


Turntable rotate disabled, display message on LCD.


TURNTABLE ROTATE SPEED








Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V

TURNTABLE ROTATE CW VALVE

TURNTABLE ROTATE CCW VALVE

TURNTABLE LEVEL SENSOR X-DIRECTION

TURNTABLE LEVEL SENSOR Y-DIRECTION

PLATFORM LEVEL SENSOR Y-DIRECTION



TURNTABLE ROTATE JOYSTICK



TURNTABLE ROTATE FLOW VALVE



Fault check

Fault checkDisplay message on LCD and sound

audible alarm.Correct problem.

Part No. 88619 Z-80/60 5 - 7




Error Source Error Type Effects Recovery Actions

Value at 5.0 V

Sound audible warning and flash primary boom down LED at the

medium rate and display message on LCD screen PRI BOOM ANG SENSOR

SHORTED HIGH. Primary boom up inhibited. Primary boom velocity limited

to 50% of default value.

Correct problem.

Value at 0 V

Sound audible warning and flash primary boom down LED at the

medium rate and display message on LCD screen PRI BOOM ANG SENSOR

SHORTED LOW. Primary boom up inhibited. Primary boom velocity limited

to 50% of default value.

Correct problem.

Not calibrated

Sound audible warning at the medium rate and display message on LCD screen PRI BOOM ANG SENSOR NOT CALIBRATED, inhibit primary

boom up from platform control.

Calibrate primary boom angle sensor.



Value at 5.0 V

Value too high

Value too low

Value at 0 V









warning device.Self-clearing, (transient)

Value at 5.0 V

Value Too High

Value Too Low

Value at 0 V


PROPEL VALVES FWD PROPEL VALVES REV

PROPEL EDC FWD PROPEL EDC REV


PRIMARY BOOM ANGLE SENSOR


PROPEL JOYSTICK


5 - 8 Z-80/60 Part No. 88619



Error Source Error Type Effects Recovery ActionsMOTOR SPEED VALVE

BRAKE VALVE

AUX PROPEL VALVE

PLAT LEV UP VALVE

PLAT LEV DN VALVE

PLAT ROT CW VALVE

PLAT ROT CCW VALVE

JIB UP VALVE

JIB DN VALVE

JIB SWITCHES

PLAT ROT SWITCHES

Value at 5.0 V

Value too high

Value too low

Value at 0 V





Value at 5.0 V

Value too high

Value too low

Value at 0 V

Value at 5.0 V

Value too high

Value too low

Value at 0 V

Value at 5.0 V

Value too high

Value too low

Value at 0 V

Value at 5.0 V

Value too high

Value too low

Value at 0 V

LF STEER VALVE

RF STEER VALVE

LR STEER VALVE

RR STEER VALVE

FOOTSWITCH TIMEOUT Display message on LCD display. Recycle power.


Fault check

STEERING JOYSTICK


Fault Check, (both contacts closed)

Affected functions disabled, display message on LCD.


LF STR ANG SNSR Limited speed and direction frozen at

zero and neutral, alarm sounds.Power up controller with problem

corrected.



RR STR ANG SNSRLimited speed and direction frozen at


corrected.

Fault checkLimited speed and direction frozen at

zero and neutral, alarm sounds.Power up controller with the problem

corrected.

RF STR ANG SNSRLimited speed and direction frozen at


corrected.

LR STR ANG SNSRLimited speed and direction frozen at


corrected.

Part No. 88619 Z-80/60 5 - 9


REV AFord Engine ECM Fault Code Chart

Code Problem Cause Solution

111 Closed Loop Multiplier High (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks.

Repair wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks.

112 HO2S Open/Inactive (Bank 1)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections OR replace sensor.

113 HO2S Open/Inactive S(Bank 2)



114 Post-cat oxygen sensor open

The post cat Heated Oxygen Sensor wiring and/or connections are open or shorted OR sensor is cold, non-responsive or inactive for 60 seconds or longer.

Repair wiring and/or connections OR replace the post cat oxygen sensor.

121 Closed Loop Multiplier High (Gasoline)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

122 Closed Loop Multiplier Low (Gasoline)

MAP, IAT or ECT sensors not in correct position OR wiring and/or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck open OR there is electro-magnetic interference from a faulty crankshaft and/or camshaft position sensor.

Adjust or replace sensors OR clean or repair fuel injectors.

124 Closed Loop Multiplier Low (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR fuel quality is poor OR fuel system components may be faulty.

Repair wiring and/or connections OR replace sensor OR replace fuel OR test and repair the fuel system components.

133 Gasoline cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.

Repair exhaust leaks OR there is an emissions compliance issue. Contact Ford Power Products for assistance.

134 LPG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.


135 NG cat monitor There are exhaust leaks OR the catalyst system efficiency is below the acceptable level.


141 Adaptive Lean Fault - High Limit (Gasoline)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum or exhaust leaks OR one or more fuel injectors faulty or stuck closed OR fuel quality is poor OR fuel pressure is too low.

Repair heated oxygen sensor wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

142 Adaptive Rich Fault - Low Limit (Gasoline)

MAP, IAT or ECT sensors not in correct position OR wiring and/or connections for sensors open or shorted OR sensor is faulty OR one or more fuel injectors are stuck closed OR there is electro-magnetic interference from a faulty crankshaft and/or camshaft position sensor.

Adjust or replace sensors OR clean or repair fuel injectors.

143 Adaptive Learn High (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel quality is poor OR fuel system components may be faulty.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR replace fuel OR test and repair the fuel system components.

111 Closed Loop Multiplier High (LPG)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks.

Repair wiring and/or connections OR replace sensor OR repair vacuum and exhaust leaks.

112 HO2S Open/Inactive (Bank 1)



113 HO2S Open/Inactive S(Bank 2)



114 Post-cat oxygen sensor open

The post cat Heated Oxygen Sensor wiring and/or connections are open or shorted OR sensor is cold, non-responsive or inactive for 60 seconds or longer.

Repair wiring and/or connections OR replace the post cat oxygen sensor.

121 Closed Loop Multiplier High (Gasoline)

Heated Oxygen Sensor wiring and/or connections open or shorted OR sensor is faulty OR there are vacuum leaks or exhaust leaks OR fuel pressure is low OR the fuel injectors need cleaning or replacing.

Repair wiring and/or connections OR replace sensor OR repair any vacuum and exhaust leaks OR test the fuel pressure OR clean or replace the fuel injectors.

5 - 10 Z-80/60 Part No. 88619


REV AFORD ECM FAULT CODE CHART


144 Adaptive Learn Low (LPG) Engine wire harness may have an intermittent short to 5V DC or 12V DC OR fuel system components may be faulty.

Repair short in engine wire harness OR test and repair the fuel system components.

161 System Voltage Low Battery is faulty OR alternator is not charging OR battery supply wiring to ECM is open or shorted.

Replace battery OR repair alternator OR repair battery supply wiring to ECM.

162 System Voltage High Alternator is overcharging the battery when engine RPM is greater than 1500 rpm. Repair or replace the alternator.

211 IAT High Voltage IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too cold.

Repair wiring and/or connections OR replace sensor OR direct warmer air into air intake.

212 IAT Low Voltage IAT sensor wiring and/or connections are open or shorted OR sensor is faulty OR engine intake air temperature is too hot.

Repair wiring and/or connections OR replace sensor OR direct cooler air into air intake.

213 IAT Higher Than Expected (1)

Air intake temperature is greater than 200° F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty.

Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor.

214 IAT Higher Than Expected (2)

Air intake temperature is greater than 210° F with the engine greater than 1000 rpm OR air intake system has leaks OR IAT sensor is faulty.

Check air intake system for damage and proper routing of air intake components OR replace the IAT sensor.

215 Oil Pressure Low Faulty oil pressure sensor OR sensor wiring and/or connections open or shorted OR engine oil level too low.

Replace oil pressure sensor OR repair sensor wiring and/or connections OR fill engine oil level to specification.

221 CHT/ECT High Voltage Engine cooling system is malfunctioning OR sensor wires and/or connections open or shorted OR sensor is faulty.

Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor.

222 CHT/ECT Low Voltage

Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.

Repair engine cooling system problems OR repair open or shorted wiring to sensor OR replace sensor OR fill engine coolant level to specification.

223 CHT Higher Than Expected (1)

Coolant temperature at the cylinder head is 240° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.


224 CHT Higher Than Expected (2)

Coolant temperature at the cylinder head is 250° F. Engine cooling system is malfunctioning and overheating the engine OR sensor wires and/or connections open or shorted OR sensor is faulty OR coolant level is low.


231 MAP High Pressure Open or shorted wiring and/or connections to MAP sensor OR sensor is faulty.

Repair wiring and/or connections to sensor OR replace MAP sensor.

232 MAP Low Voltage Open or shorted wiring and/or connections to MAP sensor OR sensor is faulty.

Repair wiring and/or connections to sensor OR replace MAP sensor.

234 BP High Pressure MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM.

235 BP Low Pressure MAP sensor is faulty OR ECM is faulty. Replace MAP sensor OR replace the ECM.

242 Crank Sync Noise Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.

Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace sensor.

243 Never Crank Synced At Start

Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


Part No. 88619 Z-80/60 5 - 11


REV A FORD ECM FAULT CODE CHART


245 Camshaft Sensor Noise Camshaft position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR sensor is faulty.


253 Knock Sensor Open Knock sensor wiring and/or connections open or shorted OR sensor is faulty.

Repair wiring and/or connections to knock sensor OR replace knock sensor.

254 Excessive Knock Signal Knock sensor wiring and/or connections open or shorted OR there is excessive engine vibration OR sensor is faulty.

Check for excessive engine vibration OR repair wiring and/or connections to knock sensor OR replace knock sensor.

311 Injector Driver #1 Open Open wiring and/or connections to fuel injector #1 OR fuel injector #1 is faulty OR ECM is faulty.

Repair wiring and/or connections to fuel injector #1 OR replace fuel injector #1 OR replace the ECM.

312 Injector Driver #1 Shorted Wiring and/or connections to fuel injector #1 shorted OR fuel injector #1 is faulty OR ECM is faulty.














351 Fuel Pump Loop Open or High Side Short To Ground

Open wiring and/or connections to fuel pump OR fuel pump power shorted to ground OR fuel pump is faulty.

Repair wiring and/or connections to fuel pump OR replace fuel pump.

352 Fuel Pump High Side Shorted To Power

Wiring and/or connections to fuel pump shorted to power OR fuel pump is faulty.

Repair wiring and/or connections to fuel pump OR replace fuel pump.

353 MegaJector delivery pressure higher than expected

Fuel pressure too high OR LPG lockoff not sealing correctly OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty.

Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace MegaJector.

354 Megajector delivery pressure lower than expected

Fuel pressure too low OR LPG lockoff not opening completely OR the line between the MegaJector and carburetor is kinked or restricted or is leaking OR engine cooling system is not operating properly OR MegaJector is faulty.

Check fuel pressure OR repair LPG lockoff OR repair the line between the MegaJector and carburetor OR repair engine cooling system OR replace the MegaJector.

355 MegaJector communication lost

The ECM doesn’t get any response from the MegaJector, or an incorrect response for 500ms period or longer.

Check CAN circuits for continuity and shorts to power or ground and for continuity and repair as necessary OR replace the MegaJector.

361 MegaJector voltage supply high

The MegaJector detects voltage greater than 18 volts for 5 seconds anytime the engine is cranking or running.

Repair charging system OR replace the MegaJector.

362 MegaJector voltage supply low

The MegaJector detects voltage less than 9.5 volts for 5 seconds anytime the engine is cranking or running.

Repair VBAT power or ground circuit to ECM and MegaJector OR replace battery OR repair charging system OR replace the MegaJector.


5 - 12 Z-80/60 Part No. 88619


REV AFORD ECM FAULT CODE CHART


363 Megajector internal actuator fault detection

The MegaJector detects an internal fault. Open or short in power, ground or CAN circuits.s

Check Power, Ground and CAN circuits at MegaJector and all connections and repair as necessary OR MegaJector has an internal fault. Contact Ford Power Products for assistance.

364 Megajector internal circuitry fault detection

The MegaJector detects an internal circuitry failure. Open or short in power, ground or CAN circuits.


365 MegaJector internal communication fault detection

The MegaJector detects an internal communications failure. Open or short in power, ground or CAN circuits.


411 Coil Driver #1 Open Open wiring and/or connections to ignition coil #1 OR ignition coil #1 is faulty.

Repair wiring and/or connections to ignition coil #1 OR replace ignition coil #1.

412 Coil Driver #1 Shorted Wiring and/or connections to ignition coil #1 shorted OR ignition coil #1 is faulty.


413 Coil Driver #2 Open Open wiring and/or connections to ignition coil #2 OR ignition coil #2 is faulty.


414 Coil Driver #2 Shorted Wiring and/or connections to ignition coil #2 shorted OR ignition coil #2 is faulty.


511 FPP1 High Voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

512 FPP1 Low Voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

513 FPP1 Higher than IVS Limit Not used. If this fault appears on your machine, contact Genie Industries Service Department.

514 FPP1 Lower than IVS Limit Not used. If this fault appears on your machine, contact Genie Industries Service Department.

521 FPP2 High Voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

522 FPP2 Low Voltage Not used. If this fault appears on your machine, contact Genie Industries Service Department.

531 TPS1 (Signal Voltage) High

The #1 throttle position sensor wiring and/or connections open or shorted OR there is a poor system ground connection OR throttle position sensor #1 is faulty.

Be sure system ground connections are in place and secure OR repair wiring and/or connections to sensor OR replace throttle position sensor #1.

532 TPS1 (Signal Voltage) Low



533 TPS2 (Signal Voltage) High



534 TPS2 (Signal Voltage) Low



363 Megajector internal actuator fault detection

The MegaJector detects an internal fault. Open or short in power, ground or CAN circuits.s


Part No. 88619 Z-80/60 5 - 13


REV A FORD ECM FAULT CODE CHART


535 TPS1 Higher than TPS2

The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty.

Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors.

536 TPS1 Lower than TPS2

The throttle position sensor wiring and/or connections for either TPS1 or TPS2 open or shorted OR there is a poor system ground connection OR one or both throttle position sensors are faulty.

Be sure engine harness wiring and connections are in place and secure OR repair wiring and/or connections to one or both TPS sensors OR replace one or both TPS sensors.

537 Throttle Unable to Open Governor actuator is stuck closed OR wiring and/or connections open or shorted OR governor actuator is faulty.

Repair wiring and/or connections to governor actuator OR replace the governor actuator.

538 Throttle Unable to Close Governor actuator is stuck open OR wiring and/or connections open or shorted OR governor actuator is faulty.

Repair wiring and/or connections to governor actuator OR replace the governor actuator.

545 Governor Interlock Failure Engine harness wiring and/or connections open or shorted OR there is a poor system ground connection OR ECM is faulty.

Repair wiring and/or connections in engine harness OR replace the ECM.

551 Max Governor Speed Override

ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.

Re-program ECM OR repair binding throttle operation OR repair any air leaks between the throttle body and cylinder head.

552 Fuel Rev Limit ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.


553 Spark Rev Limit ECM needs to be re-programmed OR throttle is sticking open OR there are air leaks between the throttle body and cylinder head.


611 COP Failure Loose wire connections to ECM OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts to ECM to be sure they are secure OR replace ECM.

612 Invalid Interrupt Loose wire connections to ECM OR ECM is faulty.


613 A/D Loss Loose wire connections to ECM OR ECM is faulty.


614 RTI 1 Loss Loose wire connections to ECM OR ECM is faulty.


615 Flash Checksum Invalid Loose wire connections to ECM OR ECM is faulty.


616 RAM Failure Loose wire connections to ECM OR ECM is faulty.


631 External 5V DC Ref Lower than Expected

Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM.

632 External 5V DC Ref Higher than Expected

Engine harness wiring and/or connections open or shorted to ground OR there is a faulty engine sensor OR ECM is faulty.

Locate and repair any engine harness wiring damage or shorts OR locate and troubleshoot or repair faulty engine sensor OR replace ECM.

655 RTI 2 Loss Loose wire connections to ECM OR ECM is faulty.


656 RTI 3 Loss Loose wire connections to ECM OR ECM is faulty.S


5 - 14 Z-80/60 Part No. 88619



Section 6 • SchematicsJuly 2006

Part No. 88619 Z-80/60 6 - 1

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 rules andoperating instructions printed in theOperator's Manual on your machine.

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.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunction

discovered

Identify

symptomsTroubleshoot

Return to

service

Inspect

and test

Perform

repairproblem

solved

problem

still exists

REV B

July 2006Section 6 • Schematics

6 - 2 Z-80/60 Part No. 88619

Circuit numbering1 Circuit numbers consist of three parts: the circuit

prefix, circuit number and circuit suffix. Thecircuit prefix indicates the type of circuit. Thecircuit number describes the function of thecircuit. The circuit suffix provides anabbreviation for the number or may be used tofurther define the function of this portion of thecircuit. It also may be used to indicate the finalend of the circuit, i.e., LS or limit sw.

2 The circuit number may be used more than oncein a circuit.

For Example:

C 74 PL – This is the circuit for the lockoutvalve #1. C stands for control, 74 is the number of the circuitfor the primary #1 lock out valve.PL stands for Primary Lockout.

S 62 BST – This is the circuit that communicates to the onboardcomputers of the machine that the boom is fully stowed. Sstands for safety, 62 is the number of the circuit for boomstowed and BST stands for Boom Stowed.

P 48 LP – P stands for power. 48 is the circuit number for worklamps and LP stands for Lamp.

R 48 LP – R stands for relay. In this case it is the wire thatfeeds the relay coil for the work lamp. All other numbers remainthe same.

Circuit prefixC ..... Control

D ..... Data

E ...... Engine

G ..... Gauges

N ..... Neutral

P ...... Power

R ..... Relay Output

S ...... Safety

V ...... Valve

Circuit suffixDefinition SuffixAC Generator GENAlternator Field AFAngle ANGAuxiliary Boom Valve ABVAuxiliary Forward Valve AFVAuxiliary Hydraulic Pump AHAuxiliary Platform Valve APVAuxiliary Reverse Valve ARVAuxiliary Steer/Drive Valve ASVAxle Extend Valve AXEAxle Oscillate AXOAxle Retract Valve AXRAxle Front Position FAPAxle Rear Position RAPBattery BATBoom Extended BEXBoom Stowed BSTBrake BRKBypass Valves BVCalibrate CALCAN Signal CANCAN Shield SHDCATS Module CATChain Break CNKData High DTHData Low DTLDrive Chassis Controller DCNDrive Enable DEDrive Enable Left DELDrive Enable Right DERElectrical Displacement Control EDCEnvelope Light ENVEngine Speed Select ESPEngine Status Lamp ESLEnvelope Lockout ENLExtend/retract Lockout ERLFilter Restricted FLRFilter Switch FLTFlashing Beacon FBFloat Switch FSFootswitch Signal FTSForward FWDFuel Pump FPFuel Select (gas/LP) FLFuel Solenoid FSL

Wire Circuit Legend

REV B


Part No. 88619 Z-80/60 6 - 3

WIRE CIRCUIT LEGEND

Definition SuffixFunction Enable FEGround Control TCNGround GNDHorn HRNHigh RPM HSHydraulic Generator HGIgnition IGNJib Bellcrank Down JBDJib Bellcrank Up JBUJib Sensor JBSJib U/D Control JUDJib Down JDJib Up/Down Flow Control JFCJib Select Valve JSVJib Up JUJib E/R Control JERJib Ext JBEJib Ret JBRJib Rotate Left (CCW) JRLJib Rotate Right (CW) JRRJoystick 5 VDC Power JPWLamps LPSLeft Front LFLeft Front Steer Sensor LFSLeft Rear LRLeft Rear Steer Sensor LRSLimit Switch LSLift Speed Reduction LSRLoad Sensor LDSLockout LOLow RPM LSLow fuel LOFMotor Shift (Speed) MSMulti Function Valve MFVPlatform Control PCNPrimary Ext/Ret Lockout PELPlatform Level Down PLDPlatform Level Flow Control PLFPlatform Level Up PLUPlatform Rotate Flow Control PRFPlatform Rotate Control PRCPlatform Rotate Left (CCW) PRLPlatform Rotate Right (CW) PRRPower PWRPower to Length Sensor PSLPlatform Tilt Alarm PTAPlatform Tilt Sensor PTS

Definition SuffixPressure Comp Enable PCEPressure Sender PSRPressure Switches PSPrimary Boom Angle Sensor PBSPrimary Boom Down PBDPrimary Boom Ext/Ret Lockout Valve PBLPrimary Boom Extend PBEPrimary Boom Extend/Retract Flow Control PERPrimary Boom Retract PBRPrimary Boom Angle Sensor PBSPrimary Boom Down PBDPrimary Boom Ext/Ret Lockout Valve PBLPrimary Boom Extend PBEPrimary Boom Extend/Retract Flow Control PERPrimary Boom Retract PBRPrimary Boom Up PBUPrimary Boom Up/Dwn Flow Control PUDPrimary Boom Extend/Retract Signal PLSPrimary Boom Up/Down Signal PESPrimary Lockout PLPrimary Length Sensor PSLPropel Signal JPLProgram Setup Enable PSEPropel Lockout PLLProportional Valve PRVProximity Sensor PXSReceptacle RECRecovery RCVRetract Lockout RLReturn RETReverse REVRight Front RFRight Front Steer Sensor RFSRight Rear RRRight Rear Steer Sensor RRSRPM RPMSecondary Boom Angle Sensor SBSSecondary Boom Elevated SBLSec Boom Down SBDSec Boom Extend SBESec Boom Extend/Retract Flow Control SERSec Boom Retract SBRSec Boom Up SBUSec Boom Up/Dwn Flow Control SUDSecondary Boom SBThis list continues on the next page.

REV B


6 - 4 Z-80/60 Part No. 88619

WIRE CIRCUIT LEGEND

Definition SuffixSecondary Boom Lockout Valve (Extend) SLESecondary Boom Lockout Valve (Riser Down) SLDSensor SENSpare SPSpeed Sensor SSStart Aid (Glow Plug or choke) SAStarter STRSteer Control Signal STCSteering Valve Clockwise SCWSteering Valve Counter Clockwise SCCTemp Sender TSRTemp Switches TSTether TETTilt Alarm X axis TAXTilt Alarm Y axis TAYTurntable or Ground Control Panel TCNTurntable Rotate Flow Control TRFTurntable Rotate Right (CW) TRRTurntable Rotate Signal TRSTurntable Tilt Alarm TTATurntable Tilt Sensor TTSTest Switch TSW

Wire Coloring1 All cylinder extension colors are solid and all

retract functions are striped black. When usingblack wire, the stripe shall be white.

2 All rotations that are LEFT or CW are solid,RIGHT or CCW are striped and black. When thewire is black, the stripe is white.

3 All proportional valve wiring is striped.

Wire Color LegendBL BlueBL/BK Blue/BlackBL/RD Blue/RedBL/WH Blue/WhiteBK BlackBK/RD Black/RedBK/WH Black/WhiteBR BrownGR GreenGR/BK Green/BlackGR/WH Green/WhiteRD RedRD/BK Red/BlackRD/WH Red/WhiteOR OrangeOR/BL Orange/BlueOR/BK Orange/BlackOR/RD Orange/RedWH WhiteWH/BK White/BlackWH/RD White/RedYL Yellow

REV B


Part No. 88619 Z-80/60 6 - 5

WIRE CIRCUIT LEGEND

Color, Circuit #, and Primary functionRD 1 Primary boom up driveRD/BK 2 Primary boom down driveRD/WH 3 Primary boom up/dwn FC

proportional valve driveWH 4 Turntable rotate left valve driveWH/BK 5 Turntable rotate right valve driveWH/RD 6 Turntable rotate FC proportional

valve driveBK 7 Primary boom extendBK/WH 8 Primary boom retractBK/RD 9 Primary boom Extend/Retract

proportional valve driveBL 10 Secondary boom up valve driveBL/BK 11 Secondary boom down valve driveBL/WH 12 Secondary boom up/dwn FC

proportional valve driveBL/RD 13 Drive enableOR 14 Platform level up valveOR/BK 15 Platform level down valveOR/RD 16 Platform up/dwn FC proportional

valve driveGR 17 Platform rotate left valve driverGR/BK 18 Platform rotate right valve driverGR/WH 19 Jib select valve driver circuitRD 20 12 battery supplyWH 21 12 ignition supplyBK 22 Keyswitch power to platform

ESTOPWH 23 Power to platformRD 24 Power to warning sendersWH/BK 25 Power to oil pressure senderWH/RD 26 Power to temp senderRD 27 Auxiliary powerRD/BK 28 Platform level alarmRD/WH 29 Drive motor shift (speed)WH 30 Forward/EDC-A

Color, Circuit #, and Primary functionWH/BK 31 Reverse/EDC-BWH/RD 32 BrakeBK 33 StartBK/WH 34 Start aid (glow plug or choke)BK/RD 35 High engine speed selectBL 36 Steer clockwiseBL/BK 37 Steer counterclockwiseBL/WH 38 GasBL/RD 39 LPOR 40 Limit switch signal stowedOR/BK 41 RPM signalOR/RD 42 Boom retracted signalGR 43 Jib upGR/BK 44 Jib downGR/WH 45 AC GeneratorWH 46 Drive hornWH/BK 47 Output power enableWH/RD 48 Work lampWH/BK 49 Motion lampBL 50 Auxiliary boomBL/WH 51 Auxiliary steerBL/RD 52 Auxiliary platformWH/BK 53 Boom envelope safety valve cutoffBK/WH 54 Power to safety interlock switches

(engine)GR/BK 55 Axle oscillationRD 56 Foot switch/TCON estop powerRD/WH 57 Boom down safety interlockRD/BK 58 Safety interlock to engineGR/WH 59 Chain break circuitGR/WH 60 Axle extendGR 61 Axle retractOR 62 Boom stowed (safety)OR/RD 63 Power to boom envelope safety

switchThis list continues on the next page.

REV B


6 - 6 Z-80/60 Part No. 88619

Color, Circuit #, and Primary functionBK 99 J1708 - (low)WH/RD 100 Outrigger loweredWH/BK 101 Outrigger raisedOR 102 Pothole protector upOR/RD 103 Pothole protector downBK/WH 104 Proprietary data buss –

(i.e. ITT or AP)BK/RD 105 Proprietary data buss +

(i.e. ITT or AP)GR 106 SpareRD 107 Alternator fieldBL/WH 108 Engine statusGR/WH 109 Sensor pwrBK 110 Sensor returnOR 111 Steer signalRD 112 Steer signal to solenoid valveOR/RD 113 Multi function valveBK/RD 114 Load moment overweightRD/BK 115 Load moment underweightOR 116 Hydraulic oil coolerRD 117 Flashing beaconOR 118 Lift speed reductionBL 119 Hydraulic pressure sensor outputOR 120 Oil cooler fanGR 121 Axle oscillate LEFTGR/BK 122 Axle oscillate RIGHTRD/BK 123 Primary boom angle signal

operationalRD/WH 124 Secondary boom angle signal

operationalWH/RD 125 Secondary boomlockout

(Ext Enable)WH/BK 126 Secondary boom lockout

(Riser Down Enable)GR 127 ECU test switchOR/RD 128 Low engine speed

Color, Circuit #, and Primary functionOR/BK 64 Power for operational switchesBL/WH 65 Low fuel indicationBL 66 Drive enableBL 67 Secondary boom not stowedRD 68 Primary boom lowered

(operational)BL 69 Primary boom #1 extendedBL/WH 70 Primary boom #2 retractedBL/BK 71 Primary boom #2 extendedGN 72 Secondary boom extendGN/BK 73 Secondary boom retractRD 74 Primary #1 LockoutRD/WH 75 Primary #2 LockoutBL 76 Pri boom #3 extendedWH 77 Lower angle #1 operationalWH/BK 78 Upper angle #2 operationalBK 79 power from TCON ESTOPN/A 80 Can 2.0/J1939 ShieldGR 81 Can 2.0/J1939 LowYL 82 Can 2.0/J1939 HighGR/WH 83 Tilt signal x axisGR/BK 84 Tilt signal y axisGR 85 Tilt sensor powerOR 86 Hydraulic filter restrictedRD 87 Platform level safety powerRD/BK 88 Platform level safety outputBR 89 Platform level safety groundRD/BK 90 Proximity killRD/WH 91 Gate InterlockWH/BK 92 Motor speed (LO/HI)WH/RD 93 Motor bypassWH 94 Load sensorOR 95 Tether ESTOP returnRD 96 Tether powerBK 97 Tether ESTOP powerWH 98 J1708 + (high)

WIRE CIRCUIT LEGEND

REV B


Part No. 88619 Z-80/60 6 - 7

WIRE CIRCUIT LEGEND

Color, Circuit #, and Primary functionRD/BK 129 Descent alarmWH/RD 130 Travel alarmBL 131 Motion alarmGR 132 Platform load inputGR/WH 133 Platform load alarmGR/BK 134 Key switch powerBL/WH 135 Fuel pumpRD 136 Power to safety moduleRD/WH 137 Propel power (P_38)RD/BK 138 Pri boom up/sec boom dwn-Ext

(P_11/30)WH/RD 139 Turntable rot FC safety (P_39)OR/RD 140 Boom envelope safetyRD 141 Primary boom angle signal safetyOR 142 Secondary boom angle signal

safetyBL/RD 143 Drive enable leftBL/WH 144 Drive enable rightRD/WH 145 CalibrateBL 146 Jib bellcrank up FCBL/BK 147 Jib bellcrank down FCBL/WH 148 Jib bellcrank sensorGR/WH 149 Jib Up/Down FCGR/BK 150 Hydraulic generator bypassGR 151 Hydraulic EDCoutputBK 152 Injector retardBK 153 Jib extendBK/WH 154 Jib retractOR/RD 155 Pressure comp enableGN/WH 156 Jib Up/DownBK/RD 157 Jib Ext/RetBL/RD 158 SpareBL/WH 159 Steer joystick signalWH/RD 160 Propel joystick signalWH/BK 161 Sec boom joystick signalOR 162 Joystick 5 VDC power

Color, Circuit #, and Primary functionBL/WH 163 Pri extend/retract signalRD/WH 164 Pri up/down signalWH/RD 165 TT Rotate signalOR 166 Boom length signal safetyOR/BK 167 Boom length signal operationalBL/RD 168 Primary boom hydraulic valve

lockoutGN 169 Envelope active LEDWH/RD 170 Load sense relay sourceWH/BK 171 Load sense relay sinkBL 172 UP/DN flow control groundBK 173 Ext/Ret flow control groundWH 174 Key switch power, ground positionWH/BK 175 Load sensor signal operationalGN/WH 176 Secondary extend/retract FCBL/RD 177 Extend/retract lockoutBK 178 Control module status lightGN 179 Drive power relayBK 180 Lift power relayOR 181 48 Volt alternator field (or battery)RD 182 24 Volt batteryBL 183 Envelope or load sense recoveryWH 184 Program setup enableWH 185 Encode ABL 186 Encode BBL 187 Bootstrap or program enableGR 188 Safety cross checkBK 189 Data receiveBK/WH 190 Data transmitWH/RD 191 Multi-Function pressure reliefWH/BK 192 Jib rotate leftWH/RD 193 Jib rotate rightWH/RD 194 Speed select inputOR/RD 195 Electric brake sourceYL 196 2.5V Sensor powerBR N/A Ground or return

REV B


6 - 8 Z-80/60 Part No. 88619

Limit Switches and Angle Sensors

Types of Limit SwitchesThere are two types of limit switches, found invarious locations throughout the machine:mechanical-type operational or safety switches.As in aircraft, which features redundant safetysystems, each mechanical operational switch isbacked up with a separate, independentlyfunctioning safety switch.

The mechanical-type operational or safetyswitches are used to sense a positive displacementor movement of the limit switch actuator, or arm, asthe machine moves through its range of operationalfunctions. Included in this group are envelope limitswitches which sense the extended length andangle of the booms and rotational position of theturntable.

For example, when the secondary boom is fullyraised and the operational switch is activated, ittells the ECM at the ground controls to startextending the secondary boom.

Another example is the drive enable limit switch,which disables the drive function anytime the boomis rotated past the rear axles, indicated by the'circle' end of the drive chassis.In some cases, the engine will be stopped if safetyparameters are exceeded.

Limit Switch NumberingLSP1AO Primary boom angle stowedLSP1RO Primary boom length retractedLSP1EO Primary boom length fully extendedLSS1AO Secondary boom angle, fully stowedLSS2AO Secondary boom angle, fully raisedLSS3AO Secondary boom angle, 25° to 30°LSS2AS Secondary boom angle safetyLSS1RO Secondary boom fully retractedLSS1RS Secondary boom fully retracted, safetyLSJ1EO Platform level fully extendedLST1O Drive enable mechanicalLSA1OS Oscillate axle, right sideLSA2OS Oscillate axle, left side

O OperationalS Safety

D DownA AngleE ExtendR Retract

Numbering Legend

LS P 1 R OLS Limit switch

J Jib boomP Primary BoomS Secondary BoomT Turntable

Switch number

REV B


Part No. 88619 Z-80/60 6 - 9

LIMIT SWITCHES AND ANGLE SENSORS

Limit Switch and Angle Sensor Legend

LSA1OS: Limit switch, Axle #1 Oscillating Operational.Activates the axle oscillate circuit on the right side.

LSA2OS: Limit switch, Axle #2 Oscillating Operational.Activates the axle oscillate circuit on the left side.

LST1O: Limit switch, Operational. Activates the drive enablezone.

Turntable Angle Sensor: Measures the X axis and Y axis ofthe turntable. The alarm sounds at 4.5 degrees.

Primary Boom Angle Sensor (PBS): Measures the Y axisangle of the primary boom. The operational range shall be +33degrees to +73 degrees. The safety cutouts are set at +70degrees and will disable boom up and stop the engine.

Platform Angle Sensor: Measures the angle of the platform.The range of measurement is +/- 20 degrees. The safety cutoutis set at +/- 10 degrees from gravity and will disable the primaryand secondary boom up/down functions and the platform levelup/down functions.

LSS2AO: Limit switch, Secondary Boom #2 Angle OperationalSwitch. Secondary boom angle full extension, angle up all theway (secondary boom extend allowed).

LSS3AO: Limit switch, Secondary Boom #3 Angle OperationalSwitch. Secondary boom elevated to 30-35 degrees. Used toswitch platform/primary boom leveling parameters.

LSS2AS: Limit switch, Secondary Boom #2 Angle SafetySwitch. Secondary boom angle full extension, angle up all theway (secondary boom extend allowed).Backup switch for LSS2AO.

LSS1RO: Limit switch, Secondary Boom #1 Retract OperationalSwitch. Secondary boom fully retracted(secondary boom down allowed).

LSS1RS: Limit switch, Secondary Boom #1 Retract SafetySwitch. Secondary boom fully retracted(secondary boom down allowed). Backup switch for LSS1RO.

LSS1AO: Limit switch, Secondary Boom #1 Angle OperationalSwitch. Open when the secondary boom is fully lowered, closeswhen the boom is raised out of the stowed position. This switchlimits the drive speed and disables the drive motor destroke.The other contacts close when the boom is fully loweredallowing the platform to be tucked underneath the mast fortransport.

LSP1AO: Limit Switch, Primary Boom #1 Angle Operational.One side closes when the primary boom is raised from thestowed position, disabling the drive motor destroke and limitingthe drive speed. The other side of the switch closes when theboom is fully lowered allowing the platform to be tuckedunderneath the mast for transport.

LSJ1EO: Limit Switch, Jib Boom #1. Closes when the platformleveling cylinder is fully extended, disabling the primary boomdown function.

LSP1EO: Limit Switch, Primary Boom #1 Extend Operational.Switch closes as the primary boom extends the last 6 to 12inches signaling the computer.

LSP1RO: Limit Switch, Primary Boom #1 Retract Operational.Switch closes when the primary boom is fully retracted.

PLATFORMANGLE

SENSOR

JIBBOOM

LSJ1EO

PRIMARYBOOM

DRIVE CHASSISCONTROL BOX

LSA2OS

LSA1OS

TURNTABLEANGLE SENSOR

LST1O

LSS1AO

LSS1RS

LSS2AS

LSS2AO

LSS3AO

LSP1EO

LSS1RO

LSP1AO

LSP1RO

PRIMARYBOOM ANGLESENSOR

SECONDARYBOOM

REV B


6 - 10 Z-80/60 Part No. 88619

Drive Chassis and Platform Controller Pin Legend

PIN NUMBERING FOR23 PIN

CONNECTORS

16 23

1 8

PCONPLATFORM

CONTROLLER

J211 = (UNUSED)

2 = P52PCON - BL/RD

3 = (UNUSED)

4 = S56PRV - RD

6 = (UNUSED)

5 = (UNUSED)

7 = P56PRV - RD

8 = (UNUSED)

9 = (UNUSED)

10 = D80SHIELD

12 = (UNUSED)

14 = (UNUSED)

16 = C46HRN - WH

15 = C47OUT - WH/BK

13 = (UNUSED)

11 = (UNUSED)

17 = D81CAN(-) - GR

18 = D82CAN(+) - YL

19 = (UNUSED)

20 = (UNUSED)

21 = (UNUSED)

22 = (UNUSED)

23 = P23PCON - BK

PCONPLATFORM

CONTROLLER

J221 = VLVRET7 - BR

2 = (UNUSED)

3 = C17PRL - GR

4 = C18PRR - GR/BK

6 = C44JD - GR/BK

5 = C43JU - GR

7 = C14PLU - OR

8 = C15PLD - OR/BK

9 = (UNUSED)

10 = R90PXS - RD/BK

12 = (UNUSED)

14 = (UNUSED)

16 = R56PTS - RD

15 = C88PTS - RD/BK

13 = (UNUSED)

11 = C90PXS - RD/BK

17 = C56PTS - RD

18 = S14PLU - RD

19 = PLATRET - BR

20 = C84TAY - GR/BK

21 = P85PTS - GR

22 = PTSRET - BR

23 = P87PTS - RD

J21BLACK23 PIN

CONNECTOR

J22WHITE23 PINCONNECTOR

DCONDRIVE CHASSISCONTROLLER

J311 = GND-DCON - BR

2 = P21DCON - WH

3 = P53LS - RD

4 = (UNUSED)

6 = C61AXRT - GR

5 = S56PRV - RD

7 = (UNUSED)

8 = AXLE RET GND

9 = C61LS - GR

10 = D80SHLD

12 = RS232 TXD

14 = (UNUSED)

16 = (UNUSED)

15 = C61LS(A) - GR

13 = BOOT

11 = RS232 RXD

17 = D81CAN(-) - GR

18 = D82CAN(+) - YL

19 = RS232 GND

20 = (UNUSED)

21 = (UNUSED)

22 = (UNUSED)

23 = C61LS(A) - GR

DRIVE CHASSISCONTROLLER

J32

DCON

1 = VLVRET - BR

2 = V61AXRT - GR

3 = V60AXEX - GR/WH

4 = V29MS - RD/WH

6 = V52AFV - BL/RD

5 = (UNUSED)

7 = V52REV - BL/RD

8 = V36RRS - BL

9 = V37RRS - BL/BK

10 = C111RRS - OR

12 = C111RFS - OR

14 = VLVRET2 - BR

16 = V36LRS - BL

15 = V32BRK - WH/RD

13 = C111LFS - OR

11 = C111LRS - OR

17 = V37LRS - BL/BK

18 = V36RFS - BL

19 = P110RT - BK

20 = P109ANG - GR/WH

21 = V37RFS - BL/BK

22 = V36LFS - BL

23 = V37LFS - BL/BK

J32WHITE23 PIN

CONNECTOR

J31BLACK23 PINCONNECTOR

REV B


Part No. 88619 Z-80/60 6 - 11

Engine Relay and Fuse Panel Legend

1 2

5 6

3 4

7 8

CR17

CR5 OPTIONRELAY

CR2

F17 F7

LABEL GENIE P/N

34052

34052

34052

60536

60536

F7

F17

CR2

CR5

CR17

IGNITION/FUEL RELAY

HORN RELAY

HYDRAULIC OIL COOLER FAN RELAY

FUSE, 20A, HYDRAULIC OIL COOLER FAN

FUSE, 20A, STARTER AND ALTERNATOR

DESCRIPTION

GM 3.0L

34052

34052

34052

60536

60536

88151

61225

60536

GENIE P/NLABEL

F7

F16

F17

F20

CR1

CR2

CR5

CR17

START RELAY

IGNITION/FUEL RELAY

HORN RELAY



FUSE, 70A, ENGINE RPM AND COLD START


FUSE, 20A, ENGINE RPM

DESCRIPTION

DEUTZ F4L 913(before serial number 339)

1 2

5 6

3 4

7 8

CR2 CR17

CR5OPTIONRELAY

CR1 PR2

F16

F17 F7

F20

61225PR2 STARTING AID RELAY

34052

34052

61225

60536

101340

61225

60536

GENIE P/NLABEL

F7

F20

F22

CR1

CR28

CR5

CR15

START RELAY

ENGINE RUN/ALTERNATOR FIELD RELAY

HORN RELAY

GLOW PLUG RELAY


FUSE, 20A, ENGINE RPM

FUSE, 60A, GLOW PLUG

DESCRIPTION

DEUTZ BF4L-2011(after serial number 338)

1 2

5 6

3 4

7 8

CR28 CR17

CR5

R21

CR1

F20

F22 F7

F23

94327F23 FUSE, 30A, ENGINE

CR15

B1

B2

GND

34052CR17 HYDRAULIC OIL COOLER FAN RELAY

REV B


6 - 12 Z-80/60 Part No. 88619

Engine Relay and Fuse Panel Legend

LABEL GENIE P/N

61255

34052

34052

34052

60536

CR4

F7

CR1

CR5

CR17

START RELAY

HORN RELAY


RPM RELAY

FUSE, 20A, HYDRAULIC OIL COOLER

DESCRIPTION

FORD LRG 425

PERKINS 804C-33(after serial number 328)

1 2

5 6

3 4

7 8

CR2 CR17

CR5 CR1

F16

F17 F7

F20

1 2

5 6

3 4

7 8

CR28 CR17

CR5 CR1

F16

F22 F7

F17

CR4 CR15

R21

GND

B1

B2

R21

GND

B1

B2

60536F17 FUSE, 20A, STARTER AND ALTERNATOR

34052

34052

61225

34052

61225

60536

GENIE P/NLABEL

CR4

F17

CR1

CR2

CR5

CR15

START RELAY

IGNITION POWER RELAY

HORN RELAY

GLOW PLUG RELAY

RPM RELAY

FUSE, 20A, ENGINE

DESCRIPTION

34052CR17 HYDRAULIC OIL COOLER FAN RELAY

88151F22 FUSE, 70A, GLOW PLUG

94327

60536

F7

F16

FUSE, 30A, OIL COOLER, RPM

FUSE, 20A, STARTER

34052

34052

34052

34052

34052

60536

60536

60536

GENIE P/NLABEL

F7

F16

F17

CR1

CR2

CR4

CR5

CR17

START RELAY

IGNITION/FUEL RELAY

HORN RELAY

RPM RELAY



FUSE, 20A, ENGINE RPM AND COLD START


DESCRIPTION

PERKINS 704-30(before serial number 329)

1 2

5 6

3 4

7 8

CR2 CR17

CR5OPTIONRELAY

CR1 CR4

F16

F17 F7

REV B


Part No. 88619 Z-80/60 6 - 13

Turntable Controller Pin Legend

REV B


6 - 14 Z-80/60 Part No. 88619

Electrical Symbols Legend

REV B


Part No. 88619 Z-80/60 6 - 15

Hydraulic Symbols Legend

Pumpfixed displacement

Motorbi-directional

Shut off valve

Check valve

2 position, 3 way, shuttle valve

Double actingcylinder

Priorityflow regulator valve

Differentialsensing valve

Solenoid operatedproportional valve

Hydraulic oil cooler

Brake

Pilot operated 3 position,3 way, shuttle valve

Filter withbypass valverelief setting

25 psi(1.7 bar)

Motor2-speed,

bi-directional

Pumpbi-directional,

variable displacement

E

Pump prime mover(engine or motor)

Directional valve(mechanically activated)

o

Relief valvewith pressure setting

200 psi(13.8 bar)

Orifice with size

.035"(0.89 mm)

Solenoid operated 3 position,4 way, directional valve

Directional valvepilot operated

2 position, 2 way

Flow divider/combiner valvewith pressure balancing orifice

and flow percentages

50% 50%

Counterbalance valvewith pressure and pilot ratio

(206.8 bar)3000 psi

3:1

Solenoid operated 2 position,3 way, directional valve

2 position, 2 waysolenoid valve

Accumulator


6 - 16 Z-80/60 Part No. 88619


REV C

July 2006 Section 6 • Schematics

Electrical Schematic Legend

Part No. 88619 Z-80/60 6 - 17

TCON MEMBRANE PANEL

BOOMCW

PLTFRMCW

PLTFRMDOWN

JIBDOWN

JIBUP

PLTFRMCCW

BOOMCCW

TURTLE

RABBIT

SEC.DOWN

BOOMDOWN

ROOMRET

BOOMEXT

PLTFRMUP

1235 4678910

11

12

1315

P11

14

J11

SEC.UP

AUXILIARY

BOOMUP

GAS/LP

ENGSPEED

-BUTTON

+BUTTON

START

SCROLLR

STRTASST

SCRLF/ENT

1245 3678911

10

12

13

14

P10

15

J10

(P15)+(ECU POWER)

AUXILIARY HYD RECOVERY SIGNAL

MULTI FUNCTION VLV RECOVERY SIGNAL

BOOM RET RECOVERY SIGNAL

BOOM DWN RECOVERY SIGNAL

P_30

(P15)+(ECU POWER)

BOOM UP/DWN FC RECOVERY SIGNAL

BOOM EXT/RET FC RECOVERY SIGNAL

LOCKOUT VALVE #1 SIG



(P15)+(ECU POWER)

P_30

PRI BOOM DOWN STATUS

PRI BOOM LENGTH 100' STATUS






(P15)+(ECU POWER)







P_30

TO

PLD

TOMICRO

TOMICRO

TOMICRO






TO MICRO

P_22R

P_30

P7R

P10







P_22R

P_30

P10

P7R


P9AP9A

TOMICRO

TOPLD

TOMICRO

TOMICRO

TOMICRO

TOMICRO

TOMICRO

TOPLD

TOMICRO

TOPLD

TOMICRO

TOPLD

TOMICRO

TOMICRO

TO

MICRO

AUX_RELAY

VALVE_RTN6

SEC.BOOMF.C.

ROTATE_CCW_VLV

ROTATE_CW_VLV

BOOMOVERLOAD

BOOMREVERSELOAD

HYD_FILTER2

HYD_FILTER1

MULTI_FUNCT_VLV

SEC_UP_VLV

SEC_RET_VLV

SEC_EXT_VLV

PRI_RET_VALVE

PRI_EXTEND_VLV

PRI_UP_VLV

PRI_DOWN_VLV

DRIVELIGHTSRELAY

SEC_DWN_VLV

VALVE_RTN5

VALVE_RTN7

P4-31

C27AUX-RD

VALVERTN6

VALVERTN7

P4-21

P4-16

P4-11

C10SBU-BL

C04TRL-WH

VLVRET5-BR

VLVRET5-BR

C01PBU-RD

C07PBE-BK

VLVRET5-BR

P4-34

P4-35

P4-32

P4-29

P4-30

P4-27

P4-24

P4-25

P4-26

P4-28

P4-33

P4-23

P4-22

P4-20

P4-18

P4-17

P4-15

P4-19

P4-12

P4-13

P4-10

P4-08

P4-06

P4-05

P4-07

P4-09

P4-14

P4-04

SEC

BOOM

EXT

SEQ

#1VLV

SEC

BOOM

DOWN

SEQ

#2

VALVE

TURNTABLE_ROTATE_VLV

TOMICRO

TOPLD

P11P11

BOOM_UP/DOWN_VLV

VALVE_RTN4

P4-01

MANIFOLD HARN

J14 WHITE 35 PIN

VLVRET4-BR

P4-02

-

+1C84TAY-GN/BK

P4-03

BOOM_EXT/RET_VLV

P6R1 P6R1

P22R

P7R

P10

(SM)+(AH)

P22R

TO MICRO

13

74HC08

1214

U95

P_22

OUT PWR ENABLE (OE)

P_22

P_9B

PWR TO TCON ESTOP

TO HORN BUTTON

OUT PWR ENABLE

OUT 1

OUT 2ST

IN2

IN1

BTS621Vbb

P22R

((~SM)+(AH))(P_22)

BTS650

INOUT

VbbP7R

P_6R2 GND

VbbBTS621

P_6R2

GND

ST

IN2OUT 1

OUT 2

IN1

P_710

8

74HC08

P_7

TO

HO

RN

BU

TTO

N

(SM

)+(A

H)

P7R

P9A

(~SM)+(AH)AUX HYD (AH)

5

4

23

5

74HC08

~SLP MODE (~SM)

TCON MODE(TM)

P_7

FUNC ENABLE (FE)

P6R11

74HC08

(OE)46

((~SM)+(AH))(P_7)

BTS650

INOUT

Vbb

8

74HC08

10

(~SM)+(AH)

(BM STOWED)

BTS650

INOUT

Vbb

P_6R2

IS

((~SM)+(AH))(BM STOWED)

OUT 1

BTS621

IN1

IN2

Vbb

OUT 2ST

(TM)(FE)

((~SM)+(AH))(OE)

GND

P_7

P_7

BOOM STOWED

TCON MODE

IS

9

(P15)+(ECUPOWER)IS

9

TO HORN BUTTON

PWR TO TCON ESTOP

P_9B

P_22

OUT PWR ENABLE

P_22

P_6R2

PWR TO TCON ESTOP

TO HORN BUTTON

P_22

OUT PWR ENABLE

J127 LOADPSENSE LED

21

RED ALARMPLED

P_7

TCON MODE

BOOM STOWED

P_7

TCON MODE

P_7

TCON MODE

(P15)+(ECU POWER)

P_11

TO

PM

ICR

O

TO

PM

ICR

O

5V 12V

14

P10

7 GND

TOPMICROTOPMICRO

TO

PM

ICR

O

PCON POWER

U32

P_1

P10

P6R1

P9A

PCON POWER

20A

CB TO

PM

ICR

O

P_11

74HC08

VALVE_RTN3

ACGENERATOR

ALTERNATORRPM

VALVERTN_2

TT_TILT_X_AXIS

TT_TILT_Y_AXIS

ACGENERATOR

REV

FWD

EDCFWD

EDCREV

IGN/FUEL

THROTTLE

OIL/WATER_TEMP

TT_TILT_SNSR_GND

OIL_PRESSURE

TT_TILT_SNSR_PWR

STARTERRELAY

SERVICEHRN

VALVERTN#1

BATECU-PWR

P1-16

P1-19

P1-21

C84TAY-GN/BK

P1-12

P1-11

P1-01

ENGINE HARN

J13 WHITE 23 PIN

P1-23

P1-13

P1-15

P1-14

P1-17

P1-20

P1-18

P1-22

P1-08

P1-03

P1-02

P1-06

P1-05

P1-04

P1-07

P1-10

P1-09

BATECUGND

SYSBATGND

SYS_BAT_PWR

BATECU-PWR

POWER HARN

J15 BLACK 4 PIN

P1-01

P1-03

P1-04

P1-02

P10

PCON POWER

P9A

P6R1

P10

PCON POWER

P9A

P6R1

P11P11

TOPLD

U32

U31

TOMICRO

TOMICRO

TOPLD

TOMICRO

PCON POWER

P6R1

PWR TO TCON ESTOP

OUT PWR ENABLE

TCON MODE

P11

PCON POWER

P7R

P_22

P11

P6R1

P_7

U30

P_30

VLV

RET

LSB13AO

LSB14AO

DIGITALIN

BOOMSTOWED

SECANGINPUT

PRIANGINPUT

TOPLD

P2SEQ

LSS1AO

LSS2AO

LSP1EO

LSP1RO

LSP1AO

LSB12RO

.LSB2RO

P1SEQ

FST1S

P_18

P_12

P_14

P_10

P_9B

P_7R

P_9A

P_11

P_6R2

LST10

SNSRGND

OPERSW

PWR

SNSR

PWR

PRESSURE

GA

P2-31

P2-21

P2-16

P2-11

P2-33

P2-34

P2-35

P2-32

P2-28

P2-29

P2-30

P2-27

P2-26

P2-24

P2-25

P2-22

P2-19

P2-20

P2-17

P2-15

P2-14

P2-18

P2-23

P2-13

P2-12

P2-10

P2-09

P2-08

P2-07

P2-05

P2-06

P2-04

DCONECUGND

DCONECUPWR

LIMIT SWITCH HARN P2-01J12 BLACK 35 PIN

P2-02

P_6R1

P2-03

TOPLD

TOMICRO

TOMICRO

P6R1P7RTO HORN BUTTON P7R P7R P7RP7R

P_22R

P_30







BL/WH

PLAT

2 1

CGROUND

OFF

E

2 1

GROUND

TCON ESTOP

1

USERV BYPASS

RECOVERY

2

3

X

4

OFF

DGROUND

OFF

PLAT

2 1

P23PCON-BK

Y

34

PLAT

G-PMODEGR/BK

GROUND

PLAT

WH/BK

1 2

OFF

PLAT

B

2 1

GROUND

34

1

W

2

C47OUT

WH/BK

V

12

P_15-OR/BK

C47OUTWH/BK

S1PBU-OR

ALM-GND-BR

ALMPWR-RD

P_7PLAT-GR/WH

TCONMODE

AZ

JOYSTICK (JC3)

75 6431765 23 4

J25

JOYSTICK (JC2)

JOYSTICK (JC1)

TURNTABLE ROTATE

7 15421 3 67654321

J28

J27

J26

JOYSTICK (JC5)

2

H4_PWR-OR

H4_GND-BR

H2_GND-BR

H1_PWR-OR

H1_GND-BR

H3_GND-BR

H3_YOUT-GN

H4_STEER-BL

H4_YOUT-WH

H4_XOUT-PR

H3_PWR-OR

H2_PWR-OR

H2_YOUT-YL

H1_XOUT-RD

H1_YOUT-BK

E-STOP (P2)JIBPLATFORM

ROTATE

PCON

ALARMPLATFORM

LEVEL

GND13-BR

GND6-BR

JIBUP-GN

GND16-BR

GND12-BR

ESTOPRET-BK

PLATLVLDN-OR/BK

PLATLVLUP-OR

PLATROTR-GN/BK

PLATROTL-GN

ALARM+RD/BK

ESTOPPWR-RD/BK

JIBDN-GN/BK

SEC BOOM UP/DWNPCON DRIVE & STEERINGPRI BOOM EXT/RETBOOM UP/DWN &

PCON MEMBRANE PANEL (MS1)

OFFRUN

BL/BK

C47OUTWH/BK

C47OUTGR/BK

P53LS-BK/WH

P23PCON-BK

OR/BK

RD/WH

OR

GR/WH

RD

SRV

REC-WH

P56PRV-RD

S56PRV-RD/BK

3 2 1

J17

7 6 45

BM3'I

BM100'I

PCONMODE

P6R1

ECUPOWER

PRILO#1O

BMDWNO

BME/RFCO

BMRETO

MLTFNCVLV

O

AUXHYDO

BMDWNSTI

11

14

13

12

10

9 8

P11

16

15

TCONMODE

OPER.REC.

P7-GN/WH

P22

P7R

ALARMGND

ALARMPWR

START

9

P2

P2

876

P2

P2

5

P2

P2

4

P2

21

P2

P2

P2

9

P1

P1

3876

P1

P1

43

P1

P1

P1

5

P1

J24B 10PINJ24A 10PIN

10

10

PIN CKT #P P2 RS232_RXDP3 RS232_TXDP5 RS232_GND

ON CIRCUIT BOARDPDB9 CONNECTOR

ECU POWER

TO MICRO

P15P15

OPER.REC.

SERV.OR

P15

10

876 94321 5

P7R

TETHERESTOP-BL/RD

TCONESTOP-BL/WH

PWRTOTCONESTOP-BL/BK

SERV.OROPER.REC.

OUTPUTPWRENABLE

VIC

EO

RR

EC

OV

ER

YM

OD

E

J23 10PINMEMBRANE/LED INTERFACE CARD

INS

ER

VO

RR

EC

OV

ER

YP

RO

VID

ES

PW

RTO

MIN

IMA

LH

AR

DW

AR

E

HORN

21

P1

P1

15

16

11

13

12

14

86 7 10

92 3 4 5120

19

ECU

P7R

GND6-BR

GND12-BR

GND13-BR

GND16-BR

16

15

17

14

12

13

11

9 10

8765431 2

P20 18

ESTOP PWR-RD/BK

H3_GND-BR

H3_PWR-OR

H2_GND-BR

H2_PWR-OR

H4_YOUT-WH

H4_XOUT-PR

H4_STEER-BL

H3_YOUT-GN

H2_YOUT-YL

H1_YOUT-BK

H1_XOUT-RD

H1_PWR-OR

H1_GND-BR

H4_PWR-OR

H4_GND-BR

PLATLVLUP-OR

PLATLVLDN-OR/BK

ESTOPRET-BK

JIBUP-GN

JIBDN-GN/BK

PLATROTL-GN

PLATROTR-GN/BK

ALARM+RD/BK

ESTOPPWR-RD/BK

OUT 1IN1

BTS621

U22

P6

6 Vbb

OUT 2ST

GND

3

IN2

BTS650

OUT

U21

IN

Vbb

IS

CAN

HIGH

DIAG/TETHERPWR

DIAG/TETHERGND

TETHERFUNCENBL

TETESTOPRET

RS232GND

CANLOW

BOOT

P_7

P_22

WORKLT

CALFREQ2

TETESTOPPWR

RS232TXD

RS232RXD

CANSHIELD

FLASHINGBEACON

CALFREQ1

PWR-PCONESTOP

OUTPWRENBL

TCON

PCONGND

PCONPOWER

HORNRELAYCOIL

P1-21

BOOM HARNP1-18

P1-19

P1-17

P1-15

P1-16

P1-12

P1-13

P1-11

P1-10

P1-09

P1-14

P1-06

P1-05

P1-01

P1-23

P1-22

P1-20 J11 BLACK 23 PIN

P1-07

P1-08

P1-04

P1-02

P1-03

CAN+

PWR-PCON

ESTOP

P22

P7

PIN CKT #P P2 RS232_RXDP3 RS232_TXDP5 RS232_GND

HRNRLYCNTRL

OUTPWRENBL

PCONPWR

PCONGND

CAN-

P1-21

P1-19

P1-18

BOOM HARN

J21 BLACK 23 PIN

P1-16

P1-15

P1-12

P1-11

P1-01

P1-23

P1-22

P1-17

P1-20

P1-14

P1-13

P1-10

P1-09

P1-08

P1-07

P1-06

P1-05

P1-04

P1-02

P1-03

U30

P224

P6

1

SLP_MODE

P7

5

P6

U20

2

VLV

RTN

LOADSNSRIN

LOADSNSRGND

LOADSNSRPWR

PLLVLCYLEXT

SAFEPLTILTGND

SAFEPLTILTPWR

PLTILTSNSRGND

PLTILTSNSRPWR

FOOTSW

RTN

PLTILTSNSR

PROXKILLCMD

SAFEPLTILTOUT

PROXKILLGND

PROPVLV1_B

PROPVLV1_A

PROPVLV2_B

PROPVLV2_A

ON/OFFVLV3_A

ON/OFFVLV3_B

FOOTSW

PWR

P1-18

P1-19

P1-21

P1-15

P1-16

P1-01

P1-11

P1-12

BK

GN

WH

J22 WHITE 23 PIN

PCON MANIFOLDP1-20

P1-17

P1-22

P1-23

P1-02

P1-03

P1-04

P1-05

P1-06

P1-07

P1-08

P1-09

P1-10

P1-13

P1-14

P1-23

P1-21

P1-22

P1-20

P1-18

P1-17

P1-16

P1-15

P1-14

P1-12

P1-13

P1-11

P1-19

P1-10

P1-03

P1-09

P1-08

P1-07

P1-06

P1-05

P1-04

P1-02

P1-01

CANSHIELD

RS232RXD

RS232TXD

BOOT

CAN-

CAN+

RS232GND

P_6R1

P_7R

P12

AXLENOTEXTPWR

AXLENOTEXTSIG

DCONECUPWR

DIGINAXLERETGND

AXLENOTRETRTN

DCONECUGND

74HC08

74HC08

ON CIRCUIT BOARDPDB9 CONNECTOR

N EN7

J31 23 PINPDRIVE CHASSISPHARNESSJ32 23 PINPDRIVE CHASSISPHARNESS

P2-23

P2-18

P2-20

P2-19

P2-22

P2-21

P2-11

P2-13

P2-12

P2-14

P2-15

P2-16

P2-17

BRAKE

VALVERTN2

P2-08

P2-09

P2-10

P2-07

P2-01

P2-02

P2-04

P2-05

P2-06

P2-03

VALVERTN1

MOTORSPEED

AUXFORWARD

AUXREVERSE

OSCIL;ATESTOWED

RFSTEERRIGHT

LFSTEERLEFT

STEERSNSRGND

STEERSNSRPWR

RFSTEERLEFT

LFSTEERRIGHT

RFSTEERSNSR

LRSTEERSNSR

RRSTEERSNSR

RRSTEERLEFT

RRSTEERRIGHT

LRSTEERSNSR

LRSTEERRIGHT

LRSTEERLEFT

FUELTYPE

SPARE2

COORDSTEER

CRABSTEER

REARSTEER

FRONTSTEER

AXLEEXTEND

DRIVESPEED

ENGINESPEED

SPARE1

AXLERETRACT

DRIVEENABLE

AUXILIARY

ACGENERATOR

STARTASSIST

PLD

BMU/DFCO

C72SBE-BL/WH

C73SBR-BL/RD

C10SBU-BL

P125SBLE-WH/RD

P126SBLD-WH/BK

-

0D

EG

RE

ES

EN

SO

RA

LA

RM

SE

TA

T4

.5D

EG

RE

ES

3

4RET85TTSR-BR

P85TTSR-GR

6

5

REDRD/12VDC

DETAIL C OPT 120VAC W/REGULATOR

BRN

YEL

BRN

11

0V

AC

PR

EG

ULA

TO

R

BR/R45GEN(A)

BR/P45GEN(B)

YL/BAT GND

J31-TILTSNSR

P31-ENGHARN

P126SBLD-WH/BK

P125SBLE-WH/RD

PURPLEPURPLE/F45GEN

J34P34

SEE DETAIL D FOR 220VAC GENERATOR W/REGULATOR.

12VOLT

5

87a

871

286

30 4

85

3TO DRIVEPLAMPS

C11SBD-BL/BK

R49LP-WT/BK

PP P

C27AUX-RD

VALVERTN6

VALVERTN7

C05TRRWH/BK

C04TRL-WH

C10SBU-BL

C73SBR-BL/RD

C72SBE-BL/WT

C08PBR-BK/WH

VLVRET5-BR

C12SBFC-BLU/WT

C01PBU-RD

C02PBD-RD/BK

C07PBE-BK

C06TRF-WH/RD

V125SBLE-WH/RD

P126SBLD-WH/BK

V126SBLD-WH/BK

3

2

4

V125SBLE-WH/RD

P126SBLD-WH/BK

V126SBLD-WH/BK

8630

87a 8785

CR28PENG ALTPRELAY

C21IGN-WH

B1ENG-RD

JXX JXX

P

V125SBLE-WH/RD

V126SBLD-WH/BK

87a

D7R116HYD-OR

C25PSR-WT/BK

C26TSR-WT/RD

DUETZ BF4L2011 ENGINE SHOWNPSEE DETAIL "A" FOR PERKINS PDETAIL "B" FOR FORD.

R21IGN-WH

C03PBF-RD/WH

VLVRET4-BR

C09PERF-BK/RD

1P125SBLE-WH/RD P125SBLE-WH/RD

P85TTSR-GR

RET85TTSR-BR

VLVRET2-BR

C21IGN-WH

C46HRN-WH

C33STR-BK

C30EDC-WH

CB 87a

30A1

8730

P32-GEN HARNJ32-ENG HARN

2 58586

WT1

RDBK3

GR2

C45GEN-GR/WH

WHT-NEUTRAL

C26TSR-WH/RD

C25PSR-WH/BK

B1ENG-RDB1ENG-RDB1ENG-RDB1ENG-RD

BLK-120VAC

MAIN

AUX

RD

RD

B2BAT-RD

B1BAT-RD C33STR-BK

C67SBD-BL

C77SBU-WH

S12SBL-BL/WH

GNDDCN-BR

P21DCN-WH

P53LS-WH/BK

S56PRV-RD

C73SBR-BL/RD

C124SBL RD/WH

C68PBD-RD

S12SBL-BL/WH

P54ENG-BK/WH

P58LSRD/BK

C68PBD-RD

C73SBR-BL/RD

C64LS-OR/BK

C65LOF-BL/WH

C66DREN-BL

P54ENG-BK/WH

P54ENG-BK/WH

C66DREN-BL

P58LS-RD/BK

C64LS-OR/BK

SNSR

GND-BR

P53LS-WH/BK

P109PBTS-GR/WH

C68PBD-RD

C64LS-OR/BK

P126SBLD-WH/BK

V125SBLE-WH/RD

C21IGN-WH

V126SBLD-WH/BK

P126SBLD-WH/BK

V125SBLE-WH/RD

V126SBLD-WH/BK

P34SA-BK/WH

P116HYD-OR

WH-PULL IN

P116HYD-OR

P34SA-BK/WH

C34SA-BK/WH

V125SBLE-WH/RD

P126SBLD-WH/BK

20A

F7

F22

20A

F20

20A

60A

F23

V126SBLD-WH/BK

V125SBLE-WH/RD

P126SBLD-WH/BK

V126SBLD-WH/BK

RD

RD

P35RPM-BK/RD

B1ENG-RD

F7 OIL COOLERPF20 HI/LO COOLERPF22 GLOW PLUGPF23 ENG/ST/ALT

R21IGN-WH

85 87

86

CR17POILPCOOLERPRELAY

RD-HOLD

B

GND-

MOM N.O.

TIME DELAY

87a 8785

8630

CGND-

AUX+

ACR5PHORNPRELAY

87a8785

RD-HOLD

CR15PST AIDPRELAY

OTS1PN.O.

GND04-BR

GND04-BR

321

C30EDC-WH

C31EDC-WH/BK

C116HYD-WH

J57

D2

C41RPM-OR/BK

P46HRN(A)-WH

VLVRET2-BR

C107AF-RD

8630

WH-PULL

IN

BATGND(A)-BK

85

8630

87a 87

CR1PSTARTERPRELAY

P33STR-BK

2122

RD

BK

BR

WH

4 3 2 1

C64LS-OR/BK

C68PBD-RD

C21IGN-WH

P116HYD-OR

C35RPM-BK/RD

TROMBETTA

P53LS-WH/BK

SJ1-WH/RD

C73SBR-BL/RD

C67SBD-BL

C77SBU-WH

SJ1-WH/RD

P53LS-WH/BK

C64LS-OR/BK

C64LS-OR/BK

C64LS-OR/BK

P53LS-WH/BK

SJ1-WH/RD

V125SBLE-WH/RD

P125SBLE-WH/RD

V126SBLD-WH/BK

P126SBLD-WH/BK

P58LS-RD/BK

S59SBE-GR/WH

S59SBE-GR/WH

P58LS-RD/BK

C65LOFL-BL/WH

C64LS-OR/BK

C64LS-OR/BK

1018/19PCABLE

5 64 73 11

4 3 2 1

BR

WH

BK

RD

22 21

RD

BK

22

BR

21

WH

1314

BR

BK

RD

WH

21

RD

22

BK

WH

BR

12 11

BR

WH

BK

RD

4 3 2 14 3 2 12 14 3 2 12 1

WH/BK

WH/RD

WH

RD/BK

RD/WH

BK

OR

12 11

RD

BK

WH

BR

RD

WH

BKWH

21

RD

BR

BK

22

BR

4 3 2 1

V126SBLD-WH/BK

P126SBLD-WH/BK

P125SBLE-WH/RD

V125SBLE-WH/RD

BK

C64LS-OR/BK

C77SBU-WH

C67SBD-BL

C64LS-OR/BK

C64LS-OR/BK

C66DREN-BL

C73SBR-BL/RD

C64LS-OR/BK

C65LOFL-BL/WH

C64LS-OR/BK

P53LS-WH/BK

SJ1-WH/RD

P58LS-RD/BK

S59SBE-GR/WH

S59SBE-GR/WH

SJ1-WH/RD

BL/RD

OR/RD

P58LS-RD/BK

BK/RD

P53LS-WH/BK

C64LS-OR/RD

C124SBLRD/WH

BL/WH

18

/19

PC

AB

LE

12189321

J20BP12 WAYJ20AP4 WAY

GNDDCN-BR

S56PRV-RD

GNDDCN-BR

S56PRV-RD

BL

BL/BK

GN

OR/BK

18

/19

PC

AB

LEP21DCN-WH

P53LS-WH/BK

P21DCN-WH

P53LS-WH/BK

BK/WH

GN/WH

GN/BK

RD

2

S12SBL-BL/WH

SNSRGND-BR

SNSRGND-BR

P54ENG-BK/WH

C70PBR-BL/WH

C71PBE-BL/BK

SJ1-WH/RD

SNSRGND-BR

C123PBDRD/BK

P109PBTS-GR/WH

C64LS-OR/BK

S59SBE-GR/WH

C64LS-OR/BK

C64LS-OR/BK

C124SBLRD/WH

4 3 2 1

P125SBLE-WH/RDP125SBLE-WH/RDP125SBLE-WH/RDP125SBLE-WH/RDS59SBE-GR/WH

30

3

4

120VAC

15A

RESET CB

AUTO

TTROTCW

VLV

(J70)

TTROTCCW

VLV

(J71)

(DWNENABLE)SECBMDNSEQ#2

(EXTENABLE)SECBMEXTSEQ#1

D8

OILPRESSURE

OILTEMPSENDER

BATGND-BR

BATGND-BR

FU

EL

SO

LE

NO

ID

HY

DR

AU

LIC

PO

ILC

OO

LE

RFA

N

BA C D

HOLD

PULLIN J120

D1

PR1

C27AUX-RD

TE

MP

PS

W

DU

AL

PC

OIL

PE

DC

HO

RN

PR

ELA

Y

BATGND-BR

H1

BAT

GND-BR

TO

J4

-32

PW

HIT

E3

5P

IN

NC

BRN NO

14 13

B1B2

STA

RTE

RAU

XH

YD

PE

LE

CTR

ON

ICS

PB

ATTE

RY

STA

RT

BA

T

BK

WH

RD

BR

4 3 2 1

BAT

GND-BR

14

22

13

21

NC

BRN NO

GLO

WP

LU

G

PR

ELA

Y

GLO

WP

LU

G

ENGINEBLOCK

SE

RV

ICE

PH

OR

N

AU

XH

YD

PC

ON

TA

CTO

R

STA

RTE

RR

ELA

Y

AU

XH

YD

PU

MP

HI/LO

SP

EE

DP

SO

LE

NO

ID

ALTE

RN

ATO

R

GRN

14 13

NC

BLU NO

14 13

NO

RED NO

2324

ORNPUR

NC

NO

1314

NC

NC

22 21

YEL

NC

NC

22 21

NC

13

NOWHT

WHT

WHT

1413

NO

NC

14

WH/BK

WH/RD

RD/BK

RD/WH

WH

8

BK

WH

RD

BR

4 3 2 1

BK

WH

RD

BR

RD

WH

BK

BR

4 3 2 12 1

WH

BK

BR

RD

WH

BK

RD

BR

4 3 2 14 3 2 1

WH

BK

BR

RD

RD

WH

BK

BK

2 1

WH

BR

RD

BR

4 3 2 1

PE

XTE

ND

ED

PJ4

4

PJ5

1

48 PJ4

9

YP

J4

7

GN

GN/BK

BL

BL/BK

OR/BK

BK/WH

73 11 2 641210J114

12 WAY

-++ -

-+

EG

Y-A

XIS

ILT

SN

SR

RD

14

22

13

21

NC

14

22

13

21

NCNO

14

24

13

2314 13

NC

22 21

21

NC

1112

22

GRNNO

BLU NONOREDORN NOPUR NC

22 21

12 11

NC

21

NC

1314

2222

14

21

13

NC

YEL NCNOWHT

WHT

WHTNO

PJ5

1

PJ4

9

48YP

J4

7

PE

XTE

ND

ED

PJ4

4

PRI BOOM ANG SENSOR

NC

NO

4 3 2 1

CO

OLE

RP

RE

LA

Y

RD D5 D3

VLVRET-BR

R34SA-BK/WH

WH

RD

BK

2122

PRIDWNVLV

(J60)

PRIEXTVLV

(J62)

PRIUPVLV

(J59)

PRIRETVLV

(J63)

SEC.BMF.C.(J64)

SECUPVLV

(J67)

SECDWNVLV

(J68)

SECRETVLV

(J66)

SECEXTVLV

(J65)

PRIBMUP/DNF.C.(J58)

PRIBMEXT/RETF.C.(J61)

TTROTCW/CCW

F.C.(J69)

FS

T1

SP

LO

WFU

EL

FS

GN/WH

B1ENG (12 VOLT)

GND-BRR48LP-WH/RD

RED

TO WORK LIGHTS

2

1

C46HN-WH

S56PRV-RD

P56PRV-RD/WH

6

RD

21

FOOTSWITCH

3

OPTIONAL SWINGPGATE WIRING

S56PRV-RD

P56PRV-RD/WH

C46HN-WH

1. PLAT SNSR GNDP2. TILT SNSR SIG OUTP3. TILT SNSR PWRP4. TILT SW GNDP5. PWR TO TILT SWP6. OUTPUT FROM TILT SWBK

-+

-+

GN

WH

J556431 2 5

C56PTS-RD

C23PTS-WH-+

NOTUSED

C56FTS-RD

R56FTS-RD

BK

WH

BK

1 2

J84

WH

BK

BR

4 3 2 1

J82

WH

J119

FOOTSW (FS1)

NC

22 21

RD

RD

PLATFORM PTILT SENSORPASSEMBLY

S56PRV(B)-RD

V121AXO-GR

S56PRV(B)-RD

S56PRV(A)-RD

S56PRV(A)-RD

S56PRV-RD

S56PRV-RD

WH

RD

BR

4 3 2 1

BK

NC

2122

4 3 2 1

J105

4 3 2 1

J104

BK

BR

RD

WH

22 21

WH

21

RD

BR

BK

22

V122AXO-GR/WH

JIBUP(J78)

JIBDOWN(J79)

PLATROTCCW

(J77)

PLATROTCW

(J76)

PLATLEVELUP(J80)

PLATLEVELDN(J81)

4 3 2 1

BR

RED

TO FLASHING BEACON

GND-BRR49LP-WH/BK5

4

3

P52PCON-WH

GNDPCON-BR

2

1

D82CAN+ -YL

D81CAN- -GR

C47OUT-WH/BK

21

NC

NO

13INTERLOCK

SWING GATE

GNDPCON-BR

C47OUT-WH/BK

D81CAN- -GR

P52PCON-WH

D82CAN+ -YL

D81CAN- -GR

GNDDCN-BR

S56PRV-RD

P21DCN-WH

P53LS-WH/BK

D81CAN- -GR

P21DCN-WH

P53LS-WH/BK

GNDDCN-BR

S56PRV-RD

D82CAN+ -YL D82CAN+ -YL

22

14

2 1

WH

RD

BR

BK

13

NC

2122

14

NC

2 1

WH

RD

BK

BR

13

NO

14

RD

BK

14 13

22

NC

21

WH

OVERLOAD PLIMIT SWPLSP1OLS

AAA AJ16-DRIVE CHASSIS HARN

NO

NC

OVERLOAD LIMIT SWPLSP1OLS (SHOWN IN POVERLOADED CONDITION)LSJ1EOPPLATFORM LEVELPCYL FULLY EXTPSWITCHP(STOWED POS)

NORMAL SWITCH POSITIONPSHOWN FOR: LSJ1EO

NO NO

13

NO

14

14

NC

NO

1313

NO

NC

14

LSA2OSLSA1OSAXLE LS POSCILLATEPLIMIT SWITCHP(STOWED POS)AXLE RS POSCILLATEPLIMIT SWITCHP(STOWED POS)

V122AXO-GR/WH

V121AXO-GR

NORMAL SWITCH POSITIONPSHOWN FOR: LSA1OSP LSA2OSP PROX KILLP SWING GATE

BBCAN LOW GRN

B BGRN

2 2

1 1

BK

WH

DCON GND

P7RWH

BK22

11J18-DRIVE CHASSIS HARN

P RING

2

1

2

1

WH/BK

RD

P6R1

DCON PWRRD

22

11

WH/BK

J17-DRIVE CHASSIS HARN

D81CAN- -GR

GNDDCN-BR

S56PRV-RD

GNDDCN-BR

S56PRV-RD

P21DCN-WHP21DCN-WH

P53LS-WH/BK

D81CAN- -GR

P53LS-WH/BK

D82CAN+ -YL D82CAN+ -YL CAN HIGH YELYEL

J34-LIMIT SW HARN

J33-BOOM HARN

J35-LIMIT SW HARN

NO P23PCON-BK

LSP1PROXPPROXIMITYPKILL SWITCHPOPTIONAL

P23PCON-BK

J110J109J107 J108

BK

BK

BL

RD

BL

BK

RD

BL

RD

BK

RD

BL

S13-RFSTEERRIGHT

S12-LRSTEERRIGHT

S14-LFSTEERRIGHT

Y58-LRSTEERLEFT(J94)

Y59-RFSTEERRIGHT(J95)

Y62-LFSTEERLEFT(J98)

Y61-LFSTEERRIGHT(J97)

Y60-RFSTEERLEFT(J96)

Y56-RRSTEERLEFT(J92)

Y55-RRSTEERRIGHT(J91)

Y27-TWOSPEEDMOTORSTROKE(J87)

Y2-BRAKERELEASE(J106)

S11-RRSTEERRIGHTSNSR

Y57-LRSTEERRIGHT(J93)

CA BCA BCA BCA B

Y57OSCILLATERIGHT(J86)

Y56OSCILLATELEFT(J85)

C83TAX-GN/WH

TU

RN

TA

BLE

TIL

TP

SE

NS

OR

+2C83TAX-GN/WH

C34SA-BK/WH

C35RPM-BK/RD

C26TSR-WH/RD

C25PSR-WH/BK

C31EDC-WH/BK

C41RPM-OR/BK

GND-BR

B1BAT-RD

B1BAT-RD

GND-BR

C123PBD

RD/BK

C56FTS-RD

P53LS-WH/BK

S12SBL-BL/WH

P54ENG-BK/WH

P54ENG-BK/WH

P58LSRD/BK

C73SBR-BL/RD

S12SBL-BL/WH

C73SBR-BL/RD

C72SBE-BL/WH

P126SBLD-WH/BK

C05TRR-WH/BK

P125SBLE-WH/RD

R49LP-WT/BK

C08PBR-BK/WH

C11SBD-BL/BK

C02PBD-RD/BK

C12SBFC-BL/WH

C09PERF-BK/RD

C03PBF-RD/WH

C06TRF-WH/RD

SNSRGND-BR

P109PBS-GR/WH

C124SBLRD/WH

C70PBR-BL/WH

C71PBE-BL/BK

C77SBU-WH

C67SBD-BL

C66DREN-BL

C68PBD-RD

C65LOF-BL/WH

C64LS-OR/BK

P53LS-WH/BK

C64LS-OR/BK

P53LS-WH/BK

S56PRV-RD

GNDDCN-BR

P21DCN-WH

P53LS-WH/BK

P54ENG-BK/WH

S14PLU-OR

GND-DCN-BR

P21DCN-WH

P53LS-RD

S56PRV-RD

S56PRV-RD

D81CAN--GR

D82CAN+-YL

V29MS-RD/WH

VLVRET-BRN

VLVRET2-BRN

V36RRS-BL

V37RRS-BL/BK

C111RRS-OR

C111LRS-OR

C111RFS-OR

C111LFS-OR

P110RT-BK

V36LRS-BL

V37LRS-BL/BK

V36RFS-BL

V32BRK-WH/RD

P109ANG-GR/WH

V37RFS-BL/BK

V36LFS-BL

V37LFS-BL/BK

P23PCON-BK

C46HN-WH

D82CAN+-YL

D81CAN--GR

C47OUT-WHT/BLK

P56PRV-RD/WH

S56PRV-RD

GNDPCON-BR

P52PCON-WH

PTSRET-BR

P87PTS-RD

PLATRET-BR

P85PTS-GR

C84TAY-GR/BK

C90PXS-RD/BK

C88PTS-RD/BK

C43JU-GR

C14PLU-OR

C44JD-GR/BK

C15PLD-OR/BK

R90PXS-RD/BK

C17PRL-GR

VLVRET-BRN

C18PRR-GR/BK

P56FTS-RD

D82CAN+-YL

D81CAN--GR

P23PCON-BK

GNDPCON-BR

P52PCON-WH

C46HN-WH

C47OUT-WH/BK

S56PRV-RD

P56PRV-RD/WH

R48LP-WH/RD

R49LP-WH/BK

ALL SWITCHES ARE SHOWN IN THE BOOM STOWED POSITION

ALL SWITCHES ARE SHOWN IN THE "OUT OF BOX" POSITION

S-500

ER

FE

TE

RFE

TETY

CU

TO

UT

DE

G

ER

FE

T

DE

G

ETY

CU

TO

UT

ER

FE

T

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

F

F

AUX.PUMP

-

+

-

+

FAN

SEE DETAIL "D" FOR 220VACGENERATOR W/REGULATOR.

MA

INA

UX

8587a

4

87

5

8630

1 2

R3

3S

TR

-BK

C3

5R

PM

-BK

/RD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TG

ND

-BR

TO

J4

-32

PW

HIT

E3

5P

IN

SE

RV

ICE

HO

RN

ALT

ER

NA

TO

R

AU

XH

YD

PU

MP

STA

RT

BA

T

AU

XH

YD

EL

EC

TR

ON

ICS

BA

TT

ER

Y

STA

RT

ER

RE

LA

Y

AU

XH

YD

CO

NTA

CT

OR

ENGINE BLOCK

STA

RT

ER

HO

RN

RE

LA

Y

FU

EL

PU

MP

FU

EL

SO

LE

NO

ID

HY

DR

AU

LIC

OIL

CO

OL

ER

FA

N

GL

OW

PL

UG

STA

RT

AID

RE

LA

Y

HI/L

OS

PE

ED

SO

LE

NO

ID

TR

OM

BE

TTA

DU

AL

CO

ILE

DC

OIL

PR

ES

SU

RE

OIL

TE

MP

SE

ND

ER

TE

MP

SW

CO

OL

ER

RE

LA

Y

BA

TG

ND

BR

P4

6H

RN

(A)-

WH

B1B2 C2

7A

UX

-RD

BA

TG

ND

-BR

PR

1

C4

1R

PM

-OR

/BK

C1

07

AF

-RD

R11

6H

YD

-OR

R3

4S

A-B

K/W

H

OTS1N.O.

J120

H1A B DC

RD

BK

HO

LD

RD

BK

J56

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

VLV

RE

T2

-BR

J57

30 86

8787a 85

CR4

R2

1IG

N-W

H

R2

1IG

N-W

H

C2

5P

SR

-WT

/BK

C2

6T

SR

-WT

/RD

ACC11

6H

YD

CR2

CR5

HORNRELAY

87

CR130

87a

STARTERRELAY

86

85

P46HN-WH

P35RPM-RD

P116HYD-OR

P34SA-BK/WH

C3

4S

A-B

K/W

H

P3

5R

PM

-RD

CR15

GLOW PLUGRELAY

87a85 87

86 30

P11

6H

YD

-OR

C2

1IG

N-W

H

3086

8785 87a

CR17

OIL COOLERRELAY

R21IGN-WH

3086

8785 87a

ENG/FUELRELAY

C34SA-BK/WH

F2

2

70

A

20

A

F1

7

20

A

F1

6

F7

30

A

P21IGN-WH

FUSE INFOF7 HYD CLR/RMPF16 STARTF17 ENGINEF22 GLOW PLUGS

B1

BA

T-R

D

B2

BA

T-R

D

C3

3S

TR

-BK

C21IGN-WH

P2

1IG

N-W

H

P21IGN-WH

15ABK-120VAC

C26TSR-WT/RD

C25PSR-WT/BK

ED

CR

EV

ED

CF

WD

IGN

/FU

EL

BA

TE

CU

-PW

R

TH

RO

TT

LE

SY

SB

AT

GN

D

BA

TE

CU

GN

D

TU

RN

TA

BL

ET

ILT

SE

NS

OR

11

0V

AC

RE

GU

LA

TO

R

BK P45GEN(B)

P3

1-E

NG

HA

RN

J3

1-T

ILT

SN

SR

WH-NEUTRAL

AUTORESET CB

120VAC

C45GEN-GR/WHGR

BR

BK/WH F45GEN

BK

BK/WH

RD30

86 85

87

4

5

1

2

30A

WT

BR

P32-GEN HARN87a

CB 3

RD 12VDC

WH R45GEN(A)

BR BAT GND

RED

WH

BR

DETAIL "C" OPT 120VAC W/REGULATOR

P1

-15

C2

5P

SR

-WH

/BK

C3

5R

PM

-BK

/RD

BA

TE

CU

-RD

BA

TV

LV

-RD

BA

TG

ND

-BR

BA

TG

ND

-BR

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

C3

3S

TR

-BK

C2

6T

SR

-WH

/RD

C3

4S

A-B

K/W

H

C4

6H

RN

-WH

C2

1IG

N-W

H

P1

-04

P1

-02

P1

-01

P1

-03

POWER HARN

J15 BLACK 4 PIN

P1

-14

P1

-11

P1

-12

P1

-09

P1

-10

P1

-13

P1

-07

P1

-04

P1

-05

P1

-06

P1

-02

P1

-03

P1

-01

P1

-08

ENGINE HARN

J13 WHITE 23 PIN

FW

D

RE

V

-C84TAY-GN/WH

VLV

RE

T2

-BR

C4

1R

PM

-OR

/BK

J32-ENG HARN

C83TAX-GN/WH

P85TTSR-GR

RET85TTSR-BR

0-2

0D

EG

RE

ES

EN

SO

RA

LA

RM

AT

4.5

DE

GR

EE

S

6

5

4

3

2-+

P1

-23

P1

-22

P1

-21

P1

-19

P1

-18

P1

-20

P1

-16

P1

-17

1 +

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

-

+

-

+

PUMPAUX.

FAN

F

F

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

50

0

4.5

DE

GR

EE

S

B2

BA

T-R

D

B1

BA

T-R

D

8587a

487

5

8630

1 2

8587a

487

5

8630

1 2

C1

07

AF

-RD

HORNRELAY OIL COOLER

RELAY87a5

85

487

286

130

BA

TG

ND

-BR

TO J4-32PWHITE 35 PIN

ENGINE BLOCK

BA

TT

ER

Y

AU

XH

YD

EL

EC

TR

ON

ICS

SE

RV

ICE

PH

OR

N

HO

RN

PR

EL

AY

CO

OL

ER

RE

LA

Y

TE

MP

SW

HY

DR

AU

LIC

OIL

CO

OL

ER

FA

N

TR

OM

BE

TTA

AU

XH

YD

ALT

ER

NA

TO

R

STA

RT

BA

T

STA

RT

ER

STA

RT

ER

RE

LA

Y

AU

XH

YD

PU

MP

CO

NTA

CT

OR

DU

AL

CO

ILE

DC

P4

6H

RN

(A)-

WH

VLV

RE

T2

-BR

R11

6H

YD

-OR

BA

TG

ND

-BR

A

BA

TG

ND

-BR

C2

7A

UX

-RD

PR

1

H1 BA C D

OTS1N.O.

C3

1E

DC

-WH

/BK

C11

6H

YD

-WH

R16

C3

0E

DC

-WH

P2

0P

WR

-RD

R3

3S

TR

-BK

C2

1IG

N-W

H

P11

6H

YD

-OR

CR5CR17

P116HYD-OR P116HYD-OR

F7

B1BAT-RD

C39LP-BL/RD

C21IGN-WH

B1BAT-RD

C35RPM-BK/RD

C25PSR-WT/BK

C26TSR-WT/RD

C33STR-BK

20

A

20

A

F1

7

C41RPM-OR/BK

OIL

PR

ES

SU

RE

CO

OL

AN

TT

EM

P

FORD 42 PIN CONNECTOR

C1

27

TS

W-G

R

C1

08

ES

L-B

L/W

T

C3

8F

P-B

L/W

T

R2

1IG

N-W

H

C3

9L

P-B

L/R

D

C3

3S

TR

-BK

R3

3S

TR

-BK

C2

1IG

N-W

H

C2

6T

SR

-WT

/RD

C2

5P

SR

-WT

/BK

C4

1R

PM

-OR

/BK

C3

5R

PM

-BK

/RD

246182 237 11513 9 345

B1

BA

T-R

D

BA

TT

-

P32-GEN HARN

P1

-03

P1

-01

P1

-02

P1

-04

POWER HARN C35RPM-BK/RD

C3

5R

PM

-BK

/RD

C2

1IG

N-W

H

C4

6H

RN

-WH

C4

1R

PM

-OR

/BK

C2

6T

SR

-WH

/RD

C3

3S

TR

-BK

C2

5P

SR

-WH

/BK

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

VLV

RE

T2

-BR

C3

9L

P-B

L/R

D

BRBATGND-BR

MA

INA

UX

RD

WHC45GEN-GR/WH

B1BAT-RD

J32-ENG HARN

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TV

LV

-RD

BA

TE

CU

-RD

J15 BLACK 4 PIN

ED

CF

WD

ED

CR

EV

RE

V

FW

D

TH

RO

TT

LE

IGN

/FU

EL

BA

TE

CU

GN

D

SY

SB

AT

GN

D

BA

TE

CU

-PW

R

J13 WHITE 23 PIN

ENGINE HARN P1

-01

P1

-03

P1

-02

P1

-06

P1

-05

P1

-04

P1

-08

P1

-13

P1

-10

P1

-09

P1

-12

P1

-11

P1

-14

P1

-15

P1

-17

P1

-16

P1

-18

P1

-19

P1

-07

P1

-20

P1

-21

P1

-22

P1

-23

3

BRBR GND5

87a

871

2 86

30 4

85

3

22

0V

AC

RE

GU

LA

TO

R

AUTOSEE DETAIL C FOR120VAC GENERATOR W/REGULATOR.

BK-220VAC

RESET CB

10A

BK/WH

BK

WH-NEUTRAL

220VAC

GR

BR

BK/WH F45GEN

BK P45GEN(B)

WH

RD30A

WH/R45GEN(A)

RD/12VDC

OPT 220VAC W/REGULATOR

DETAIL "D"

J31-TILT SNSR

4RET85TTSR-BR

P85TTSR-GR

6

5

1

2C83TAX-GN/WH

C84TAY-GN/BK -+-

+

-

+

-

+

AUX.PUMP

FAN

F

F

View 1

View 7 View 8 View 9View 11

View 12

View 5View 4View 3

Deutz F4L-913

View 11Deutz BF4L-2011

View 14Perkins 704-30

View 14Perkins 804-C33 View 15

Ford LRG-425

C83TAX-GN/WH

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-23

P1

-22

P1

-21

RDRD/12VDC30A

5

87a

87

1

2 86

30 4

85

3

J3

1-T

ILT

SN

SR

SEE DETAIL B FOR 120VAC GENERATOR


GENERATOR W/O REGULATOR.10ABK-220VAC

220VAC

AUTORESET CB

WH-NEUTRAL

GR

BR

22

0V

AC

RE

GU

LA

TO

R

BR GND

WH/R45GEN(A)

BK/WH F45GEN

BK P45GEN(B)

WH

BR

BK

BK/WH

P85TTSR-GR

DETAIL C


RET85TTSR-BR

C84TAY-GN/BK

C83TAX-GN/WH



6

5

4

3

2

1

-

-

+

+

BA

TE

CU

-PW

R

SY

SB

AT

GN

D

BA

TE

CU

GN

D

FW

D

RE

V

IGN

/FU

EL

TH

RO

TT

LE

ED

CR

EV

ED

CF

WD

View 16Hydraulic Generator Option

DCONView 2

PCONTCON

View 6TCON

View 10Limit Switches

Electrical Schematic Layout



Electrical Schematic - View 1Drive Chassis Controller (DCON)

REV C

1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N


Electrical Schematic - View 1Drive Chassis Controller (DCON)

6 - 18 Z-80/60 Part No. 88619

GN

D-D

CN

-BR

P2

1D

CN

-WH

P5

3L

S-R

D

S5

6P

RV

-RD

S5

6P

RV

-RD

D8

1C

AN

--G

R

D8

2C

AN

+-Y

L

V2

9M

S-R

D/W

H

VLV

RE

T-B

RN

VLV

RE

T2

-BR

N

V3

6R

RS

-BL

V3

7R

RS

-BL

/BK

C111

RR

S-O

R

C111

LR

S-O

R

C111

RF

S-O

R

C111

LF

S-O

R

P11

0R

T-B

K

V3

6L

RS

-BL

V3

7L

RS

-BL

/BK

V3

6R

FS

-BL

V3

2B

RK

-WH

/RD

P1

09

AN

G-G

R/W

H

V3

7R

FS

-BL

/BK

V3

6L

FS

-BL

V3

7L

FS

-BL

/BK

OS

CIL

LA

TE

ST

OW

ED

RF

ST

EE

RR

IGH

T

LF

ST

EE

RL

EF

T

ST

EE

RS

NS

RG

ND

ST

EE

RS

NS

RP

WR

RF

ST

EE

RL

EF

T

LF

ST

EE

RR

IGH

T

RF

ST

EE

RS

NS

R

LR

ST

EE

RS

NS

R

RR

ST

EE

RS

NS

R

RR

ST

EE

RL

EF

T

RR

ST

EE

RR

IGH

T

LR

ST

EE

RS

NS

R

LR

ST

EE

RR

IGH

T

LR

ST

EE

RL

EF

T

VA

LV

ER

TN

1

MO

TO

RS

PE

ED

AU

XF

OR

WA

RD

AU

XR

EV

ER

SE

P2

-08

P2

-09

P2

-10

P2

-07

P2

-01

P2

-02

P2

-04

P2

-05

P2

-06

P2

-03

BR

AK

E

VA

LV

ER

TN

2

P2

-18

P2

-20

P2

-19

P2

-22

P2

-21

P2

-11

P2

-13

P2

-12

P2

-14

P2

-15

P2

-16

P2

-17 J31 23 PIN

DRIVE CHASSISHARNESS

J32 23 PINDRIVE CHASSISHARNESSP

2-2

3

DCON EN7

AX

LE

NO

TE

XT

PW

R

AX

LE

NO

TE

XT

SIG

DC

ON

EC

UP

WR

DIG

INA

XL

ER

ET

GN

D

AX

LE

NO

TR

ET

RT

N

DC

ON

EC

UG

ND

CA

NS

HIE

LD

RS

23

2R

XD

RS

23

2T

XD

BO

OT

CA

N-

CA

N+

RS

23

2G

ND

P_

6R

1

P_

7R

P1

2

P1

-10

P1

-03

P1

-09

P1

-08

P1

-07

P1

-06

P1

-05

P1

-04

P1

-02

P1

-01

P1

-21

P1

-22

P1

-20

P1

-18

P1

-17

P1

-16

P1

-15

P1

-14

P1

-12

P1

-13

P1

-11

P1

-19

P1

-23

Continued on View 7

Continued on View 2

REV C


Electrical Schematic - View 2Platform Controls (PCON)

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A

Part No. 88619 Z-80/60 6 - 19

C5

6F

TS

-RD

S1

4P

LU

-OR

P2

3P

CO

N-B

K

C4

6H

N-W

H

D8

2C

AN

+-Y

L

D8

1C

AN

--G

R

C4

7O

UT

-WH

T/B

LK

P5

6P

RV

-RD

/WH

S5

6P

RV

-RD

GN

DP

CO

N-B

R

P5

2P

CO

N-W

H

PT

SR

ET

-BR

P8

7P

TS

-RD

PL

AT

RE

T-B

R

P8

5P

TS

-GR

C8

4TA

Y-G

R/B

K

C9

0P

XS

-RD

/BK

C8

8P

TS

-RD

/BK

C4

3JU

-GR

C1

4P

LU

-OR

C4

4JD

-GR

/BK

C1

5P

LD

-OR

/BK

R9

0P

XS

-RD

/BK

C1

7P

RL

-GR

VLV

RE

T-B

RN

C1

8P

RR

-GR

/BK

P5

6F

TS

-RD

FU

EL

TY

PE

SP

AR

E2

CO

OR

DS

TE

ER

CR

AB

ST

EE

R

RE

AR

ST

EE

R

FR

ON

TS

TE

ER

AX

LE

EX

TE

ND

DR

IVE

SP

EE

D

EN

GIN

ES

PE

ED

SP

AR

E1

AX

LE

RE

TR

AC

T

DR

IVE

EN

AB

LE

AU

XIL

IAR

Y

AC

GE

NE

RA

TO

R

STA

RT

AS

SIS

T

74HC08

74HC08

ON CIRCUIT BOARDDB9 CONNECTOR

P1

-20

P1

-17

P1

-22

P1

-23

P1

-02

P1

-03

P1

-04

P1

-05

P1

-06

P1

-07

P1

-08

P1

-09

P1

-10

P1

-13

P1


PCON MANIFOLD

WH

GN

BK

P1

-01

P1

-11

P1

-12

P1

-18

P1

-19

P1

-21

P1

-15

P1

-16

LO

AD

SN

SR

IN

LO

AD

SN

SR

GN

D

LO

AD

SN

SR

PW

R

PL

LV

LC

YL

EX

T

SA

FE

PL

TIL

TG

ND

SA

FE

PL

TIL

TP

WR

PL

TIL

TS

NS

RG

ND

PL

TIL

TS

NS

RP

WR

FO

OT

SW

RT

N

PL

TIL

TS

NS

R

PR

OX

KIL

LC

MD

SA

FE

PL

TIL

TO

UT

PR

OX

KIL

LG

ND

PR

OP

VLV

1_

B

PR

OP

VLV

1_

A

PR

OP

VLV

2_

B

PR

OP

VLV

2_

A

ON

/OF

FV

LV

3_

A

ON

/OF

FV

LV

3_

B

FO

OT

SW

PW

R

VLV

RT

N

2

U2

0

P6

5

1SLP_MODE

P7

P224

P6

P1

-23

P1

-22

P1

-17

P1

-20

P1

-14

P1

-13

P1

-10

P1

-09

P1

-08

P1

-07

P1

-06

P1

-05

P1

-04

P1

-02

P1

-03

P1

-01

P1

-16

P1

-15

P1

-12

P1

-11 J21 BLACK 23 PIN

P1

-21

P1

-19

P1

-18

BOOM HARN

CA

N-

PIN CKT #P2 RS232_RXDP3 RS232_TXDP5 RS232_GND

HR

NR

LY

CN

TR

L

OU

TP

WR

EN

BL

PC

ON

PW

R

PC

ON

GN

D

P7

P2

2

PW

R-P

CO

NE

ST

OP

CA

N+

ISIN

VbbBTS650

OUT

U21

IN2

3

OUT 2STGND

Vbb6OUT 1IN1BTS621

U22

P6

H3

_G

ND

-BR

H3

_P

WR

-OR

H2

_G

ND

-BR

H2

_P

WR

-OR

H4

_Y

OU

T-W

H

H4

_X

OU

T-P

R

H4

_S

TE

ER

-BL

H3

_Y

OU

T-G

N

H2

_Y

OU

T-Y

L

H1

_Y

OU

T-B

K

H1

_X

OU

T-R

D

H1

_P

WR

-OR

H1

_G

ND

-BR

H4

_P

WR

-OR

H4

_G

ND

-BR

PL

AT

LV

LU

P-O

R

PL

AT

LV

LD

N-O

R/B

K

ES

TO

PR

ET

-BK

JIB

UP

-GN

JIB

DN

-GN

/BK

PL

AT

RO

TL

-GN

PL

AT

RO

TR

-GN

/BK

AL

AR

M+

RD

/BK

ES

TO

PP

WR

-RD

/BK

18

5431 2

P2

0 16

15

17

14

12

13

11

9 10

876G

ND

6-B

R

GN

D1

2-B

R

GN

D1

3-B

R

GN

D1

6-B

R

P7R

ECU

20

19

86 7 10

92 3 4 51 15

16

11

13

12

14

21

P1

P1

HO

RN

J23 10PIN MEMBRANE/LED INTERFACE CARD

P7R

54321 10

876 9

10

10

J24B 10PINJ24A 10PIN

876

P1

P1

43

P1

P1

P1

5

P1

4P

2

21

P2

P2

P2

9

P1

P1

3 9P

2

P2

876

P2

P2

5P

2

P2

STA

RT

PCON MEMBRANE PANEL (MS1)

SEC BOOM UP/DWNPCON DRIVE & STEERINGPRI BOOM EXT/RETBOOM UP/DWN &

ES

TO

PP

WR

-RD

/BK

JIB

DN

-GN

/BK

ES

TO

PR

ET

-BK

PL

AT

LV

LD

N-O

R/B

K

PL

AT

LV

LU

P-O

R

PL

AT

RO

TR

-GN

/BK

PL

AT

RO

TL

-GN

AL

AR

M+

RD

/BK

GN

D1

6-B

R

GN

D1

2-B

R

GN

D1

3-B

R

GN

D6

-BR

JIB

UP

-GN

PLATFORMLEVEL

PLATFORMROTATE

PCONALARM

E-STOP (P2)JIB

H3

_Y

OU

T-G

N

H4

_S

TE

ER

-BL

H4

_Y

OU

T-W

H

H4

_X

OU

T-P

R

H3

_P

WR

-OR

H2

_P

WR

-OR

H2

_Y

OU

T-Y

L

H1

_X

OU

T-R

D

H1

_Y

OU

T-B

K

H3

_G

ND

-BR

H1

_P

WR

-OR

H1

_G

ND

-BR

H2

_G

ND

-BR

H4

_P

WR

-OR

H4

_G

ND

-BR

JOYSTICK (JC5)

2

J2

8

J2

7

J2

6

4321 7 15421 3 6765

JOYSTICK (JC1)

TURNTABLE ROTATE JOYSTICK (JC2)

J2

5

5 6431765 23 4 7

JOYSTICK (JC3)

Continued on View 8

Continued on View 3

Continued onView 1

ESTOP PWR-RD/BK

Electrical Schematic - View 2Platform Controls (PCON)



Electrical Schematic - View 3Ground Controls (TCON)

REV C



1

2

3

4

5

6

7

8


6 - 20 Z-80/60 Part No. 88619

D8

2C

AN

+-Y

L

D8

1C

AN

--G

R

P2

3P

CO

N-B

K

GN

DP

CO

N-B

R

P5

2P

CO

N-W

H

C4

6H

N-W

H

C4

7O

UT

-WH

/BK

S5

6P

RV

-RD

P5

6P

RV

-RD

/WH

R4

8L

P-W

H/R

D

R4

9L

P-W

H/B

K

PLD

BM

U/D

FC

O

U3

0

P1

-23

P1

-22

P1

-20

J11 BLACK 23 PIN

P1

-07

P1

-08

P1

-04

P1

-02

P1

-03

P1

-05

P1

-01

P1

-17

P1

-15

P1

-16

P1

-12

P1

-13

P1

-11

P1

-10

P1

-09

P1

-14

P1

-06

P1

-21

BOOM HARNP1

-18

P1

-19

CA

LF

RE

Q2

TE

TE

ST

OP

PW

R

RS

23

2T

XD

RS

23

2R

XD

CA

NS

HIE

LD

FL

AS

HIN

GB

EA

CO

N

CA

LF

RE

Q1

PW

R-P

CO

NE

ST

OP

OU

TP

WR

EN

BL

TC

ON

PC

ON

GN

D

PC

ON

PO

WE

R

HO

RN

RE

LA

YC

OIL

CA

NL

OW

BO

OT

P_

7

P_

22

WO

RK

LT

DIA

G/T

ET

HE

RP

WR

DIA

G/T

ET

HE

RG

ND

TE

TH

ER

FU

NC

EN

BL

TE

TE

ST

OP

RE

T

RS

23

2G

ND

CA

NH

IGH

TE

TH

ER

ES

TO

P-B

L/R

D

TC

ON

ES

TO

P-B

L/W

H

PW

RT

OT

CO

NE

ST

OP

-BL

/BK

SE

RV

.O

RO

PE

R.R

EC

.

OU

TP

UT

PW

RE

NA

BL

E

VIC

EO

RR

EC

OV

ER

YM

OD

E

PW

RIN

SE

RV

OR

RE

CO

VE

RY

PR

OV

IDE

SP

WR

T OM

INIM

AL

HA

RD

WA

RE

OP

ER

.R

EC

.

SE

RV

.O

R

P1

5

P15P15

ECU POWER

TO MICRO


PIN CKT #P2 RS232_RXDP3 RS232_TXDP5 RS232_GND

TC

ON

MO

DE

OP

ER

.R

EC

.

P7

-GN

/WH

P2

2

P7

R

AL

AR

MG

ND

AL

AR

MP

WR

11

14

13

12

10

9 8

P11

16

15

BM

10

0'I

PC

ON

MO

DE

P6

R1

EC

UP

OW

ER

PR

IL

O#

1O

BM

DW

NO

BM

E/R

FC

O

BM

RE

TO

MLT

FN

CV

LV

O

AU

XH

YD

O

BM

DW

NS

TI

BM

3'I

3 2 1

J17

7 6 45

S5

6P

RV

-RD

/BK

SR

VR

EC

-WH

P5

6P

RV

-RD

OR

/BK

RD

/WH

OR

GR

/WH

RD

C4

7O

UT

WH

/BK

C4

7O

UT

GR

/BK

P5

3L

S-B

K/W

H

P2

3P

CO

N-B

K

BL

/BK

OFFRUN

AZ

P_

7P

LA

T-G

R/W

H

TC

ON

MO

DE

P_

15

-OR

/BK

C4

7O

UT

WH

/BK

S1

PB

U-O

R

AL

M-G

ND

-BR

AL

MP

WR

-RD V

12

C4

7O

UT

WH

/BK

1

W

2

34

OFF

PLAT

B

2 1GROUND

GROUND

PLAT

WH

/BK1 2

PLAT

G-P

MO

DE

GR

/BK

34

Y

P2

3P

CO

N-B

K

OFF

PLAT2 1

OFFDGROUND

3

X

4

1

USERV BYPASS

RECOVERY2

TCON EMERGENCYSTOP BUTTONOFF

E

2 1GROUND

PLAT2 1

CGROUND

BL/WH

TO HORN BUTTON P7R

P_7

P11

P6R1

PCON POWER

P7R

P_22 P11

OUT PWR ENABLE

TCON MODE

PWR TO TCON ESTOP

P6R1

PCON POWER

(P15)+(ECU POWER)

P_7

TCON MODE

RED ALARM LED

J127 LOADSENSELED

21

P_22

OUT PWR ENABLE

PWR TO TCON ESTOP

TO HORN BUTTON



(P15)+(ECU POWER)









Continued on View 9

TCON

Continued on View 2Continued on View 4

REV C

1

2

3

4

5

6

7

8



Electrical Schematic - View 4

Part No. 88619 Z-80/60 6 - 21

C1

23

PB

DR

D/B

K

P5

3L

S-W

H/B

K

S1

2S

BL

-BL

/WH

P5

4E

NG

-BK

/WH

P5

4E

NG

-BK

/WH

P5

8L

SR

D/B

K

C7

3S

BR

-BL

/RD

S1

2S

BL

-BL

/WH

SN

SR

GN

D-B

R

P1

09

PB

S-G

R/W

H

C1

24

SB

LR

D/W

H

C7

0P

BR

-BL

/WH

C7

1P

BE

-BL

/BK

C7

7S

BU

-WH

C6

7S

BD

-BL

C6

6D

RE

N-B

L

C6

8P

BD

-RD

C6

5L

OF

-BL

/WH

C6

4L

S-O

R/B

K

P5

3L

S-W

H/B

K

C6

4L

S-O

R/B

K

P5

3L

S-W

H/B

K

S5

6P

RV

-RD

GN

DD

CN

-BR

P2

1D

CN

-WH

P5

3L

S-W

H/B

K

P5

4E

NG

-BK

/WH

P7RTO HORN BUTTON P7R P7R

TO

PL

D

TO

MIC

RO

TO

MIC

RO

P_

6R

1P

2-0

3J12 BLACK 35 PIN

P2

-02

LIMIT SWITCH HARN P2

-01

DC

ON

EC

UG

ND

DC

ON

EC

UP

WR

P2

-33

P2

-34

P2

-35

P2

-32

P2

-28

P2

-29

P2

-30

P2

-27

P2

-26

P2

-24

P2

-25

P2

-22

P2

-19

P2

-20

P2

-17

P2

-15

P2

-14

P2

-18

P2

-23

P2

-13

P2

-12

P2

-10

P2

-09

P2

-08

P2

-07

P2

-05

P2

-06

P2

-04

P2

-11

P2

-21

P2

-16

P2

-31

PR

ES

SU

RE

GA

SN

SR

GN

D

OP

ER

SW

PW

R

SN

SR

PW

R

LS

T1

0

FS

T1

S

P_

18

P_

12

P_

14

P_

10

P_

9B

P_

7R

P_

9A

P_

11

P_

6R

2

P2

SE

Q

LS

S1

AO

LS

S2

AO

LS

P1

EO

LS

P1

RO

LS

P1

AO

LS

B1

2R

O

.LS

B2

RO

P1

SE

Q

TO

PL

D

BO

OM

ST

OW

ED

SE

CA

NG

INP

UT

PR

IA

NG

INP

UT

P_

30

VLV

RE

T

LS

B1

3A

O

LS

B1

4A

O

DIG

ITA

LIN

U3

0

P_7

P11

P6R1

PCON POWER

P7R

P_22 P11

OUT PWR ENABLE

TCON MODE

PWR TO TCON ESTOP

P6R1

PCON POWER

TO

MIC

RO

TO

MIC

RO

TO

PL

D

TO

MIC

RO

U3

2

U3

1

TO

PL

D

P11 P11

P9A

P6R1

P10

PCON POWER

P9A

P6R1

P10

PCON POWER

(P15)+(ECU POWER)

P_7

TCON MODE

P_7

TCON MODE

BOOM STOWED

P_7

TCON MODE

P_22

OUT PWR ENABLE

PWR TO TCON ESTOP

TO HORN BUTTON

P_6R2

P_22

P_9B

P_22

OUT PWR ENABLE

TO HORN BUTTON

PWR TO TCON ESTOP







(P15)+(ECU POWER)








(P15)+(ECU POWER)

P_30




Continued on View 3

Continued on View 10

Continued on View 5





REV C

July 2006


1

2

3

4

5

6

7

8


6 - 22 Z-80/60 Part No. 88619

Section 6 • Schematics

Continued on View 4

Continued on View 6


P_22R

P_30







P6R1P7R P7R

P1

-03

P1

-04

P1

-02

POWER HARN

J15 BLACK 4 PIN

P1

-01

BA

TE

CU

GN

D

SY

SB

AT

GN

D

SY

S_

BA

T_

PW

R

BA

TE

CU

-PW

R

P1

-23

P1

-13

P1

-15

P1

-14

P1

-17

P1

-20

P1

-18

P1

-22

P1

-08

P1

-03

P1

-02

P1

-06

P1

-05

P1

-04

P1

-07

P1

-10

P1

-09

P1

-01

ENGINE HARN

J13 WHITE 23 PIN

P1

-12

P1

-11

P1

-16

P1

-19

P1

-21

OIL

/WA

TE

R_

TE

MP

TT

_T

ILT

_S

NS

R_

GN

D

OIL

_P

RE

SS

UR

E

TT

_T

ILT

_S

NS

R_

PW

R

STA

RT

ER

RE

LA

Y

SE

RV

ICE

HR

N

VA

LV

ER

TN

#1

BA

TE

CU

-PW

R

IGN

/FU

EL

TH

RO

TT

LE

RE

V

FW

D

ED

CF

WD

ED

CR

EV

VA

LV

E_

RT

N3

AC

GE

NE

RA

TO

R

ALT

ER

NA

TO

RR

PM

VA

LV

ER

TN

_2

TT

_T

ILT

_X

_A

XIS

TT

_T

ILT

_Y

_A

XIS

AC

GE

NE

RA

TO

R

74HC08

P_11

TO

MIC

RO

20

A

CB

PCON POWER

P6R1

P9A

P10

P_

1

U32

PCON POWER

TO

MIC

RO

TO MICROTO MICRO

GND7

5V12V

14

P10

TO

MIC

RO

TO

MIC

RO P_11

9

(P1

5)+

(EC

UP

OW

ER

)IS 9

IS

BOOM STOWED

TCON MODE

P_7

GND P_

7

OUT 1

BTS621IN1IN2

Vbb

OUT 2ST(TM)(FE)

((~SM)+(AH))(OE)

((~SM)+(AH))(BM STOWED)

IS

BTS650

INOUT

Vbb

P_6R2

8

74HC08

10(~SM)+(AH)

(BM STOWED)((~SM)+(AH))(P_7)

BTS650

INOUT

Vbb

(OE)46

FUNC ENABLE (FE)

P6

R11

74HC08

TCON MODE(TM)

P_7

~SLP MODE (~SM)(~SM)+(AH)AUX HYD (AH)

54

23

5

74HC08

P9A

TO

HO

RN

BU

TT

ON

(SM

)+(A

H)

P7

R

P_

7

P_710

8

74HC08

IN1

GNDSTIN2

OUT 1

OUT 2

Vbb BTS621

P_6R2P

_6

R2 GND

((~SM)+(AH))(P_22)

BTS650

INOUT

VbbP7R

OUT 1

OUT 2STIN2IN1

BTS621VbbP22R

PWR TO TCON ESTOP

TO HORN BUTTON

OUT PWR ENABLE

P_22

P_9B

P_22

OUT PWR ENABLE (OE)

U95

121413

74HC08

TO MICRO(SM)+(AH)

P22R

P7R

P10

P22R

(P15)+(ECU POWER)



P_30





(P15)+(ECU POWER)

REV C

1

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8




Part No. 88619 Z-80/60 6 - 23

C7

3S

BR

-BL

/RD

C7

2S

BE

-BL

/WH

P1

26

SB

LD

-WH

/BK

C0

5T

RR

-WH

/BK

P1

25

SB

LE

-WH

/RD

R4

9L

P-

WT

/BK

C0

8P

BR

-BK

/WH

C11

SB

D-B

L/B

K

C0

2P

BD

-RD

/BK

C1

2S

BF

C-B

L/W

H

C0

9P

ER

F-B

K/R

D

C0

3P

BF

-RD

/WH

C0

6T

RF

-WH

/RD

P6R1

P4

-03

BO

OM

_E

XT

/RE

T_

VLV

P4

-02

VLV

RE

T4

-BR

P4

-01

MANIFOLD HARN

J14 WHITE 35 PIN

BO

OM

_U

P/D

OW

N_

VLV

VA

LV

E_

RT

N4

P11

TO

MIC

RO

TO

PL

D

SE

CB

OO

ME

XT

SE

Q#

1V

LV

SE

CB

OO

MD

OW

NS

EQ

#2

VA

LV

E

TU

RN

TA

BL

E_

RO

TA

TE

_V

LV

P4

-34

P4

-35

P4

-32

P4

-29

P4

-30

P4

-27

P4

-24

P4

-25

P4

-26

P4

-28

P4

-33

P4

-23

P4

-22

P4

-20

P4

-18

P4

-17

P4

-15

P4

-19

P4

-12

P4

-13

P4

-10

P4

-08

P4

-06

P4

-05

P4

-07

P4

-09

P4

-14

P4

-04

C1

0S

BU

-BL

C0

4T

RL

-WH

VLV

RE

T5

-BR

VLV

RE

T5

-BR

C0

1P

BU

-RD

C0

7P

BE

-BK

VLV

RE

T5

-BR

P4

-11

P4

-21

P4

-16

C2

7A

UX

-RD

VA

LV

ER

TN

6

VA

LV

ER

TN

7

P4

-31

VA

LV

E_

RT

N7

SE

C.B

OO

MF.C

.

RO

TA

TE

_C

CW

_V

LV

RO

TA

TE

_C

W_

VLV

BO

OM

OV

ER

LO

AD

BO

OM

RE

VE

RS

EL

OA

D

HY

D_

FIL

TE

R2

HY

D_

FIL

TE

R1

MU

LT

I_F

UN

CT

_V

LV

SE

C_

UP

_V

LV

SE

C_

RE

T_

VLV

SE

C_

EX

T_

VLV

PR

I_R

ET

_V

ALV

E

PR

I_E

XT

EN

D_

VLV

PR

I_U

P_

VLV

PR

I_D

OW

N_

VLV

DR

IVE

LIG

HT

SR

EL

AY

SE

C_

DW

N_

VLV

VA

LV

E_

RT

N5

AU

X_

RE

LA

Y

VA

LV

E_

RT

N6

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

TO

PL

D

TO

MIC

RO

TO

PL

D

TO

MIC

RO

TO

PL

D

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

TO

PL

D

P9A


P7R

P10

P_22R

P_30TO MICRO






TO

PL

D

TO

MIC

RO

TO

MIC

RO

TO

MIC

RO

P_30

J1

0

12

13

14

P1

0

15

678911

10

1245 3

SC

RO

LL

R

ST

RT

AS

ST

SC

RL

F/E

NT

STA

RT

SE

C.U

P

AU

XIL

IAR

Y

BO

OM

UP

GA

S/L

P

EN

GS

PE

ED

-B

UT

TO

N

+B

UT

TO

N

J11

12

13

15

P11

14

678910

11

1235 4

JIB

UP

PLT

FR

MC

CW

BO

OM

CC

W

TU

RT

LE

RA

BB

IT

SE

C.D

OW

N

BO

OM

DO

WN

RO

OM

RE

T

BO

OM

EX

T

PLT

FR

MU

P

BO

OM

CW

PLT

FR

MC

W

PLT

FR

MD

OW

N

JIB

DO

WN

TCON MEMBRANE PANEL

Continued on View 5






REV C



1

2

3

4

5

6

7

8


6 - 24 Z-80/60 Part No. 88619

GN

D-D

CN

-BR

P2

1D

CN

-WH

P5

3L

S-R

D

S5

6P

RV

-RD

S5

6P

RV

-RD

D8

1C

AN

--G

R

D8

2C

AN

+-Y

L

V2

9M

S-R

D/W

H

VLV

RE

T-B

RN

VLV

RE

T2

-BR

N

V3

6R

RS

-BL

V3

7R

RS

-BL

/BK

C111

RR

S-O

R

C111

LR

S-O

R

C111

RF

S-O

R

C111

LF

S-O

R

P11

0R

T-B

K

V3

6L

RS

-BL

V3

7L

RS

-BL

/BK

V3

6R

FS

-BL

V3

2B

RK

-WH

/RD

P1

09

AN

G-G

R/W

H

V3

7R

FS

-BL

/BK

V3

6L

FS

-BL

V3

7L

FS

-BL

/BK

Y5

7O

SC

ILL

AT

ER

IGH

T(J

86

)

Y5

6O

SC

ILL

AT

EL

EF

T(J

85

)

CA BCA BCA BCA B

Y5

8-L

RS

TE

ER

LE

FT

(J9

4)

Y5

9-R

FS

TE

ER

RIG

HT

(J9

5)

Y6

2-L

FS

TE

ER

LE

FT

(J9

8)

Y6

1-L

FS

TE

ER

RIG

HT

(J9

7)

Y6

0-R

FS

TE

ER

LE

FT

(J9

6)

Y5

6-R

RS

TE

ER

LE

FT

(J9

2)

Y5

5-R

RS

TE

ER

RIG

HT

(J9

1)

Y2

7-T

WO

SP

EE

DM

OT

OR

ST

RO

KE

(J8

7)

Y2

-BR

AK

ER

EL

EA

SE

(J1

06

)

S11

-RR

ST

EE

RR

IGH

TS

NS

R

Y5

7-L

RS

TE

ER

RIG

HT

(J9

3)

S1

4-L

FS

TE

ER

RIG

HT

S1

2-L

RS

TE

ER

RIG

HT

S1

3-R

FS

TE

ER

RIG

HT

RD

BK

RD

BL

BK

BL

RD

BL

BK

RD

BL

BK

J108J107 J110J109

D82CAN+ -YL

P21DCN-WH

P53LS-WH/BK

GNDDCN-BR

S56PRV-RD

D81CAN- -GRV

12

2A

XO

-GR

/WH

V1

21

AX

O-G

R

AXLE LSOSCILLATELIMIT SWITCH(STOWED POS)

AXLE RSOSCILLATELIMIT SWITCH(STOWED POS)

LSA1OS LSA2OS

13

NO

NC

14 14

NC

NO

13

V1

22

AX

O-G

R/W

H

WH

21

RD

BR

BK

22

BK

BR

RD

WH

22 21

J104

4 3 2 1 4 3 2 1

J105

S5

6P

RV

(B)-

RD

V1

21

AX

O-G

R

S5

6P

RV

(B)-

RD

S5

6P

RV

(A)-

RD

S5

6P

RV

(A)-

RD

S5

6P

RV

-RD

S5

6P

RV

-RD

P2

-08

P2

-09

P2

-10

P2

-07

P2

-01

P2

-02

P2

-04

P2

-05

P2

-06

P2

-03

P2

-18

P2

-20

P2

-19

P2

-22

P2

-21

P2

-11

P2

-13

P2

-12

P2

-14

P2

-15

P2

-16

P2

-17

J31 23 PIN DRIVECHASSIS HARNESS

J32 23 PIN DRIVECHASSIS HARNESSP

2-2

3

P1

-10

P1

-03

P1

-09

P1

-08

P1

-07

P1

-06

P1

-05

P1

-04

P1

-02

P1

-01

P1

-21

P1

-22

P1

-20

P1

-18

P1

-17

P1

-16

P1

-15

P1

-14

P1

-12

P1

-13

P1

-11

P1

-19

P1

-23

Continued on View1

Continued on View 8

REV C

1

2

3

4

5

6

7

8




Part No. 88619 Z-80/60 6 - 25

C5

6F

TS

-RD

S1

4P

LU

-OR

P2

3P

CO

N-B

K

C4

6H

N-W

H

D8

2C

AN

+-Y

L

D8

1C

AN

--G

R

C4

7O

UT

-WH

T/B

LK

P5

6P

RV

-RD

/WH

S5

6P

RV

-RD

GN

DP

CO

N-B

R

P5

2P

CO

N-W

H

PT

SR

ET

-BR

P8

7P

TS

-RD

PL

AT

RE

T-B

R

P8

5P

TS

-GR

C8

4TA

Y-G

R/B

K

C9

0P

XS

-RD

/BK

C8

8P

TS

-RD

/BK

C4

3JU

-GR

C1

4P

LU

-OR

C4

4JD

-GR

/BK

C1

5P

LD

-OR

/BK

R9

0P

XS

-RD

/BK

C1

7P

RL

-GR

VLV

RE

T-B

RN

C1

8P

RR

-GR

/BK

P5

6F

TS

-RD

NO

LSP1 PROXPROXIMITYKILL SWITCHOPTIONAL

P23PCON-BK

J34-LIMIT SW HARN

J33-BOOM HARN

J35-LIMIT SW HARN

D82CAN+ -YL CAN HIGH YELYEL

D81CAN- -GR

P53LS-WH/BK

P21DCN-WH

GNDDCN-BR

S56PRV-RD

J17-DRIVE CHASSIS HARN

WH/BK

RD22

11

2

1

2

1

WH/BK

RD

P6R1

DCON PWR

P RING

WH

BK22

11J18-DRIVE CHASSIS HARN

2 2

1 1

BK

WH

DCON GND

P7R

B BGRN

BBCAN LOW GRN

NORMAL SWITCH POSITIONSHOWN FOR: LSA1OS

LSA2OSPROX KILLSWING GATE

13

NO

14

NO NO

NORMAL SWITCH POSITIONSHOWN FOR: LSJ1EO

OVERLOAD LIMIT SWLSP1OLS (SHOWN INOVERLOADED CONDITION)

LSJ1EOPLATFORM LEVELCYL FULLY EXT SWITCH(STOWED POS)

NC

NO

A AJ16-DRIVE CHASSIS HARN AA

OVERLOADLIMIT SWLSP1OLS

WH

RD

BK

14 13

22

NC

21

13

NO

14

NC2 1

WH

RD

BK

BR

13

NC

2122

14

2 1

WH

RD

BR

BK

22

14

D82CAN+ -YL

P21DCN-WH

P53LS-WH/BK

GNDDCN-BR

S56PRV-RD

D81CAN- -GR

21

NC

NO

13 INTERLOCKSWING GATE

C47OUT-WH/BK

D82CAN+ -YL

D81CAN- -GR2

1

P52PCON-WH

GNDPCON-BR

5

4

3

4 3 2 1

BR

JIB

UP

(J7

8)

JIB

DO

WN

(J7

9)

PL

AT

RO

TC

CW

(J7

7)

PL

AT

RO

TC

W(J

76

)

PL

AT

LE

VE

LU

P(J

80

)

PL

AT

LE

VE

LD

N(J

81

)

NC

2122

WH

RD

BR

4 3 2 1

BK

PLATFORMTILT SENSORASSEMBLY

RD

RD

NC

22 21J119

FOOTSW (FS1)

WH

WH

BK

BR

4 3 2 1

J82

BK

1 2

J84

BK

WH

NO

TU

SE

D

C5

6F

TS

-RD

R5

6F

TS

-RD

-+

C5

6P

TS

-RD

C2

3P

TS

-WH

6431 2 5 J55

WH

GN

BK

-+

-+

1. PLAT SNSR GND2. TILT SNSR SIG OUT3. TILT SNSR PWR4. TILT SW GND5. PWR TO TILT SW6. OUTPUT FROM TILT SW

3

OPTIONAL SWINGGATE WIRING

RD

21

FOOTSWITCH

6

C46HN-WH

S56PRV-RD

P56PRV-RD/WH 2

1


P1

-20

P1

-17

P1

-22

P1

-23

P1

-02

P1

-03

P1

-04

P1

-05

P1

-06

P1

-07

P1

-08

P1

-09

P1

-10

P1

-13

P1


PCON MANIFOLD

WH

GN

BK

P1

-01

P1

-11

P1

-12

P1

-18

P1

-19

P1

-21

P1

-15

P1

-16

LO

AD

SN

SR

IN

LO

AD

SN

SR

GN

D

LO

AD

SN

SR

PW

R

PL

LV

LC

YL

EX

T

SA

FE

PL

TIL

TG

ND

SA

FE

PL

TIL

TP

WR

PL

TIL

TS

NS

RG

ND

PL

TIL

TS

NS

RP

WR

FO

OT

SW

RT

N

PL

TIL

TS

NS

R

PR

OX

KIL

LC

MD

SA

FE

PL

TIL

TO

UT

PR

OX

KIL

LG

ND

PR

OP

VLV

1_

B

PR

OP

VLV

1_

A

PR

OP

VLV

2_

B

PR

OP

VLV

2_

A

ON

/OF

FV

LV

3_

A

ON

/OF

FV

LV

3_

B

FO

OT

SW

PW

R

VLV

RT

N

P1

-23

P1

-22

P1

-17

P1

-20

P1

-14

P1

-13

P1

-10

P1

-09

P1

-08

P1

-07

P1

-06

P1

-05

P1

-04

P1

-02

P1

-03

P1

-01

P1

-16

P1

-15

P1

-12

P1


P1

-21

P1

-19

P1

-18

BOOM HARN

CA

N-

PIN CKT #PP2 RS232_RXDP3 RS232_TXDP5 RS232_GND

HR

NR

LY

CN

TR

L

OU

TP

WR

EN

BL

PC

ON

PW

R

PC

ON

GN

D

P7

P2

2

PW

R-P

CO

NE

ST

OP

CA

N+

Continued on View 2

Continued on View 9

Continued on View 7

PL

AT

TIL

TS

EN

SO

R

0-2

0D

EG

YA

XIS

SAFE

TYC

UTO

UT

SAFE

TYC

UTO

UT

10

DE

G1

0D

EG

PO

WE

RF

ET

PO

WE

RF

ET





REV C



1

2

3

4

5

6

7

8


6 - 26 Z-80/60 Part No. 88619

D8

2C

AN

+-Y

L

D8

1C

AN

--G

R

P2

3P

CO

N-B

K

GN

DP

CO

N-B

R

P5

2P

CO

N-W

H

C4

6H

N-W

H

C4

7O

UT

-WH

/BK

S5

6P

RV

-RD

P5

6P

RV

-RD

/WH

R4

8L

P-W

H/R

D

R4

9L

P-W

H/B

K

P23PCON-BK

D82CAN+ -YL

D81CAN- -GR

P21DCN-WH

P53LS-WH/BK

GNDDCN-BR

S56PRV-RD

GNDPCON-BR

C47OUT-WH/BK

D81CAN- -GR

P52PCON-WH

D82CAN+ -YL

GND-BRR49LP-WH/BK

RED

TO FLASHING BEACON

S56PRV-RD

P56PRV-RD/WH

C46HN-WH

R48LP-WH/RD

RED

TO WORK LIGHTS

GND-BR

B1ENG (12 VOLT)

P53LS-WH/BK

P21DCN-WH

GNDDCN-BR

S56PRV-RD

U3

0

P1

-23

P1

-22

P1


P1

-07

P1

-08

P1

-04

P1

-02

P1

-03

P1

-05

P1

-01

P1

-17

P1

-15

P1

-16

P1

-12

P1

-13

P1

-11

P1

-10

P1

-09

P1

-14

P1

-06

P1

-21

BOOM HARNP1

-18

P1

-19

CA

LF

RE

Q2

TE

TE

ST

OP

PW

R

RS

23

2T

XD

RS

23

2R

XD

CA

NS

HIE

LD

FL

AS

HIN

GB

EA

CO

N

CA

LF

RE

Q1

PW

R-P

CO

NE

ST

OP

OU

TP

WR

EN

BL

PC

ON

GN

D

PC

ON

PO

WE

R

HO

RN

RE

LA

YC

OIL

CA

NL

OW

BO

OT

P_

7

P_

22

WO

RK

LT

DIA

G/T

ET

HE

RP

WR

DIA

G/T

ET

HE

RG

ND

TE

TH

ER

FU

NC

EN

BL

TE

TE

ST

OP

RE

T

RS

23

2G

ND

CA

NH

IGH

87a

87

86 85

30

87a

87

86 85

30

TCON Continued on View 3


Continued on View 8

REV C

1

2

3

4

5

6

7

8



Electrical Schematic - View 10Limit Switches

Part No. 88619 Z-80/60 6 - 27C

12

3P

BD

RD

/BK

P5

3L

S-W

H/B

K

S1

2S

BL

-BL

/WH

P5

4E

NG

-BK

/WH

P5

4E

NG

-BK

/WH

P5

8L

SR

D/B

K

C7

3S

BR

-BL

/RD

S1

2S

BL

-BL

/WH

SN

SR

GN

D-B

R

P1

09

PB

S-G

R/W

H

C1

24

SB

LR

D/W

H

C7

0P

BR

-BL

/WH

C7

1P

BE

-BL

/BK

C7

7S

BU

-WH

C6

7S

BD

-BL

C6

6D

RE

N-B

L

C6

8P

BD

-RD

C6

5L

OF

-BL

/WH

C6

4L

S-O

R/B

K

P5

3L

S-W

H/B

K

C6

4L

S-O

R/B

K

P5

3L

S-W

H/B

K

S5

6P

RV

-RD

GN

DD

CN

-BR

P2

1D

CN

-WH

P5

3L

S-W

H/B

K

P5

4E

NG

-BK

/WH

2122

FS

T1

SL

OW

FU

EL

FS

GN

/WH

NC

NO

4 3 2 1

PRI BOOM ANG SENSOR WHT WHTWHTNO YEL NCNO

14

2222

14

21

13NC

22 21

12 11

NC

21

NC13

ORN NOPUR NC GRN NOBLU NONORED

14 13NC

22 21

21NC

1112

22 14

22

13

21

NC14

22

13

21

NCNO

14

24

13

23

RD

70

TO

35

DE

GY

-AX

IS

TIL

TS

NS

R

-+-++ -

J114

12 WAY

73 11 2 641210

GN

GN

/BK

BL

BL

/BK

OR

/BK

BK

/WH

LS

P1

EO

3'F

RO

MF

UL

LY

EX

TE

ND

ED

J4

4

LS

S2

AO

RA

ISE

DO

PE

RJ5

1

LS

T1

OD

RV

EN

AB

LE

J4

8

LS

S1

RO

SE

CR

ET

OP

ER

J4

9

LS

S2

AS

RA

ISE

DS

AF

ET

YJ4

7

BR

4 3 2 1W

HB

K

BK

2 1

WH

BR

RD

4 3 2 1

WH

BK

BR

RD

RD

2 1

WH

BK

BR

RD

WH

BK

RD

BR

4 3 2 1

BK

WH

RD

BR

4 3 2 1

BK

WH

RD

BR

RD

WH

BK

BR

4 3 2 1

8

WHTWHTWHT

1413

NO

NC14

WH

/BK

WH

/RD

RD

/BK

RD

/WH

WH

YEL

NC

NC

22 21NC13NO ORNPUR

NC

NO

1314NC

NC

22 21

GRN

14 13NC

BLU NO

14 13NO

RED NO

2324

BRN NO

14

22

13

21

NC

BK

WH

RD

BR

4 3 2 1

NC

BRN NO

14 13

P125SBLE-WH/RDS59SBE-GR/WH

4 3 2 1

S1

2S

BL

-BL

/WH

SN

SR

GN

D-B

R

SN

SR

GN

D-B

R

P5

4E

NG

-BK

/WH

C7

0P

BR

-BL

/WH

C7

1P

BE

-BL

/BK

SJ1

-WH

/RD

SN

SR

GN

D-B

R

C1

23

PB

DR

D/B

K

P1

09

PB

TS

-GR

/WH

C6

4L

S-O

R/B

K

S5

9S

BE

-GR

/WH

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

KC

12

4S

BL

RD

/WH

RD

2

BK

/WH

GN

/WH

GN

/BK

P53LS-WH/BK

P21DCN-WH

18

/19

CA

BL

E BL

BL

/BK

GN

OR

/BK

GNDDCN-BR

S56PRV-RD

J20B12 WAY

J20A4 WAY

18

/19

CA

BL

E 12189321

V1

26

SB

LD

-WH

/BK

P1

26

SB

LD

-WH

/BK

P1

25

SB

LE

-WH

/RD

V1

25

SB

LE

-WH

/RD

BK

C6

4L

S-O

R/B

KC

77

SB

U-W

H

C6

7S

BD

-BL

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

K

C6

6D

RE

N-B

L

C7

3S

BR

-BL

/RD

C6

4L

S-O

R/B

K

C6

5L

OF

L-B

L/W

H

C6

4L

S-O

R/B

K

P5

3L

S-W

H/B

K

SJ1

-WH

/RD

P5

8L

S-R

D/B

K

S5

9S

BE

-GR

/WH

S5

9S

BE

-GR

/WH

SJ1

-WH

/RD

BL

/RD

OR

/RD

P5

8L

S-R

D/B

K

BK

/RD

P5

3L

S-W

H/B

K

C6

4L

S-O

R/R

DC

12

4S

BL

RD

/WH

BL

/WH

4 3 2 1

BR

WH

BKWH

21

RD

BR

BK

22 12 11

RD

BK

WH

BR

RD

OR

2 1

WH

/BK

WH

/RD

WH

RD

/BK

RD

/WH

BK

4 3 2 1 4 3 2 14 3 2 12 1

21

RD

22

BK

WH

BR

12 11

BR

WH

BK

RD

BR

WH

BK

RD

22 21

RD

BK

22

BR

21

WH

1314

BR

BK

RD

WH

4 3 2 1

1118/19CABLE

5 64 73 10

V1

25

SB

LE

-WH

/RD

P1

25

SB

LE

-WH

/RD

V1

26

SB

LD

-WH

/BK

P1

26

SB

LD

-WH

/BK

P5

8L

S-R

D/B

K

S5

9S

BE

-GR

/WH

S5

9S

BE

-GR

/WH

P5

8L

S-R

D/B

K

C6

5L

OF

L-B

L/W

H

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

K

P5

3L

S-W

H/B

K

SJ1

-WH

/RD

C7

3S

BR

-BL

/RD

C6

7S

BD

-BL

C7

7S

BU

-WH

SJ1

-WH

/RD

P5

3L

S-W

H/B

K

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

K

C6

4L

S-O

R/B

K

SJ1-WH/RD

P53LS-WH/BK

C6

4L

S-O

R/B

KC

68

PB

D-R

D

4 3 2 1

2122

RD

BK

BR

WH

V126SBLD-WH/BK

V125SBLE-WH/RD

P126SBLD-WH/BK

C68PBD-RD

C64LS-OR/BK

P1

09

PB

TS

-GR

/WH

P5

3L

S-W

H/B

K

SN

SR

GN

D-B

R

C64LS-OR/BK

P58LS-RD/BK

C66DREN-BL

S1

2S

BL

-BL

/WH

P5

4E

NG

-BK

/WH

P5

8L

SR

D/B

K

C6

8P

BD

-RD

C7

3S

BR

-BL

/RD

C6

4L

S-O

R/B

K

C6

5L

OF

-BL

/WH

C6

6D

RE

N-B

L

P5

4E

NG

-BK

/WH

P5

4E

NG

-BK

/WH

C73SBR-BL/RD

C124SBL RD/WH

C68PBD-RD

P53LS-WH/BK

S56PRV-RD

GNDDCN-BR

P21DCN-WH

S12SBL-BL/WH

C6

7S

BD

-BL

C7

7S

BU

-WH

P2

-03

J12 BLACK 35 PIN

P2

-02

LIMIT SWITCH HARN P2

-01

P2

-33

P2

-34

P2

-35

P2

-32

P2

-28

P2

-29

P2

-30

P2

-27

P2

-26

P2

-24

P2

-25

P2

-22

P2

-19

P2

-20

P2

-17

P2

-15

P2

-14

P2

-18

P2

-23

P2

-13

P2

-12

P2

-10

P2

-09

P2

-08

P2

-07

P2

-05

P2

-06

P2

-04

P2

-11

P2

-21

P2

-16

P2

-31

LS

P1

AO

P2

-SE

Q

BM

ST

WD

P1

-SE

Q

P_

10

P_

9B

P_

7R

P_

9A

P_

11

P_

30

ALL SWITCHES ARE SHOWN IN THE "OUT OF BOX" POSITION

ALL SWITCHES ARE SHOWN IN THE BOOM STOWED POSITION

SA

FE

TY

CU

TO

UT

S

80

DE

G

PO

WE

RF

ET

Continued on View 9


Continued on View 4

80

DE

G

PO

WE

RF

ET

PO

WE

RF

ET

PO

WE

RF

ET

LS

P1

RO

3'E

XT

EN

DE

DJ4

5

LS

S1

RS

3'E

XT

EN

DE

DJ4

6

LS

S1

AO

5D

EG

J5

0

LS

P1

AO

>5

DE

GJ4

3

LS

S2

AO

RA

ISE

DO

PE

RJ5

1

LS

T1

OD

RV

EN

AB

LE

J4

8

LS

S1

RO

SE

CR

ET

OP

ER

J4

9

LS

S2

AS

RA

ISE

DS

AF

ET

YJ4

7

LS

S1

RS

3'E

XT

EN

DE

DJ4

6

LS

S1

AO

5D

EG

J5

0

LS

P1

AO

>5

DE

GJ4

3

LS

P1

EO

3'F

RO

MF

UL

LY

EX

TE

ND

ED

J4

4

LS

P1

RO

3'E

XT

EN

DE

DJ4

5

P_

6R

1

P_

6R

2

LS

B2

RO

LS

P1

RO

LS

P1

EO

Electrical Schematic - View 10Limit Switches



Electrical Schematic - View 11Deutz F4L-913 Engine (before serial number 339)

REV B


Electrical Schematic - View 11Deutz F4L-913 Engine (before serial number 339)

1

2

3

4

5

6

7

8


6 - 28 Z-80/60 Part No. 88619


Continued on View 5

8587a

4

87

5

8630

1 2

C1

07

AF

-RD

87a

5

85

4

87

2

86

1

30C3

4S

A-B

K/W

H

C1

07

AF

-RD

8587a

4

87

5

8630

1 2

P3

3S

TR

-BK

S-500

TO

J4

-32

WH

ITE

35

PIN

EN

GIN

EB

LO

CK

AU

XH

YD

EL

EC

TR

ON

ICS

BA

TT

ER

Y

AU

XIL

IAR

YP

UM

P

STA

RT

BA

TT

ER

Y

STA

RT

ER

STA

RT

ER

RE

LA

Y

TR

OM

BE

TTA

AU

XIL

IAR

YP

UM

PC

ON

TA

CT

OR

-

+

-

+

B2

C2

7A

UX

-RD

AUX.PUMP

BA

TG

ND

-BR

STARTER

B1

PR

1

+AUX

OIL

TE

MP.

SE

ND

ER

PU

LL

IN

HO

LD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TG

ND

-BR

HO

RN

RE

LA

Y

ALT

ER

NA

TO

R

HO

RN

TE

MP

ER

AT

UR

ES

WIT

CH

HY

DR

AU

LIC

OIL

CO

OL

ER

RE

LA

Y

FL

AM

ES

TA

RT

FU

EL

VA

LV

E

FL

AM

MA

BL

ES

TA

RT

IGN

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R

FL

AM

MA

BL

ES

TA

RT

RE

LA

Y

DU

AL

CO

ILE

DC

HI/

LO

SP

EE

DS

OL

EN

OID

OIL

PR

ES

SU

RE

HY

DR

AU

LIC

OIL

CO

OL

ER

FA

N

FU

EL

SO

LE

NO

ID

IGN

ITIO

N/

ALT

ER

NA

TO

RR

EL

AY

FAN

R3

4S

A-B

K/W

H

VLV

RE

T-B

RVLV

RE

T2

-BR

BK

RD

WHVLV

RE

T2

-BR

P4

6H

RN

(A)-

WH

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

H1

PU

LL

IN

HO

LD

DCA BJ120

C4

1R

PM

-OR

/BK

COM

-BATHORNRELAY

CR5

C11

6H

YD

-WH

87a

5

85

4

87

2

86

1

30

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

WH

-PU

LL

IN

BA

TG

ND

(A)

-B

K

RD

-HO

LD

J57

1 2 3OTS1

N.O.

PR2START AID

RELAY

C2

6T

SR

-WT

/RD

C2

5P

SR

-WT

/BK

BAJ56

C

R11

6H

YD

-OR FAN BREAK

SWITCH

CR17

RELAYOIL COOLER

11

0V

AC

RE

GU

LA

TO

R

B1STAID-RD

P116HYD-OR

TROMBETTAMOM N.O.

TIME DELAY

P125SBLE-WH/RD P125SBLE-WH/RD

30 86

C35RPM-BK/RD

5

85

4

87

CR1STARTER

RELAY 87a

+BAT

1 2

F720 A

P126SBLD-WH/BK

V125SBLE-WH/RD

V126SBLD-WH/BK

F1720 A

F1720 A

BATTERYSEPARATOR

F1670 A

P33STR-BK

V126SBLD-WH/BK

V125SBLE-WH/RD

P126SBLD-WH/BK

MA

INA

UX

B2

BA

T-R

D

B1

BA

T-R

D

B1ENG-RD

C3

3S

TR

-BK

P125SBLE-WH/RDP125SBLE-WH/RD

V125SBLE-WH/RD

V126SBLD-WH/BK

P126SBLD-WH/BK

P116HYD-OR

RD-HOLD

WH-PULL IN

P11

6H

YD

-OR

C2

1IG

N-W

H

B1STAID-RD

P33STR-BK

B1

EN

G-R

D

C2

1IG

N-W

H

CR2ENGINEALTERNATORRELAY

P33STR-BK

C21IGN-WH

P126SBLD-WH/BK

V125SBLE-WH/RD

V126SBLD-WH/BK

BLK-120VAC

WHT-NEUTRAL

B1ENG-RD

C26TSR-WT/RD

C25PSR-WT/BK

SEE DETAIL C FOR 220VAC GENERATORW/REGULATOR AND DETAIL D FOR 120VACGENERATOR W/O REGULATOR.

120V AC

AUTORESET CB

15A


B1

BA

T-R

D

GN

D-B

R

B1

BA

T-R

D

GN

D-B

R

J15 BLACK 4 PINPOWER HARNESS

P1

-04

P1

-02

P1

-01

P1


ENGINE HARNESS

SY

S_

BA

T_

PW

R

BA

TE

CU

-PW

R

SY

SB

AT

GN

D

BA

TE

CU

GN

D

C4

1R

PM

-OR

/BK

VLV

RE

T2

-BR

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

C2

5P

SR

-WH

/BK

C3

3S

TR

-BK

C2

6T

SR

-WH

/RD

C3

4S

A-B

K/W

H

C4

6H

RN

-WH

C3

5R

PM

-BK

/RD

C2

1IG

N-W

H

J32-ENG HARNESS

C45GEN-GR/WH

30A

1 WT

3 BK

2 GR

RD


CB

P1

-18

P1

-09

P1

-07

P1

-04

P1

-05

P1

-06

P1

-02

P1

-03

P1

-01

P1

-08

P1

-16

P1

-17

P1

-14

P1

-15

P1

-11

P1

-12

P1

-10

P1

-13

C84TAY-GN/BK

C83TAX-GN/WH

P85TTSR-GR

RET85TTSR-BR

P1

-23

P1

-22

P1

-21

P1

-19

P1

-20

30 41

86 85

87

52

RD/12VDC

BR/R45GEN(A)

BR/P45GEN(B)

YL/BAT GND

DETAIL "B"OPTIONAL 120VAC W/REGULATOR

87a 3

P3

1-E

NG

HA

RN

ES

S

J3

1-T

ILT

SN

SR

RED

BRN

BRN

YEL

6

C84TAY-GN/BK

C83TAX-GN/WH

P85TTSR-GR

RET85TTSR-BR

-


5

4

3

2

-+

+

0-20 DEGREESENSOR ALARMSET AT 4.5 DEGREES

1

ALT

ER

NA

TO

RR

PM

SE

RV

ICE

HR

N

STA

RT

ER

RE

LA

Y

TT

_T

ILT

_S

NS

R_

PW

R

AC

GE

NE

RA

TO

R

OIL

_P

RE

SS

UR

E

TT

_T

ILT

_S

NS

R_

GN

D

OIL

/WA

TE

R_

TE

MP

FW

D

RE

V

TH

RO

TT

LE

IGN

/FU

EL

BA

TE

CU

-PW

R

VA

LV

ER

TN

#1

ED

CR

EV

ED

CF

WD

VA

LV

ER

TN

_2

AC

GE

NE

RA

TO

R

TT

_T

ILT

_Y

_A

XIS

TT

_T

ILT

_X

_A

XIS

BLK-120VAC

WHT-NEUTRAL

SEE DETAIL "C"FOR 220VAC GENERATORW/REGULATOR ANDDETAIL "B"FOR 120VACGENERATOR W/ REGULATOR.

120V AC

AUTORESET CB

15A

J32-ENG HARNESS

C45GEN-GR/WH

30A

1 WT

3 BK

2 GR

RD


CB

30 41

86 85

87

52

DETAIL "D"OPTIONAL 120VAC W/O REGULATOR

87a 3

GR

TO J3 WHITE23 PIN ENGINEHARNESSP1-22


BATGND-BR

C45GEN-GR/WH

BR

WH

B1BAT-RD RD

J32-ENGINEHARNESS

RDRD/12VDC30A

5

87a

87

1

2 86

30 4

85

3

SEE DETAIL B FOR 120VAC GENERATOR



220VAC

AUTORESET CB

WH-NEUTRAL

GR

BR

22

0V

AC

RE

GU

LA

TO

R

BR GND

WH/R45GEN(A)

BK/WH F45GEN

BK P45GEN(B)

WH

BR

BK

BK/WH

DETAIL "C"



REV A

1

2

3

4

5

6

7

8



Part No. 88619 Z-80/60 6 - 29

Electrical Schematic - View 11Deutz BF4L-2011 Engine (after serial number 338)

C83TAX-GN/WH

TURNTABLE

TILT

SENSOR

+2C83TAX-GN/WH

C3

4S

A-B

K/W

H

C3

5R

PM

-BK

/RD

C2

6T

SR

-WH

/RD

C2

5P

SR

-WH

/BK

C3

1E

DC

-WH

/BK

C4

1R

PM

-OR

/BK

GN

D-B

R

B1

BA

T-R

D

B1

BA

T-R

D

GN

D-B

R

RD D5 D3

VLV

RE

T-B

R

R3

4S

A-B

K/W

H

WH

RD

BK

CO

OL

ER

RE

LA

Y

GL

OW

PL

UG

RE

LA

Y

GL

OW

PL

UG

EN

GIN

EB

LO

CK

SE

RV

ICE

HO

RN

AU

XH

YD

CO

NTA

CT

OR

STA

RT

ER

RE

LA

Y

AU

XH

YD

PU

MP

BA

TG

ND

-BR

AU

XH

YD

EL

EC

TR

ON

ICS

BA

TT

ER

Y

STA

RT

BA

T

STA

RT

ER

B2 B1

BA

TG

ND

-BR

H1

BA

TG

ND

-BR

TO

J4

-32

WH

ITE

35

PIN

HO

RN

RE

LA

Y

DU

AL

CO

ILE

DC

TE

MP

SW

C2

7A

UX

-RD

PR

1

D1J120

BA C D

HO

LD

PU

LL

IN

BA

TG

ND

-BR

BA

TG

ND

-BR

OIL

PR

ES

SU

RE

OIL

TE

MP

SE

ND

ER

D8

30

P125SBLE-WH/RDP125SBLE-WH/RDP125SBLE-WH/RD

C2

1IG

N-W

H

P11

6H

YD

-OR

C3

5R

PM

-BK

/RD

TROMBETTA

P3

3S

TR

-BK

87a 87

CR1STARTERRELAY 85

8630

C1

07

AF

-RD

86 30

WH

-PU

LL

IN

BA

TG

ND

(A)

-B

K

C4

1R

PM

-OR

/BK

P4

6H

RN

(A)-

WH

VLV

RE

T2

-BR

D2

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

C11

6H

YD

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J57

GN

D0

4-B

R

GN

D0

4-B

R

321 OTS1N.O.

CR15ST AIDRELAY

RD

-HO

LD

87a8785

CR5HORNRELAYCGND-

AUX+

A

87a 87 85

8630

BGND-

MOM N.O.TIME DELAY RD-HOLD

85 87

86CR17 OILCOOLERRELAY

R21IGN-WH

F7 OIL COOLERF20 HI/LO COOLERF22 GLOW PLUGF23 ENG/ST/ALTB

1E

NG

-RD

P3

5R

PM

-BK

/RD

RD

RD

V126SBLD-WH/BK

20

AF7

F2

2

20

A

F2

0

20

A

60

A

F2

3

V125SBLE-WH/RD

P126SBLD-WH/BK

C3

4S

A-B

K/W

H

P116HYD-OR

P34SA-BK/WH

WH-PULL IN

P34SA-BK/WH

P116HYD-OR

V126SBLD-WH/BK

P126SBLD-WH/BK

V125SBLE-WH/RD

V126SBLD-WH/BK

C21IGN-WH

P126SBLD-WH/BK

V125SBLE-WH/RD

C3

3S

TR

-BK

RD

RD

B2

BA

T-R

D

B1

BA

T-R

D

MA

INA

UX

B1ENG-RD B1ENG-RD B1ENG-RD

C26TSR-WH/RD

C25PSR-WH/BK

B1ENG-RD

C2

1IG

N-W

H

C4

6H

RN

-WH

C3

3S

TR

-BK

C3

0E

DC

-WH

VLV

RE

T2

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RET85TTSR-BR

P85TTSR-GR

1P125SBLE-WH/RD

DUETZ BF4L2011 ENGINE

R2

1IG

N-W

H

C2

5P

SR

-WT

/BK

C2

6T

SR

-WT

/RD

R11

6H

YD

-OR

D7

87a

C2

1IG

N-W

H

B1

EN

G-R

D

CR28ENG ALTRELAY87a 87 85

8630

V126SBLD-WH/BK

V125SBLE-WH/RD

P126SBLD-WH/BK3

2

4

P34 J34

J3

1-T

ILT

SN

SR

P3

1-E

NG

HA

RN

5

6

3

4RET85TTSR-BR

P85TTSR-GR

0D

EG

RE

ES

EN

SO

RA

LA

RM

SE

TA

T4

.5D

EG

RE

ES

-

P1

-03

P1

-04

P1

-02

POWER HARN

J15 BLACK 4 PIN

P1

-01

BA

TE

CU

GN

D

SY

SB

AT

GN

D

SY

S_

BA

T_

PW

R

BA

TE

CU

-PW

R

P1

-23

P1

-13

P1

-15

P1

-14

P1

-17

P1

-20

P1

-18

P1

-22

P1

-08

P1

-03

P1

-02

P1

-06

P1

-05

P1

-04

P1

-07

P1

-10

P1

-09

P1

-01

ENGINE HARN

J13 WHITE 23 PIN

P1

-12

P1

-11

C84TAY-GN/BK

P1

-16

P1

-19

P1

-21

OIL

/WA

TE

R_

TE

MP

TT

_T

ILT

_S

NS

R_

GN

D

OIL

_P

RE

SS

UR

E

TT

_T

ILT

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NS

R_

PW

R

STA

RT

ER

RE

LA

Y

SE

RV

ICE

HR

N

VA

LV

ER

TN

#1

BA

TE

CU

-PW

R

IGN

/FU

EL

TH

RO

TT

LE

RE

V

FW

D

ED

CF

WD

ED

CR

EV

VA

LV

E_

RT

N3

AC

GE

NE

RA

TO

R

ALT

ER

NA

TO

RR

PM

VA

LV

ER

TN

_2

TT

_T

ILT

_X

_A

XIS

TT

_T

ILT

_Y

_A

XIS

AC

GE

NE

RA

TO

R

1C84TAY-GN/BK -

+

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

S-500

FAN

-

+

-

+

AUX.PUMP

ALT

ER

NA

TO

R



Continued on View 5

HI/L

OS

PE

ED

SO

LE

NO

ID

HY

DR

AU

LIC

OIL

CO

OL

ER

FA

N FU

EL

SO

LE

NO

ID

3

4

120VAC

15A

RESET CBAUTO

BLK-120VAC

WHT-NEUTRAL

C45GEN-GR/WH2 58586

WT1

RDBK3

GR2

J32-ENG HARN

CB 87a

30A 187

30P32-GEN HARN



BR/R45GEN(A)

BR/P45GEN(B)

YL/BAT GND

BRN

YEL

BRN

11

0V

AC

RE

GU

LA

TO

R

RD/12VDC


RED

P32-GEN HARN

BRBATGND-BR

RD

WHC45GEN-GR/WH

B1BAT-RD

J32-ENG HARN

BRBR GND5

87a

871

2 86

30 4

85

3

22

0V

AC

RE

GU

LA

TO

R

AUTOSEE DETAIL "C" FOR120VAC GENERATOR W/REGULATOR.

BK-220VAC

RESET CB

10A

BK/WH

BK

WH-NEUTRAL

220VAC

GR

BR

BK/WH F45GEN

BK P45GEN(B)

WH

RD30A

WH/R45GEN(A)

RD/12VDC


DETAIL "D"

TOJ13 WHITE 23 PINENG HARNESSP1-22

Electrical Schematic - View 11Deutz BF4L-2011 (after serial number 338)




REV C



1

2

3

4

5

6

7

8


6 - 30 Z-80/60 Part No. 88619

C7

3S

BR

-BL

/RD

C7

2S

BE

-BL

/WH

P1

26

SB

LD

-WH

/BK

C0

5T

RR

-WH

/BK

P1

25

SB

LE

-WH

/RD

R4

9L

P-

WT

/BK

C0

8P

BR

-BK

/WH

C11

SB

D-B

L/B

K

C0

2P

BD

-RD

/BK

C1

2S

BF

C-B

L/W

H

C0

9P

ER

F-B

K/R

D

C0

3P

BF

-RD

/WH

C0

6T

RF

-WH

/RD

PR

ID

WN

VLV

(J6

0)

PR

IE

XT

VLV

(J6

2)

PR

IU

PV

LV

(J5

9)

PR

IR

ET

VLV

(J6

3)

SE

C.

BM

F.C

.(J

64

)

SE

CU

PV

LV

(J6

7)

SE

CD

WN

VLV

(J6

8)

SE

CR

ET

VLV

(J6

6)

SE

CE

XT

VLV

(J6

5)

PR

IB

MU

P/D

NF.C

.(J

58

)

PR

IB

ME

XT

/RE

TF.C

.(J

61

)

TT

RO

TC

W/C

CW

F.C

.(J

69

)

(DW

NE

NA

BL

E)

SE

CB

MD

NS

EQ

#2

(EX

TE

NA

BL

E)

SE

CB

ME

XT

SE

Q#

1

TT

RO

TC

WV

LV

(J7

0)

TT

RO

TC

CW

VLV

(J7

1)

P125SBLE-WH/RD

C0

9P

ER

F-B

K/R

D

C0

3P

BF

-RD

/WH

VLV

RE

T4

-BR

P

V1

25

SB

LE

-WH

/RD

V1

26

SB

LD

-WH

/BK

JXX JXX

V126SBLD-WH/BK

V125SBLE-WH/RD

P126SBLD-WH/BK

C2

7A

UX

-RD

VA

LV

ER

TN

6

VA

LV

ER

TN

7

C0

5T

RR

WH

/BK

C0

4T

RL

-WH

C1

0S

BU

-BL

C7

3S

BR

-BL

/RD

C7

2S

BE

-BL

/WT

C0

8P

BR

-BK

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VLV

RE

T5

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C1

2S

BF

C-B

LU

/WT

C0

1P

BU

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C0

2P

BD

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C0

7P

BE

-BK

C0

6T

RF

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PP P

C11

SB

D-B

L/B

K

R4

9L

P-

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5

87a

871

286

30 4

85

3

TO DRIVELAMPS

12

VO

LT

P1

26

SB

LD

-WH

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P1

25

SB

LE

-WH

/RD

P126SBLD-WH/BK

P125SBLE-WH/RD

C7

2S

BE

-BL

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C7

3S

BR

-BL

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C1

0S

BU

-BL

P4

-03

BO

OM

_E

XT

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T_

VLV

P4

-02

VLV

RE

T4

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P4

-01

MANIFOLD HARNJ14 WHITE 35 PIN

BO

OM

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P/D

OW

N_

VLV

VA

LV

E_

RT

N4

SE

CB

OO

ME

XT

SE

Q#

1V

LV

SE

CB

OO

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OW

NS

EQ

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VA

LV

E

TU

RN

TA

BL

E_

RO

TA

TE

_V

LV

P4

-34

P4

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P4

-32

P4

-29

P4

-30

P4

-27

P4

-24

P4

-25

P4

-26

P4

-28

P4

-33

P4

-23

P4

-22

P4

-20

P4

-18

P4

-17

P4

-15

P4

-19

P4

-12

P4

-13

P4

-10

P4

-08

P4

-06

P4

-05

P4

-07

P4

-09

P4

-14

P4

-04

C1

0S

BU

-BL

C0

4T

RL

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VLV

RE

T5

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VLV

RE

T5

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C0

1P

BU

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C0

7P

BE

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VLV

RE

T5

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P4

-11

P4

-21

P4

-16

C2

7A

UX

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VA

LV

ER

TN

6

VA

LV

ER

TN

7

P4

-31

VA

LV

E_

RT

N7

SE

C.

BO

OM

F.C

.

RO

TA

TE

_C

CW

_V

LV

RO

TA

TE

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W_

VLV

BO

OM

OV

ER

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AD

BO

OM

RE

VE

RS

EL

OA

D

HY

D_

FIL

TE

R2

HY

D_

FIL

TE

R1

MU

LT

I_F

UN

CT

_V

LV

SE

C_

UP

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LV

SE

C_

RE

T_

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SE

C_

EX

T_

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PR

I_R

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PR

I_E

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D_

VLV

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I_U

P_

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PR

I_D

OW

N_

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DR

IVE

LIG

HT

SR

EL

AY

SE

C_

DW

N_

VLV

VA

LV

E_

RT

N5

AU

X_

RE

LA

Y

VA

LV

E_

RT

N6

TO

MIC

RO

TO

MIC

RO


Continued on View 6

REV C


1

2

3

4

5

6

7

8


Part No. 88619 Z-80/60 6 - 31

Electrical Schematic - View 13GM 3.0L Engine

OIL

PR

ES

SU

RE

SE

ND

ER

CO

OL

AN

TT

EM

PE

RA

TU

RE

SE

ND

ER

HY

DR

AU

LIC

OIL

CO

OL

ER

FA

N

HY

DR

UA

LIC

OIL

CO

OL

ER

RE

LA

Y

ALT

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NA

TO

R

AU

XIL

IAR

YP

UM

P

STA

RT

BA

TT

ER

Y

AU

XIL

IAR

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UM

P/

EL

EC

TR

ON

ICS

BA

TT

ER

Y

STA

RT

ER

STA

RT

ER

RE

LA

Y

TR

OM

BE

TTA

AU

XIL

IAR

YP

UM

PC

ON

TA

CT

OR

HO

RN

MA

INA

UX

ENGINE BLOCK

B2

-

+

B2

BA

T-R

D

SEE ES0185FOR GM DETAIL

PU

MP

+B

L/W

T

C4

1R

PM

-OR

/BKP11

6H

YD

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C2

1IG

N-W

H

FAN

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

TO

J4

-32

WH

ITE

35

PIN

AUX.PUMP

B1

-

+

STARTER C2

7A

UX

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PR

1

BA

TG

ND

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BA

TG

ND

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BA

TG

ND

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HO

RN

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LA

Y

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MP

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AT

UR

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WIT

CH

DU

AL

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ILE

DC

D

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P3

3S

TR

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1R

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C3

0E

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TG

ND

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P4

6H

RN

(A)-

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C11

6H

YD

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R11

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C3

1E

DC

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CR5HORNRELAY

C1

07

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8587a

4

87

5

8630

1 2

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87a

5

85

4

87

2

86

1

30

BA

TG

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IGN

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ALT

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EL

AY

10

SEE ES0185 FOR GM DETAIL

C2

5P

SR

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6T

SR

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ME

DS

PD

RE

Q

NO

TU

SE

D

NO

TU

SE

D

986 753 421

BA

TG

ND

BR

NO

TU

SE

D

1211

8587a

4

87

5

86301 2

P116HYD-OR

B1ENG-RD

P116HYD-OR

CR2ENGINE

RELAY

B1ENG-RD

C27AUX-RD

B1

BA

T-R

D

F1720 A

BATTERYSEPARATOR

F720 A

C26TSR-WT/RD

C33STR-BK

C35RPM-BK/RD

C39LP-BL/RD

C25PSR-WT/BK

C21IGN-WH

C41RPM-OR/BK

C2

1IG

N-W

H

B1

EN

G-R

D

R2

1IG

N-W

H

R2

1IG

N-W

H

C2

7A

UX

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C3

3S

TR

-BK

C3

5R

PM

-BK

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C3

9L

P-B

L/R

D

FUELPUMP

J15 BLACK 4 PIN

POWER HARN

C3

4S

A-B

K/W

H

C4

6H

RN

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C2

1IG

N-W

H

C3

5R

PM

-BK

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BA

TE

CU

-RD

BA

TV

LV

-RD

BA

TG

ND

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BA

TG

ND

-BR

ENGINE HARN

J13 WHITE 23 PIN

P1

-04

P1

-02

P1

-01

P1

-03

P1

-07

P1

-04

P1

-05

P1

-06

P1

-02

P1

-03

P1

-01

C3

9L

P-B

L/R

D

VLV

RE

T2

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C3

0E

DC

-WH

C3

1E

DC

-WH

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C2

5P

SR

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C3

3S

TR

-BK

C2

6T

SR

-WH

/RD

C4

1R

PM

-OR

/BK

P1

-20

P1

-19

P1

-18

P1

-16

P1

-17

P1

-15

P1

-14

P1

-11

P1

-12

P1

-09

P1

-10

P1

-13

P1

-08

P1

-23

P1

-22

P1

-21

J3

1-T

ILT

SN

SR

P85TTSR-GR

RET85TTSR-BR

C84TAY-GN/BK

C83TAX-GN/WH



6

5

4

3

2

1

-

-+

+

BA

TE

CU

-PW

R

SY

SB

AT

GN

D

BA

TE

CU

GN

D

FW

D

RE

V

IGN

/FU

EL

TH

RO

TT

LE

ED

CR

EV

ED

CF

WD


BATGND-BR

C45GEN-GR/WH

BR

WH

B1BAT-RD RD

J32-ENGINEHARNESS

RDRD/12VDC30A

5

87a

871

2 86

30 4

85

3

SEE DETAIL "B" FOR 120VAC GENERATOR

W/REGULATOR AND DETAIL "D" FOR 120VAC


220VAC

AUTORESET CB

WH-NEUTRAL

GR

BR

22

0V

AC

RE

GU

LA

TO

R

BR GND

WH/R45GEN(A)

BK/WH F45GEN

BK P45GEN(B)

WH

BR

BK

BK/WH

DETAIL "C"



Continued on View 5

BLK-120VAC

WHT-NEUTRAL


120V AC

AUTORESET CB

15A

J32-ENG HARNESS

C45GEN-GR/WH

30A

1 WT

3 BK

2 GR

RD


CB

30 41

86 85

87

52


87a 3

GR



Electrical Schematic - View 13GM 3.0L Engine


Electrical Schematic - View 14Perkins 704-30 Engine (before serial number 329)

REV B


1

2

3

4

5

6

7

8


6 - 32 Z-80/60 Part No. 88619

Electrical Schematic - View 14Perkins 704-30 Engine (before serial number 329)

FU

EL

SO

LE

NO

ID

HY

DR

AU

LIC

OIL

CO

OL

ER

FA

N

HY

DR

AU

LIC

OIL

CO

OL

ER

RE

LA

Y

GL

OW

PL

UG

STA

RT

ING

AID

RE

LA

Y

IGN

ITIO

N-

ALT

ER

NA

TO

R/

FU

EL

RE

LA

Y

HO

RN

RE

LA

Y

ALT

ER

NA

TO

R

HI/L

OS

PE

ED

SO

LE

NO

ID

AU

XIL

IAR

YP

UM

P

STA

RT

BA

TT

ER

Y

AU

XIL

IAR

YP

UM

P/

EL

EC

TR

ON

ICS

BA

TT

ER

Y

STA

RT

ER

STA

RT

ER

RE

LA

Y

TR

OM

BE

TTA

AU

XIL

IAR

YP

UM

PC

ON

TA

CT

OR

HO

RN

BA

TG

ND

-BR

BA

TE

CU

GN

D

ENGINE BLOCK

B1B2

-

+

-

+

STARTER

P3

3S

TR

-BK

CR1STARTER

RELAY 87a

F1720 A

F1620 A

F720 A

B1

BA

T-R

D

BATTERYSEPARATOR

B2

BA

T-R

D

MA

INA

UX

BA

TV

LV

-RD

BA

TG

ND

-BR

SY

SB

AT

GN

DP

1-0

2

P1

-01J15 BLACK 4 PIN

POWER HARNESS

P1

-03

C3

3S

TR

-BK

P3

3S

TR

-BK

B1

STA

ID-R

D

87a

5

85

4

87

2

86

1

30

C3

4S

A-B

K/W

H

C1

07

AF

-WH

R3

3S

TR

-BK

C3

5R

PM

-BK

/RD

C2

7A

UX

-RD

PR

1

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

BA

TG

ND

-BR

TO

J4

-32

WH

ITE

35

PIN

AUX.PUMP

BA

TG

ND

-BR

DU

AL

CO

ILE

DC

C

H1

A B

PU

LL

IN

HO

LD

1PR2

DJ120

8587a

4

87

5

8630

1 2

BA

TG

ND

BR

P4

6H

RN

(A)-

WH

C4

1R

PM

-OR

/BK

8587a

4

87

5

8630

1 2C

31

ED

C-W

H/B

K

C3

0E

DC

-WH

VLV

RE

T2

-BR

J57

BK

BK 4

3

5

67

CR4STARTINGAID RELAY

CR5HORNRELAY

B1

BA

T-R

D

R3

3S

TR

-BK

TEMPERATURE CONTROLTIME DELAY

STARTING AIDRELAY MODULE

FAN

R3

4S

A-B

K/W

H

PU

LL

IN

HO

LD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TG

ND

-BR

TE

MP

ER

AT

UR

ES

WIT

CH

WH

RD

BK

J56

OIL

PR

ES

SU

RE

SE

ND

ER

CO

OL

AN

TT

EM

PE

RA

TU

RE

SE

ND

ER

C11

6H

YD

R11

6H

YD

-OR

OTS1

N.O.

C1

07

AF

-WH

B AC

CR2ENG/FUEL

RELAY87a

5

85

4

87

2

86

1

30

C2

5P

SR

-WT

/BK

C2

6T

SR

-WT

/RD

C21IGN-WH

C107AF-WH

P116HYD-OR

B1STAID-RD21

8630

4

85

5

87

B1BAT-RD

B1ENG-RD

P33STR-BK P33STR-BK

CR17OIL COOLERRELAY

P11

6H

YD

-OR

C2

1IG

N-W

H

B1

EN

G-R

D

B1ENG-RD

C26TSR-WT/RD

C25PSR-WT/BK

C84TAY-GN/BK

C83TAX-GN/WH

P85TTSR-GR

RET85TTSR-BR

GR

BK-120VAC

WH-NEUTRAL

C2

6T

SR

-WH

/RD

BA

TE

CU

-RD

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

C2

5P

SR

-WH

/BK

C3

3S

TR

-BK

C3

4S

A-B

K/W

H

C4

6H

RN

-WH

C2

1IG

N-W

H

C3

5R

PM

-BK

/RD


CBJ32-ENG HARNESS

C45GEN-GR/WH

30

86

1

2

30A

WT

BR

RD

VLV

RE

T2

-BR

C4

1R

PM

-OR

/BK

BK/WHBK/WH F45GEN P3

1-E

NG

HA

RN

J3

1-T

ILT

SN

SR

W/REGULATOR AND DETAIL "D" FOR 120VACSEE DETAIL "C" FOR 220VAC GENERATOR

GENERATOR W/O REGULATOR.15A

AUTORESET CB

120V AC

3

WH R45GEN(A)

BK P45GEN(B)

BR BAT GND

DETAIL "B"OPT 120VAC W/REGULATOR

BR

RD 12VDC

85

87

4

5

87a 6

RED

WH

BK

BR

11

0V

AC

5

4

3

2

1

-

-

+

+



ED

CR

EV

ED

CF

WD

IGN

/FU

EL

BA

TE

CU

-PW

R

TH

RO

TT

LE

P1

-01

P1


ENGINE HARNESS

P1

-11

P1

-12

P1

-09

P1

-10

P1

-13

P1

-07

P1

-04

P1

-05

P1

-06

FW

D

RE

V

P1

-02

P1

-03

P1

-08

P1

-23

P1

-22

P1

-21

P1

-19

P1

-18

P1

-20

P1

-16

P1

-17

P1

-15

P1

-14

RE

GU

LA

TO

R



Continued on View 5

BLK-120VAC

WHT-NEUTRAL


120V AC

AUTORESET CB

15A

J32-ENG HARNESS

C45GEN-GR/WH

30A

1 WT

3 BK

2 GR

RD


CB

30 41

86 85

87

52


87a 3

GR


REV A


MA

INA

UX

8587a

4

87

5

8630

1 2

R3

3S

TR

-BK

C3

5R

PM

-BK

/RD

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TG

ND

-BR

TO

J4

-32

PW

HIT

E3

5P

IN

SE

RV

ICE

HO

RN

ALT

ER

NA

TO

R

AU

XH

YD

PU

MP

STA

RT

BA

T

AU

XH

YD

EL

EC

TR

ON

ICS

BA

TT

ER

Y

STA

RT

ER

RE

LA

Y

AU

XH

YD

CO

NTA

CT

OR

ENGINE BLOCK

STA

RT

ER

HO

RN

RE

LA

Y

FU

EL

PU

MP

FU

EL

SO

LE

NO

ID

HY

DR

AU

LIC

OIL

CO

OL

ER

FA

N

GL

OW

PL

UG

STA

RT

AID

RE

LA

Y

HI/L

OS

PE

ED

SO

LE

NO

ID

TR

OM

BE

TTA

DU

AL

CO

ILE

DC

OIL

PR

ES

SU

RE

OIL

TE

MP

SE

ND

ER

TE

MP

SW

CO

OL

ER

RE

LA

Y

BA

TG

ND

BR

P4

6H

RN

(A)-

WH

B1B2 C2

7A

UX

-RD

BA

TG

ND

-BR

PR

1

C4

1R

PM

-OR

/BK

C1

07

AF

-RD

R11

6H

YD

-OR

R3

4S

A-B

K/W

H

OTS1N.O.

J120

H1A B DC

RD

BK

HO

LD

RD

BK

J56

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

VLV

RE

T2

-BR

J57

30 86

8787a 85

CR4

R2

1IG

N-W

H

R2

1IG

N-W

H

C2

5P

SR

-WT

/BK

C2

6T

SR

-WT

/RD

ACC11

6H

YD

CR2

CR5

HORNRELAY

87

CR130

87a

STARTERRELAY

86

85

P46HN-WH

P35RPM-RD

P116HYD-OR

P34SA-BK/WH

C3

4S

A-B

K/W

H

P3

5R

PM

-RD

CR15

GLOW PLUGRELAY

87a85 87

86 30

P11

6H

YD

-OR

C2

1IG

N-W

H

3086

8785 87a

CR17

OIL COOLERRELAY

R21IGN-WH

3086

8785 87a

ENG/FUELRELAY

C34SA-BK/WH

F2

2

70

A

20

A

F1

7

20

A

F1

6

F7

30

A

P21IGN-WH

FUSE INFOF7 HYD CLR/RPMF16 STARTF17 ENGINEF22 GLOW PLUGS

B1

BA

T-R

D

B2

BA

T-R

D

C3

3S

TR

-BK

C21IGN-WH

P2

1IG

N-W

H

P21IGN-WH

15ABK-120VAC

C26TSR-WT/RD

C25PSR-WT/BK

ED

CR

EV

ED

CF

WD

IGN

/FU

EL

BA

TE

CU

-PW

R

TH

RO

TT

LE

SY

SB

AT

GN

D

BA

TE

CU

GN

D

TU

RN

TA

BL

ET

ILT

SE

NS

OR

11

0V

AC

RE

GU

LA

TO

R

BK P45GEN(B)

P3

1-E

NG

HA

RN

J3

1-T

ILT

SN

SR

WH-NEUTRAL

AUTORESET CB

120VAC

C4

5G

EN

-GR

/WH

GR

BR

BK/WH F45GEN

BK

BK/WH

RD30

86 85

87

4

5

1

2

30A

WT

BR

P32-GEN HARN87a

CB 3

RD 12VDC

WH R45GEN(A)

BR BAT GND

RED

WH

BR


P1

-15

C2

5P

SR

-WH

/BK

C3

5R

PM

-BK

/RD

BA

TE

CU

-RD

BA

TV

LV

-RD

BA

TG

ND

-BR

BA

TG

ND

-BR

C3

0E

DC

-WH

C3

1E

DC

-WH

/BK

C3

3S

TR

-BK

C2

6T

SR

-WH

/RD

C3

4S

A-B

K/W

H

C4

6H

RN

-WH

C2

1IG

N-W

H

P1

-04

P1

-02

P1

-01

P1

-03

POWER HARN

J15 BLACK 4 PIN

P1

-14

P1

-11

P1

-12

P1

-09

P1

-10

P1

-13

P1

-07

P1

-04

P1

-05

P1

-06

P1

-02

P1

-03

P1

-01

P1

-08

ENGINE HARN

J13 WHITE 23 PIN

FW

D

RE

V

-C84TAY-GN/WH

VLV

RE

T2

-BR

C4

1R

PM

-OR

/BK

J32-ENG HARN

C83TAX-GN/WH

P85TTSR-GR

RET85TTSR-BR

0-2

0D

EG

RE

ES

EN

SO

RA

LA

RM

AT

4.5

DE

GR

EE

S

6

5

4

3

2-+

P1

-23

P1

-22

P1

-21

P1

-19

P1

-18

P1

-20

P1

-16

P1

-17

1 +

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

-

+

-

+

PUMPAUX.

FAN

Continued on View 5



P32-GEN HARN

BRBATGND-BR

RD

WHC45GEN-GR/WH

B1BAT-RD

J32-ENG HARN

BRBR GND5

87a

871

2 86

30 4

85

3

22

0V

AC

RE

GU

LA

TO

R


BK-220VAC

RESET CB

10A

BK/WH

BK

WH-NEUTRAL

220VAC

GR

BR

BK/WH F45GEN

BK P45GEN(B)

WH

RD30A

WH/R45GEN(A)

RD/12VDC


DETAIL "D"


1

2

3

4

5

6

7

8



Electrical Schematic - View 14Perkins 804C-33 Engine (after serial number 328)

Part No. 88619 Z-80/60 6 - 33


Electrical Schematic - View 14Perkins 804C-33 Engine (after serial number 328)


Electrical Schematic - View 15Ford LRG 425 Engine

REV A


1

2

3

4

5

6

7

8


6 - 34 Z-80/60 Part No. 88619

Electrical Schematic - View 15Ford LRG 425 Engine

ALTERNATOR

REGULATOR

BAT.+

IND.

STA.

BAT.-

EXCT.

50

0

4.5

DE

GR

EE

S

B2

BA

T-R

D

B1

BA

T-R

D

8587a

487

5

8630

1 2

8587a

487

5

8630

1 2

C1

07

AF

-RD

HORNRELAY OIL COOLER

RELAY87a5

85

487

286

130

BA

TG

ND

-BR

TO J4-32WHITE 35 PIN

ENGINE BLOCK

BA

TT

ER

Y

AU

XH

YD

EL

EC

TR

ON

ICS

SE

RV

ICE

PH

OR

N

HO

RN

PR

EL

AY

CO

OL

ER

RE

LA

Y

TE

MP

SW

HY

DR

AU

LIC

OIL

CO

OL

ER

FA

N

TR

OM

BE

TTA

AU

XH

YD

ALT

ER

NA

TO

R

STA

RT

BA

T

STA

RT

ER

STA

RT

ER

RE

LA

Y

AU

XH

YD

PU

MP

CO

NTA

CT

OR

DU

AL

CO

ILE

DC

P4

6H

RN

(A)-

WH

VLV

RE

T2

-BR

R11

6H

YD

-OR

BA

TG

ND

-BR

A

BA

TG

ND

-BR

C2

7A

UX

-RD

PR

1

H1 BA C D

OTS1N.O.

C3

1E

DC

-WH

/BK

C11

6H

YD

-WH

R16

C3

0E

DC

-WH

P2

0P

WR

-RD

R3

3S

TR

-BK

C2

1IG

N-W

H

P11

6H

YD

-OR

CR5CR17

P116HYD-OR P116HYD-OR

F7

B1BAT-RD

C39LP-BL/RD

C21IGN-WH

B1BAT-RD

C35RPM-BK/RD

C25PSR-WT/BK

C26TSR-WT/RD

C33STR-BK

20

A

20

A

F1

7

C41RPM-OR/BK

OIL

PR

ES

SU

RE

CO

OL

AN

TT

EM

P

FORD 42 PIN CONNECTOR

C1

27

TS

W-G

R

C1

08

ES

L-B

L/W

T

C3

8F

P-B

L/W

T

R2

1IG

N-W

H

C3

9L

P-B

L/R

D

C3

3S

TR

-BK

R3

3S

TR

-BK

C2

1IG

N-W

H

C2

6T

SR

-WT

/RD

C2

5P

SR

-WT

/BK

C4

1R

PM

-OR

/BK

C3

5R

PM

-BK

/RD

246182 237 11513 9 345

B1

BA

T-R

D

BA

TT

-

P1

-03

P1

-01

P1

-02

P1

-04

POWER HARN C35RPM-BK/RD

C3

5R

PM

-BK

/RD

C2

1IG

N-W

H

C4

6H

RN

-WH

C4

1R

PM

-OR

/BK

C2

6T

SR

-WH

/RD

C3

3S

TR

-BK

C2

5P

SR

-WH

/BK

C3

1E

DC

-WH

/BK

C3

0E

DC

-WH

VLV

RE

T2

-BR

C3

9L

P-B

L/R

D

MA

INA

UX

BA

TG

ND

-BR

BA

TG

ND

-BR

BA

TV

LV

-RD

BA

TE

CU

-RD

J15 BLACK 4 PIN

ED

CF

WD

ED

CR

EV

RE

V

FW

D

TH

RO

TT

LE

IGN

/FU

EL

BA

TE

CU

GN

D

SY

SB

AT

GN

D

BA

TE

CU

-PW

R

J13 WHITE 23 PIN

ENGINE HARN P1

-01

P1

-03

P1

-02

P1

-06

P1

-05

P1

-04

P1

-08

P1

-13

P1

-10

P1

-09

P1

-12

P1

-11

P1

-14

P1

-15

P1

-17

P1

-16

P1

-18

P1

-19

P1

-07

P1

-20

P1

-21

P1

-22

P1

-23

3

J31-TILT SNSR

4RET85TTSR-BR

P85TTSR-GR

6

5

1

2C83TAX-GN/WH

C84TAY-GN/BK -+-

+

-

+

-

+

AUX.PUMP

FAN

Continued on View 5


FUELPUMP

P32-GEN HARN

BRBATGND-BR

RD

WHC45GEN-GR/WH

B1BAT-RD

J32-ENG HARN

BRBR GND5

87a

871

2 86

30 4

85

3

22

0V

AC

RE

GU

LA

TO

R


BK-220VAC

RESET CB

10A

BK/WH

BK

WH-NEUTRAL

220VAC

GR

BR

BK/WH F45GEN

BK P45GEN(B)

WH

RD30A

WH/R45GEN(A)

RD/12VDC


DETAIL "D"



15ABK-120VAC

11

0V

AC

RE

GU

LA

TO

R

BK P45GEN(B)

WH-NEUTRAL

AUTORESET CB

120VAC

C4

5G

EN

-GR

/WH

GR

BR

BK/WH F45GEN

BK

BK/WH

RD30

86 85

87

4

5

1

2

30A

WT

BR

P32-GEN HARN87a

CB 3

RD 12VDC

WH R45GEN(A)

BR BAT GND

RED

WH

BR


REV A

1

2

3

4

5

6

7

8



Electrical Schematic - View 16Hydraulic Generator Option

Part No. 88619 Z-80/60 6 - 35

Theory of Operation

Adjustments

1. A request from PCON to turn the Generator on commands TCON to enable the High RPM output and the generator output.

DCON enables the motor stroke valve switching the motors to high speed/low torque mode.

2. The SX controller is turned ON supplying power to bypass valve and the change over relay.

The EDC valve is switched over to the output of the SX controller.

3. When the AC generator is turned OFF the SX module will ramp the output to the EDC to threshold preventing cavitation to the

hydraulic motor powering the generator. When threshold is reached the bypass valve is turned OFF.

4. The generator output is turned off when an operator engages the footswitch.

The propel function has a time delay to ensure the SX controller ramps the drive pump off and disengages the dump valve.

1. Connect a digital multimeter (DMM) with a frequency counter to the 110 vac outlet.

Adjust the potentiometer until a frequency of 66.5 HZ is obtained with no load on the generator.

L1

L2

L3N

RED

ORANGE

BLACK

GREEN

GREEN

BLACK

WHITE

RED

8 GA 4 CONDUCTOR

208 VACOUTLET

SILVER

GREEN

L1 L2 L3

NEUTRAL BUSS BAR12.5 KW HYDRAULIC GENERATOR

NEMA 4 CONTROL BOX

50 AMP 3 POLE CIRCUIT BREAKERWITH INTEGRAL GFI

BRASS

SILVER

120 VACGFI

GREEN 12GA

BLACK 12GA

110 VAC GFI

BRASS

BLACK

GREEN

WHITE

XY

Z

8 GA 5 CONDUCTOR

20 AMP CIRCUITBREAKER

GROUNDSTUD ONPANEL

12 GA 3 CONDUCTOR

1 2

3

N

5 4

6

BLACK 12GA

ENCLOSURE

A1 BATTERY +A2 SENSOR POWER +5 VDCA3 BATTERY-B1 VALVE 0 FWD COILB2 VALVE 1 NCB3 DIGITAL OUTPUT BYPASS/OMRONC1 TxDC2 RxDC3 /BOOTD1 ANALOG 0 JOYSTICKD2 ANALOG 1 NCD3 DIG IN 3 NCE1 NOT USEDE2 NOT USEDE3 NOT USEDF1 DIG IN 0 PF2 DIG IN 1 GENERATOR ONF3 DIG IN 2

12

5

BK

8

1011

9

7

6

WH

COLOR

34

2WH/BK

PIN#

1

CKT#

WH/BK

COLOR

WH

OR/RD

RD/WH

BL/RD

BK/RDBR

WH/RDBR

RD

RD/BK

GR/WHGR/WHGR/BKGR/BK

GRBR

BRWH/BKWH

BR

GND

P23PCONV150HGC45GEN

GND

C31EDC-(A)

C30EDC+(A)

GND

GNDC31EDC-C30EDC+

GND

Harness

Inside Enclosure

2 4

6

81 3

5 7

RS232RxDRS232TxD

CR

4H

IGH

IDLE

RE

LA

YC

45

GE

NG

R/W

H

V151HG GRV150HG GR/BK

2 1

3

BY

PA

SS

CO

IL

MO

TO

RS

TR

OK

EV

ALV

E

SX Controller

OMRONRELAY

P23CON

J3

-2

J2

-4

J1

-5

J4

-35

J1

-18

J1

-17

J1

-17

J1

-18

J1

-17

J1

-18

D81CAN- -GRD82CAN+ -YL

TIME DELAYMODULE 4S

5 SW INPUT3 GND

1 N.O.

2 COM

8 N.C.

TOBAT2 +

PCON

TCON

DCON

1k ohms124 ohms

124 ohms

ABC

J3

-10

J3

-9

12 GA 3 CONDUCTOR

DR

IVE

ED

C+

DR

IVE

ED

C-

Electrical Schematic - View 16Hydraulic Generator Option



Electrical Schematic - View 17Safety Circuits

REV C


1

2

3

4

5

6

7

8


6 - 36 Z-80/60 Part No. 88619

Electrical Schematic - View 17Safety Circuits

12 VBATT

TO:PRI UP/DN FCVALVE(J14-02)SEC BM FC(J14-06)

LR STEER LEFTVALVE(J32-17)LR STEER RIGHTVALVE(J32-16)RR STEER LEFTVALVE(J32-09)RR STEER RIGHTVALVE(J32-08)SPARE VALVE(J32-03)

P11 BLACK 35 PIN (TCON)P12 BLACK 35 PIN (TCON)P21 BLACK 23 PIN (PCON)P22 WHITE 23 PIN (PCON)P34 DEUTSCH DTP 2 PIN CONNP18 DEUTSCH DTP 2 PIN CONNP31 BLACK 23 PIN (DCON)P55 6 WAY DEUTSCH AT PLAT LEVEL SENSORP17 16 WAY MOLEX IN TCON

TO:LF STEER LEFTVALVE(J32-23)LF STEER RIGHTVALVE(J32-22)RF STEER LEFTVALVE(J32-21)RF STEER RIGHTVALVE(J32-18)

TO:PRI BM EXT/RETFC VALVEP(P14-03)TT ROTFC VALVE(P14-04)PAUX HYDRELAY(P14-32)

PLATFORMMANIFOLDHARNESS

PCON

Safety Circuits P7R

PCON

S56PRV RD

SEC COMPCABLE

R56FTS RD

TCON

(PM)(~SM)

12 VBATT

P6P22-16

PM - PCON MODE~SM - NOT SLP MODE

P11-06

P7

PCONPRI COMPCABLE

TO:FWD VALVE(P13-05)REV VALVE(P13-06)

C56FTS RD

FOOT SWP22-17

P7S56PRV RD

01 P21-04

LOWER LIMITSWITCH HARNTCON

P7R

DRIVECHASSIS

ELECTRICROTATOR

P31-05

((~SM)+AH)P7

P7

TCON

((~SM)+AH)

(TM)(FE)

74HC08

12 VBATT

P7

TM - TCON MODEFE - FUNC ENABLE

Safety Circuits P22 and P22R

TCON

TORECOVERYPLD

TORECOVERYSW (V)

P7R12 VBATT

TCON

S56PRV RDP12-05

P17-08S56PRV RD

S56PRV RDWH WH

P34-01 P18-01

P12

P31-06

P17-09P17-12 P15

RECOVERY SW (Z)

TO:SPAREVALVE(J32-02)

~SM - NOT SLP MODEAH - AUX HYD

TO:IGN/FUEL RELAY(J13-03)LSS1RS 3' EXT

YELLOW

18/19 CABLEPBAS18/19 CABLETCON

RECOVERY SW (V)P17-08

PLAT ROT CCWP7RP52 PCON WHP52 PCON WHPCON PWR12 VBATT

SEC COMPCABLE

TCON

P11 BLACK 35 PIN (TCON)04 ROUND DEUTSCH CONN (8 WAY)P21 BLACK 23 PIN (PCON)P22 WHITE 23 PIN (PCON)P55 6 WAY DEUTSCH AT PLAT LEVEL SENSORP17 16 WAY MOLEX IN TCON

P55-06PRI COMPCABLE

PCONPLATFORM TILTSENSOR


P22-23 P55-05

P87PTS RD


PCON SEC COMPCABLE

PRI COMPCABLE

P21-07P22-15C88PTS RD/BK P22

02

P56PRV RD/WH P56PRV RD/WH

S56PRV RD

04

Safety Circuits P6R2, P10, P18, AND P9B

P11-02

P18

TCON

LOWER LIMITSW HARNESS

P10

P12-12

P12-08

NOT SLEEP MODEAND FOOT SW

P21-02JIB UPJIB DOWN

PLAT ROT CW

PLAT UPPLAT DOWN


P12 BLACK 35 PIN (TCON)P20B 12 WAY DEUTSCHP114 12 WAY DEUTSCH @ PBAS

NCFOPP

11 12

LSS2AS RAISEDPURPLE

01

BRRD


02

(~S

M+

AH

)(P

_2

2)

(~S

M+

AH

)

TCONP22R

74HC08

P17-10P11-07P22

P56PRV RD

P12-09

P12-34WH/RDRD/WHLSS1RS 3' EXTYELLOW

Safety Circuits P6R1, P14, P12, P11 AND P30

P12-04

P6R2 P54ENG-BK/WH

P12


TCON

P14

P12-10

P12-11

P12 BLACK 35 PIN (TCON)P20B 12 WAY DEUTSCHP114 12 WAY DEUTSCH @ PBAS

SJ1 WH/RDP20B-01 P114-04

BK/WHP20B-12P114-02

OR/BKNCP

11 12

01

BRRD02 P12-07

P58LS RD/BK

WHBK

NCFOP

21 22LSS2AS RAISEDPURPLE

03 0418/19 CABLE

RD/BK WH/BK18/19 CABLEPBAS


P6R1P12-03

P53LS-WH/BK

P114-06S59SBE GR/WH

0403 NCP

21 22BK WH

P20B-02RD WH

P114-08 P20B-03S12SBL BL/WH

ECUMONITOR

TO:PRI UP VALVE(J14-07)AC GENERATOR(J13-22)STARTER RELAY(J13-09)

TO:SEC EXTVALVE(J14-21)SEC DOWNVALVEP(J14-12)

P_9B

TCON

ECUMONITOR

P_30

P_11


Hydraulic Schematic2 Wheel Drive with 2 Wheel Steer - View 1

REV C



1

2

3

4

5

6

7

8


6 - 37 Z-80/60 Part No. 88619

M

CHARGE FILTER

51 psi3.5 bar

PLATFORM LEVEL0.65 gpm / 2.46 L/min

JIB BOOM1.25 gpm / 0.75 gpm

4.75 L/min / 2.84 L/min

PLATFORM ROTATE0.3 gpm / 1.14 L/min

TANK

1.7(6.4)

0.3(1.1)5

(19)0.9

(3.4)17

(64.5)

25 psi1.72 bar

102 psi7 L/min

102 psi7 L/min

HIGH PRESSURE FILTERS

500 psi34.5 bar

F F E E

0.1gpm0.38 L/min

0.030 inch0.762 mm

5 cu in82 cc

PLATFORM MANIFOLD

E

3200 psi220.6 bar

PRIMARY BOOMEXTEND/RETRACT

9.7 / 4.4 gpm / 36.7 / 16.7 L/min

PRIMARY LIFT7.1 / 5.1 gpm / 26.8 / 19.3 L/min

HA

H

0.1 gpm0.38 L/min

SECONDARY BOOMEXTEND/RETRACT

6.1 / 2.1 gpm / 23 / 7.95 L/min

SECONDARY BOOM LIFT5 / 3.6 gpm / 18.9 / 13.63 L/min

EC E

D DA A

DEM1

B

M4

M5

L1 L2 S

M2

ø.030

TANK

T1

AUX2

PMP

RRETREXTR2R1T4T3PRETPEXT2P2P1TRRTRL

OSC TO OCFROM OCT5LSSTR

PTEST

LSTEST

PMAN

PMP2

AUX

AUXILIARYPUMP

T2

2B 3 1 5 2A 4 6

3 1 5 2 4 6

FUNCTIONMANIFOLD

TURNTABLEROTATE

3 gpm / 11.4 L/min

PEXT1

JDJUPLU PLDPRL PRR

ACCUMULATOR

P1

P

T

T1

LS

3000 psi207 bar

G B

1300 psi89.6 bar

1300 psi89.6 bar

2500 psi172 bar

2500 psi172 bar

2600 psi179 bar

HYDRAULIC ROTARY COUPLER

A

3625 psi250 bar

3625 psi250 bar

320 psi22 bar

DRIVEPUMP

FUNCTIONPUMP

3 gpm11.4 L/min

PTEST2

COUNTERBALANCE VALVE

RATIO PRESSURE

1000 psi / 69 bar

2000 psi / 138 bar

2500 psi / 172 bar

3:1

3000 psi / 207 bar

1.5:1

3:1

3:1

3:1

1.5:1

3300 psi / 227.5 bar

3500 psi / 241.3 bar

3:1 3500 psi / 241.3 bar

3:1 2000 psi / 138 bar

A

B

C

D

E

F

G

H

B

P

E

V

X

U

K

R

S

F

G

O

H

J

IT Y

L

W

AM

N

C

Z

AA

AB

AD

AEAG

AF

AH

AC

AI

AJ

GAGR

GB

GIGLGM

GN

GJ

KK

LLMM

GK

GC

GD

GEGFGH

GG

GO

GP GQ

D

Q

REV C



1

2

3

4

5

6

7

8


Part No. 88619 Z-80/60 6 - 38

TWO WHEELSTEER MANIFOLD

FRONT RIGHTSTEERING

2.3 gpm8.7 L/min

2.3 gpm8.7 L/min

1.2 gpm4.5 L/min

1.2 gpm4.5 L/min

FRONT LEFTSTEERING

E E

OSCILLATE CYLINDERS

E E

T

PO

FLB FLR FRB FRR

TEST

OL OR

PS LS

OSCILLATE MANIFOLD

CDR CDL

2B 3 1 5 2A 4 6

3 1 5 2 4 6


800 psi55 bar

DRIVEMANIFOLD

M1REARLEFT

M3

M5

50%

50%

REARRIGHT

M7

T A BTEST

X

CDL

CDR

LBRAKE

L2SPEED

R2SPEED

RBRAKE

4.5 gpm17 L/min

280 psi19.3 bar

0.030 inch0.762 mm

BABB

BC BD

BE

BF BKBG BL

BH BOBPBQ

BI BMBJ

EB

EA

ECED

EE

EGEI

EJ

EH

EF

BN

DIVERTERMANIFOLD

MTR B MTR A

G2

CLRPMP B

OIL

COOLER

G1270 PSI @3.5 GPM

G2 G1

HYDRAULIC WELDER OPTION

31

0.031

31

B

A

PMP A

HY

DR

AU

LIC

RO

TA

RY

CO

UP

LE

R

21 CC

12.5 KW GENERATOR

DRIVEPUMP

CBB

CBC

CBA

CBE

CBD





REV C



1

2

3

4

5

6

7

8


6 - 39 Z-80/60 Part No. 88619

M

CHARGE FILTER

51 psi3.5 bar



4.75 L/min / 2.84 L/min


TANK

1.7(6.4)

0.3(1.1)5

(19)0.9

(3.4)17

(64.5)

25 psi1.72 bar

102 psi7 L/min

102 psi7 L/min


500 psi34.5 bar

F F E E

0.1gpm0.38 L/min

0.030 inch0.762 mm

5 cu in82 cc

PLATFORM MANIFOLD

E

3200 psi220.6 bar


9.7 / 4.4 gpm / 36.7 / 16.7 L/min


HA

H

0.1 gpm0.38 L/min


6.1 / 2.1 gpm / 23 / 7.95 L/min


EC E

D DA A

DEM1

B

M4

M5

L1 L2 S

M2

ø.030

TANK

T1

AUX2

PMP



PTEST

LSTEST

PMAN

PMP2

AUX

AUXILIARYPUMP

T2

2B 3 1 5 2A 4 6

3 1 5 2 4 6

FUNCTIONMANIFOLD

TURNTABLEROTATE

3 gpm / 11.4 L/min

PEXT1

JDJUPLU PLDPRL PRR

ACCUMULATOR

P1

P

T

T1

LS

3000 psi207 bar

G B

1300 psi89.6 bar

1300 psi89.6 bar

2500 psi172 bar

2500 psi172 bar

2600 psi179 bar


A

3625 psi250 bar

3625 psi250 bar

320 psi22 bar

DRIVEPUMP

FUNCTIONPUMP

3 gpm11.4 L/min

PTEST2


RATIO PRESSURE

1000 psi / 69 bar

2000 psi / 138 bar

2500 psi / 172 bar

3:1

3000 psi / 207 bar

1.5:1

3:1

3:1

3:1

1.5:1

3300 psi / 227.5 bar

3500 psi / 241.3 bar

3:1 3500 psi / 241.3 bar

3:1 2000 psi / 138 bar

A

B

C

D

E

F

G

H

B

P

E

V

X

U

K

R

S

F

G

O

H

J

IT Y

L

W

AM

N

C

Z

AA

AB

AD

AEAG

AF

AH

AC

AI

AJ

GAGR

GB

GIGLGM

GN

GJ

KK

LLMM

GK

GC

GD

GEGFGH

GG

GO

GP GQ

D

Q

REV C



1

2

3

4

5

6

7

8


Part No. 88619 Z-80/60 6 - 40

FOUR WHEEL STEER MANIFOLD

FRONT RIGHTSTEERING

2.3 gpm8.7 L/min

2.3 gpm8.7 L/min

2.3 gpm8.7 L/min

2.3 gpm8.7 L/min

1.2 gpm4.5 L/min

1.2 gpm4.5 L/min

1.2 gpm4.5 L/min

1.2 gpm4.5 L/min

FRONT LEFTSTEERING

REAR LEFTSTEERING

REAR RIGHTSTEERING

E E

OSCILLATE CYLINDERS

E E

T

PO

FLB FLR FRB FRR RLB RLR RRB RRR

TEST

OL OR

PS LS

OSCILLATE MANIFOLD

CDR CDL

2B 3 1 5 2A 4 6

3 1 5 2 4 6


800 psi55 bar

M1REARLEFT

M3

M5

50%

50%

REARRIGHT

M7

T A BTEST

X

CDL

CDR

LBRAKE

L2SPEED

R2SPEED

RBRAKE

4.5 gpm17 L/min

280 psi19.3 bar

0.030 inch0.762 mm

2WD DRIVEMANIFOLD

CA CP CQ

CICX CLCJCR CV CW CK

CT CUCZCAA CG

CH

CD CADCAE

CE CF

CCCOCMCNCYCSCAC CAB

CB

EB

EA

ECED

EE

EGEI

EJ

EH

EF

DIVERTERMANIFOLD

MTR B MTR A

G2

CLRPMP B

OIL

COOLER

G1270 PSI @3.5 GPM

G2 G1


31

0.031

31

B

A

PMP A

HY

DR

AU

LIC

RO

TA

RY

CO

UP

LE

R

21 CC

12.5 KW GENERATOR

DRIVEPUMP

CBB

CBC

CBA

CBE

CBD





REV C



1

2

3

4

5

6

7

8


6 - 41 Z-80/60 Part No. 88619

M

CHARGE FILTER

51 psi3.5 bar



4.75 L/min / 2.84 L/min


TANK

1.7(6.4)

0.3(1.1)5

(19)0.9

(3.4)17

(64.5)

25 psi1.72 bar

102 psi7 L/min

102 psi7 L/min


500 psi34.5 bar

F F E E

0.1gpm0.38 L/min

0.030 inch0.762 mm

5 cu in82 cc

PLATFORM MANIFOLD

E

3200 psi220.6 bar


9.7 / 4.4 gpm / 36.7 / 16.7 L/min


HA

H

0.1 gpm0.38 L/min


6.1 / 2.1 gpm / 23 / 7.95 L/min


EC E

D DA A

DEM1

B

M4

M5

L1 L2 S

M2

ø.030

TANK

T1

AUX2

PMP



PTEST

LSTEST

PMAN

PMP2

AUX

AUXILIARYPUMP

T2

2B 3 1 5 2A 4 6

3 1 5 2 4 6

FUNCTIONMANIFOLD

TURNTABLEROTATE

3 gpm / 11.4 L/min

PEXT1

JDJUPLU PLDPRL PRR

ACCUMULATOR

P1

P

T

T1

LS

3000 psi207 bar

G B

1300 psi89.6 bar

1300 psi89.6 bar

2500 psi172 bar

2500 psi172 bar

2600 psi179 bar


A

3625 psi250 bar

3625 psi250 bar

320 psi22 bar

DRIVEPUMP

FUNCTIONPUMP

3 gpm11.4 L/min

PTEST2


RATIO PRESSURE

1000 psi / 69 bar

2000 psi / 138 bar

2500 psi / 172 bar

3:1

3000 psi / 207 bar

1.5:1

3:1

3:1

3:1

1.5:1

3300 psi / 227.5 bar

3500 psi / 241.3 bar

3:1 3500 psi / 241.3 bar

3:1 2000 psi / 138 bar

A

B

C

D

E

F

G

H

B

P

E

V

X

U

K

R

S

F

G

O

H

J

IT Y

L

W

AM

N

C

Z

AA

AB

AD

AEAG

AF

AH

AC

AI

AJ

GAGR

GB

GIGLGM

GN

GJ

KK

LLMM

GK

GC

GD

GEGFGH

GG

GO

GP GQ

D

Q

REV C



1

2

3

4

5

6

7

8


Part No. 88619 Z-80/60 6 - 42

DRIVE MANIFOLD

M1REARLEFT

M3

M5

2 gpm7.6 L/min

2 gpm7.6 L/min

50%

50%

REARRIGHT

M7

2 gpm / 7.6 L/min

T

M2

FRONTLEFT

M4

A BTEST

50%

280 psi19.3 bar

50%

X50%

50%

M6

FRONTRIGHTM8

0.030 inch0.762 mm

TWO WHEELSTEER MANIFOLD

FRONT RIGHTSTEERING

2.3 gpm8.7 L/min

2.3 gpm8.7 L/min

1.2 gpm4.5 L/min

1.2 gpm4.5 L/min

FRONT LEFTSTEERING

E E

OSCILLATE CYLINDERS

E E

T

PO

FLB FLR FRB FRR

TEST

OL OR

PS LS

LBRAKE

L2SPEED

CDL

CDR

OSCILLATE MANIFOLD

RBRAKE

R2SPEED

CDR CDLLBRAKE

L2SPEED

R2SPEED

RBRAKE

2B 3 1 5 2A 4 6

3 1 5 2 4 6


800 psi55 bar

FA

FHFR

FN

FP

FG

FB

FE

FF

FD

FC

FJ

FL

FM

FQ

FI

FKFO

BABB

BC BD

BE

BF BKBG BL

BH BOBPBQ

BI BMBJ BN

DIVERTERMANIFOLD

MTR B MTR A

G2

CLRPMP B

OIL

COOLER

G1270 PSI @3.5 GPM

G2 G1


31

0.031

31

B

A

PMP A

HY

DR

AU

LIC

RO

TA

RY

CO

UP

LE

R

21 CC

12.5 KW GENERATOR

DRIVEPUMP

CBB

CBC

CBA

CBE

CBD





REV C



1

2

3

4

5

6

7

8


6 - 43 Z-80/60 Part No. 88619

M

CHARGE FILTER

51 psi3.5 bar



4.75 L/min / 2.84 L/min


TANK

1.7(6.4)

0.3(1.1)5

(19)0.9

(3.4)17

(64.5)

25 psi1.72 bar

102 psi7 L/min

102 psi7 L/min


500 psi34.5 bar

F F E E

0.1gpm0.38 L/min

0.030 inch0.762 mm

5 cu in82 cc

PLATFORM MANIFOLD

E

3200 psi220.6 bar


9.7 / 4.4 gpm / 36.7 / 16.7 L/min


HA

H

0.1 gpm0.38 L/min


6.1 / 2.1 gpm / 23 / 7.95 L/min


EC E

D DA A

DEM1

B

M4

M5

L1 L2 S

M2

ø.030

TANK

T1

AUX2

PMP



PTEST

LSTEST

PMAN

PMP2

AUX

AUXILIARYPUMP

T2

2B 3 1 5 2A 4 6

3 1 5 2 4 6

FUNCTIONMANIFOLD

TURNTABLEROTATE

3 gpm / 11.4 L/min

PEXT1

JDJUPLU PLDPRL PRR

ACCUMULATOR

P1

P

T

T1

LS

3000 psi207 bar

G B

1300 psi89.6 bar

1300 psi89.6 bar

2500 psi172 bar

2500 psi172 bar

2600 psi179 bar


A

3625 psi250 bar

3625 psi250 bar

320 psi22 bar


RATIO PRESSURE

A

B

C

D

E

F

G

1000 psi / 69 bar

2000 psi / 138 bar

2500 psi / 172 bar

3:1

3000 psi / 207 bar

1.5:1

3:1

3:1

3:1

1.5:1

3300 psi / 227.5 bar

3500 psi / 241.3 bar

3:1 3500 psi / 241.3 barH

3:1 2000 psi / 138 bar

DRIVEPUMP

FUNCTIONPUMP

3 gpm11.4 L/min

PTEST2

B

P

E

V

X

U

K

R

S

F

G

O

H

J

IT Y

L

W

AM

N

C

Z

AA

AB

AD

AEAG

AF

AH

AC

AI

AJ

GAGR

GB

GIGLGM

GN

GJ

KK

LLMM

GK

GC

GD

GEGFGH

GG

GO

GP GQ

D

Q

REV C



1

2

3

4

5

6

7

8


Part No. 88619 Z-80/60 6 - 44

DRIVE MANIFOLD

M1REARLEFT

M3

M5

2 gpm7.6 L/min

2 gpm7.6 L/min

50%

50%

REARRIGHT

M7

2 gpm / 7.6 L/min

T

M2

FRONTLEFT

M4

A BTEST

50%

280 psi19.3 bar

50%

X

50%

50%

M6

FRONTRIGHTM8

0.030 inch0.762 mm

FOUR WHEEL STEER MANIFOLD

FRONT RIGHTSTEERING

2.3 gpm8.7 L/min

2.3 gpm8.7 L/min

2.3 gpm8.7 L/min

2.3 gpm8.7 L/min

1.2 gpm4.5 L/min

1.2 gpm4.5 L/min

1.2 gpm4.5 L/min

1.2 gpm4.5 L/min

FRONT LEFTSTEERING

REAR LEFTSTEERING

REAR RIGHTSTEERING

E E

OSCILLATE CYLINDERS

E E

T

PO

FLB FLR FRB FRR RLB RLR RRB RRR

TEST

OL OR

PS LS

LBRAKE

L2SPEED

CDL

CDR

OSCILLATE MANIFOLD

RBRAKE

R2SPEED

CDR CDLLBRAKE

L2SPEED

R2SPEED

RBRAKE

2B 3 1 5 2A 4 6

3 1 5 2 4 6


800 psi55 bar

FA

FHFR

FN

FP

FG

FB

FE

FF

FD

FC

FJ

FL

FM

FQ

FI

FKFO

CA CP CQ

CICX CLCJCR CV CW CK

CT CUCZCAA CG

CH

CD CADCAE

CE CF

CCCOCMCNCYCSCAC CAB

CB

DIVERTERMANIFOLD

MTR B MTR A

G2

CLRPMP B

OIL

COOLER

G1270 PSI @3.5 GPM

G2 G1


31

0.031

31

B

A

PMP A

HY

DR

AU

LIC

RO

TA

RY

CO

UP

LE

R

21 CC

12.5 KW GENERATOR

DRIVEPUMP

CBB

CBC

CBA

CBE

CBD



Dis

trib

ute

d B

y:

California Proposition 65

WARNINGWARNINGThe exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.Phone +61 7 3375 1660

Fax +61 7 3375 1002

Genie ChinaPhone +86 21 53852570

Fax +86 21 53852569

Genie MalaysiaPhone +65 98 480 775

Fax +65 67 533 544

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Fax +81 3 3453 6083

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Fax +82 25 583 910

Genie BrasilPhone +55 11 41 665 755

Fax +55 11 41 665 754

Genie HollandPhone +31 183 581 102

Fax +31 183 581 566

Genie ScandinaviaPhone +46 31 575100

Fax +46 31 579020

Genie FrancePhone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Genie IbericaPhone +34 93 579 5042

Fax +34 93 579 5059

Genie GermanyPhone +49 (0)4202 88520

Fax +49 (0)4202 8852-20

Genie U.K.Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Genie Mexico CityPhone +52 55 5666 5242

Fax +52 55 5666 3241

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0/6

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Part No.88619

Rev B1

(from

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r1

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)

Documents

88619 Z-80/60 Service Manual