Service Manual

Serial Number Range

TM from Z80-101 to Z8013-4591

Z-80/60

Part No. 88619

Rev F3
February 2015
 February 2015

Introduction

Important
Read, understand and obey the safety rules and
operating instructions in the Genie Z-80/60
Operator's Manual before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.

Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.

Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie Copyright © 2003 by Genie Industries
policy. Therefore, product specifications are
88619 Rev F June 2011
subject to change without notice. First Edition, Seventh Printing
Readers are encouraged to notify Genie of errors "Genie" and "Z" are registered trademarks of
and send in suggestions for improvement. All Genie Industries in the USA and many other
countries.
communications will be carefully considered for
future printings of this and all other manuals. Printed on recycled paper

Printed in U.S.A.

Contact Us:
http://www.genieindustries.com
e-mail: techsup@genieind.com

ii
Z-80/60 Part No. 88619
February 2015

INTRODUCTION

Serial Number Legend

Model: Z-80/60
Serial number: Z8006-12345
Model year: 2006 Manufacture date: 01/05/06
Electrical schematic number: ES0188
Machine unladen weight:

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

Maximum number of platfrm occupants: 2
Maximum allowable side force : 150 lb / 670 N
Maximum allowable inclination of the chassis:
0 deg Z80 06 - 12345
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 86 ft/ 26.38 m
Model Sequence
Maximum platform reach : 60 ft/ 18.28 m number
Gradeability: N/A
Country of manufacture: USA Model year
This machine complies with:
ANSI A92.5-
CAN B.354.4-

Genie Industries Serial label

18340 NE 76th Street (located under cover)
Serial number
Redmond, WA 98052 (stamped on chassis)
USA

PN - 77055

iii
Part No. 88619 Z-80/60
 February 2015

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iv
Z-80/60 Part No. 88619
February 2015 Section 1 • Safety Rules

Safety Rules

Danger
Failure to obey the instructions and safety rules in
this manual, and the Operator's Manual will result
in death or serious injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance
and repair procedures are performed.

Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

v
Part No. 88619 Z-80/60
Section 1 • Safety Rules
SAFETY RULES
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
vi Z-80/60
July 2013
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
Part No. 88619
July 2013

Table of Contents

Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iii

Section 1 Safety Rules

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

Section 2 Rev Specifications

G Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 2
Function Speeds Specifications ............................................................................. 2 - 2
Hydraulic Oil Specifications ................................................................................... 2 - 3
Hydraulic Component Specifications ...................................................................... 2 - 4
Manifold Component Specifications ....................................................................... 2 - 5
Valve Coil Resistance Specifications ..................................................................... 2 - 5
GM 3.0L EFI Engine .............................................................................................. 2 - 6
Ford LRG-425 Engine ............................................................................................. 2 - 7
Continental TME27 Engine .................................................................................... 2 - 9
Deutz F4L-913 Engine (before serial number 339) ................................................ 2 - 10
Deutz BF4L-2011 (from serial number 339 to 2177) .............................................. 2 - 11
Deutz TD2011L04i Engine (from serial number 2178) ........................................... 2 - 13
Perkins 704-30 Engine ......................................................................................... 2 - 15
Perkins 804C-33 / 804D-33 Engine ...................................................................... 2 - 16
Machine Torque Specifications ............................................................................ 2 - 17
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 18
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 19

Section 3 Rev Scheduled Maintenance Procedures

Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5

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TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

E 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
A-4 Perform Engine Maintenance ....................................................................... 3 - 8
A-5 Check the Hydraulic Filter Condition Indicators .......................................... 3 - 10
A-6 Perform 30 Day Service ............................................................................. 3 - 11
A-7 Perform Engine Maintenance - Continental Models .................................... 3 - 11
A-8 Perform Engine Maintenance - Perkins and Continental Models ................. 3 - 12
A-9 Perform Engine Maintenance ..................................................................... 3 - 13
A-10 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14
A-11 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 14
A-12 Replace the Drive Hub Oil .......................................................................... 3 - 16
A-13 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 18
G Checklist B Procedures
B-1 Inspect the Batteries .................................................................................. 3 - 19
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 20
B-3 Test the Key Switch ................................................................................... 3 - 22
B-4 Check the Exhaust System ....................................................................... 3 - 22
B-5 Inspect the Engine Air Filter ....................................................................... 3 - 23
B-6 Engine Maintenance - Deutz F4L913 and Continental Models .................... 3 - 24
B-7 Check the Tires, Wheels and Lug Nut Torque ............................................ 3 - 25
B-8 Confirm the Proper Brake Configuration ...................................................... 3 - 25
B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 26
B-10 Test the Ground Control Override ............................................................... 3 - 27
B-11 Test the Platform Self-leveling ................................................................... 3 - 28
B-12 Test the Engine Idle Select Operation ........................................................ 3 - 29
B-13 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 3 - 30

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TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

B-14 Test the Drive Brakes ................................................................................ 3 - 31
B-15 Test the Drive Speed - Stowed Position ..................................................... 3 - 31
B-16 Test the Drive Speed - Raised or Extended Position ................................. 3 - 32
B-17 Test the Alarm and Optional Flashing Beacon ........................................... 3 - 33
B-18 Perform Hydraulic Oil Analysis .................................................................. 3 - 33
B-19 Check and Adjust the Engine RPM ............................................................ 3 - 34
B-20 Test the Safety Envelope and Safety Circuits ............................................ 3 - 37
B-21 Test the Primary Boom Self-leveling .......................................................... 3 - 40
B-22 Test the Primary Boom Angle Sensor ........................................................ 3 - 41
B-23 Inspect the Fuel Tank Cap Venting Systems ............................................. 3 - 42
B-24 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 43
D Checklist C Procedures
C-1 Perform Engine Maintenance - Diesel Models ............................................ 3 - 44
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 45
C-3 Test the Platform Overload System (if equipped) ....................................... 3 - 45
C-4 Replace the Engine Air Filter ...................................................................... 3 - 47
C-5 Replace the Fuel Filter/Water Separator - Diesel Models ............................ 3 - 48
C-6 Perform Engine Maintenance - GM and Ford Models ................................. 3 - 50
E Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 51
D-2 Check the Free-wheel Configuration ........................................................... 3 - 52
D-3 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 53
D-4 Inspect for Turntable Bearing Wear ............................................................ 3 - 54
D-5 Replace the Drive Hub Oil .......................................................................... 3 - 55
D-6 Perform Engine Maintenance ..................................................................... 3 - 56
D-7 Replace the Hydraulic Filter Elements ........................................................ 3 - 57

Part No. 88619 Z-80/60 ix

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TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

D Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 61
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 63
E-3 Perform Engine Maintenance ..................................................................... 3 - 64
E-4 Perform Engine Maintenance - Ford Models ............................................... 3 - 65
E-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 66
E-6 Perform Engine Maintenance - Deutz BF4L2011 / TD2011L04i Models ...... 3 - 67
E-7 Perform Engine Maintenance - Deutz BF4L2011 / TD2011L04i Models ...... 3 - 68
E-8 Perform Engine Maintenance - Deutz BF4L2011 Models ............................ 3 - 68

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1
E Display Module ...................................................................................................... 4 - 2
F Platform Controls
1-1 ALC-1000 Circuit Board .............................................................................. 4 - 10
1-2 Membrane Decal ........................................................................................ 4 - 11
1-3 Joysticks ................................................................................................... 4 - 13
C Platform Components
2-1 Platform ..................................................................................................... 4 - 19
2-2 Platform Leveling Cylinder .......................................................................... 4 - 19
2-3 Platform Rotator ......................................................................................... 4 - 21
2-4 Calibrate the Platform Overload System (if equipped) ................................ 4 - 23
B Jib Boom Components
3-1 Jib Boom .................................................................................................... 4 - 26
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 28
D Boom Components
4-1 Primary Boom Cable Track ........................................................................ 4 - 30
4-2 Primary Boom ............................................................................................ 4 - 33
4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 36
4-4 Primary Boom Extension Cylinder .............................................................. 4 - 38

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TABLE OF CONTENTS

Section 4 Rev Repair Procedures, continued

4-5 Primary Boom Angle Sensor ...................................................................... 4 - 40
4-6 Secondary Boom Cable Track .................................................................... 4 - 42
4-7 Secondary Boom ........................................................................................ 4 - 43
4-8 Secondary Boom Lift Cylinder .................................................................... 4 - 45
4-9 Secondary Boom Extension Cylinder ......................................................... 4 - 47
C Engines
5-1 RPM Adjustment ........................................................................................ 4 - 49
5-2 Flex Plate ................................................................................................... 4 - 49
5-3 Engine Fault Codes - Gasoline/LPG Models ............................................... 4 - 56
B Ground Controls
6-1 Service Bypass/Recovery Keyswitch ......................................................... 4 - 57
6-2 Circuit Boards ............................................................................................ 4 - 59
6-3 Membrane Decal ........................................................................................ 4 - 60
B Hydraulic Pumps
7-1 Function Pump ........................................................................................... 4 - 61
7-2 Drive Pump ................................................................................................ 4 - 62
E Manifolds
8-1 Function Manifold - View 1 ......................................................................... 4 - 64
8-2 Function Manifold - View 2 ......................................................................... 4 - 66
8-3 Valve Adjustments - Function Manifold ...................................................... 4 - 68
8-4 Platform Manifold ....................................................................................... 4 - 74
8-5 Turntable Rotation Manifold ........................................................................ 4 - 76
8-6 Platform Rotate Manifold ............................................................................ 4 - 77
8-7 2 Wheel Steer and Oscillate Manifold (before serial number 990) ............... 4 - 78
8-8 2 Wheel Steer and Oscillate Manifold (from serial number 990) .................. 4 - 82
8-9 4 Wheel Steer and Oscillate Manifold (before serial number 990) ............... 4 - 88
8-10 4 Wheel Steer and Oscillate Manifold (from serial number 990) .................. 4 - 94
8-11 Oil Diverter Manifold (welder option) ........................................................... 4 - 99

Part No. 88619 Z-80/60 xi

 July 2013

TABLE OF CONTENTS

Section 4 Rev Repair Procedures, continued

8-12 Traction Manifold, 2WD ........................................................................... 4 - 100
8-13 Valve Adjustments, 2WD Traction Manifold .............................................. 4 - 102
8-14 Traction Manifold, 4WD ............................................................................. 4 - 104
8-15 Valve Adjustments, 4WD Traction Manifold .............................................. 4 - 106
8-16 Valve Coils ................................................................................................ 4 - 107
B Turntable Rotation Components
9-1 Turntable Rotation Assembly .................................................................... 4 - 109
B Axle Components
10-1 Steer Sensors ........................................................................................... 4 - 111
10-2 Hub and Bearings, 2WD Models ................................................................ 4 - 114
10-3 Oscillating Axle Cylinders ......................................................................... 4 - 116

Section 5 Rev Fault Codes

Introduction ............................................................................................................ 5 - 1
C Fault Diagnostics Control System .......................................................................... 5 - 2
How to Clear Secopndary Boom Safety Switch Faults ......................................... 5 - 10
B Ford Engine ECM Fault Code Chart ..................................................................... 5 - 11
B Continental Engine ECM Fault Code Chart ........................................................... 5 - 16

Section 6 Rev Schematics

Introduction ............................................................................................................ 6 - 1
B Wire Circuit Legend ................................................................................................ 6 - 2
C Limit Switches and Angle Sensors ......................................................................... 6 - 8
C Drive Chassis and Platform Controller Pin Legend ............................................... 6 - 10
D Engine Relay and Fuse Panel Legend .................................................................. 6 - 11
C Turntable Controller Pin Legend ........................................................................... 6 - 14
B Electrical Symbols Legend .................................................................................. 6 - 15
B Hydraulic Symbols Legend .................................................................................. 6 - 16

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TABLE OF CONTENTS

Section 6 Rev Schematics, continued

D Electrical Schematic Legend ................................................................................ 6 - 17
C Electrical Schematic - View 1, Drive Chassis Controller (DCON) ......................... 6 - 20
D Electrical Schematic - View 2, Platform Controls (PCON) .................................... 6 - 21
(before serial number 1167)
A Electrical Schematic - View 2, Platform Controls (PCON) .................................... 6 - 23
(from serial number 1167 to 2510)
D Electrical Schematic - View 3, Ground Controls (TCON) ...................................... 6 - 26
(before serial number 2511)
C Electrical Schematic - View 4 (before serial number 2511) ................................... 6 - 27
C Electrical Schematic - View 5 .............................................................................. 6 - 30
(before serial number 2511)
C Electrical Schematic - View 6, Ground Controls (TCON) ...................................... 6 - 31
(before serial number 2511)
C Electrical Schematic - View 7 (before serial number 2511) ................................... 6 - 34
C Electrical Schematic - View 8 (before serial number 2511) ................................... 6 - 35
D Electrical Schematic - View 9 .............................................................................. 6 - 38
(before serial number 2511)
C Electrical Schematic - View 10, Limit Switches ................................................... 6 - 39
(before serial number 2511)
B Electrical Schematic - View 11, Deutz F4L-913 Engine ........................................ 6 - 42
(before serial number 339)
C Electrical Schematic - View 11, Deutz BF4L-2011 / TD2011L04i Engine .............. 6 - 43
(from serial number 339 to 2316)
A Electrical Schematic - View 11, Deutz BF4L-2011 / TD2011L04i Engine .............. 6 - 46
(from serial number 2313 to 2510)
C Electrical Schematic - View 12 ............................................................................ 6 - 48
(before serial number 2511)
A Electrical Schematic - Perkins 704-30 Engine ...................................................... 6 - 50
(before serial number 329)
C Electrical Schematic - Perkins 804C-33 / 804D-33 Engine ................................... 6 - 51
(from serial number 329 to 2316)
A Electrical Schematic - Perkins 804C-33 / 804D-33 Engine ................................... 6 - 54
(from serial number 2317 to 2510)
A Electrical Schematic - Perkins 804D-33 Engine ................................................... 6 - 55
(from serial number 2511)

Part No. 88619 Z-80/60 xiii

 July 2013

TABLE OF CONTENTS

Section 6 Rev Schematics, continued

B Electrical Schematic - Continental TME27 Engine ............................................... 6 - 58
(before serial number 2511)
A Electrical Schematic - Continental TME27 Engine ............................................... 6 - 59
(from serial number 2510)
A Electrical Schematic - Ford LRG 425 Engine ....................................................... 6 - 62
C Electrical Schematic - GM 3.0L Engine ............................................................... 6 - 63
A Electrical Schematic - Safety Circuits .................................................................. 6 - 65
A Electrical Schematic - Generator Options ............................................................ 6 - 68
A Electrical Schematic - Welder Generator Option .................................................. 6 - 69
A Electrical Schematic (ES0508B) (from serial number 2511) ................ at end of manual
D Hydraulic Schematic, 2 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 72
(before serial number 990)
D Hydraulic Schematic, 2 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 74
(from serial number 990 to 2674)
A Hydraulic Schematic, 2 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 75
(serial number 1543 and from serial number 2675)
D Hydraulic Schematic, 4 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 78
(before serial number 990)
D Hydraulic Schematic, 4 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 80
(from serial number 990 to 2674)
A Hydraulic Schematic, 4 Wheel Drive (2 and 4 Wheel Steer) ................................. 6 - 81
(serial number 1543 and from serial number 2675)
A Hydraulic Schematic, Hydraulic Generator Options .............................................. 6 - 83

xiv Z-80/60 Part No. 88619

February 2015 Section 2 • Specifications

REV G
Specifications
Machine Specifications Fluid capacities

Tires and wheels Fuel tank 35 gallons

132.5 liters
Tire size
(foam filled and non-marking) 18-625 FF LPG tank 33.5 lbs
15.2 kg
Tire size
(Hi-flotation) 445D50/70 Hydraulic tank 45 gallons
170 liters
Tire ply rating
(foam filled and non-marking) 16 Hydraulic system 80 gallons
(including tank) 303 liters
Tire weight, new foam-filled (minimum) 622 lbs
(Rough terrain) 282 kg Drive hubs 50 fl oz
(before serial number 958) 1.5 liters
Tire ply rating
(Hi-flotation) 14 Drive hubs 44 fl oz
(after serial number 957) 1.3 liters
Overall tire diameter 40.7 in
(foam filled and non-marking) 103.3 cm Turntable rotation drive hub 40 fl oz
1.2 liters
Overall tire diameter 45.47 in
(Hi-flotation) 115.5 cm Drive hub oil type: EP 80-90W gear oil
API Service Classification GL5
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

Tire Pressure (Hi-flotation) 80 lbs / 5.5 bar

Wheel lugs 10 @ 3/4 -16

Lug nut torque, lubricated 320 ft-lbs

434 Nm

Lug nut torque, dry 420 ft-lbs

570 Nm

For operational specification, refer to the

Operator's Manual.

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

Performance Specifications Function speeds

Drive speed, maximum Primary boom up, retracted

(models with rough terrain tires) (retracted -35° to 65°) 60 to 70 seconds

Stowed position 40 ft / 8.7-9.3 sec Primary boom down, retracted

12.2 m / 8.7-9.3 sec (retracted -35° to 65°) 75 to 85 seconds

Raised or extended position 40 ft / 40-45 sec Secondary boom up, retracted 38 to 48 seconds
12.2 m / 40-45 sec Secondary boom down, retracted 38 to 48 seconds
Drive speed, maximum
Primary boom up, extended
(models with Hi-flotation tires)
(-35° to 65°) 80 to 96 seconds
Stowed position 40 ft / 13.6-14.5 sec
Primary boom down, extended
12.2 m / 13.6-14.5 sec
(-35° to 65°) 80 to 96 seconds
Raised or extended position 40 ft / 62-70 sec
12.2 m / 62-70 sec Primary Boom extend 48 to 52 seconds

Gradeability - Refer to Operator's Manual Primary Boom retract 38 to 42 seconds

Braking distance, maximum Jib Boom up 23 to 33 seconds

High range on paved surface 6 ft Jib Boom down 21 to 31 seconds

1.83 m
Platform Rotate 160° 10 to 14 seconds

Turntable rotate, 360°

boom fully retracted 114 to 126 seconds

Turntable rotate, 360°

boom extended 200 to 240 seconds

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

Hydraulic Oil Specifications Continued use of Chevron Aviation

A hydraulic oil when ambient
Hydraulic Oil Specifications temperatures are consistently
above 32°F / 0°C may result in
Hydraulic oil type Chevron Rando HD Premium component damage.
MV equivalent
Viscosity grade Multi-viscosity Note: Use Chevron Aviation A hydraulic oil when
Viscosity index 200 ambient temperatures are consistently
below 0°F / -18°C.
Cleanliness level, minimum 15/13
Note: Use Shell Tellus T46 hydraulic oil when oil
Water content, maximum 200 ppm
temperatures consistently exceed 205°F / 96°C.
Chevron Rando HD Premium MV oil is fully
Note: Genie specifications require additional
compatible and mixable with Shell Donax TG (Dexron
III) oils.
equipment and special installation instructions for
Genie specifications require hydraulic oils which are the approved optional fluids. Consult the Genie
designed to give maximum protection to hydraulic Industries Service Department before use.
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV46

Statoil Hydra Way Bio SE 32
BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046

Quintolubric 822

Mineral based Shell Tellus T32

Shell Tellus T46
Chevron Aviation A

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

Hydraulic Component Auxiliary pump

Specifications Type: two-section fixed displacement gear pump

Drive pump Displacement - Section 1 (inner) 0.159 cu in

2.61 cc
Type: bi-directional variable displacement piston pump
Flow rate @ 2687 rpm 1.7 gpm
Displacement 2.81 cu in 6.4 L/min
46 cc
Displacement - Section 2 (outer) 0.051 cu in
Flow rate @ 2300 rpm 28 gpm 0.84 cc
106 L/min
Flow rate @ 2687 rpm 0.3 gpm
Drive pressure, maximum 3625 psi 1.1 L/min
250 bar
Function manifold
Charge pump
System relief pressure 3200 psi
Type: gerotor (measured at PTEST port) 220.6 bar

Displacement 0.85 cu in Primary boom down relief pressure 1300 psi

13.9 cc (measured at PTEST port) 89.6 bar

Flow rate @ 2300 rpm 9 gpm Secondary boom down relief pressure 2500 psi
34 L/min (measured at PTEST port) 172 bar

Charge pressure @ 2300 rpm 320 psi Secondary boom up relief pressure 2500 psi
Neutral position 22 bar (measured at PTEST port) 172 bar

Function pumps Primary boom extend relief pressure 1300 psi

(measured at PTEST port) 89.6 bar
Type: two-section tandem gear pump
Secondary boom extend relief pressure 2600 psi
Displacement - Pump 1 (inner) 1.94 cu in (measured at PTEST port) 179 bar
31.8 cc
Platform manifold relief pressure 3000 psi
Flow rate @ 2300 rpm 17 gpm 207 bar
64.4 L/min
Platform manifold flow regulator 3 gpm
Displacement - Pump 2 (outer) 0.58 cu in 11.4 L/min
9.5 cc
Oscillate manifold
Flow rate @ 2300 rpm 5 gpm
19 L/min Oscillate relief pressure (item BE or CH) 800 psi
55.1 bar

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

Drive manifold Valve Coil Resistance

Hot oil relief pressure 280 psi Specifications
19.3 bar
Note: The following coil resistance specifications
Brakes are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
Brake release pressure 215 psi temperature, the coil resistance will typically
14.8 bar
increase or decrease by 4% for each 18°F / 20°C
Drive motors that your air temperature increases or decreases
from 68°F / 20°C.
Displacement per revolution, variable 0.9 to 2.7 cu in
(2 speed motor) 14.7 to 45 cc Proportional solenoid valve, 12V DC 4.8 Ω
(schematic items G, W and AB)
Hydraulic tank return filter
Proportional solenoid valve, 12V DC 9Ω
High pressure filter Beta 3 ≥ 200
(schematic items R)
High pressure filter 102 psi
3 position 4 way solenoid valve, 12V DC 9Ω
bypass pressure 7 bar
(schematic items BA, BB, CA, CB, CP, CQ,
Medium pressure filter Beta 3 ≥ 200 GB, GP and GQ)

Medium pressure filter 51 psi 3 position 4 way solenoid valve, 10V DC 6.3 Ω
bypass pressure 3.5 bar (schematic items O and S)

Hydraulic tank return filter 10 micron with 2 position 2 way solenoid valve, 10V DC 3.3 Ω
25 psi / 1.7 bar bypass (schematic items J)

2 position 2 way solenoid valve, 10V DC 6.3 Ω

(schematic items C and P)
Manifold Component
2 position 3 way solenoid valve, 10V DC 6.3 Ω
Specifications (schematic items H, V, X, Z, AA, EE and EF)

Plug torque 2 position 3 way solenoid valve, 12V DC 9Ω

(schematic items BC, BD, CE, CF,
SAE No. 2 50 in-lbs / 6 Nm FB and FC)
SAE No. 4 14 ft-lbs / 18.9 Nm

SAE No. 6 23 ft-lbs / 31.2 Nm

SAE No. 8 36 ft-lbs / 48.8 Nm

SAE No. 10 62 ft-lbs / 84.1 Nm

SAE No. 12 84 ft-lbs / 113.9 Nm

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

GM 3.0L EFI Engine Starter motor

Displacement 181 cu in Normal engine cranking speed 350 rpm

3 liters Current draw, normal load 400A
Number of cylinders 4 Current draw, maximum load 600A
Bore & stroke 4 x 3.6 inches Current draw, minimum 100A
101.6 x 91.44 mm
Batteries
Horsepower
Type 12V DC
Intermittent 67 @ 2300 rpm
50 kW @ 2300 rpm Group 31
Continuous 60 @ 2300 rpm Quantity 2
45 kW @ 2300 rpm
Cold cranking ampere 1000A
Firing order 1-3-4-2
Reserve capacity @ 25A rate 200 minutes
Low idle 1650 rpm
Frequency 386.1 Hz Electronic fuel pump

High idle 2300 rpm Fuel pressure, static 9 to 11 psi

Frequency 538.2 Hz 0.6 to 0.76 bar

Compression ratio 9.25:1 Fuel flow rate 0.3 gpm

1.14 L/min
Compression pressure - minimum 100 psi
Pressure (psi or bar) of lowest cylinder 6.9 bar Fuel Requirement
must be at least 75% of highest cylinder
For fuel requirements, refer to the engine Operator's
Valve clearances Zero lash + 1 full turn Manual on your machine.

Lubrication system Ignition system

Oil pressure - minimum 18 psi Spark plug type AC ACMR-43-LTS

(operating temp. @ 2000 rpm) 1.24 bar
Spark plug gap 0.040 inch
Oil capacity 5 quarts 1.01 mm
(including filter) 4.7 liters
Engine coolant
Oil viscosity requirements
Capacity 12 quarts
Extreme operating temperatures my require the use of 11.4 liters
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine. Alternator

Output 66A, 12V DC

Fan belt deflection 0.5 inch

12 mm

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

Ford LRG-425 EFI Engine Oil pressure switch specifications

Displacement 153 cu in Torque 8-18 ft-lbs

2.5 liters 11-24 Nm

Number of cylinders 4 Oil pressure switch point 3-5 psi

0.21-0.34 bar
Bore & stroke 3.78 x 3.4 in
96.01 x 86.36 mm Starter motor

Horsepower Normal engine cranking speed 200 to 250 rpm

Continuous 60 @ 2500 rpm Current draw, normal load 140-200A

45 kW @ 2500 rpm Current draw, maximum load 800A
Intermittent 70 @ 2500 rpm Current draw, no load 70A
52 kW @ 2500 rpm
Maximum circuit voltage drop 0.5V DC
Firing order 1-3-4-2 while starting (normal temperature)
Low idle 1600 rpm Battery
Frequency 396.8 Hz
Type 12V DC
High idle 2500 rpm
Frequency 620 Hz Group 34/78
Compression ratio 9.4:1 Quantity 1
Compression pressure (approx.) Cold cranking ampere 900A
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder. Reserve capacity @ 25A rate 200 minutes

Valve clearances - 0.035 to 0.055 in Electronic fuel pump

collapsed tappet 0.889 to 1.397 mm
Fuel pressure, static 64 psi
Lubrication system 4.4 bar

Oil pressure 40 to 60 psi Fuel flow rate 0.58 gpm

(operating temp. @ 2000 rpm) 2.75 to 4.1 bar 2.18 L/min

Oil capacity 5 quarts Fuel requirement

(including filter) 4.7 liters
For fuel requirements, refer to the engine Operator's
Oil viscosity requirements Manual on your machine.

Extreme operating temperatures may require the use of Ignition system

alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine. Spark plug type Motorcraft AWSF-52C

Spark plug gap 0.042 to 0.046 in

1.07 to 1.18 mm

Spark plug torque 5 to 10 ft-lbs

7 to 14 Nm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

Engine coolant

Capacity 11.5 quarts

10.9 liters

Coolant temperature switch

Torque 8-18 ft-lbs

11-24 Nm

Temperature switch point 230° F

112° C

Alternator

Output 95A, 13.8V DC

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

Continental TME27 Engine Fuel Requirement

Displacement 164 cu in For fuel requirements, refer to the engine Operator's

2.68 liters Manual on your machine.

Number of cylinders 4 Electronic fuel pump

Bore and stroke 3.58 x 4.06 inches Fuel pressure, static 55 psi
91 x 103.2 mm 3.8 bar

Horsepower 59 @ 2500 rpm Fuel flow rate 0.42 gpm

44 kW @ 2500 rpm 1.59 L/min

Firing order 1-3-4-2 Batteries

Compression ratio 8.2:1 Type 12V DC

Compression pressure Group 31

Pressure (psi or bar) of the lowest cylinder must be at Quantity 2
least 75% of the highest cylinder.
Cold cranking ampere 1000A
Low idle - computer controlled 1600 rpm
Frequency 53.33 Hz Reserve capacity @ 25A rate 200 minutes
High idle - computer controlled 2500 rpm Alternator output 65A @ 13.8V DC
Frequency 83.33 Hz
Fan belt deflection 1/2inch
Valve clearance, warm 12 mm
Intake 0.014 in
0.36 mm

Exhaust 0.018 in
0.46 mm

Lubrication system

Oil pressure 40 to 60 psi

2.75 to 4.14 bar

Oil capacity 7 quarts

(including filter) 6.65 liters

Oil viscosity requirements

Units ship with 15W-40.

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

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

Deutz F4L- 913 Engine Injection system

(before serial number 339) Injection pump make IMSA

Displacement 249.3 cu in Injection pump pressure 8702 psi

4.085 liters 600 bar

Number of cylinders 4 Injector opening pressure 3626 psi

250 bar
Bore and stroke 4.02 x 4.92 inches
102.1 x 125 mm Fuel Requirement

Horsepower 76 @ 2300 rpm For fuel requirements, refer to the engine Operator's
57 kW @ 2300 rpm Manual on your machine.

Firing order 1-3-4-2 Batteries

Compression ratio 18:1 Type 12V DC

Compression pressure Group 31

Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder. Quantity 2

Low idle - no load 1300 rpm Cold cranking ampere 1000A

Frequency 385.7 Hz Reserve capacity @ 25A rate 200 minutes
High idle - no load 2300 rpm Alternator output 55A, 12V DC
Frequency 570.4 Hz
Fan belt deflection 3 /8
to 1/2 inch
Valve clearance, cold 9 to 12 mm
Intake 0.006 in
0.15 mm

Exhaust 0.006 in
0.15 mm

Lubrication system

Oil pressure 40 to 60 psi

2.75 to 4.14 bar

Oil capacity 14.3 quarts

(including filter) 13.5 liters

Oil viscosity requirements

Units ship with 15W-40.

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

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

Deutz BF4L-2011 Engine Lubrication system

(from serial number 339 to 2177) Oil pressure, hot 40 to 60 psi
(at 2000 rpm) 2.8 to 4.1 bar
Displacement 189.6 cu in
3.1 liters Oil capacity 11 quarts
(including filter) 10.4 liters
Number of cylinders 4
Oil viscosity requirements
Bore and stroke 3.7 x 4.409 inches
94 x 112 mm Units ship with 15W-40.
Extreme operating temperatures my require the use of
Horsepower alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Continuous 69 @ 2500 rpm
51 kW @ 2500 rpm Oil temperature switch

Net intermittent 73 @ 2500 rpm Torque 8-18 ft-lbs

54 kW @ 2500 rpm 11-24 Nm
Firing order 1-3-4-2 Oil temperature switch point 275°F
135°C
Low idle 1500 rpm
Frequency 372 Hz Oil pressure switch

High idle 2350 rpm Torque 8-18 ft-lbs

Frequency 582.8 Hz 11-24 Nm

Compression ratio 17.5:1 Oil pressure switch point 7 psi

0.48 bar
Compression pressure
Pressure (psi or bar) of the lowest cylinder must be at
least 75% of the highest cylinder.

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in
0.3 mm

Exhaust 0.020 in
0.5 mm

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum 15,000 psi

1034 bar

Injector opening pressure 3046 psi

210 bar

Fuel Requirement

For fuel requirements, refer to the engine Operator's

Manual on your machine.

Starter motor

Current draw, normal load 140-200A

Cranking speed 200-250 rpm

Battery - Engine starting and control system

Type 12V DC, Group 31

Quantity 2
Cold cranking ampere 1000
Reserve capacity @ 25A rate 200 minutes

Alternator output 80A @ 14V DC

Fan belt deflection 3 /8

to 1/2 inch
9 to 12 mm

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

Deutz TD2011L04i Engine Oil viscosity requirements

(from serial number 2178) -22°F to 86°F / -30°C to 30°C 5W-30
(synthetic)
Displacement 220.9 cu in
3.62 liters -4°F to 104°F / -20°C to 40°C 10W-40

Number of cylinders 4 Above 5°F / -15°C 15W-40

Bore and stroke 3.78 x 4.92 inches Units ship with 15W-40.
96 x 125 mm Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Horsepower Engine Operator Handbook on your machine.
Net intermittent @ 2400 rpm 74 / 55 kW
Oil temperature switch
Induction system turbocharged
Installation torque 8-18 ft-lbs
Firing order 1-3-4-2 11-24 Nm

Low idle 1500 rpm Oil temperature switch point 275°F

383 Hz 135°C

High idle 2350 rpm Oil pressure switch

599 Hz
Installation torque 8-18 ft-lbs
Compression ratio 17.5:1 11-24 Nm

Compression pressure Oil pressure switch point 22 psi

Pressure (psi or bar) of the lowest cylinder must be at 1.5 bar
least 75% of the highest cylinder.
Fuel injection system
Governor centrifugal mechanical
Injection pump make Motorpal
Valve clearance, cold
Injection pump pressure, maximum
Intake 0.012 in 15,000 psi
0.3 mm 1034 bar

Exhaust 0.020 in Injector opening pressure 3046 psi

0.5 mm 210 bar

Lubrication system Fuel requirement

Oil pressure, hot 40 to 60 psi For fuel requirements, refer to the engine Operator's
(at 2000 rpm) 2.8 to 4.1 bar Manual on your machine.
Oil capacity 12.8 quarts Starter motor
(including filter) 12.1 liters
Current draw, normal load 140-200A

Cranking speed 250-350 rpm

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

Battery - Auxiliary power units

Type 6V DC
Quantity 2
AH rating 285AH
Reserve capacity @ 25A rate 745 minutes

Battery - Engine starting and control system

Type 12V DC, Group 31

Quantity 2
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes

Alternator output 80A @ 14V DC

Fan belt deflection 3 /8

to 1/2 inch
9 to 12 mm

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

Perkins 704-30 Engine Injection system

Displacement 183 cu in Injection pump make Zexel PFR-KX

3 liters Injection pump pressure 2755 psi
Number of cylinders 4 190 bar

Bore and stroke 3.82 x 3.94 inches Injector opening pressure 3626 psi
97 x 100 mm 250 bar

Horsepower 61 @ 2300 rpm Fuel Requirement

45.5 kW @ 2500 rpm For fuel requirements, refer to the engine Operator's
Firing order 1-3-4-2 Manual on your machine.

Compression ratio 17.5:1 Engine coolant

Compression pressure 300 to 500 psi Capacity 11.5 quarts

20.7 to 34.5 bar 10.9 liters
Pressure (psi or bar) of lowest cylinder must be within Batteries
50 psi / 3.45 bar of highest cylinder
Type 12V DC
Low idle 1600 rpm
Frequency 246.7 Hz Group 31
High idle 2300 rpm Quantity 2
Frequency 385.4 Hz
Cold cranking ampere 1000A
Governor centrifugal mechanical
Reserve capacity @ 25A rate 200 minutes
Valve clearance, cold
Alternator output 65A, 12V DC
Intake 0.014 in
Fan belt deflection 3/8 in
0.35 mm
10 mm
Exhaust 0.014 in
0.35 mm

Lubrication system

Oil pressure @ 2300 rpm 41 psi

2.8 bar

Oil capacity 7.4 quarts

(including filter) 7 liters

Oil viscosity requirements

Units ship with 15W-40.

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

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

Perkins 804C-33 Engine Oil viscosity requirements

Perkins 804D-33 Engine Units ship with 15W-40.
Extreme operating temperatures my require the use of
Displacement 201 cu in alternative engine oils. For oil requirements, refer to the
3.3 liters Engine Operator Handbook on your machine.

Number of cylinders 4

Bore and stroke 3.70 x 4.72 inches Injection system

94 x 120 mm
Injection pump make Zexel 10641-3932
Horsepower 63 @ 2600 rpm
47 kW @ 2600 rpm Injection pump pressure 1707 to 1849 psi
117.7 to 127.5 bar
Firing order 1-3-4-2
Injector opening pressure ~2000 psi
Compression ratio 22:1 ~138 bar

Compression pressure 300 to 500 psi Fuel Requirement

20.7 to 34.5 bar
Pressure (psi or bar) of lowest cylinder must be For fuel requirements, refer to the engine Operator's
within 50 psi / 3.45 bar of highest cylinder Manual on your machine.

Low idle 1650 rpm Engine coolant

Frequency 335.5 Hz
Capacity 12.5 quarts
Low idle with generator 1400 rpm 11.8 liters
Frequency 284.7 Hz
Batteries
High idle 2300 rpm
Frequency 467.7 Hz Type 12V DC

Governor mechanical all speed Group 31

Valve clearance, cold Quantity 2

Intake 0.0098 in Cold cranking ampere 1000A

0.25 mm Reserve capacity @ 25A rate 200 minutes
Exhaust 0.0098 in Alternator output 90A, 12V DC
0.25 mm
Fan belt deflection 3/8 to 1/2 in
Lubrication system 9 to 12 mm
Oil pressure @ 2000 rpm 40-60 psi
2.8-4.1 bar

Oil capacity 10.6 quarts

(including filter) 10 liters

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

Machine Torque Specifications

Platform rotator

1-8 center bolt, GR 5, dry 640 ft-lbs

867 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-lbs

244 Nm

Rotate drive hub mounting bolts, lubricated 80 ft-lbs

108.4 Nm

Backlash plate mounting bolts, lubricated 280 ft-lbs

379 Nm

Drive motor and hubs

Drive hub mounting bolts, lubricated 160 ft-lbs*

*(use blue thread locking compound) 217 Nm

Drive hub mounting bolts, dry 210 ft-lbs

284 Nm

Drive motor mounting bolts, lubricated 80 ft-lbs*

*(use blue thread locking compound) 108.4 Nm

Drive motor mounting bolts, dry 110 ft-lbs

149 Nm

Drive hub oil plug, O-ring seal 13 ft-lbs

18 Nm

Continuous improvement of our products is a

Genie policy. Product specifications are
subject to change without notice.

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

Section 2 • Specifications February 2015

SPECIFICATIONS REV G

Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. Note: The O-rings used in the Parker Seal Lok®
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
SAE O-ring Boss Port available in the O-ring field service kit (Genie part
(tube fitting - installed into Aluminum) number 49612).
SAE Dash size Torque 2 Lubricate the O-ring before installation.
-4 14 ft-lbs / 18.9 Nm 3 Be sure that the face seal O-ring is seated and
retained properly.
-6 23 ft-lbs / 31.2 Nm
4 Position the tube and nut squarely on the face
-8 36 ft-lbs / 48.8 Nm seal end of the fitting and tighten the nut finger
-10 62 ft-lbs / 84.1 Nm tight.

-12 84 ft-lbs / 113.9 Nm 5 Tighten the nut or fitting to the appropriate

torque per given size as shown in the table.
-16 125 ft-lbs / 169.5 Nm
6 Operate all machine functions and inspect the
-20 151 ft-lbs / 204.7 Nm hoses and fittings and related components to
confirm that there are no leaks.
-24 184 ft-lbs / 250 Nm

SAE O-ring Boss Port Seal-Lok® Fittings

(tube fitting - installed into Steel) (hose end)

SAE Dash size Torque SAE Dash size Torque

-4 15 ft-lbs / 20.3 Nm -4 18 ft-lbs / 24.4 Nm

-6 35 ft-lbs / 47.5 Nm -6 30 ft-lbs / 40 Nm

-8 60 ft-lbs / 81.3 Nm -8 40 ft-lbs / 55 Nm

-10 100 ft-lbs / 135.6 Nm -10 60 ft-lbs / 80 Nm

-12 135 ft-lbs / 183 Nm -12 85 ft-lbs / 115 Nm

-16 200 ft-lbs / 271 Nm -16 110 ft-lbs / 150 Nm

-20 250 ft-lbs / 334 Nm -20 140 ft-lbs / 190 Nm

-24 305 ft-lbs / 414 Nm -24 180 ft-lbs / 245 Nm

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

February 2015 Section 2 • Specifications

REV G SPECIFICATIONS

4.6 8.8 10.9 12.9

Part No. 88619 Z-80/60 2 - 19

Section 2 • Specifications February 2015

REV G

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2 - 20 Z-80/60 Part No. 88619

June 2011 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.

Each procedure includes a description, safety

Observe and Obey: warnings and step-by-step instructions.

Symbols Legend
Maintenance inspections shall be completed by
a person trained and qualified on the Safety alert symbol—used to alert
maintenance of this machine. personnel to potential personal
injury hazards. Obey all safety
Scheduled maintenance inspections shall be
messages that follow this symbol
completed daily, quarterly, six months, annually to avoid possible injury or death.
and every two years as specified on the
Maintenance Inspection Report. Used to indicate the presence of
an imminently hazardous situation
Failure to perform each procedure which, if not avoided, will result in
as presented and scheduled could death or serious injury.
result in death, serious injury or
substantial machine damage. Used to indicate the presence of a
potentially hazardous situation
Immediately tag and remove from service a which, if not avoided, could result
damaged or malfunctioning machine. in death or serious injury.
Repair any machine damage or malfunction Safety alert symbol—used to
before operating machine. indicate the presence of a
potentially hazardous situation
Machines that have been out of service for a
which, if not avoided, may result
period more than three months must complete
in minor or moderate injury.
the quarterly inspection.
Used to indicate the presence of a
Unless otherwise specified, perform each
potentially hazardous situation
procedure with the machine in the following which, if not avoided, may result in
configuration: property damage.
· Machine parked on a firm, level surface
Indicates that a specific result is expected after
· Boom in the stowed position performing a series of steps.
· Turntable rotated with the boom between
the circle-end (yellow arrow) wheels Indicates that an incorrect result has occurred
after performing a series of steps.
· Turntable secured with the turntable
rotation lock pin
· Key switch in the off position with the
key removed
· Wheels chocked
· All external AC power supply disconnected
from the machine

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

Section 3 • Scheduled Maintenance Procedures
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
Note: The following symbols have been used in
this manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold engine will be
required to perform this procedure.
Indicates that a warm engine will be
required to perform this procedure.
Indicates that dealer service is required
to perform this procedure.
3-2
June 2011
Pre-delivery Preparation Report
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation report
to use for each inspection. Store completed forms
as required.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, six months, annual, and two years.
The Scheduled Maintenance Procedures Section
and the Maintenance Inspection Report have been
divided into five subsections—A, B, C, D and E.
Use the following chart to determine which
group(s) of procedures are required to perform a
scheduled 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 contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental
regulations and requirements.
Z-80/60 Part No. 88619
June 2011 Section 3 • Scheduled Maintenance Procedures

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

Pre-Delivery Preparation
Section 3 • Scheduled Maintenance Procedures June 2011

Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing the
The Pre-delivery Preparation is performed prior to each Pre-operation Inspection, the Maintenance items and the
delivery. The inspection is designed to discover if anything Function Tests.
is apparently wrong with a machine before it is put into
service. Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
A damaged or modified machine must never be used. If instructions in the operator’s manual.
damage or any variation from factory delivered condition is
discovered, the machine must be tagged and removed If any inspection receives an N, remove the machine from
from service. service, repair and re-inspect it. After repair, place a check
in the R box.
Repairs to the machine may only be made by a qualified
service technician, according to the manufacturer's Legend
specifications. Y = yes, completed
Scheduled maintenance inspections shall be performed by N = no, unable to complete
qualified service technicians, according to the R = repaired
manufacturer's specifications and the requirements listed Comments
in the responsibilities manual.

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

Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
3-4 Z-80/60
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Part No. 88619
Rev B
June 2012
2011 Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Model Checklist A - Rev E Y N R Checklist B - Rev G Y N R
A-1 Inspect the manuals B-1 Batteries
Serial number and decals B-2 Electrical wiring
Date A-2 Pre-operation B-3 Key switch
inspection
B-4 Exhaust system
Hour meter A-3 Function tests
B-5 Engine Air Filter
A-4 Engine maintenance
Machine owner B-6 Engine maintenance-
A-5 Hydraulic filter Deutz 913, Perkins and
condition indicators Continental models
Inspected by (print)
Perform after 40 hours: B-7 Lug nut torque
Inspector signature A-6 30 Day Service B-8 Brake configuration
Perform after 50 hours: B-9 Drive hub maintenance
Inspector title A-7 Engine maintenance- B-10 Ground control override
Continental models
Inspector company B-11 Platform self leveling
Perform every 50 hours:
B-12 Engine idle select
Instructions A-8 Engine maintenance-
B-13 Fuel select operation
· Make copies of this report to use for Perkins and Continental
each inspection. models B-14 Drive brakes
Perform every 100 hours: B-15 Drive speed - stowed
· Select the appropriate checklist(s) for
the type of inspection to be performed. A-9 Engine maintenance B-16 Drive speed - raised
or extended
A-10 Rotation bearing
Daily or 8 hour B-17 Alarm and beacon
Inspection: A A-11 Filter/separator
B-18 Hydraulic oil analysis
Quarterly or 250 hour Perform after 150 hours:
B-19 Engine RPM
Inspection: A+B A-12 Replace drive hub oil
B-20 Safety envelope and
Six Month or 500 hour Perform every 200 hours:
circuits
Inspection: A+B+C A-13 Engine maintenance-
B-21 Primary boom
Annual or 1000 hours GM and Ford models
self-leveling
Inspection: A+B+C+D
B-22 Primary boom
2 Year or 2000 hour angle sensor
Inspection: A+B+C+D+E
B-23 Fuel and hydraulic tank
cap venting system
Perform every 400 hours:
· Place a check in the appropriate box B-24 Engine maintenance-
after each inspection procedure is GM and Ford models
completed.
· Use the step-by-step procedures in
this section to learn how to perform Comments
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

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

Section 3 • Scheduled Maintenance Procedures 2012
June 2011

MAINTENANCE INSPECTION REPORT REV E

Model Checklist C - Rev E Y N R Checklist E - Rev D Y N R

C-1 Engine maintenance
Serial number
C-2 Grease platform
Date overload (if equipped)
C-3 Test the platform
Hour meter overload (if equipped)
C-4 Engine Air Filter
Machine owner C-5 Replace filter/separator
E-1 Replace hydraulic oil
E-2 Wheel bearings,
2WD models
E-3 Engine maintenance
Perform every 2400 hours:
E-4 Engine maintenance-
Ford models

Inspected by (print) Perform every 800 hours: Perform every 3000 hours:
C-6 Engine maintenance- E-5 Engine maintenance-
Inspector signature GM and Ford models Deutz and Perkins
models
Inspector title Checklist D - Rev E Y N R Perform every 5000 hours:
D-1 Boom wear pads E-6 Engine maintenance-
Inspector company Deutz 2011 models
D-2 Free-wheel
configuration Perform every 6000 hours:
Instructions
· Make copies of this report to use for D-3 Turntable rotation bolts E-7 Engine maintenance-
each inspection. Deutz 2011 models
D-4 Turntable bearing wear
Perform every 12000 hours:
· Select the appropriate checklist(s) for D-5 Drive hub oil
the type of inspection to be performed. E-8 Engine maintenance-
D-6 Engine maintenance
Deutz 2011 models
Daily or 8 hour Perform every 1000 hours:
Inspection: A D-7 Replace hydraulic filters
Quarterly or 250 hour
Inspection: A+B Comments
Six Month or 500 hour
Inspection: A+B+C
Annual or 1000 hours
Inspection: A+B+C+D
2 Year or 2000 hour
Inspection: A+B+C+D+E

· Place a check in the appropriate box

after each inspection procedure is
completed.
· Use the step-by-step procedures in
this section to learn how to perform
these inspections.
· If any inspection receives an “N”, tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired

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June 2011 Section 3 • Scheduled Maintenance Procedures

REV E
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Maintaining the operator’s and safety manuals in and damage.
good condition is essential to safe machine Result: The machine is equipped with all
operation. Manuals are included with each required decals, and all decals are legible and
machine and should be stored in the container in good condition.
provided in the platform. An illegible or missing
manual will not provide safety and operational Result: The machine is not equipped with all
information necessary for a safe operating required decals, or one or more decals are
condition. illegible or in poor condition. Remove the
machine from service until the decals are
In addition, maintaining all of the safety and replaced.
instructional decals in good condition is mandatory
for safe machine operation. Decals alert operators 4 Always return the manuals to the storage
and personnel to the many possible hazards container after use.
associated with using this machine. They also Note: Contact your authorized Genie distributor or
provide users with operation and maintenance Genie Industries if replacement manuals or decals
information. An illegible decal will fail to alert are needed.
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and
safety manuals are present and complete in the
storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate for
the machine and all manuals are legible and in
good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove the
machine from service until the manual is
replaced.

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

Section 3 • Scheduled Maintenance Procedures June 2011

CHECKLIST A PROCEDURES REV E

A-2
Perform Pre-operation Inspection
Genie specifications require that this procedure be
performed daily or every 8 hours, whichever
comes first.
Completing a pre-operation inspection is essential
to safe machine operation. The pre-operation
inspection is a visual inspection performed by the
operator prior to each work shift. The inspection is
designed to discover if anything is apparently
wrong with a machine before the operator performs
the function tests. The pre-operation inspection
also serves to determine if routine maintenance
procedures are required.
Complete information to perform this procedure is
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
A-4
Perform Engine Maintenance
Engine specifications require that this procedure
be performed daily or every 8 hours, whichever
comes first.
Deutz Models:
Required maintenance procedures and additional
engine information are available in the
Deutz 913 Operation Manual
(Deutz part number 0297 7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Deutz TD2011 Operation Manual
(Deutz part number 0312 3547)..

Deutz 913 Operation Manual

Genie part number 62446
A-3
Perform Function Tests Deutz BF4L2011 Operation Manual
Genie part number 84794
Genie specifications require that this procedure be
performed daily or every 8 hours, whichever Deutz TD2011 Operation Manual
comes first. Genie part number 139320

Completing the function tests is essential to safe

machine operation. Function tests are designed to
discover any malfunctions before the machine is
put into service. A malfunctioning machine must
never be used. If malfunctions are discovered, the
machine must be tagged and removed from
service.

Complete information to perform this procedure is

available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.

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Perkins Models:
Required maintenance procedures and additional
engine information are available in the
Perkins 704-30 User's Handbook
(Perkins part number TPD 1336E) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Perkins 804D Operation and Maintenance
Manual (Perkins part number SEBU8324-00).
Perkins 704-30 User's Handbook
Genie part number 101840
Perkins 804C-33 Operation and Maintenance Manual
Genie part number 111332
Perkins 804D-33 Operation and Maintenance Manual
Genie part number 228841
GM Models:
Required maintenance procedures and additional
engine information are available in the
GM 3.0L Operator Handbook
(GM part number 36100007).
GM 3.0L Operator Handbook
Genie part number 77738
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
Ford Models:
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302).
Ford LRG-425 EFI Operator Handbook
Genie part number 84792
Continental Models:
Required maintenance procedures and additional
engine information are available in the
Continental TME27 Owner's Manual
(Continental part number WM10303).
Continental TME27 Owner's Manual
Genie part number 111901
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Z-80/60 3-9
Section 3 • Scheduled Maintenance Procedures June 2011

CHECKLIST A PROCEDURES REV E

A-5 Medium and high pressure filters:

Check the Hydraulic Filter Note: The medium and high pressure filters are
Condition Indicators mounted to the engine side bulkhead.

4 Inspect the filter condition indicators.

Maintaining the hydraulic filters in good condition is b

essential to good system performance and safe
machine operation. The filter condition indicators
will show when the hydraulic flow is bypassing a
clogged filter. If the filters are not frequently
checked and replaced, impurities will remain in the a
hydraulic system and cause component damage. c

Note: There are four hydraulic filters on the

machine: one tank return filter, one medium
pressure filter and two high pressure filters. All the a high pressure filters
filters have condition indicators on them, except b filter condition indicators
c medium pressure filter
the medium pressure filter.

1 Start the engine from the ground controls. Result: The filter condition indicators should be
operating with the plungers in the green area.
2 Press and release the engine idle select button
to change the engine rpm to high idle. Result: If any of the indicators display the
plunger in the red area, this indicates that a
Tank return filter: hydraulic filter is being bypassed and the filter
needs to be replaced. See D-7, Replace the
3 Open the ground control side turntable cover Hydraulic Filter Elements.
and inspect the filter condition indicator gauge.
Result: The needle on the gauge should be
operating in the green area. If the needle is in
the red area, this indicates that the hydraulic
filter is being bypassed and the filter needs to
be replaced. See D-7, Replace the Hydraulic
Filter Elements.

a filter condition indicator gauge

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June 2011 Section 3 • Scheduled Maintenance Procedures

REV E CHECKLIST A PROCEDURES

A-6 A-7
Perform 30 Day Service Perform Engine Maintenance -
Continental Models

The 30 day maintenance procedure is a one time

sequence of procedures to be performed after the
first 30 days or 40 hours of usage. After this
interval, refer to the maintenance checklists for
continued scheduled maintenance.
1 Perform the following maintenance procedures:
· A-10 Grease the Turntable Rotation
Bearing and Rotate Gear
· B-7 Check the Tires, Wheels and
Lug Nut Torque
Engine specifications require that this one-time
procedure be performed after the first 50 hours.
Required maintenance procedures and additional
engine information are available in the
Continental TME27 Owner's Manual
(Continental part number WM10303).
Continental TME27 Owner's Manual
Genie part number 111901

· B-9 Check the Drive Hub Oil Level and

Fastener Torque To access the engine:
· D-3 Check the Turntable Rotation 1 Remove the engine tray retaining fastener
Bearing Bolts located under the engine tray. Swing the engine
· D-7 Replace the Hydraulic tray out and away from the machine.
Filter Elements
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.

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

Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-8
Perform Engine Maintenance -
Perkins and Continental Models
Engine specifications require that this procedure
be performed every 50 hours or weekly, whichever
comes first.
Perkins Models:
Required maintenance procedures and additional
engine information are available in the
Perkins 704-30 User's Handbook
(Perkins part number TPD 1336E) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Perkins 804D Operation and Maintenance
Manual (Perkins part number SEBU8324-00).
Perkins 704-30 User's Handbook
Genie part number 101840
Perkins 804C-33 Operation and Maintenance Manual
Genie part number 111332
Perkins 804D-33 Operation and Maintenance Manual
Genie part number 228841
3 - 12
June 2011
REV E
Continental Models:
Required maintenance procedures and additional
engine information are available in the
Continental TME27 Owner's Manual
(Continental part number WM10303).
Continental TME27 Owner's Manual
Genie part number 111901
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Z-80/60 Part No. 88619
June 2011 Section 3 • Scheduled Maintenance Procedures

REV E CHECKLIST A PROCEDURES

A-9 Ford Models:

Perform Engine Maintenance Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302).
Engine specifications require that this procedure
be performed every 100 hours. Ford LRG-425 EFI Operator Handbook
Genie part number 84792
GM Models:

Required maintenance procedures and additional

engine information are available in the
GM 3.0L Operator Handbook
(GM part number 36100007).
GM 3.0L Operator Handbook
Genie part number
Perkins Models:
Continental Models:
Required maintenance procedures and additional
engine information are available in the
Continental TME27 Owner's Manual
(Continental part number WM10303).
77738
Continental TME27 Owner's Manual
Genie part number 111901

Required maintenance procedures and additional

engine information are available in the
Perkins 704-30 User's Handbook
(Perkins part number TPD 1336E) OR the
Perkins 804C-33 Operation and Maintenance
Manual
(Perkins part number SEBU7853-00).
Perkins 704-30 User's Handbook
Genie part number 101840
Perkins 804C-33 Operation and Maintenance Manual
Genie part number 111332
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.

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

Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
A-10
Grease the Turntable Rotation
Bearing and Rotate Gear
Genie specifications require that this procedure be
performed every 100 hours of operation. Perform
this procedure more often if dusty conditions exist.
Frequent application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an improperly greased bearing and gear will
result in component damage.
1 Locate the grease fitting next to the ground
control box.
2 Pump grease into the turntable rotation bearing.
Rotate the turntable in increments of
4 to 5 inches / 10 to 13 cm at a time and repeat
this step until the entire bearing has been
greased.
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
June 2011
REV E
A-11
Inspect the Fuel Filter/Water
Separator - Diesel Models
Note: Genie specifications require that this
procedure be performed every 100 hours or
monthly, whichever comes first.
Proper maintenance of the fuel filter/water
separator is essential for good engine
performance. Failure to perform this procedure can
lead to poor engine performance and/or hard
starting, and continued use may result in
component damge. Extremely dirty conditions may
require this procedure be performed more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, well-
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
Perkins Models:
1 Put on protective clothing and eye wear.
2 Open the engine side turntable cover and locate
the fuel filter/water separator next to the
hydraulic return filter on the bulkhead.
3 Inspect the filter bowl for water buildup.
Result: If water is present in the filter bowl
continue with steps 4 through 8.
Z-80/60 Part No. 88619
June 2011
REV E
4 Loosen the vent plug located on the fuel filter/
water separator head.
e
d
a vent plug
b drain plug
c filter bowl
d separator head
5 Loosen the drain plug located at the bottom of
the bowl. Allow the water to drain into a suitable
container until fuel starts to come out.
Immediately tighten the drain plug.
6 Tighten the vent plug.
Note: If the fuel filter/water separator is completely
drained, you must prime the fuel filter/water
separator before starting the engine. See C-6,
Replace The Fuel Filter/Water Separator Element -
Perkins Models, for instructions on how to prime
the fuel filter/water separator.
7 Clean up any fuel that may have spilled.
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
CHECKLIST A PROCEDURES
8 Start the engine from the ground controls and
check the fuel filter/water separator and vent
a plug for leaks.
b Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the
machine. Repair the leak
immediately.
Deutz Models:
c
1 Put on protective clothing and eye wear.
2 Remove the engine tray retaining fastener
located under the engine tray. Swing the
engine tray out and away from the machine.
3 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
4 Locate the fuel filter/water separator next to the
oil filter.
Z-80/60 3 - 15
Section 3 • Scheduled Maintenance Procedures June 2011

CHECKLIST A PROCEDURES REV E

5 Loosen the drain plug located at the bottom of A-12

the filter. Allow the water to drain into a suitable
container until fuel starts to come out. Replace the Drive Hub Oil
Immediately tighten the drain plug.
Note: Do not completely drain the filter.

Manufacturer drive hub specifications require that

this one-time procedure be performed after the
first 150 hours.
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil after the first 150 hours of
a
use may cause the machine to perform poorly and
continued use may cause component damage.
b
Drive Hubs:

1 Select the drive hub to be serviced. Drive the

machine until one of the two plugs is at the
a fuel filter/water separator
b drain valve lowest point.

6 Clean up any fuel that may have spilled. 2 Remove both plugs and drain the oil into a
suitable container.
7 Start the engine from the ground controls and
check the fuel filter/water separator for leaks. 3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
Explosion and fire hazard. If a fuel
leak is discovered, keep any
additional personnel from entering
the area and do not operate the a

machine. Repair the leak

immediately.
8 Swing the engine back to its original position
and install the engine pivot plate retaining
fastener. models with pipe plugs models with o-ring plugs

3 - 16 Z-80/60 Part No. 88619

June 2011 Section 3 • Scheduled Maintenance Procedures

REV E CHECKLIST A PROCEDURES

4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Apply pipe thread sealant to the plugs. Install
the plugs.
5 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugs
into the drive hub.
6 Repeat steps 1 through 5 for the other drive
hub.
Turntable Rotate Drive Hub:

1 Secure the turntable from rotating with the

turntable rotation lock pin.

a motor
b motor/brake mounting bolts
c brake
d drive hub
e drive hub mounting bolts

4 Remove the plug from the side of the drive hub.

Drain the oil from the hub into a container of
adequate capacity. Refer to Section 2,
Specifications.
unlocked locked
5 Install the drive hub. Torque the drive hub
mounting bolts to specification. Refer to
2 Remove the motor/brake mounting bolts, and
Section 2, Specifications.
then remove the motor and brake from the drive
hub and set them to the side. 6 Install the brake and motor onto the drive hub.
Torque the motor/brake mounting bolts to
Component damage hazard.
specification. Refer to Section 2, Specifications.
Hoses can be damaged if they are
kinked or pinched. 7 Fill the hub with oil from the side hole until the
oil level is even with the bottom of the hole.
3 Remove the drive hub mounting bolts, and use
Apply pipe thread sealant to the plug. Install the
a lifting device to remove the drive hub from the
plug.
machine.
8 Adjust turntable rotation gear backlash. Refer to
Tip-over hazard. Failure to secure
Repair Procedure 9-1, How to Adjust the
the turntable from rotating iwht the
Turntable Rotation Gear Backlash.
turntable rotation lock pin could
cause the machine to tip over
resulting in death or serious injury.

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

Section 3 • Scheduled Maintenance Procedures June 2011

CHECKLIST A PROCEDURES REV E

F

A-13 Ford Models:

Perform Engine Maintenance - Required maintenance procedures and additional
GM and Ford Models engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302).

Ford LRG-425 EFI Operator Handbook

Engine specifications require that this procedure Genie part number 84792
be performed every 200 hours.

Proper engine maintenance, following the engine

manufacturer's maintenance schedule, is essential To access the engine:
to good engine performance and service life.
1 Remove the engine tray retaining fastener
Failure to perform the maintenance procedures
located under the engine tray. Swing the engine
can lead to poor engine performance and
tray out and away from the machine.
component damage.
2 Install the fastener that was just removed
GM Models:
through the engine tray and into the engine tray
Required maintenance procedures and additional anchor hole in the turntable.
engine information are available in the Crushing hazard. Failure to install
GM 3.0L Operator Handbook the fastener into the engine tray
(GM part number 36100007). anchor hole to secure the engine
tray from moving could result in
GM 3.0L Operator Handbook death or serious injury.
Genie part number 77738

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June 2011
REV F
G
Checklist B Procedures
B-1
Inspect the Batteries
Note: Genie specifications require that this
procedure be performed every 250 hours or
quarterly, whichever comes first.
Proper battery condition is essential to good
engine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in engine component
damage and hazardous conditions.
Electrocution/burn hazard. Contact
with hot or live circuits could result
in death or serious injury. Remove
all rings, watches and other
jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
free of corrosion.
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
3 Be sure that the battery hold downs and cable
connections are tight.
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
4 Be sure that the battery separator wire
connections are tight.
5 Fully charge the batteries and allow them to rest
at least 6 hours.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
7 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjusted
specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 11.
Result: One or more battery cells display a
specific gravity of 1.217 or below. Proceed to
step 8.
8 Perform an equalizing charge, OR fully charge
the batteries and allow them to rest at least 6
hours.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
Z-80/60 3 - 19
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
10 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display a specific gravity
of 1.277 or greater. The battery is fully charged.
Proceed to step 13.
Result: The difference in specific gravity
readings between cells is greater than 0.1 OR
the specific gravity of one or more cells is less
than 1.177. Replace the battery.
11 Check the battery acid level. If needed,
replenish with distilled water to 1/8 inch / 3 mm
below the bottom of the battery fill tube. Do not
overfill.
12 Install the vent caps and neutralize any
electrolyte that may have spilled.
3 - 20
June 2011
REV G
B-2
Inspect the Electrical Wiring
Maintaining electrical wiring in good condition is
essential to safe operation and good machine
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in
unsafe operating conditions and may cause
component damage.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, 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 the
machine.
a engine tray anchor hole
b engine tray retaining fastener
3 Locate the engine tray anchor hole at the pivot
end of the engine tray.
Z-80/60 Part No. 88619
June 2011
REV G
4 Install the bolt that was just removed into the
anchor hole to secure the engine tray from
moving.
Crushing hazard. Failure to install
the bolt into the engine tray to
secure it from moving could result
in 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.
7 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· Inside of the ground control box
· Hydraulic manifold wiring
· Hydraulic oil cooler wiring
8 Inspect for a liberal coating of dielectric grease
at the following location:
· All wire harness connectors to the ground
control box
· Hydraulic manifold wiring
9 Start the engine from the ground controls and
raise the secondary boom above the turntable
covers.
10 Inspect the turntable area for burnt, chafed and
pinched cables.
Part No. 88619 Z-80/60
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
11 Lower the secondary boom to the stowed
position and turn the engine off.
12 Inspect the following areas for burnt, chafed,
corroded, pinched and loose wires:
· 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 from
the engine tray anchor hole at the pivot end of
the engine tray.
14 Inspect for a liberal coating of dielectric grease
at the following location:
· All wire harness connectors to the platform
control box
· Hydraulic manifold wiring
15 Swing the engine tray in towards the machine.
16 Install the bolt that was just removed into the
original hole to secure the engine tray.
Crushing hazard. Failure to install
the bolt into the engine tray to
secure it from moving could result
in death or serious injury.
3 - 21
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-3
Test the Key Switch
Proper key switch action and response is essential
to safe machine operation. The machine can be
operated from the ground or platform controls and
the activation of one or the other is accomplished
with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
a hazardous operating situation.
1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Turn the key switch to ground control, start the
engine and then turn the key switch to platform
control.
3 Check all machine function from the ground
controls.
Result: All machine functions should not
operate.
4 Turn the key switch to ground control.
5 Check all machine function from the platform
controls.
Result: All machine functions should not
operate.
6 Turn the key switch to the off position.
Result: The engine should stop and no
functions should operate.
3 - 22 Z-80/60
June 2011
REV G
B-4
Check the Exhaust System
Maintaining the exhaust system is essential to
good engine performance and service life.
Operating the engine with a damaged or leaking
exhaust system can cause component damage
and unsafe operating conditions.
Bodily injury hazard. Do not
inspect while the engine
is running. Remove the key to
secure from operation.
Bodily injury hazard. Beware of
hot engine components. Contact
with hot engine components may
cause severe burns.
1 Remove the engine tray retaining fastener.
Swing the engine tray out away from the
machine.
a engine tray anchor hole
b engine tray retaining fastener
Part No. 88619
June 2011
REV G
2 Locate the engine tray anchor hole at the pivot
end of the engine tray.
3 Install the bolt that was just removed into the
anchor hole to secure the engine tray from
moving.
Crushing hazard. Failure to install
the bolt into the engine tray to
secure it from moving could result
in death or serious injury.
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.
7 Remove the engine tray retaining fastener from
the engine tray anchor hole at the pivot end of
the engine tray.
8 Swing the engine tray in towards the machine.
9 Install the bolt that was just removed into the
original hole to secure the engine tray.
Crushing hazard. Failure to install
the bolt into the engine tray to
secure it from moving could result
in death or serious injury.
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-5
Inspect the Engine Air Filter
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first. Perform this procedure more often if dusty
conditions exist.
Note: Perform this procedure with the engine off.
1 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.
a
b
c
a retaining clamp
b canister end cap
c dust discharge valve
2 Disconnect the retaining clamp from the air
cleaner canister.
3 Remove the filter element.
4 Clean the inside of the canister and the gasket
with a damp cloth.
5 Inspect the air filter element. If needed, blow
from the inside out using low pressure dry
compressed air, or carefully tap out dust.
6 Install the filter element.
7 Install the air filter canister end cap and connect
the end cap retaining clamp.
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Section 3 • Scheduled Maintenance Procedures June 2011

CHECKLIST B PROCEDURES REV G

B-6 Continental Models:

Perform Engine Maintenance - Required maintenance procedures and additional
Deutz, Perkins and Continental engine information are available in the
Continental TME27 Owner's Manual
Models (Continental part number WM10303).

Continental TME27 Owner's Manual

Genie part number 111901
Engine specifications require that this procedure
be performed every 250 hours.
To access the engine:
Deutz Models:
1 Remove the engine tray retaining fastener
Required maintenance procedures and additional located under the engine tray. Swing the engine
engine information are available in the tray out and away from the machine.
Deutz 913 Operation Manual
(Deutz part number 0297 7341) 2 Install the fastener that was just removed
through the engine tray and into the engine tray
Deutz 913 Operation Manual
anchor hole in the turntable.
Genie part number 62446 Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
Perkins Models: tray from moving could result in
death or serious injury.
Required maintenance procedures and additional
engine information are available in the
Perkins 704-30 User's Handbook
(Perkins part number TPD 1336E) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00).

Perkins 704-30 User's Handbook

Genie part number 101840

Perkins 804C-33 Operation and Maintenance Manual

Genie part number 111332

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B-7 B-8
Check the Tires, Wheels Confirm the Proper
and Lug Nut Torque Brake Configuration

Maintaining the tires and wheels in good
condition, including proper wheel fastener torque,
is essential to safe operation and good
performance. Tire and/or wheel failure could result
in a machine tip-over. Component damage may
also result if problems are not discovered and
repaired in a timely fashion.
Note: The tires on this machine are foam filled and
do not need air added to them with the exception
of High Flotation tires.
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Section 2, Specifications.
Proper brake configuration is essential to safe
operation and good machine performance.
Hydrostatic brakes and hydraulically-released,
spring-applied individual wheel brakes can appear
to operate normally when they are actually not fully
operational.
1 Check each drive hub disconnect cap to be
sure it is in the engaged position.
disengaged position
engaged position
2 Be sure the free-wheel valve on the drive pump
is closed (clockwise).
Note: The free-wheel valve is located on the drive
pump.

a c

a drive pump
b screwdriver
c lift pump
d free-wheel valve

Note: The free-wheel valve should always remain

closed.

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B-9 2 Remove the plug located at 90 degrees and

Check the Drive Hub Oil Level
and Fastener Torque
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and
continued use may cause component damage.
Drive hubs:
1 Drive the machine to rotate the hub until one of
the plugs is located on top and the other one is
at 90 degrees.
a
check the oil level.
Result: The oil level should be even with the
bottom of the side plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.
4 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugs
into the drive hub. Torque to Specification.
Refer to Section 2, Specifications.
5 Check the torque of the drive hub mounting
fasteners. Refer to Section 2, Specifications.
6 Repeat steps 1 through 4 for the other drive
hubs.

a. models with pipe plugs

b. models with o-ring plugs

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Turntable rotate drive hub:
1 Remove the plug located on the side of the hub
and check the oil level.
Result: The oil level should be even with the
bottom of the plug hole opening.
a b
a drive hub
b plug
2 If necessary, add oil until the oil level is even
with the bottom of the plug hole opening.
3 Apply pipe thread sealant to the plug, and
install the plug in the drive hub.
6 Check the torque of the turntable rotate drive
hub mounting fasteners. Refer to Section 2,
Specifications.
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-10
Test the Ground Control Override
A properly functioning ground control override is
essential to safe machine operation. The ground
control override function is intended to allow
ground personnel to operate the machine from the
ground controls whether or not the Emergency
Stop button on the platform controls is in the ON or
OFF position. This function is particularly useful if
the operator at the platform controls cannot return
the boom to the stowed position.
1 Push in the platform red Emergency Stop
button to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boom
function through a partial cycle.
Result: All boom functions should operate.
Z-80/60 3 - 27
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-11
Test the Platform Self-leveling
Automatic platform self-leveling throughout
the full cycle of primary boom raising and lowering
is essential for safe machine operation. The
platform is maintained level by the communication
between the platform level sensor and the
turntable level sensor. If the platform becomes out
of level, the computer at the ground controls will
open the appropriate solenoid valve(s) at the
platform manifold to maintain a level platform.
A platform self-leveling failure creates an unsafe
working condition for platform and ground
personnel.
1 Start the engine from the ground controls.
2 Press and hold a function enable/speed select
button and fully retract the primary boom.
3 Push one of the LCD
screen buttons shown until
platform angle is
displayed.
4 Press and hold a function enable/speed select
button and adjust the platform to zero degrees
using the platform level up/down buttons.
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June 2011
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5 Push and hold a function enable/speed select
button and fully raise the primary boom while
observing the platform angle shown on the LCD
display.
Result: The platform should remain level at
all times to within ±2 degrees.
Note: If the platform becomes out of level, the tilt
alarm will sound and the Platform Not Level
Indicator will flash at the ground controls. The
platform level up/down buttons will only work in the
direction that will level the platform. Level the
platform until the indicator light turns off.
6 Push and hold a function enable/speed select
button and fully lower the primary boom.
Result: The platform should remain level at
all times to within ±2 degrees.
Note: If the platform becomes out of level, the tilt
alarm will sound and the Platform Not Level
Indicator will flash at the ground controls. The
platform level up/down buttons will only work in the
direction that will level the platform. Level the
platform until the indicator light turns off.
Part No. 88619
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B-12 6 Turn the key switch to platform controls.

Test the Engine Idle Select 7 At the platform controls, press the engine idle
select button until high idle (rabbit symbol) is
Operation selected.
A properly operating engine idle select function Result: The engine should change to high idle.
is essential to good engine performance and safe
machine operation. There are three settings.
a b c
Low idle (turtle symbol) allows the operator
to control multiple boom and/or drive functions
simultaneously, though at reduced speed. This
setting maintains a consistent low idle.
High idle (rabbit symbol) allows the operator
to control multiple boom and/or drive functions
simultaneously. This setting maintains a
consistent high idle.
d
Foot switch activated high idle (rabbit and foot
switch symbols) should be used for normal a foot switch activated high idle
machine operation. This selection activates high indicator light
idle only when the foot switch is pressed down. b low idle indicator light
c high idle indicator light
d engine rpm select button
1 Turn the key switch to ground controls.
2 Pull out the red Emergency Stop button to the 8 Press the engine idle select button until low idle
on position at both the ground and platform (turtle symbol) is selected.
controls. Result: The engine should change to low idle.
3 Start the engine from the ground controls. 9 Press the engine idle select button until the foot
4 Push and release the rpm select button until switch activated high idle (rabbit and foot switch
high rpm is selected (rabbit symbol). symbol) is selected.

Result: The engine should change to high idle. Result: The engine should not change to
high idle.
5 Push and release the rpm select button until low
rpm is selected (turtle symbol). 10 Press down the foot switch.

Result: The engine should return to low idle. Result: The engine should change to high idle.

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B-13
Test the Fuel Select Operation -
Gasoline/LPG Models
The ability to select and switch between
gasoline and LPG fuels as needed is essential to
safe machine operation. A fuel selection can be
made whether the engine is running or not.
Switching malfunctions and/or the failure of the
engine to start and run properly in both fuel
modes and through all idle speeds can indicate
fuel system problems that could develop into a
hazardous situation.
Note: Perform this test after checking the gasoline
and LPG fuel levels, and warming the engine to
normal operating temperature.
6 Release the foot switch and shut the engine off
by pushing the red Emergency Stop button in to
the off position.
7 Pull the red Emergency Stop button out to the
on 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 engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Note: The engine may hesitate momentarily and
then continue to run on the selected fuel if the fuel
source is switched while the engine is running.

1 Turn the key switch to platform controls and pull

out the red Emergency Stop buttons out to the
on position at both the ground and platform
controls.
2 Press the fuel select button to gasoline mode.
3 Start the engine from the platform controls and
allow the engine to run at low idle.
4 At the platform controls, press the engine idle
select button until foot switch activated high idle
(rabbit and foot switch symbol) is selected.
5 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.

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B-14
Test the Drive Brakes
Proper brake action is essential to safe machine
operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
noise. Hydraulically-released individual wheel
brakes can appear to operate normally when they
are actually not fully operational.
Collision hazard. Be sure that the
machine is not in free-wheel or
partial free-wheel configuration.
See B-8, Confirm the Proper
Brake Configuration.
Note: Select a test area that is firm, level and 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 foot
switch activated high idle (rabbit and foot switch
symbol) is selected, then lower the boom into
the stowed position.
4 Choose a point on the machine (i.e., contact
patch of a tire) as a visual reference for use
when crossing the test line.
5 Bring the machine to top drive speed before
reaching the test line. Release the drive
controller when your reference point on the
machine crosses the test line.
6 Measure the distance between the test line and
your machine reference point. Refer to
Section 2, Specifications.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-15
Test the Drive Speed -
Stowed Position
Proper drive function movement is essential to
safe machine operation. The drive function should
respond quickly and smoothly to operator control.
Drive performance should also be free of
hesitation, jerking and unusual noise over the
entire proportionally controlled speed range.
Note: Select a test area that is firm, level and free
of obstructions.
Note: Perform this procedure with the boom in the
stowed position.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Press the engine rpm select button until the foot
switch activated high idle (rabbit and foot switch
symbol) is selected.
4 Choose a point on the machine; i.e., contact
patch of a tire as a visual reference for use
when crossing the start and finish lines.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Section 2, Specifications.
Z-80/60 3 - 31
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CHECKLIST B PROCEDURES REV G

B-16 7 Continue at full speed and note the time when

the machine reference point crosses the finish
Test the Drive Speed - line. Refer to Section 2, Specifications.
Raised or Extended Position 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., contact
Proper drive function movement is essential to patch of a tire, as a visual reference for use
safe machine operation. The drive function should when crossing the start and finish lines.
respond quickly and smoothly to operator control.
11 Bring the machine to top drive speed before
Drive performance should also be free of
reaching the start line. Begin timing when your
hesitation, jerking and unusual noise over the
reference point on the machine crosses the
entire proportionally controlled speed range.
start line.
Note: Select a test area that is firm, level and free
12 Continue at top speed and note the time when
of obstructions.
the machine reference point crosses the finish
1 Create start and finish lines by marking two line. Refer to Section 2, Specifications.
lines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Press the engine rpm select button until the foot
switch activated high idle (rabbit and foot switch
symbol) is selected.
4 Press down the foot switch and raise the boom
until the engine switches to low idle.
5 Choose a point on the machine; i.e., contact
patch of a tire as a visual reference for use
when crossing the start and finish lines.
6 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.

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B-17
Test the Alarm and Optional
Flashing Beacon
An alarm and optional flashing beacon are installed
to alert operators and ground personnel of
machine proximity and motion. There are four
alarm option modes that can be activated based on
user preference or requirement. Refer to Display
Module in the Repair Section for information.
1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Result: The alarm should sound twice. The
flashing beacon (if equipped) should be on and
flashing.
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-18
Perform Hydraulic Oil Analysis
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
may cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
See E-1, Test or Replace the Hydraulic Oil.
Z-80/60 3 - 33
Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-19
Check and Adjust the
Engine RPM
Maintaining the engine rpm at the proper setting for
both low and high idle is essential to good engine
performance and service life. The machine will not
operate properly if the rpm is incorrect and
continued use may cause component damage.
Ford, GM and Continental models:
Note: The engine rpm is controlled by the ECM
and can only be adjusted by re-programming the
ECM. If rpm adjustment or service is required,
please contact Genie Industries Service
Department or your local engine dealer.
Deutz F4L913 models:
1 Start the engine from the ground controls.
2 Push one of the LCD screen buttons shown
until engine rpm is displayed. Refer to Section
2, Specifications.
Skip to step 11 if the low idle rpm is correct.
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June 2011
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3 Remove the secondary idle adjustment screw
cap from the secondary idle adjustment screw
on the injection pump. Loosen the locknut.
a primary idle adjustment screw
b secondary idle adjustment screw
4 Turn the secondary adjustment screw
counterclockwise until the adjustment screw is
loose. Tighten the locknut.
Note: Be sure the adjustment screw is loosened
until there is no spring tension felt.
5 Remove the primary idle adjustment screw cap
from the primary idle adjustment screw on the
injection pump. Loosen the locknut.
6 Adjust the primary idle adjustment screw until
low idle meets specification. Tighten the
locknut.
7 Install the primary idle adjustment screw cap
and tighten. Do not over tighten.
8 Loosen the secondary idle adjustment screw
locknut.
Z-80/60 Part No. 88619
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9 Adjust the secondary adjustment screw until the Skip to step 5 if the low idle rpm is correct.
low idle meets specification. Tighten the
locknut. 3 Loosen the locknut on the low idle adjustment
screw.
10 Install the secondary idle adjustment screw cap
and tighten. Do not over tighten.
11 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Refer to Section 2, Specifications.
If the high idle is correct, disregard adjustment
step 12.

12 Loosen the yoke lock nut. Turn the high idle

adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.

Deutz BF4L2011 models: a b

1 Start the engine from the ground controls. a low idle adjustment screw
2 Push one of the LCD b high idle adjustment screw
screen buttons shown until 4 Adjust the low idle adjustment screw until low
engine rpm is displayed. idle meets specification. Tighten the locknut.
Refer to Section 2, Specifications.
5 Push and hold the function enable/high speed
button. Note the engine rpm on the display.
Refer to Section 2, Specifications.
If the high idle is correct, disregard adjustment
step 6.

6 Loosen the yoke lock nut. Turn the high idle

adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.

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Perkins models: 4 Push and hold the function enable/high speed

1 Start the engine from the ground controls.
2 Push one of the LCD
screen buttons shown until
engine rpm is displayed.
Refer to Section 2, Specifications.
Skip to step 4 if the low idle rpm is correct.
3 Loosen the low idle lock nut and turn the low
idle adjustment screw clockwise to increase the
rpm, or counterclockwise to decrease the rpm.
Tighten the low idle lock nut and confirm the
rpm.
button. Note the engine rpm on the display.
Refer to Section 2, Specifications.
If high idle rpm is correct, disregard
adjustment step 5.
5 Loosen the yoke lock nut, then turn the high idle
adjustment nut and solenoid boot
counterclockwise to increase the rpm or
clockwise to decrease the rpm. Tighten the
yoke lock nut and confirm the rpm.
Note: Be sure the solenoid fully retracts when
activating high idle.

a b c d

a solenoid boot
b high idle adjustment nut
c yoke lock nut
d yoke
e low idle adjustment screw
f low idle lock nut

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B-20 6 Remove the fasteners from the turntable riser

Test the Safety Envelope and
Circuits
Testing the machine safety envelope is critical to
safe machine operation. If the boom is allowed to
operate when a safety switch is not functioning
correctly, the machine stability is compromised and
may tip over. Refer to Section 6 for limit switch and
angle sensor information.
Secondary Boom #1 Angle Safety Limit Switch,
LSS2AS
cover at the platform end of the secondary
boom. Remove the cover.
7 Locate the Deutsch connectors from the
secondary safety retract switch (LSS1RS) near
the chassis at the platform end of the
secondary boom. The connection will be
marked with yellow zip ties on the wire
assembly. Disconnect the connectors.
8 Locate the Deutsch connectors from the
secondary boom #1 retract operational limit
switch (LSS1RO) at the end of the secondary
boom.The connection will be marked with red
zip ties on the wire assembly. Disconnect the
connectors.

1 Turn the key switch to ground control and pull 9 Install a wire jumper between pin 1 and pin 2 of
out the red Emergency Stop buttons out to the the Deutsch connector on the wire harness
on position at both the ground and platform removed in step 8.
controls. 10 Install a second wire jumper between pin 3 and
2 Start the engine from the ground controls. pin 4 of the Deutsch connector on the wire
harness.
3 Simultaneously push the
LCD screen buttons Result: The display should show = 0FT.
shown to activate status
mode.
4 Push one of the LCD
screen buttons shown
until secondary boom
length is displayed.
5 Fully raise the secondary boom and extend the
secondary boom approximately 2 feet / 61 cm.

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Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
11 Press and hold the high speed function enable
button and lower the secondary boom.
Result: The secondary boom should lower to
60° and the engine should stop.
Result: If the engine does not stop at 60° and
the secondary boom continues to lower, the
secondary boom #2 angle safety limit switch
(LSS2AS) is out of adjustment or the wiring
circuit is faulty and will need to be replaced or
repaired. Immediately remove the machine
from service until repairs are made.
Bodily injury hazard. If the
secondary boom lowers to less
than 60° without stopping the
engine, stop immediately and
raise the secondary boom above
60°. Failure to raise the secondary
boom could result in death or
serious injury.
12 Remove the key from the main key switch,
insert it into the service bypass/recovery key
switch, turn the key to Service Bypass mode
and raise the scondary boom above 60° using
auxiliary power.
13 Remove the wire jumpers installed in steps 9
and 10 and connect the wire harness to
LSS1RO removed in step 8.
14 Fully raise the secondary boom and extend the
secondary boom approximately 1 foot / 30.5
cm.
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June 2011
REV G
15 Turn the service bypass/recovery key switch
back to run, return the key to the main key
switch and start the engine from the ground
controls.
16 Re-connect the Deutsch connector from the
secondary safety retract switch (LSS1RS)
removed in step 7.
Secondary Boom #1 Retracted Safety
Limit Switch, LSS1RS
17 Simultaneously push the
LCD screen buttons
shown to activate status
mode.
18 Push one of the LCD
screen buttons shown
until secondary boom
angle is displayed.
19 Raise the secondary boom until the display
shows >=35 DEGREES.
20 Locate the Deutsch connectors from the
secondary boom #2 angle safety limit switch
(LSS2AS) on the inside of the turntable riser.
The connection will be marked with purple zip
ties on the wire assembly. Disconnect the
connectors.
21 Locate the Deutsch connectors from the
secondary boom #2 angle operational limit
switch (LSS2AO) on the inside of the turntable
riser. The connection will be marked with green
zip ties on the wire assembly. Disconnect the
connectors.
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22 Install a wire jumper between pins 1 and 2 of

the Deutsch connector on the wire harness
removed in step 21.
Result: The display should show AT 65 DEGREES.
23 Press and hold the low speed function enable
button and extend the secondary boom.
Result: The secondary boom should extend no
more than 12 inches / 30.5 cm and stop. The
engine should stop and the display will show
P9B SAFETY FAULT and P11 SAFETY FAULT.

Result: If the engine does not stop and the

secondary boom continues to extend, the
secondary boom #1 retracted safety limit switch
(LSS1RS) is out of adjustment or the wiring
circuit is faulty and will need to be replaced or
repaired.
Bodily injury hazard. If the
secondary boom continues to
extend without stopping the
engine, stop immediately and
retract the secondary boom.
Failure to retract the secondary
boom could result in death or
serious injury.
24 Remove the wire jumpers installed in step 22
and connect the wire harness to LSS2AO.
25 Re-connect the Deutsch connector from the
secondary boom #2 angle safety limit switch
(LSS2AS) removed in step 20.

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B-21 4 Fully raise the secondary boom while watching

the display at the ground controls. Stop when
Test the Primary Boom the secondary boom just begins to extend.
Self-leveling Result: The primary boom should remain level
Note: The primary boom self-leveling function is at all times to within ±2 degrees.
adjustable on machines with software revision 1.03 Note: If the platform becomes out of level, the tilt
and lower. This function is not adjustable on alarm will sound and the platform not level
machines with a software revision higher than indicator will turn on. Level the platform until the
1.03. Refer to Repair Procedure 6-1, How to indicator light turns off.
Determine the Revision Level.
Automatic primary boom self-leveling throughout
the full cycle of secondary boom raising and
lowering is essential for safe machine operation.
The primary boom is maintained level by the
communication between the platform level sensor
and the turntable level sensor. If the platform
becomes out of level, the computer at the ground
controls will open the appropriate solenoid valve(s)
at the function manifold to maintain a level primary
boom.

1 Turn the key switch to ground control and pull

out the red Emergency Stop buttons out to the
on position at both the ground and platform
controls.
2 Push one of the LCD
screen buttons shown
until primary boom angle
is displayed.
3 Start the engine and level the platform until the
displays shows 0 DEGREES.

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B-22 3 Start the engine from the ground controls.

Test the Primary Boom Angle 4 Raise the primary boom. The display will begin
showing a boom angle of 40°.
Sensor
5 Continue raising the primary boom until the
A properly functioning primary boom angle sensor display shows 65°.
(PBAS) is essential to safe machine operation. The
primary boom angle sensor is used to limit the Result: The primary boom should stop.
angle of the primary boom relative to the angle of
Result: The primary boom does not stop.
the secondary boom and gravity. The ECM at the
Immediately release the function enable button
ground controls (TCON) monitors the position and
and lower the boom. Calibrate the limit switch.
angle of the primary boom using the signal from
Refer to Repair Procedure 4-7 How to Calibrate
PBAS. The PBAS signal is used to control the
the Primary Boom Limit Switch.
ramping of the primary boom as well as velocity
control, limiting the speed of the primary boom to Tip-over hazard. If the boom does
1.3 feet / 0.4 meters per second. not stop at 65°, immediately
release the function enable button
Note: Perform this procedure on a firm, level and lower the primary boom.
surface. Failure to lower the boom could
1 Turn the key switch to ground control and pull cause the machine to tip over
out the red Emergency Stop buttons out to the resulting in death or serious injury.
on position at both the ground and platform
controls.
2 Push one of the LCD
screen buttons shown
until primary boom angle
is displayed.

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

Section 3 • Scheduled Maintenance Procedures
CHECKLIST B PROCEDURES
B-23
Inspect the Fuel and Hydraulic
Tank Cap Venting Systems
Genie requires that this procedure be performed
every 250 hours or quarterly, whichever comes
first. Perform this procedure more often if dusty
conditions exist.
Free-breathing fuel and hydraulic tank caps are
essential for good machine performance and
service life. A dirty or clogged tank cap may cause
the machine to perform poorly and continued use
may cause component damage. Extremely dirty
conditions may require that the caps be inspected
more often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, well-
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.
3 - 42
June 2011
REV G
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.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulic
tank.
6 Check for proper venting.
Result: Air passes through the hydraulic tank
cap. Proceed to step 8.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 7.
Note: When checking for positive tank cap venting,
air should pass freely through the cap.
7 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 6.
8 Install the breather cap onto the hydraulic tank.
Z-80/60 Part No. 88619
June 2011 Section 3 • Scheduled Maintenance Procedures

REV G CHECKLIST B PROCEDURES

B24 To access the engine:

Perform Engine Maintenance -
GM and Ford Models
Engine specifications require that this procedure
be performed every 400 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
GM Models:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.

Required maintenance procedures and additional

engine information are available in the
GM 3.0L Operator Handbook
(GM part number 36100007).

GM 3.0L Operator Handbook

Genie part number 77738

Ford Models:

Required maintenance procedures and additional

engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302).

Ford LRG-425 EFI Operator Handbook

Genie part number 84792

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

January32011
Section • Scheduled Maintenance Procedures
Checklist C Procedures
C-1
Perform Engine Maintenance
Engine specifications require that this procedure
be performed every 500 hours.
Deutz Models:
Required maintenance procedures and additional
engine information are available in the
Deutz 913 Operation Manual
(Deutz part number 0297 7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Deutz TD2011 Operation Manual
(Deutz part number 0312 3547)..
Deutz 913 Operation Manual
Genie part number 62446
Deutz BF4L2011 Operation Manual
Genie part number 84794
Deutz TD2011 Operation Manual
Genie part number 139320
Perkins Models:
Required maintenance procedures and additional
engine information are available in the
Perkins 704-30 User's Handbook
(Perkins part number TPD 1336E) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Perkins 804D Operation and Maintenance
Manual (Perkins part number SEBU8324-00).
3 - 44
June 2011
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F
Perkins 704-30 User's Handbook
Genie part number 101840
Perkins 804C-33 Operation and Maintenance Manual
Genie part number 111332
Perkins 804D-33 Operation and Maintenance Manual
Genie part number 228841
Continental Models:
Required maintenance procedures and additional
engine information are available in the
Continental TME27 Owner's Manual
(Continental part number WM10303).
Continental TME27 Owner's Manual
Genie part number 111901
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Z-80/60 Part No. 88619
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C-2
Grease the Platform Overload
Mechanism (if equipped)
Genie specifications require that this procedure be
performed every 500 hours or 6 months, whichever
comes first. Perform this procedure more often if
dusty conditions exist.
Application of lubrication to the platform overload
mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
overload mechanism could result in the system not
sensing an overloaded platform condition and will
result in component damage.
1 Locate the grease fittings on each pivot pin of
the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting using a multi-purpose grease.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)
or equivalent
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
C-3
Test the Platform Overload
System (if equipped)
Genie specifications require that this procedure be
performed every 500 hours or 6 months, whichever
comes first.
Testing the platform overload system regularly is
essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stability
could be compromised resulting in the machine
tipping over.
Note: Perform this procedure with the machine on
a firm, level surface.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.
Z-80/60 3 - 45
Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
4 Using a suitable lifting device, place a test
weight equal to that of the available capacity
one of the locations shown.
Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights
are on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
Illustration 1
5 Carefully move the test weight to each
remaining location. Refer to Illustration 1.
Result: The platform overload indicator lights
should be off at both the ground and platform
controls and the alarm should not sound.
Result: The platform overload indicator lights
are on and the alarm is sounding. Calibrate the
platform overload system. Refer to Repair
Procedure 2-4, How to Calibrate the Platform
Overload System (if equipped).
3 - 46
June 2011
REV E
6 Using a suitable lifting device, place an
additional 50 lbs / 23 kg of weight onto the
platform.
Result: The alarm should sound. The platform
overload indicator light should be flashing at the
platform controls and “PLATFORM
OVERLOAD” should be displayed on the LCD
screen at the ground controls.
Result: The alarm is not sounding OR the
platform overload indicator light is not flashing
OR “PLATFORM OVERLOAD” is not displayed
on the LCD screen at the ground controls.
Calibrate the platform overload system. Refer
to Repair Procedure 2-4, How to Calibrate the
Platform Overload System (if equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
7 Carefully move the test weights to each
remaining location on the platform.
Refer to Illustration 1.
Result: The alarm should sound.
The platform overload indicator lights should be
flashing at both the ground and platform
controls.
Result: The alarm does not sound and the
platform overload indicator lights are not
flashing. Calibrate the platform overload
system. Refer to Repair Procedure 2-4,
How to Calibrate the Platform Overload System
(if equipped).
Note: There may be a 2 second delay before the
overload indicator lights flash and the alarm
sounds.
8 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
Z-80/60 Part No. 88619
June 2011 Section 3 • Scheduled Maintenance Procedures

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9 Turn the key switch to ground control. C-4

10 Test all machine functions from the ground
controls.
Result: All ground control functions should not
operate.
11 Press and hold the auxiliary power button.
Note: The engine must be shut off to access
auxiliary power.
12 Using auxiliary power, test all machine functions
from the ground controls.
Result: All ground control functions should
operate except extend.
13 Using a suitable lifting device, lift the additional
test weight from the platform.
Result: The platform overload indicator lights
should turn off at both the ground and platform
controls and the alarm should not sound.
Replace the Engine Air Filter
Engine specifications require that this procedure
be performed every 500 hours or 6 months,
whichever comes first.
Maintaining the engine air filter in good condition is
essential to good engine performance and service
life. Failure to perform this procedure can lead to
poor engine performance and component
damage..
Note: Perform this procedure with the engine off.
1 Open the engine side cover. Empty the dust
discharge valve by pressing together the sides
of the discharge slot. Clean the discharge slot
as needed.

Note: There may be an 2 second delay before the

overload indicator lights and alarm turn off.
a
14 Start the engine and test all machine functions
from the ground controls.
Result: All ground control functions should b
operate normally.
15 Turn the key switch to platform control.
16 Test all machine functions from the platform
controls. c

Result: All platform control functions should

operate.
Note: If the platform overload system is not
a retaining clamp
operating properly, Refer to 2-4, How to Calibrate b canister end cap
the Platform Overload System (if equipped). c dust discharge valve

17 Using a suitable lifting device, remove the

remaining test weights from the platform.

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

Section 3 • Scheduled Maintenance Procedures
CHECKLIST C PROCEDURES
Perkins 804C-33 or 804D-33 Models:
2 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
3 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
All Models:
4 Release the clamps from the end cap of the air
filter canister. Remove the end cap.
5 Remove the filter element.
6 Clean the inside of the canister and the gasket
with a damp cloth.
7 Install the new filter element.
8 Install the air filter canister end cap and connect
the end cap retaining clamp.
3 - 48 Z-80/60
June 2011
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C-5
Replace the Fuel/Water
Separator - Diesel Models
Genie specifications require that this procedure be
performed every 500 hours or annually, whichever
comes first.
Regular replacement of the fuel filter/water
separator is essential for good engine
performance. Failure to perform this procedure can
lead to poor engine performance and/or hard
starting, and continued use may result in
component damage. Extremely dirty conditions
may require this procedure be performed more
often.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, well-
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Note: Perform this procedure with the engine off.
1 Open the engine side turntable cover and locate
the fuel filter/water separator.
Note: The fuel filter/water separator is located near
the hydraulic pump.
Part No. 88619
June 2011 Section 3 • Scheduled Maintenance Procedures

REV E CHECKLIST C PROCEDURES

2 Disconnect and plug the fuel supply hose from 8 Apply a thin layer of oil onto the element gasket.
the fuel tank to the fuel filter/water separator Install the filter/bowl assembly onto the filter
head. head. Tighten the drain plug and vent plug.
3 Loosen the vent plug located on the fuel filter/ Component damage hazard. The
water separator head. drain plug and vent plug can be
damaged if they are
overtightened.
a 9 Install the fuel supply hose from the fuel tank to
the fuel filter/water separator. Tighten the
d
clamp.
10 Clean up any diesel fuel that may have spilled
during the installation procedure.
c
11 Use a permanent ink marker to write the date
b and number of hours from the hour meter on
the filter element.
Bleed the fuel system:

a vent plug
b drain plug
c filter bowl
d separator head
4 Place a suitable container under the filter bowl.
Loosen the drain plug located at the bottom of
the bowl. Completely drain the fuel.
5 Rotate the filter bowl counterclockwise and
remove it from the element.
6 Rotate the filter element counterclockwise and
remove it from the filter head.
7 Install the filter bowl onto the new filter element.
Note: Before bleeding the system, fill the fuel tank.
12 Loosen the vent plug located on the
fuel filter/water separator head.
13 Operate the priming lever of the fuel lift pump
until fuel, free from air, comes from the vent
plug. Tighten the vent plug.
14 Loosen the air vent screw, located on top of the
fuel injection pump.
15 Tighten the air vent screw when air stops
coming through the air vent.
16 Clean up any diesel fuel that may have spilled
during the bleeding procedure and dispose of
properly.
17 Start the engine from ground controls and
check for leaks.

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

Section 3 • Scheduled Maintenance Procedures June 2011

CHECKLIST C PROCEDURES REV E

C-6 To access the engine:

Perform Engine Maintenance -
GM and Ford Models
Engine specifications require that this procedure
be performed every 800 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
GM Models:
Required maintenance procedures and additional
engine information are available in the
GM 3.0L Operator Handbook
(GM part number 36100007).
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.

GM 3.0L Operator Handbook

Genie part number 77738

Ford Models:
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302).

Ford LRG-425 EFI Operator Handbook

Genie part number 84792

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

June 2012
2011 Section 3 • Scheduled Maintenance Procedures

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D
Checklist D Procedures
D-1
Check the Boom Wear Pads
Maintaining the boom wear pads in good condition
is essential to safe machine operation. Wear pads
are placed on boom tube surfaces to provide a low
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued
use of extremely worn wear pads may result in
component damage and unsafe operating
conditions.
Boom wear pad specifications Minimum
Primary Boom
1 Start the engine from the ground controls.
2 Raise the end of the boom to a comfortable
working height (chest high), then extend the
boom 1 foot / 30 cm.
3 Measure each wear pad.
Result: Replace the wear pad if it is less than
specification. If the wear pad is not less than
specification, shim as necessary to obtain
minimum clearance with no binding.
Note: The minimum shim clearance for the primary
boom wear pads is .030 inch / .76 mm and the
maximum allowable shim clearance is .090 inch /
2.29 mm. The minimum shim clearance for the
secondary boom wear pads is .030 inch / .76 mm
and the maximum allowable shim clearance is .125
inch / 3.2 mm.

5/8
Note: If the wear pads are still within specification,
Top, bottom and side wear pads inch
15.9 mm
refer to refer to Repair Procedure 4-2, How to Shim
the Boom.
Primary Extension Boom
4 Extend and retract the boom through the entire
Top wear pads 5/8inch range of motion to check for tight spots that
15.9 mm may cause binding or scraping of the boom.

Side wear pads 1/2 inch Note: Always maintain squareness between the
12.7 mm outer and inner boom tubes.

Secondary Boom

Top wear pads 1/2 inch

12.7 mm

Side and bottom wear pads 7/8 inch

22.2 mm

Secondary Extension Boom

Top wear pads 5/8 inch

15.9 mm

Side wear pads 1/2inch

12.7 mm

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

Section 3 • Scheduled Maintenance Procedures June 2012

CHECKLIST D PROCEDURES REV E

D-2 5 Manually rotate each non-steer wheel.

Check the Free-wheel Result: Each non-steer wheel should rotate with
minimum effort.
Configuration
6 Re-engage the drive hubs by turning over
the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
remove the blocks.
Proper use of the free-wheel configuration is
essential to safe machine operation. The Collision hazard. Failure to
free-wheel configuration is used primarily for re-engage the drive hubs could
towing. A machine configured to free-wheel without result in death or serious injury
operator knowledge may cause death or serious and property damage.
injury and property damage.
4WD models:
Collision hazard. Select a work
7 Chock the non-steering wheels to prevent the
site that is firm and level.
machine from rolling.
Component damage hazard. If the
8 Center a lifting jack with a minimum capacity of
machine must be towed, do not
25,000 lbs / 12000 kg under the drive chassis
exceed 2 mph / 3.2 km/h.
between the steer wheels.
1 Chock the steer wheels to prevent the machine
9 Lift the wheels off the ground and then place
from rolling.
blocks under the drive chassis for support.
2 Center a lifting jack of ample capacity
10 Disengage the drive hubs by turning over the
(20,000 lbs / 10,000 kg) under the drive chassis
drive hub disconnect caps on each steer wheel
between the wheels at the non-steer end of the
hub.
machine.
3 Lift the wheels off the ground and place blocks disengaged position
under the drive chassis for support.
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each
non-steer wheel hub. engaged position

disengaged position

engaged position

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June 2012 Section 3 • Scheduled Maintenance Procedures

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11 Manually rotate each steer wheel. D-3

Result: Each steer wheel should rotate with Check the Turntable Rotation
minimum effort.
Bearing Bolts
12 Re-engage the drive hubs by turning over
the drive hub disconnect caps. Rotate each
wheel to check for engagement. Lift the
machine and remove the blocks.
Maintaining proper torque on the turntable bearing
Collision hazard. Failure to bolts is essential to safe machine operation.
re-engage the drive hubs could Improper bolt torque could result in an unsafe
result in death or serious injury operating condition and component damage.
and property damage.
1 Raise the secondary boom approximately
All models: 8 feet / 2.4 m.
13 Be sure the free-wheel valve on the drive pump 2 Remove the engine tray retaining fastener.
is closed (clockwise). Swing the engine tray out away from the
machine.
Note: The free-wheel valve is located on the drive
pump, and should always remain closed.

a c

a engine tray anchor hole

b engine tray retaining fastener

a drive pump 3 Locate the engine tray anchor hole at the pivot
b screwdriver end of the engine tray.
c lift pump
d free-wheel valve

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

Section 3 • Scheduled Maintenance Procedures June 2012

CHECKLIST D PROCEDURES REV E

4 Install the bolt that was just removed into the 1 15

10
anchor hole to secure the engine tray from 13 7

moving. 6 12

Crushing hazard. Failure to install 18 4

the bolt into the engine tray to
secure it from moving could result 3 17

in death or serious injury. 11 5

5 Confirm that each turntable mounting bolt is 8 14

16 9
torqued in sequence to specification. Refer to 2
Section 2, Specifications.
Bolt torque sequence
(from below chassis)

28 1
8 Lower the secondary boom to the stowed
24 5
20 9 position.
16 13
12 17 9 Remove the engine tray retaining fastener from
8 21 the engine tray anchor hole at the pivot end of
4 25 the engine tray.
30 29
26 3 10 Swing the engine tray in towards the machine.
22 7 11 Install the bolt that was just removed into the
18 11
14 15
original hole to secure the engine tray.
10 19
6 2 27 23 Crushing hazard. Failure to install
the bolt into the engine tray to
Bolt torque sequence secure it from moving could result
(from above turntable) in death or serious injury.
6 Lower the boom to the stowed position.
7 Confirm that each bearing mounting bolt under
the drive chassis is torqued in sequence to
specification. Refer to Section 2, Specifications.

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REV E CHECKLIST D PROCEDURES

D-4
a
Inspect for Turntable Bearing
Wear
b

Periodic inspection of turntable bearing wear is

essential to safe machine operation, good machine c
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious d
injury and component damage.
a turntable
Note: Perform this procedure with the machine on b dial indicator
a firm, level surface and the boom in the stowed c drive chassis
position. d turntable rotation bearing

1 Grease the turntable bearing. See A-10, Grease 5 Adjust the dial indicator need to the "zero"
the Turntable Bearing and Rotate Gear. position.

2 Torque the turntable bearing bolts to 6 Elevate the riser, but do not extend it. Move the
specification. See D-3, Check the Turntable primary boom and jib to horizontal and fully
Rotation Bearing Bolts. extend.

3 Start the machine from the ground controls and
fully elevate, but do not extend, the primary
boom and jib. The riser should remain in its
stowed position.
4 Place a dial indicator between the drive chassis
and the turntable at a point that is directly
under, or inline with, the boom and no more
than 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place
the dial indicator no more than 1 inch / 2.5 cm from
the turntable rotation bearing.
7 Note the reading on the dial indicator.
Result: The measurement is less than
0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than
0.063 inch / 1.6 mm. The bearing is worn and
needs to be replaced.
8 Move the boom sections to the positions
indicated in step 3. Visually inspect the dial
indicator to be sure the needle returns to the
"zero" position.

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Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
9 Remove the dial indicator and rotate the
turntable 90°.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
11 Lower the boom to the stowed position and turn
the machine off.
12 Remove the dial indicator from the machine.
3 - 56
June 2012
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D-5
Replace the Drive Hub Oil
Replacing the drive hub oil is essential for good
machine performance and service life. Failure to
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and
continued use may cause component damage.
Drive Hubs:
1 Select the drive hub to be serviced. Drive the
machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil into a
suitable container.
3 Drive the machine until one plug is at the top
and the other is at 90 degrees.
a models with pipe plugs
b models with o-ring plugs
Z-80/60 Part No. 88619
June 2012 Section 3 • Scheduled Maintenance Procedures

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4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole.
Apply pipe thread sealant to the plugs. Install
the plugs.
5 Models with pipe plugs: Apply pipe thread
sealant to the plugs and install the plugs.
Models with O-ring plugs: Install the plugs
into the drive hub.
6 Repeat steps 1 through 5 for the other drive
hub.
Turntable Rotate Drive Hub:

1 Secure the turntable from rotating with the

turntable rotation lock pin.

a motor
b motor/brake mounting bolts
c brake

3 Remove the drive hub mounting bolts, and use

a lifting device to remove the drive hub from the
machine.
4 Remove the plug from the side of the drive hub.
Drain the oil from the hub into a container of
unlocked locked
adequate capacity. Refer to Section 2,
2 Remove the motor/brake mounting bolts, and Specifications.
then remove the motor and brake from the drive
5 Install the drive hub. Torque the drive hub
hub and set them to the side.
mounting bolts to specification. Refer to
Component damage hazard. Section 2, Specifications.
Hoses can be damaged if they are
6 Install the brake and motor onto the drive hub.
kinked or pinched.
Torque the motor/brake mounting bolts to
specification. Refer to Section 2, Specifications.
7 Fill the hub with oil from the side hole until the
oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plug. Install the
plug.
8 Adjust turntable rotation gear backlash. Refer to
Repair Procedure 9-1, How to Adjust the
Turntable Rotation Gear Backlash.

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

Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
D-6
Perform Engine Maintenance
Engine specifications require that this procedure
be performed every 1000 hours.
Deutz Models:
Required maintenance procedures and additional
engine information are available in the
Deutz 913 Operation Manual
(Deutz part number 0297 7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Deutz TD2011 Operation Manual
(Deutz part number 0312 3547)..
Deutz 913 Operation Manual
Genie part number 62446
Deutz BF4L2011 Operation Manual
Genie part number 84794
Deutz TD2011 Operation Manual
Genie part number 139320
Perkins Models:
Required maintenance procedures and additional
engine information are available in the
Perkins 704-30 User's Handbook
(Perkins part number TPD 1336E) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Perkins 804D Operation and Maintenance
Manual (Perkins part number SEBU8324-00).
3 - 58
June 2012
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Perkins 704-30 User's Handbook
Genie part number 101840
Perkins 804C-33 Operation and Maintenance Manual
Genie part number 111332
Perkins 804D-33 Operation and Maintenance Manual
Genie part number 228841
Continental Models:
Required maintenance procedures and additional
engine information are available in the
Continental TME27 Owner's Manual
(Continental part number WM10303).
Continental TME27 Owner's Manual
Genie part number 111901
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Z-80/60 Part No. 88619
June 2012
REV E
D-7
Replace the Hydraulic Filter
Elements
Genie requires that this procedure be performed
annually or every 1000 hours, whichever comes
first. Perform this procedure more often if dusty
conditions exist.
Replacement of the hydraulic filters is essential for
good machine performance and service life. A dirty
or clogged filter may cause the machine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
Note: Perform this procedure with the engine off.
Hydraulic return filter:
1 Open the ground controls side turntable cover
and locate the hydraulic return filter mounted on
the hydraulic tank.
2 Place a suitable container under the hydraulic
tank return filter.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of fresh oil to the gasket of
the new oil filter.
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
CHECKLIST D PROCEDURES
5 Install the new hydraulic return filter element
and tighten it securely by hand. Clean up any
oil that may have spilled during the installation
procedure.
6 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.
Medium and high pressure filters:
Note: The medium pressure filter is for the charge
pump. One high pressure filter is for all boom and
steer functions. The other high pressure filter is for
the oscillating axle circuit and flatform manifold.
7 Open the engine side turntable cover and locate
the three filters mounted to the bulkhead.
a
b
a high pressure filters
b medium pressure filter
8 Place a suitable container under the filters.
9 Remove the filter housing by using a wrench on
the nut provided on the bottom of the housing.
Z-80/60 3 - 59
Section 3 • Scheduled Maintenance Procedures June 2012
2011

CHECKLIST D PROCEDURES E
REV D

10 Remove the filter element from the housing.

11 Inspect the housing seal and replace it if
necessary.
12 Install the new medium and high pressure filter
elements into the housings and tighten them
securely.
13 Clean up any oil that may have spilled during
the installation procedure.
14 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter housings.
15 Start the engine from the ground controls.
16 Inspect the filter housings and related
components to be sure that there are no leaks.

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

June 2011
REV D
Checklist E Procedures
E-1
Test or Replace the Hydraulic Oil
Replacement or testing of the hydraulic oil is
essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Note: Before replacing the hydraulic oil, the oil may
be tested by an oil distributor for specific levels of
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at
the two year inspection, test the oil quarterly.
Replace the oil when it fails the test.
Note: Perform this procedure with the boom in the
stowed position.
1 GM, Ford and Continental models: Turn the
valve on the LPG tank clockwise to the off
position
(if equipped). Then slowly disconnect the hose
from the LPG tank.
2 GM, Ford and Continental models: Open the
clamps from the LPG tank straps and remove
the LPG tank from the machine (if equipped).
3 Models with hydraulic tank shut-off valves:
Locate the two hydraulic tank valves at the
hydraulic tank through the access hole
underneath the turntable. Close the valves.
4 Place a suitable container underneath the
hydraulic tank.
Part No. 88619
Section 3 • Scheduled Maintenance Procedures
5 Remove the drain plug from the hydraulic tank
and completely drain the tank into a suitable
container. Refer to Section 2, Specifications.
6 Tag, disconnect and plug the two suction hoses
and supply hose for the auxiliary pump from the
hydraulic tank. Cap the fittings on the tank.
Note: The hoses can be accessed through the
access hole under the turntable.
7 Tag, disconnect and plug the return filter
hydraulic hose at the return filter. Cap the fitting
on the filter housing.
8 Remove the ground controls side turntable
cover.
9 Support the hydraulic tank with an appropriate
lifting device.
10 Remove the hydraulic tank mounting fasteners.
11 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulic
tank could become unbalanced
and fall if not properly supported
when removed from the machine.
12 Remove the hydraulic return filter housing
mounting fasteners. Remove the hydraulic
return filter housing from the hydraulic tank.
13 Remove the suction strainers from the tank and
clean them using a mild solvent.
14 Rinse out the inside of the tank using a mild
solvent.
Z-80/60 3 - 61
Section 3 • Scheduled Maintenance Procedures June 2011

CHECKLIST E PROCEDURES REV D

15 Install the suction strainers using a thread 24 Prime the pump. Refer to Repair Procedure
sealant on the threads. 7-2, How to Prime the Pump.
16 Install the drain plug using a thread sealant on Note: Always use pipe thread sealant when
the threads. installing the suction hose fittings and the drain
plug.
17 Install the hydraulic return filter housing onto the
hydraulic tank. Component damage hazard. The
18 Install the hydraulic tank onto the machine. engine must not be started with
the hydraulic tank shut-off valves
19 Install the two suction hoses to the suction in the closed position or
strainers. component damage will occur. If
the tank valves are closed,
20 Install the supply hose for the auxiliary power
remove the key from the key
unit and the return filter hose.
switch and tag the machine to
Models with hydraulic tank shut-off valves: inform personnel of the condition.
21 Open the two hydraulic tank valves at the
hydraulic tank.
22 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.
23 Clean up any oil that may have spilled.

open closed

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

June 2011
REV D
E-2
Grease the Steer Axle
Wheel Bearings, 2WD Models
Genie specifications require that this procedure be
performed every 2000 hours or 2 years, whichever
comes first.
Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and pressure
washing of the machine may require that this
procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steer wheels, then center a lifting
jack with a minimum capacity of
25,000 lbs / 12000 kg under the drive chassis
between the steer wheels.
3 Raise the machine 6 inches / 15 cm Place
blocks under the drive chassis for support.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
Part No. 88619 Z-80/60
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
Skip to step 10 if there is no movement.
6 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to
seat the bearings.
Note: Rotate the hub by hand while torqueing the
castle nut to make sure the bearings seat properly.
8 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
9 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: If there is no side to side or up and
down movement, continue to step 11 and
grease the wheel bearings.
Result: If there is side to side or up and down
movement, continue to step 11 and replace the
wheel bearings with new ones.
Note: When replacing a wheel bearing, both the
inner and outer bearings, including the pressed-in
races, must be replaced.
10 Remove the dust cap from the hub. Remove the
cotter pin from the castle nut.
11 Remove the castle nut.
12 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
13 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
rear bearing.
3 - 63
Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
14 Pack both bearings with clean, fresh grease.
15 Place the large inner bearing into the rear of the
hub.
16 Install a new bearing grease seal into the hub
by pressing it evenly into the hub until it is flush.
Note: Always replace the bearing grease seal
when removing the hub.
17 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to the lip of the seal may
occur.
18 Place the outer bearing into the hub.
19 Install the washer and castle nut.
20 Tighten the slotted nut to 158 ft-lbs / 214 Nm to
seat the bearings.
21 Loosen the castle nut one full turn and then
torque to 35 ft-lbs / 47 Nm.
22 Install a new cotter pin. Bend the cotter pin
to lock it in.
23 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
3 - 64
June 2011
REV D
E-3
Perform Engine Maintenance
Engine specifications require that this procedure
be performed every 2000 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Deutz Models:
Required maintenance procedures and additional
engine information are available in the
Deutz 913 Operation Manual
(Deutz part number 0297 7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Deutz TD2011 Operation Manual
(Deutz part number 0312 3547)..
Deutz 913 Operation Manual
Genie part number 62446
Deutz BF4L2011 Operation Manual
Genie part number 84794
Deutz TD2011 Operation Manual
Genie part number 139320
Z-80/60 Part No. 88619
June 2011 Section 3 • Scheduled Maintenance Procedures

REV D CHECKLIST E PROCEDURES

Perkins Models: E-4

Required maintenance procedures and additional Perform Engine Maintenance -
engine information are available in the Ford Models
Perkins 704-30 User's Handbook
(Perkins part number TPD 1336E) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Perkins 804D Operation and Maintenance Engine specifications require that this procedure
Manual (Perkins part number SEBU8324-00). be performed every 2400 hours.

Proper engine maintenance, following the engine

Perkins 704-30 User's Handbook manufacturer's maintenance schedule, is essential
Genie part number 101840 to good engine performance and service life.
Failure to perform the maintenance procedures
Perkins 804C-33 Operation and Maintenance Manual can lead to poor engine performance and
Genie part number 111332
component damage.
Perkins 804D-33 Operation and Maintenance Manual Ford Models
Genie part number 228841
Required maintenance procedures and additional
engine information are available in the
Ford Models: Ford LRG-425 EFI Operator Handbook
(Ford part number FPP 194-302).
Required maintenance procedures and additional
engine information are available in the
Ford LRG-425 EFI Operator Handbook
Ford LRG-425 EFI Operator Handbook Genie part number 84792
(Ford part number FPP 194-302).

Ford LRG-425 EFI Operator Handbook To access the engine:

Genie part number 84792
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
To access the engine: tray out and away from the machine.

1 Remove the engine tray retaining fastener 2 Install the fastener that was just removed
located under the engine tray. Swing the engine through the engine tray and into the engine tray
tray out and away from the machine. anchor hole in the turntable.

2 Install the fastener that was just removed Crushing hazard. Failure to install
through the engine tray and into the engine tray the fastener into the engine tray
anchor hole in the turntable. anchor hole to secure the engine
tray from moving could result in
Crushing hazard. Failure to install death or serious injury.
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.

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

Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-5
Perform Engine Maintenance -
Deutz and Perkins Models
Engine specifications require that this procedure
be performed every 3000 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Deutz Models:
Required maintenance procedures and additional
engine information are available in the
Deutz 913 Operation Manual
(Deutz part number 0297 7341) OR the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Deutz TD2011 Operation Manual
(Deutz part number 0312 3547)..
Deutz 913 Operation Manual
Genie part number 62446
Deutz BF4L2011 Operation Manual
Genie part number 84794
Deutz TD2011 Operation Manual
Genie part number 139320
3 - 66
June 2011
REV D
Perkins Models:
Required maintenance procedures and additional
engine information are available in the
Perkins 704-30 User's Handbook
(Perkins part number TPD 1336E) OR the
Perkins 804C-33 Operation and Maintenance
Manual (Perkins part number SEBU7853-00) OR
the Perkins 804D Operation and Maintenance
Manual (Perkins part number SEBU8324-00).
Perkins 704-30 User's Handbook
Genie part number 101840
Perkins 804C-33 Operation and Maintenance Manual
Genie part number 111332
Perkins 804D-33 Operation and Maintenance Manual
Genie part number 228841
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Z-80/60 Part No. 88619
June 2011 Section 3 • Scheduled Maintenance Procedures

REV D CHECKLIST E PROCEDURES

E-6 To access the engine:

Perform Engine Maintenance - 1 Remove the engine tray retaining fastener
Deutz 2011 Models located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
Engine specifications require that this procedure anchor hole in the turntable.
be performed every 5000 hours. Crushing hazard. Failure to install
Proper engine maintenance, following the engine the fastener into the engine tray
manufacturer's maintenance schedule, is essential anchor hole to secure the engine
to good engine performance and service life. tray from moving could result in
Failure to perform the maintenance procedures death or serious injury.
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Deutz TD2011 Operation Manual
(Deutz part number 0312 3547).

Deutz BF4L2011 Operation Manual

Genie part number 84794

Deutz TD2011 Operation Manual

Genie part number 139320

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

Section 3 • Scheduled Maintenance Procedures
CHECKLIST E PROCEDURES
E-7
Perform Engine Maintenance -
Deutz 2011 Models
Engine specifications require that this procedure
be performed every 6000 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929) OR the
Deutz TD2011 Operation Manual
(Deutz part number 0312 3547).
Deutz BF4L2011 Operation Manual
Genie part number 84794
Deutz TD2011 Operation Manual
Genie part number 139320
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
3 - 68
June 2011
REV D
E-8
Perform Engine Maintenance -
Deutz BF4L2011 Models
Engine specifications require that this procedure
be performed every 12000 hours.
Proper engine maintenance, following the engine
manufacturer's maintenance schedule, is essential
to good engine performance and service life.
Failure to perform the maintenance procedures
can lead to poor engine performance and
component damage.
Required maintenance procedures and additional
engine information are available in the
Deutz BF4L2011 Operation Manual
(Deutz part number 0297 9929).
Deutz BF4L2011 Operation Manual
Genie part number 84794
To access the engine:
1 Remove the engine tray retaining fastener
located under the engine tray. Swing the engine
tray out and away from the machine.
2 Install the fastener that was just removed
through the engine tray and into the engine tray
anchor hole in the turntable.
Crushing hazard. Failure to install
the fastener into the engine tray
anchor hole to secure the engine
tray from moving could result in
death or serious injury.
Z-80/60 Part No. 88619
June 2011
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of this
machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the
Operator’s Manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.
Use only Genie approved replacement parts.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Machine parked on a firm, level surface
· Boom in the 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
· Wheels chocked
· All external AC power supply disconnected
from the machine
Part No. 88619
Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Perform disassembly procedures to the point
where repairs can be completed. To re-assemble,
perform the disassembly steps in reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
With safety alert symbol—used to
indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Note: Used to indicate operation or maintenance
information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
Z-80/60 4-1
Section 4 • Repair Procedures June 2011

Display Module REV E

This table lists the various screens and menu options of the operating software. Some display menus are
for informational purpose only, while others can be used to change the machine operating parameters. The
key switch must be in the off position before entering the programming mode.
Always exit the programming mode before turning the red Emergency Stop button to the off position.

Screen To Enter Information Displayed Range

Power on, Boom Type(Z80,4WS,ETC.), Engine
configuration Type, Software Version
message
Operator Default Hour meter (On power up)
Engine Speed &
Engine Oil Pressure PSI (English) &
Engine Oil Pressure kPa (metric) &
Engine Temperature F (English) @ Engine temperature is not
Engine Temperature C (metric) @ displayed until engine is
above 100°F / 38°C
Primary Boom Angle Sensor
TT Level Sensor X
TT Level Sensor Y
Platform Angle
Battery Volts
Status With the key Hydraulic Pressure PSI 0-4500 PSI
switch on, Hydraulic Pressure kPa 0-31000 kPa
press the
and Primary Boom Zone <=0 DEG, >0 DEG, =65
DEG
at the same Primary Boom Length
time = 0’, >0’, >22’
Secondary Boom Length
Secondary Boom Angle = 0 FT, > 0 FT
= 0 DEG, .>0 DEG, = 65
DEG

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

June 2011 Section 4 • Repair Procedures

REV E DISPLAY MODULE

Screen To Enter Information Displayed Range

Unit/ With the key Metric/English (measurement units) Use +/- buttons to change
Language switch off,
Display Language English, German, French,
press and Spanish, Portuguese,
hold the Italian, Dutch, and
button and Swedish. Check new
turn the key translations. Check
switch to the
scrolling of messages in
on position. Spanish with more than 75
Release the
characters.
button
and press
.
Drive With the key Forward Not Stowed Drive Speed pct 120% (default) 50% min
Functions switch off, Forward Low Drive Speed pct 120% (default) 50% min
press and
hold the Forward High Drive Speed pct 120% max and 50% min,
button and 100%(default)
turn the key Reverse Not Stowed Drive Speed pct 120% max and 50% min,
switch to the 100% (default)
on position.
Release Reverse Low Drive Speed pct 120% max and 50% min,
the button 100% (default)
and press Reverse High Drive Speed pct 120% max and 50% min,
. 100% (default)
Drive Accel pct 125% max and 25% min,
100% (default)
Drive Decel pct 125% max and 25% min,
100% (default)
Speed limit on steer angle 100% max and 0% min,
75% (default)

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

Section 4 • Repair Procedures June 2011

DISPLAY MODULE REV E

Screen To Enter Information Displayed Range

Boom With the key Primary Boom Up speed Stowed
Functions switch off,
Speeds press and Primary Boom Up speed not Stowed
hold the
button and
turn the key Primary Boom Down speed Stowed
switch to the
on position. Primary Boom Down speed not Stowed
Release the
button
and press Primary Boom Extend Speed
. 100% (default)
Primary Boom Retract Speed
Secondary Boom Up Speed Stowed
Secondary Boom Up Speed Not Stowed 120% max and 50% min,
100% (default)
Secondary Boom Down Speed Stowed
Secondary Boom Down Speed Not
Stowed
Secondary Boom Ext Speed
Secondary Boom Ret Speed
TT-Rotate speed Retracted
TT-Rotate speed Not Retracted
Jib 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,
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 75% min,
100% (default)

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

June 2011 Section 4 • Repair Procedures

REV E DISPLAY MODULE

Screen To Enter Information Displayed Range

Lift With the key Primary Boom Up/Down ramp accel % 150% max and 50% min,
Functions switch off, 100% (default) 5%
Ramps press and Primary Boom Up/Down ramp decel % increment
hold the
150% max and 50% min,
button and 100% (default) 5%
turn the key Primary Boom Extend/Retract ramp
accel % increment
switch to the
on position. 150% max and 50% min,
Release the 100% (default) 5%
Primary Boom Extend/Retract ramp
button decel % increment
and press 150% max and 50% min,
. 100% (default) 5%
Secondary Boom ramp accel %
increment

Secondary Boom ramp decel % 150% max and 50% min,

100% (default) 5%
increment
TT-Rotate ramp accel %
150% max and 50% min,
100% (default) 5%
TT-Rotate ramp decel % increment
150% max and 50% min,
Jib Up/Down ramp decel % 100% (default) 5%
increment
150% max and 50% min,
100% (default) 5%
increment
150% max and 50% min,
100% (default) 5%
increment

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

Section 4 • Repair Procedures June 2011

DISPLAY MODULE REV E

Screen To Enter Information Displayed Range

Valve With the key Reset Drive valve defaults (YES/NO)
calibration switch off, Reset Primary Boom Up/Down valve
press and defaults (YES/NO)
hold the
button and Reset Primary Boom Ext/Ret defaults
turn the key (YES/NO)
switch to the Reset Secondary Boom valve defaults
on position. (YES/NO)
Release the
button Reset TT Rotate valve defaults (YES/NO)
and press Allow Primary Boom Up/Down speed
. calibration (YES/NO)
Allow Primary Boom Ext/Ret speed
calibration (YES/NO)
Allow Secondary Boom Up/Down speed
calibration (YES/NO)
Allow TT Rotate speed calibration
(YES/NO)
Reset Drive joystick defaults (YES/NO)
Reset Pri. Boom Up/Down joystick
defaults (YES/NO)
Reset Pri. Boom Ext/Ret joystick defaults
(YES/NO)
Reset Secondary Boom joystick defaults
(YES/NO)
Reset TT Rotate joystick defaults
(YES/NO)
Reset Steer joystick defaults (YES/NO)

4-6 Z-80/60 Part No. 88619

June 2011 Section 4 • Repair Procedures

REV E DISPLAY MODULE

Screen To Enter Information Displayed Range

Sensor With the key Set Unit levels to gravity
calibration switch off,
Unit Level Y-axis Millivolts per degree
press and
hold the Unit Level X-axis Millivolts per degree
button and Set Platform level to gravity
turn the key
switch to the Platform Level Sensor Millivolts per
on position. degree
Release the Reset Blue End Blue Side Steer Sensor
button (YES/NO)
and press
. 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 = 40deg (YES/NO)
Primary Boom angle = 70deg (YES/NO)
Default With the key Reset Drive Functions (YES/NO)
Reset switch off,
Reset Boom Function Speeds (YES/NO)
press and
hold the Reset Lift Function Ramps (YES/NO)
button and Reset All (Machine Require Calibration)
turn the key (YES/NO)
switch to the
on position. Clear All Safety Switch Faults (YES/NO)
Release the
button
and press
.

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

Section 4 • Repair Procedures June 2011

DISPLAY MODULE REV E

Screen To Enter Information Displayed Range

Options With the key Boom Length Limit: No Limit (NO LT),
switch off, Secondary Extend disabled (EXT LT),
press and Secondary Function disabled (SEC LT)
hold the AC Generator Options: (NONE, BELT,
button and HI_LO, HYDRL, GHG10)
turn the key
switch to the
on position. Alarm: No, Motion (MO AL), Travel (TR
Release AL), Descent (DE AL), Travel and Decent
the button (TD AL)
and press
. Lift/Drive OPT: No (NO CO), Drive cut out
while not stowed (DCONS), Lifting or
Driving (LORDR)
Aux Drive OPT: (YES/NO)
Proximity Kill Switch (NONE/PROX)
Platform Overload (NONE PLFTS)
Work Light: (YES/NO)
Flashing Beacon: (YES/NO)
Drive Lights: (YES/NO)
30.0 max and 0.0 min, 10.0
Disable Steer Mode Change while (default)
Driving: (YES/NO)
0 to 30 minutes
Rocker Joystick Steering (YES/NO) 0 to 10 minutes, 10 is the
Chassis Tilt Cutout (YES/NO) default Only shown when
Hydraulic gen is selected.
Holding + or - button will
Foot Switch Lockout 0 to 30 minutes cause display to scroll
through options or
increment number settings
automatically. 0.2 min
inc/dec

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Platform Controls
The platform controls contains two a
printed circuit boards:
b
The LED circuit board is mounted to the underside
of the control box lid which contains the LED's. The
LED circuit board sends the input from the operator
to the platform controls ECM circuit board (PCON). c
The ECM circuit board (PCON) sends the data to
the turntable control box (TCON) for processing. f d

The platform controls ECM circuit board

(ALC-1000) communicates with the turntable
controls. The joystick controllers at the platform
controls utilize Hall Effect technology and require
e
no adjustment. The operating parameters of the
joysticks are stored in memory at the turntable
controls. If a joystick controller error occurs or if a a platform controls ALC-1000
joystick is replaced, it will need to be calibrated circuit board
before that particular machine function will operate. b primary boom extend/retract
joystick
See 1-3, How to Calibrate a Joystick. c secondary boom up/extend and
down/retract joystick
Each joystick controller should operate smoothly d drive/steer joystick controller
and provide proportional speed control over its e LED circuit board
entire range of motion. f primary boom up/down and
turntable rotate left/right joystick

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

screw inside the platform control box.
ALC-1000 Circuit Board Electrocution hazard. Contact with
electrically charged circuits could
Note: When the ALC-1000 circuit board is replaced, result in death or serious injury.
the joystick controllers will need to be calibrated. Remove all rings, watches and
See 1-3, How to Calibrate a Joystick. other jewelry.

How to Remove the ALC-1000 Component damage hazard.

Circuit Board
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Locate the cables that connect to the bottom of
the control box. Tag each cable and its location
at the control box.
3 Tag and disconnect the cables from the bottom
of the platform control box.
4 Remove the control cable plug retaining
fasteners from the bottom of the platform
control box.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
8 Carefully disconnect the wire connectors from
the circuit board.
9 Remove the ALC-1000 circuit board mounting
fasteners.
10 Carefully remove the ALC-1000 circuit board
from the platform control box.

5 Remove the platform control box lid retaining
fasteners. Open the control box lid.
6 Locate the ALC-1000 circuit board mounted to
the inside of the platform control box.
How to Remove the LED
Circuit Board
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.

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3 Locate the LED circuit board mounted to the 1-2

inside of the platform control box lid.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
4 Carefully tag and disconnect the two ribbon
cables from the membrane circuit board.
5 Remove the LED circuit board retaining
fasteners.
6 Carefully remove the LED circuit board from the
platform control box lid.
Membrane Decal
How to Replace the Membrane
Decal
The membrane decal is a special decal that
consists of a decal with an electronic membrane
on the backside. The membrane contains touch
sensitive areas that, when pushed, activates the
machine functions. The membrane buttons
activate machine functions similar to toggle
switches, but do not have any moving parts.
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
3 Carefully tag and disconnect the two ribbon
cables from the membrane circuit board.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.

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4 Close the control box lid. 1-3

5 Remove the platform controls decal from the
platform control box.
6 Carefully remove the membrane decal from the
platform control box while guiding the ribbon
cables out of the control box lid.
7 Remove any decal adhesive from the control
box lid with a mild solvent.
Note: Do not allow any solvent to come in contact
with the membrane circuit board.
8 Install the new membrane decal while guiding
the ribbon cables through the control box lid.
Note: Be sure that all LED locations on the
membrane decal align with the LEDs on the
membrane circuit board.
9 Install a new platform controls decal over the
membrane decal.
Joysticks
How to Calibrate a Joystick
The joystick controllers on this machine utilize
digital Hall Effect technology for proportional
control. If a joystick controller is disconnected or
replaced, it must be calibrated before that
particular machine function will operate.
Note: The joystick must be calibrated before the
threshold, max-out or ramping can be set.
Note: After each joystick is calibrated, check the
display at the ground control box. There should be
no calibration faults shown on the display. If
calibration faults exist, repeat steps 1 through 8 for
that joystick controlled function.
Note: Perform this procedure with the engine off.

10 Open the control box lid and carefully connect
the ribbon cables from the membrane decal to
the membrane circuit board.
Drive functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on the
ground control panel while turning the key
switch to platform controls.

3 Press the minus button twice, then press the

enter button twice.

4 Use the scroll button to scroll through the

menu until RESET DRIVE JOYSTICK DEFAULTS is
displayed. Press the button to select YES,
then press the button.

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5 Do not start the engine.
6 Locate the drive/steer joystick.
7 Move the drive/steer joystick full stroke in the
forward direction and hold for 5 seconds, then
return to the center or neutral position.
8 Move the drive/steer joystick full stroke in the
reverse direction and hold for 5 seconds, then
return to the center or neutral position.
Result: The alarm at the ground controls should
sound for a successful calibration.
Steer functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on the
ground control panel while turning the key
switch to platform controls.
8 Move the drive/steer joystick or thumb rocker
switch (if equipped) full stroke in the right
direction and hold for 5 seconds, then return to
the center or neutral position.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: If the alarm does not sound, repeat
calibration procedure.
Primary boom extend/retract functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on the
ground control panel while turning the key
switch to platform controls.
3 Press the minus button twice, then press the
enter button twice.

3 Press the minus button twice, then press the 4 Use the scroll button to scroll through the
enter button twice. menu until RESET PRIMARY BOOM EXTEND/RETRACT
JOYSTICK DEFAULTS is displayed. Press the
4 Use the scroll button to scroll through the
button to select YES, then press the button.
menu until RESET STEER JOYSTICK DEFAULTS is
displayed. Press the button to select YES, 5 Do not start the engine.
then press the button. 6 Locate the primary boom extend/retract
joystick.
5 Do not start the engine.
7 Move the primary boom extend/retract joystick
6 Locate the drive/steer joystick.
full stroke in the extend direction and hold for 5
7 Move the drive/steer joystick or thumb rocker seconds, then return to the center or neutral
switch (if equipped) full stroke in the left position.
direction and hold for 5 seconds, then return to
the center or neutral position.

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8 Move the primary boom extend/retract joystick
full stroke in the retract direction and hold for 5
seconds, then return to the center or neutral
position.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: If the alarm does not sound, repeat
calibration procedure.
Secondary boom up/down and
extend/retract functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on the
ground control panel while turning the key
switch to platform controls.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through the
menu until RESET SECONDARY BOOM JOYSTICK
DEFAULTS is displayed. Press the button to
select YES, then press the button.
5 Do not start the engine.
6 Locate the secondary boom up/down and
extend/retract joystick.
7 Move the secondary boom up/down and
extend/retract joystick full stroke in the up/
extend direction and hold for 5 seconds, then
return to the center or neutral position.
8 Move the secondary boom up/down and extend/
retract joystick full stroke in the down/retract
direction and hold for 5 seconds, then return to
the center or neutral position.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: If the alarm does not sound, repeat
calibration procedure.
Primary boom up/down functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on the
ground control panel while turning the key
switch to platform controls.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through the
menu until RESET PRIMARY BOOM UP/DOWN JOYSTICK
DEFAULTS is displayed. Press the button to
select YES, then press the button.
5 Do not start the engine.
6 Locate the primary boom/turntable rotate
joystick.
7 Move the boom/turntable rotate joystick full
stroke in the up direction and hold for 5
seconds, then return to the center or neutral
position.

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8 Move the boom/turntable rotate joystick full How to Reset a Proportional

stroke in the down direction and hold for 5
seconds, then return to the center or neutral Valve Coil Default
position. Note: This procedure only needs to be performed if
Result: The alarm at the ground controls should a proportional valve has been replaced.
sound for a successful calibration.
Note: After the valve coil defaults have been set,
Result: If the alarm does not sound, repeat each machine function threshold and default
calibration procedure. function speed must be set. See How to Set the
Function Thresholds and Default Function Speeds.
Turntable rotate functions:
1 Turn the key switch to the off position.
1 Turn the key switch to the off position.
2 Press and hold the enter button on the
2 Press and hold the enter button on the
ground control panel while turning the key
ground control panel while turning the key switch to platform controls.
switch to platform controls.
3 Press the minus button twice, then press the
3 Press the minus button twice, then press the
enter button twice.
enter button twice.
4 Use the scroll button to scroll through the
4 Use the scroll button to scroll through the
menu until the function valve that needs to be
menu until RESET TURNTABLE ROTATE LEFT/RIGHT
reset is displayed. Press the button to select
JOYSTICK DEFAULTS is displayed. Press the
YES, then press the button.
button to select YES, then press the button.
5 Do not start the engine.
6 Locate the primary boom/turntable rotate
joystick.
7 Move the boom/turntable joystick full stroke in
the left direction and hold for 5 seconds, then
return to the center or neutral position.
8 Move the boom/turntable joystick full stroke in
the right direction and hold for 5 seconds, then
return to the center or neutral position.
Result: The alarm at the ground controls should
sound for a successful calibration.
Result: If the alarm does not sound, repeat
calibration procedure.

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PLATFORM CONTROLS
How to Set the Function
Thresholds and Default
Functions Speeds
Note: Before the threshold and default function
speeds can be set, the boom function proportional
valve coil defaults must be set first.
See How to Reset a Proportional Valve Coil
Default.
Note: If a boom function proportional valve coil has
not been replaced and just want to reset the
function speed to original factory settings, begin
with step 10.
Note: Perform this procedure with the machine
parked on a firm, level surface which is free of
obstructions.
1 Start the engine from the platform controls.
2 Press down the foot switch.
Note: Be sure the engine rpm is set to foot switch
activated high idle.
Function threshold:
3 Select a joystick controlled function that needs
to have the threshold set.
4 Slowly move the joystick off center in either
direction just until the machine function starts to
move, then move the joystick very slowly
towards the neutral or center position just
before the machine function stops.
Do not let go of the joystick.
5 While holding the joystick in position, press the
engine start button at the platform controls
to set the joystick controller threshold.
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6 Repeat steps 3 through 5 for each joystick
controlled machine function (primary boom up/
down and turntable rotate left/right, primary
boom extend/retract, secondary up/down and
extend/retract, drive forward/reverse and steer
left/right).
7 Once the threshold has been set, press and hold
the engine start button until the engine shuts
off. Do not press the red Emergency Stop
button.
Note: Approximately 3 seconds after the engine
shuts off, the alarm at the ground controls will
sound to indicate the threshold settings are being
saved in memory. Release the button.
8 At the ground controls, turn the key switch to
the off position, wait a moment and then turn
the key switch to platform controls.
9 Check the display at the ground controls to be
sure there are no calibration faults.
Result: There should be no calibration faults
shown on the display. If calibration faults exist,
repeat this procedure.
Function speeds:
Note: Be sure the machine is in the stowed
position and the platform is rotated between the
round end tires.
10 Start the engine from the platform controls.
11 Select a boom function that needs the function
speed set.
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12 Boom up/down functions: Move the joystick How to Adjust the Function
full stroke in the up direction. When the alarm
sounds, move the joystick in the opposite Speeds
direction full stroke until the alarm sounds Note: Perform this procedure with the boom in the
again. Return the joystick to center. stowed position. Refer to Section 2, Specifications.
Boom extend/retract functions: Raise the
1 Pull out the red Emergency Stop button to the
primary boom until it no longer rests on the
on position at both the ground and platform
boom cradle. Then move the joystick full stroke
controls.
in the extend direction. When the alarm sounds,
move the joystick in the opposite direction full 2 Press and hold the enter button on the
stroke until the alarm sounds again. Return the ground control panel while turning the key
joystick to center. switch to ground controls.
Turntable rotate functions: Raise the primary
3 Press the plus button twice, then press the
boom until it no longer rests on the boom cradle.
Move the joystick full stroke in either the left or minus button twice.
right direction until a drive enable zone is
4 Press the scroll button until the function to
reached. Move the joystick in the opposite
direction full stroke until the alarm sounds. Now be adjusted is displayed.
move the joystick in the opposite direction full 5 Press the plus button to increase the speed
stroke until the alarm sounds again. Return the
joystick to center. or press the minus button to decrease the
speed.
13 Once the function speeds have been set, press
and hold the engine start button until the 6 Press the enter button to save the setting in
engine shuts off. Do not press the red memory.
Emergency Stop button. 7 Perform this procedure until the machine
Note: Approximately 3 seconds after the engine function speed meets specification.
shuts off, the alarm at the ground controls will
sound to indicate the speed settings are being
saved in memory. Release the button.

14 At the ground controls, turn the key switch to

the off position, wait three seconds and then
turn the key switch to platform controls.
15 Inspect the display at the ground controls to be
sure there are no calibration faults.
Note: There should be no calibration faults shown
on the display. If calibration faults exist, repeat this
procedure.

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How to Adjust the Function Ramp Rate

Ramp Rate Setting Specifications
The ramp rate setting of a joystick controls the time
at which it takes for the joystick to reach maximum Ramp rate (factory settings)
output, when moved out of the neutral position. Turntable rotate
The ramp rate settings of a joystick can be accelerate 4 seconds
changed to compensate for hydraulic pump wear decelerate 1.0 second
to maintain peak performance from the machine.
Refer to Section 2, Specifications. Primary boom up/down
accelerate 3 seconds
Note: Perform this procedure with the boom in the decelerate 0.25 second
stowed position.
Primary boom extend/retract
1 Pull out the red Emergency Stop button to the accelerate 3 seconds
decelerate 0.75 second
on position at both the ground and platform
controls. Secondary boom up/down
accelerate 7 seconds
2 Press and hold the enter button on the decelerate 0.75 second
ground control panel while turning the key
switch to ground controls. Secondary boom extend/retract
accelerate 7 seconds
3 Press the plus button twice, then press the decelerate 0.75 second
scroll button twice. Drive
accelerate 1.5 seconds
4 Press the scroll button until the function to decelerate to neutral 0.5 second
be adjusted is displayed. decelerate, change of direction 0.5 second
decelerate, coasting 0.75 second
5 Press the plus button to increase the ramp decelerate, braking 2 seconds
rate or press the minus button to decrease decelerate, shift from low to high speed 1 second
the ramp rate. decelerate, shift from high to low speed 4 seconds

6 Press the enter button to save the setting in

memory.
7 Perform this procedure until the machine
function speed meets specification.

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Platform Components
2-1 2-2
Platform Platform Leveling Cylinder

How to Remove the Platform
1 Separate the foot switch quick disconnect plug.
2 Support the platform with an appropriate lifting
device.
3 Locate the cables that connect to the bottom of
the control box. Number each cable and its
location at the platform control box.
4 Disconnect the cables from the bottom of the
platform control box.
5 Remove the platform control box mounting
fasteners. Remove the platform control box and
set it aside.
6 Remove the air line to platform bracket retaining
fasteners (if equipped).
7 Remove the weld cables from the platform
(if equipped).
8 Remove the platform mounting fasteners and
remove the platform from the machine.
Crushing hazard. The platform
could become unbalanced and fall
when it is removed from the
machine if it is not properly
supported.
The platform leveling cylinder maintains platform
leveling through the entire range of boom motion.
This allows the platform to be level with the
turntable. The ECM at the ground controls
compares the difference in readings between the
platform angle sensor and the turntable level
sensor. The ECM at the ground controls sends a
signal to the platform controls to open or close the
appropriate platform level proportional valve on the
platform manifold to maintain a level platform. The
platform leveling cylinder is equipped with
counterbalance valves to prevent movement in the
event of a hydraulic line failure.
How to Remove the Platform
Leveling Cylinder
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Extend the boom until the platform leveling
cylinder barrel-end pivot pin is accessible.
2 Raise the jib boom slightly and place blocks
under the platform.

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PLATFORM COMPONENTS
3 Lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
4 Tag, disconnect and plug the hydraulic hoses
from the platform leveling cylinder at the
bulkhead fittings located inside the boom tube
at the platform end. Cap the bulkhead fittings
on the boom tube.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
5 Remove the pin retaining fasteners from
the 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 the
jib boom with a strap or other suitable device.
Protect the cylinder rod from damage.
Crushing hazard. The jib boom
cylinder will fall if not properly
supported when the platform level
cylinder rod-end pivot pin is
removed.
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8 Use a soft metal drift to remove the barrel-end
pivot pin.
Crushing hazard. The platform
and jib boom will fall when the
platform leveling cylinder barrel-
end pivot pin is removed if not
properly supported.
9 Support the rod end of the platform level
cylinder.
10 Use a soft metal drift to tap the platform level
cylinder rod-end pivot pin half way out and
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
11 Use a soft metal drift to remove the platform
level cylinder rod-end pivot pin.
12 Carefully pull the platform leveling cylinder out
of the boom.
Crushing hazard. The jib boom
cylinder will fall if not properly
supported when the platform level
cylinder rod-end pivot pin is
removed.
How to Bleed the Platform
Leveling Cylinder
Note: Do not start the engine. Use auxiliary power
for all machine functions in this procedure.
1 Raise the jib boom to a horizontal position.
2 Push the platform level up and down buttons
through two complete platform leveling cycles
to remove any air that might be in the system.
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2-3
Platform Rotator
The platform rotator is a hydraulically activated
helical gear assembly used to rotate the platform
160 degrees.
How to Remove the
Platform Rotator
Component damage hazard. Mark
the platform mounting weldment
and the rotator flange before
removing the platform mounting
weldment. The platform mounting
weldment must be replaced in the
exact same position on the rotator
flange as it was before removal. If
a new rotator is installed or the
rotator is disassembled, proper
alignment can be achieved by
rotating the rotator all the way to
the left and then installing the
platform mounting weldment all
the way in the left position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation.
Refer to Section 2, Hydraulic Hose and Fitting
Torque Specifications.
1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Disconnect the wire harness from the platform
angle sensor.
Part No. 88619
Section 4 • Repair Procedures
PLATFORM COMPONENTS
3 Tag, disconnect and plug the hydraulic hoses
from the platform rotator manifold. Cap the
fittings on the manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
4 Remove the hose and cable clamp from the
platform support.
5 Remove the platform manifold mounting
fasteners. Lay the platform manifold to the side.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.
6 Remove the power to platform electrical outlet
box bracket mounting fasteners.
7 Remove the power to platform electrical outlet
box from the platform and lay it to the side.
8 Remove the weld cable from the platform
(if equipped).
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
9 Support the platform mounting weldment. Do
not apply any lifting pressure.
10 Remove the eight mounting bolts from the
platform mounting weldment.
11 Remove the center bolt and slide the platform
mounting weldment off of the platform rotator.
Crushing hazard. The platform
mounting weldment may become
unbalanced and fall if it is not
properly supported.
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Section 4 • Repair Procedures
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12 Support the platform rotator. Do not apply
any lifting pressure.
13 Remove the pin retaining fasteners from the jib
boom and jib boom leveling arms to platform
rotator pivot pins. Do not remove the pins.
14 Support the jib boom leveling arms with a
suitable lifting device.
15 Use a soft metal drift to remove both pins and
remove the platform rotator from the machine.
Crushing hazard. The jib boom
leveling arms may fall if they are
not properly supported when the
jib boom leveling arm pivot pin is
removed.
Component damage hazard. The
platform angle sensor is a very
sensitive instrument. It can be
damaged internally if the platform
rotator is dropped or sustains any
physical shock, even if the
damage is not visible.
How to Bleed the Platform
Rotator
Before serial number 229:
Note: Do not start the engine. Use auxiliary power
for all machine functions in this procedure.
1 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container
to collect any drainage. Secure the container to
the boom.
2 Move the platform rotate switch to the left and
then to the right through two platform rotation
cycles, continue holding the switch to the right
until the platform is fully rotated to the right.
4 - 22
June 2011
REV C
3 Open the top bleed valve, but do not remove it.
4 Move the platform rotate switch to the left until
the platform is fully rotated to the left. Continue
holding the switch until air stops coming out of
the bleed valve. Close the bleed valve.
Crushing hazard. Keep clear of
the platform during rotation.
5 Connect the clear hose to the bottom bleed
valve. Open the bottom bleed valve, but do not
remove it.
6 Hold the platform rotate switch to the right until
the platform is fully rotated to the right.
Continue holding the switch until air stops
coming out of the bleed valve. Close the bleed
valve.
Crushing hazard. Keep clear of
the platform during rotation.
7 Remove the hose from the bleed valve and
clean up any hydraulic oil that may have spilled.
8 Rotate the platform full right, then full left and
inspect the bleed valves for leaks.
After serial number 228:
1 Rotate the platform full right, then full left until
air is completely out of the rotator. Bleeding the
valve is not necessary.
Crushing hazard. Keep clear of
the platform during rotation.
Z-80/60 Part No. 88619
June 2011 Section 4 • Repair Procedures

REV C PLATFORM COMPONENTS

2-4 How to Calibrate the Platform

Platform Overload System
The platform overload system is designed to
prevent the machine from continuing to operate
when the load in the platform exceeds maximum
rated capacity. Refer to the machine serial label for
maximum capacity information.
If maximum platform capacity is exceeded, the
alarm will sound and the platform overload
indicator lights will flash at the platform control and
"PLATFORM OVERLOAD" will display on the LCD
screen at the ground control. The ground and
platform controls will become disabled. Before
normal machine operation can continue, the
excess load will need to be removed from the
platform.
If the excess load cannot be removed or if the
operator at the platform controls is unable to
correct the overloaded condition, another person at
the ground controls can operate the machine using
auxiliary power. There will be limited control of
boom functions from the ground controls when
using auxiliary power. Auxiliary power can be used
to correct the overloaded platform condition in
order to resume normal, safe operation of the
machine.
Overload System (if equipped)
Calibration of the platform overload system is
essential to safe machine operation. Continued
use of an improperly calibrated platform overload
system could result in the system failing to sense
an overloaded platform. The stability of the
machine is compromised and it could tip over.
Note: Perform this procedure with the machine on
a firm, level surface.
1 Turn the key switch to platform control. Start the
engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Remove all weight, tools and accessories from
the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform capacity
at the center of the platform floor.

Note: The engine must be turned off to use

auxiliary power.

Note: Software versions 1.03 and lower. All

ground control functions will not operate with
auxiliary control. Refer to Repair Procedure 6-1,
How to Determine the Revision Level.
Note: Recovery mode must be used. Refer to
Repair Procedure 6-1, Service Bypass / Recovery
Keyswitch.
Note: Software versions 1.04 and higher. All
ground control functions will operate from auxiliary
control. Refer to Repair Procedure 6-1, How to
Determine the Revision Level.

Part No. 88619 Z-80/60 4 - 23

Section 4 • Repair Procedures
PLATFORM COMPONENTS
5 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Proceed to step 6.
Result: The alarm is sounding. The platform
overload indicator light is flashing at the
platform controls and “PLATFORM
OVERLOAD” should is displayed on the LCD
screen at the ground controls. Slowly tighten
the load spring adjustment nut in a clockwise
direction in 10° increments until the overload
indicator light turns off, and the alarm does not
sound. Proceed to step 8.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
4 - 24
June 2011
REV C
6 Move the platform up and down by hand, so it
bounces approximately 2.5 to 5 cm / 1 to 2
inches. Allow the platform to settle.
Result: The alarm should be off. The platform
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Slowly loosen the load spring
adjustment nut in a counterclockwise direction
in 10° increments until the overload indicator
light flashes at both the platform and ground
controls, and the alarm sounds. Proceed to
step 7.
Result: The alarm should be sounding.
The platform overload indicator light should be
flashing at the platform controls and
“PLATFORM OVERLOAD” should be displayed
on the LCD screen at the ground controls.
Repeat this procedure beginning with step 5.
Note: The platform will need to be moved up and
down and allowed to settle between each
adjustment.
Note: There may be a 2 second delay before the
platform overload indicator lights and alarm
responds.
Z-80/60 Part No. 88619
June 2011 Section 4 • Repair Procedures

REV C PLATFORM COMPONENTS

7 Move the platform up and down by hand, so it 11 Test all machine functions from the ground
bounces approximately 2.5 to 5 cm / 1 to 2 controls.
inches. Allow the platform to settle.
Result: All ground control functions should not
Result: The alarm should be off. The platform operate.
overload indicator light should be off at the
12 Using a suitable lifting device, lift the test weight
platform controls and there should be no error
off the platform floor.
message on the LCD display at the ground
controls. Proceed to step 8. Result: The alarm should be off. The platform
overload indicator light should be off at the
Result: The overload indicator lights are
platform controls and there should be no error
flashing at the platform and ground controls,
message on the LCD display at the ground
and the alarm is sounding. Repeat this
controls.
procedure beginning with step 5.
Note: There may be a 2 second delay before the
Note: There may be a 2 second delay before the
overload indicator lights and alarm turn off.
platform overload indicator light and alarm
responds. 13 Test all machine functions from the ground
controls.
8 Add an additional 10 lb / 4.5 kg test weight to
the platform. Result: All ground control functions should
operate normally.
Result: The alarm should be sounding.
The platform overload indicator light should be 14 Turn the key switch to platform control.
flashing at the platform controls and
“PLATFORM OVERLOAD” should be displayed 15 Test all machine functions from the platform
on the LCD screen at the ground controls. controls.
Proceed to step 9. Result: All platform control functions should
Result: The alarm should be off. The platform operate normally.
overload indicator light should be off at the
platform controls and there should be no error
message on the LCD display at the ground
controls. Remove the additional 10 lb / 4.5 kg
test weight. Repeat this procedure beginning
with step 6.
Note: There may be a 2 second delay before the
platform overload indicator light and alarm
responds.
9 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
10 Turn the key switch to ground control.

Part No. 88619 Z-80/60 4 - 25

Section 4 • Repair Procedures June 2011

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REV C B
Jib Boom Components 1234567890123
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3-1
Jib Boom

How to Remove the Jib Boom a

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

Note: When removing a hose assembly or fitting,

the O-ring on the fitting and/or hose end must be
b
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and c
Fitting Torque Specifications.
h g f e d
1 Remove the platform mounting weldment
and the platform rotator. See 2-3, How to
a jib boom
Remove the Platform Rotator. b platform rotator upper pivot pin
c platform rotator lower pivot pin
2 Remove the hose and cable cover retaining d jib boom leveling arm
fasteners from the jib boom. Remove the hose e jib cylinder pivot pin
and cable cover from the machine. f jib boom cylinder
g primary boom lower pivot pin
3 Attach a lifting strap from an overhead crane to h primary boom upper pivot pin
the jib boom for support. Do not apply lifitng
pressure.
4 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

4 - 26 Z-80/60 Part No. 88619

June 2011
REV B
5 Support the barrel end of the jib boom cylinder
with another suitable lifting device.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
7 Use a soft metal drift to remove the pin and let
the cylinder hang down.
Crushing hazard. The jib boom
could become unbalanced and fall
if not properly supported when the
jib boom lift cylinder barrel-end
pivot pin is removed.
8 Secure the jib boom bellcrank to prevent it from
moving.
9 Remove the hose and cable clamp from the jib
boom pivot pin.
10 Remove the pin retaining fastener from the jib
boom pivot pin. Do not remove the pin.
11 Place blocks under the platform leveling
cylinder for support. Protect the cylinder from
damage.
12 Use a soft metal drift to remove the pin.
Carefully remove the jib boom from the primary
boom.
Crushing hazard. The jib boom
could become unbalanced and fall
if not properly supported when
removed from the machine.
Part No. 88619
Section 4 • Repair Procedures
JIB BOOM COMPONENTS
13 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
14 Slide both of the jib boom leveling arms off of
the jib boom cylinder rod-end pivot pin and lay
them off to the side.
15 Attach a lifting strap from an overhead crane to
the lug on the rod end of the jib boom lift
cylinder.
16 Attach a lifting strap from a second overhead
crane to the jib boom bellcrank.
17 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib boom
lift cylinder and jib boom bellcrank from the
machine.
Crushing hazard. The jib boom lift
cylinder and jib boom bellcrank
could become unbalanced and fall
if not properly supported when
they are removed from the
machine.
Crushing hazard. The platform
leveling cylinder may fall if not
supported when the rod-end pivot
pin is removed.
Z-80/60 4 - 27
Section 4 • Repair Procedures
JIB BOOM COMPONENTS
3-2
Jib Boom Lift Cylinder
How to Remove the Jib Boom
Lift Cylinder
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the jib boom slightly and place blocks
under the platform mounting weldment. Lower
the jib boom until the platform is resting on the
blocks just enough to support the platform.
Note: Do not rest the entire weight of the boom on
the blocks.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 - 28
June 2011
REV B
3 Remove the pin retaining fasteners from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out and
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
Crushing hazard. The jib boom lift
cylinder may fall if not supported
when the rod-end pivot pin is
removed.
5 Support the jib boom lift cylinder with a suitable
lifting device.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pivot
pin and let the cylinder hang down.
Crushing hazard. The platform
and jib boom lift cylinder could
become unbalanced and fall if not
properly supported when the jib
boom lift cylinder barrel-end lift
pivot pin is removed.
7 Place blocks under the platform leveling
cylinder for support. Protect the cylinder from
damage.
8 Use a soft metal drift to remove the jib boom lift
cylinder rod-end pivot pin. Remove the jib boom
lift cylinder from the machine.
Crushing hazard. The jib boom lift
cylinder could become unbalanced
and fall if not properly supported
when removed from the machine.
Z-80/60 Part No. 88619
June 2011
REV D
a b
m
h g
a primary boom lift cylinder link arm
b primary boom lift cylinder
c primary boom
d primary extension boom
e platform leveling cylinder
f upper turntable cover
g lower turntable cover
h secondary boom lift cylinder
i secondary boom
j secondary extension boom
k secondary boom hose cover
l primary boom lift cylinder lever arm
n o
w
v
u t
Part No. 88619
Section 4 • Repair Procedures
Boom Components
c d
f e
m primary boom hose cover
n primary boom link arm pivot pin
o primary lift cylinder pivot pin - rod end
p primary lift cylinder pivot pin - barrel end
q primary extend cylinder pivot pin - rod end
r platform level cylinder pivot pin - barrel end
s secondary boom pivot pin
t secondary lift cylinder pivot pin - barrel end
u secondary lift cylinder pivot pin - rod end
v secondary extend cylinder pivot pin - rod end
w secondary boom lever arm pivot pin
x primary boom pivot pin
y primary extend cylinder pivot pins - barrel end
p q r
s
Z-80/60 4 - 29
Section 4 • Repair Procedures
BOOM COMPONENTS
4-1
Primary Boom Cable Track
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses
that run through it. Removing the entire primary
boom cable track is only necessary when
performing major repairs that involve removing the
primary boom.
How to Remove the Cable Track
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Tag and disconnect the wire connectors from
the platform control box.
2 Tag, disconnect and plug the hydraulic hoses
from the counterbalance valve manifold located
on the platform rotator. Cap the fittings on the
manifold.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 - 30
June 2011
REV D
3 Remove the mounting fasteners from the power
to platform outlet box. Remove the outlet box
and lay to the side.
4 Remove the hose clamp from the platform
support.
5 Tag and disconnect the electrical connector
from the platform angle sensor.
Note: The platform angle sensor is mounted to the
platform rotator.
6 Tag and disconnect the electrical connectors for
the foot switch and jib boom limit switch.
7 Remove the platform manifold mounting
fasteners. Remove the manifold and lay to the
side.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
8 Remove the hose and cable cover retaining
fasteners from the jib boom. Remove the hose
and cable cover from the machine.
9 Remove the hose and cable clamp from the jib
boom pivot pin.
Crushing hazard. The jib boom
may fall if not supported when the
jib boom pivot pin is removed.
Z-80/60 Part No. 88619
June 2011 Section 4 • Repair Procedures

REV D BOOM COMPONENTS

10 Tag, disconnect and plug the slave cylinder 16 Support the end cover from the secondary boom
hydraulic hoses from the bulkhead fittings at the at the pivot end of the primary boom.
platform end of the primary boom. Cap the
17 Remove the cover retaining fasteners and
bulkhead fittings.
remove the cover from the machine.
Bodily injury hazard. Spraying
Crushing hazard. The secondary
hydraulic oil can penetrate and
boom hose cover could become
burn skin. Loosen hydraulic
unbalanced and fall if not properly
connections very slowly to allow
supported when removed from the
the oil pressure to dissipate
machine.
gradually. Do not allow oil to
squirt or spray. 18 Tag, disconnect and plug each hydraulic hose
from the bulkhead fittings that lead to the cable
11 Tag, disconnect and plug the jib boom cylinder
track. Cap the fittings.
hydraulic hoses. Cap the fittings.
Bodily injury hazard. Spraying
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
burn skin. Loosen hydraulic
connections very slowly to allow
connections very slowly to allow
the oil pressure to dissipate
the oil pressure to dissipate
gradually. Do not allow oil to
gradually. Do not allow oil to
squirt or spray.
squirt or spray.
19 Tag and disconnect each electrical connector to
12 Remove the cotter pin from the platform end of
wiring that leads to the cable track.
the cable track tube.
20 Pull all hoses and electrical cables through the
Note: Always replace the cotter pin with a new one
opening in the primary boom at the pivot end.
when installing the cable track.
21 Secure the upper and lower cable tracks
13 Remove the fasteners from the cable track
together.
guide at the platform end of the primary boom.
Remove the cable track guide from the 22 Attach a lifting strap from an overhead crane to
machine. the cable track.
14 Tag and disconnect the electrical connector 23 Remove all cable track mounting fasteners.
from the limit switch at the pivot end of the
24 Carefully remove the cable track from the
primary boom.
machine and lay it on a structure capable of
15 Remove all hose clamps for the primary boom supporting it.
lift cylinder hydraulic hoses.
Component damage hazard.
Note: The primary boom lift cylinder hydraulic hose The boom cable track can be
clamps are located behind the cable track. damaged if it is twisted.
Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.

Part No. 88619 Z-80/60 4 - 31

Section 4 • Repair Procedures June 2011

BOOM COMPONENTS REV D

How to Repair the Cable Track
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
5 Remove the upper rollers from the replacement
section of cable track.
6 Lift up the hoses and cables and carefully insert
the new 4-link section of cable track.

Note: A cable track repair kit is available through Component damage hazard.
the Genie Industries Service Parts Department. Hoses and cables can be
damaged if they are kinked or
1 Visually inspect the cable track and determine pinched.
which 4-link section needs to be replaced.
7 Connect the ends of the replacement cable
2 Carefully remove the snap rings from each end track section to the existing cable track using
of the damaged section of cable track. the snap rings.
3 Remove the retaining fasteners from the upper 8 Install the rollers onto the new section of cable
black rollers from the 4-link section of cable track.
track to be replaced. Remove the rollers.
9 Operate the boom extend/retract function
4 Lift up the hoses and cables and carefully through a full cycle to ensure smooth operation
remove the damaged 4-link section of cable of the cable track.
track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.

4 - 32 Z-80/60 Part No. 88619

June 2011 Section 4 • Repair Procedures

REV D BOOM COMPONENTS

4-2 Wear Pad Specifications

Primary Boom
Primary boom wear
pad specifications Minimum
How to Shim the Boom
1 Measure each wear pad. Top, bottom and
side wear pads 5/8 inch

Result: Each wear pad meets minimum (platform end of boom) 15.9 mm
specification. Proceed to step 2.
Side and bottom wear pads 1/2inch
Result: Each wear pad does not meet minimum (pivot end of boom) 12.7 mm
specification. Replace any wear pad that does
not meet minimum specification. Proceed to Top wear pads 5/8 inch

step 2. (pivot end of boom) 15.9 mm

2 Extend the boom until the wear pads are Secondary boom wear
accessible. pad specifications Minimum
3 Loosen the wear pad mounting fasteners. 5/8 inch
Top, and side wear pads
4 Install the new shims under the wear pad to (extension end of boom) 15.9 mm
obtain zero clearance and zero drag.
Bottom wear pads 1/2inch
5 Tighten the mounting fasteners. (extension end of boom) 12.7 mm
6 Extend and retract the boom through an entire 1/2 inch
Top wear pads
cycle. Check for tight spots that could cause
(pivot end of boom) 12.7 mm
binding or scraping.
Bottom and side wear pads 7/8 inch
Note: Always maintain squareness between the
outer and inner boom tubes. (pivot end of boom) 22.2 mm

Part No. 88619 Z-80/60 4 - 33

Section 4 • Repair Procedures
BOOM COMPONENTS
How to Remove the Primary
Boom
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: Perform this procedure with the boom in the
stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Remove the jib boom. See 3-1, How to Remove
the Jib Boom.
2 Remove the fasteners securing the limit switch
to the primary boom at the pivot end of the
boom. Do not disconnect the wiring. Move the
limit switch to a safe location.
3 Tag and disconnect the wire harness from the
primary boom angle sensor (PBAS).
Note: The primary boom angle sensor is located
inside the primary boom at the pivot end.
4 - 34 Z-80/60
June 2011
REV D
4 Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder. Tag, disconnect and
plug the hydraulic hoses routed through the
primary boom at the union.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
5 Attach a lifting strap from an overhead crane to
the barrel end of the primary boom lift cylinder.
6 Remove the pin retaining fasteners from the
primary boom lift cylinder barrel-end pivot pin.
7 Place blocks under both ends of the primary
boom lift cylinder for support.
8 Use a soft metal drift to remove the barrel-end
pivot pin. Rest the barrel end of the primary
boom cylinder on the blocks.
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when the pivot pin is removed.
9 Attach a lifting strap from an overhead crane to
the primary boom lift cylinder linkage arm.
Support the arm.
10 Remove the pin retaining fasteners from the
primary boom lift cylinder linkage arm where it
connects to the primary boom.
Part No. 88619
June 2011
REV D
11 Use a soft metal drift to remove the upper
primary boom lift cylinder linkage arm pivot pin.
Using a suitable lifting device remove the
linkage arm from the machine.
Crushing hazard. The upper
primary boom lift cylinder linkage
arm will fall if not properly
supported when the pivot pin is
removed.
12 Attach a 5 ton / 5000 kg overhead crane to the
center point of the primary boom.
13 Remove the pin retaining fastener from the
primary boom pivot pin.
14 Use a soft metal drift to remove the primary
boom pivot pin.
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when the pivot pin is removed.
15 Carefully remove the primary boom from the
machine and place it on a structure capable of
supporting it.
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when removed from the machine.
Note: When the primary boom is installed, the
primary boom angle sensor will need to be
calibrated.
Part No. 88619
Section 4 • Repair Procedures
BOOM COMPONENTS
How to Disassemble the
Primary Boom
Note: Complete disassembly of the primary boom
is only necessary if the outer or inner primary
boom tube must be replaced. The extension
cylinder can be removed without completely
disassembling the boom. See 4-4, How to Remove
the Primary Boom Extension Cylinder.
1 Remove the primary boom. See 4-2, How to
Remove the Primary Boom.
2 Place blocks under the barrel end of the primary
boom extension cylinder for support.
3 Remove the pin retaining fastener from the
extension cylinder barrel-end pivot pin at the
pivot end of the primary boom.
4 Use a soft metal drift to remove the pin.
Crushing hazard. The primary
boom could become unbalanced
and fall if not properly supported
when the pivot pin is removed.
5 Remove and label the location of the wear pads
from the platform end of the primary boom.
Note: Pay careful attention to the location and
number of shims used with each wear pad.
6 Attach a lifting strap from an overhead crane to
the extension boom assembly.
7 Support and slide the extension boom
assembly out of the primary boom tube and
place it on a structure capable of supporting it.
Crushing hazard. The extension
boom tube could become
unbalanced and fall if not properly
supported when removed from the
primary boom tube.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
Z-80/60 4 - 35
Section 4 • Repair Procedures
BOOM COMPONENTS
8 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
platform end of the extension tube.
Crushing hazard. The extension
cylinder could become unbalanced
and fall if not properly supported
when removed from primary boom
extension tube.
9 Use a soft metal drift to remove the pin.
Crushing hazard. The extension
cylinder could become unbalanced
and fall if not properly supported
when removed from primary boom
extension tube.
10 Attach a lifting strap from an overhead crane to
the extension cylinder.
11 Working at the end of the extension boom tube
opposite the jib boom mount, support and slide
the extension cylinder out of the extension
boom tube.
Crushing hazard. The extension
cylinder could become unbalanced
and fall if not properly supported
when removed from primary boom
extension tube.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper
balancing.
4 - 36 Z-80/60
June 2011
REV D
4-3
Primary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers
the primary boom. The primary boom lift cylinder is
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
How to Remove the Primary
Boom Lift Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Raise the primary boom to a horizontal position.
2 Raise the secondary boom until the primary
boom lift cylinder rod-end pivot pin is above the
counterweight.
Part No. 88619
June 2011
REV D
3 Attach a 5 ton / 5000 kg overhead crane to the
platform end of the primary boom. Support the
boom. Do not apply any lifting pressure.
4 Support both ends of the primary boom lift
cylinder with a second overhead crane or
similar lifting device.
5 Place blocks under the primary boom lift
cylinder linkage arms for support.
6 Tag, disconnect and plug the primary boom lift
cylinder hydraulic hoses. Cap the fittings on the
cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
7 Remove the pin retaining fastener from the
primary boom lift cylinder rod-end pivot pin.
Part No. 88619
Section 4 • Repair Procedures
BOOM COMPONENTS
8 Use a soft metal drift to remove the pin.
Crushing hazard. The primary
boom will fall if not properly
supported when the pivot pin is
removed.
Crushing hazard. The lift cylinder
will fall if not properly supported
when the pivot pin is removed.
Crushing hazard. The primary
boom lift cylinder linkage arms
may fall if not properly supported
when the pivot pin is removed.
9 Remove the primary boom lift cylinder barrel-
end pivot pin retaining fasteners.
10 Use a soft metal drift to remove the barrel-end
pivot pin. Remove the primary boom lift cylinder
from the machine.
Crushing hazard. The lift cylinder
will become unbalanced and fall if
not properly supported when the
pin is removed.
Z-80/60 4 - 37
Section 4 • Repair Procedures June 2011

BOOM COMPONENTS REV D

4-4 4 Place blocks under the barrel end of the primary

boom extension cylinder for support.
Primary Boom Extension
5 Tag, disconnect and plug the primary boom
Cylinder extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
The primary boom extension cylinder extends and
retracts the primary boom extension tube. The Bodily injury hazard. Spraying
primary boom extension cylinder is equipped with hydraulic oil can penetrate and
counterbalance valves to prevent movement in the burn skin. Loosen hydraulic
event of a hydraulic line failure. connections very slowly to allow
the oil pressure to dissipate
How to Remove the Primary gradually. Do not allow oil to
squirt or spray.
Boom Extension Cylinder
6 Working at the platform end of the boom,
Bodily injury hazard. This
remove the external snap rings from the
procedure requires specific repair
extension cylinder rod-end pivot pin.
skills, lifting equipment and a
suitable workshop. Attempting this 7 Use a soft metal drift to remove the pin.
procedure without these skills and
Crushing hazard. The primary
tools could result in death or
boom could fall when removed
serious injury and significant
from the extension boom if not
component damage. Dealer
properly supported.
service is strongly recommended.
8 Remove the barrel-end pivot pin retaining
Note: When removing a hose assembly or fitting,
fasteners.
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during 9 Place a rod through the barrel-end pivot pin and
installation. Refer to Section 2, Hydraulic Hose and twist to remove the pin.
Fitting Torque Specifications.
1 Raise the primary boom to a horizontal position.
2 Extend the primary boom until the primary
boom extension cylinder rod-end pivot pin is
accessible.
3 Remove the access cover from the pivot end of
the primary boom.

4 - 38 Z-80/60 Part No. 88619

June 2011
REV D
10 Working at the pivot end of the boom, support
and slide the extension cylinder out of the boom
extension.
Crushing hazard. The extension
cylinder could fall when removed
from the extension boom if not
properly supported.
Component damage hazard. Be
careful not to damage the primary
boom angle sensor (PBAS) when
removing the cylinder from the
primary boom.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
Note: Note the length of the cylinder after removal.
For ease of installation, the cylinder must be at the
same length for reinstallation.
Part No. 88619 Z-80/60
Section 4 • Repair Procedures
BOOM COMPONENTS
4-5
Primary Boom Angle Sensor
A properly functioning primary boom angle sensor
(PBAS) is essential to safe machine operation. The
primary boom angle sensor is used to limit the
angle of the primary boom relative to ground. The
ECM at the ground controls (TCON) monitors the
position and angle of the primary boom using the
signal from PBAS. The PBAS signal is used to
control the ramping of the primary boom as well as
velocity control, limiting the speed of the primary
boom to 1.3 feet / 0.4 meters per second.
How to Replace the Primary
Boom Angle Sensor
Note: Perform this procedure on a firm, level
surface with the boom in the stowed position.
1 Remove the retaining fasteners from the boom
end cover at the pivot end of the primary boom.
Remove the cover from the machine.
2 Locate the primary boom angle sensor inside
the primary boom at the boom pivot pin.
3 Tag and disconnect the electrical connector
from the sensor.
4 Remove the angle sensor mounting bracket
retaining fasteners.
5 Remove the wing nut from the threaded rod. Do
not disconnect the threaded rod from the clevis
yoke.
4 - 39
Section 4 • Repair Procedures
BOOM COMPONENTS
6 Remove the angle sensor and bracket
assembly.
7 Remove the sensor retaining fasteners from the
sensor bracket. Remove the angle sensor.
8 Install the new angle sensor onto the mounting
bracket.
9 Install the angle sensor and bracket assembly.
Note: The sensor should be installed rotated in a
fully counter clock-wise position.
10 Insert the threaded rod through the threaded
rod adjustment bracket.
11 Move the threaded rod to the top of the slotted
hole. Tighten the wing nut and hex nut towards
each other.
12 Connect the electrical connector to the angle
sensor.
13 Calibrate the primary boom angle sensor. See
How to Calibrate the Primary Boom Angle
Sensor.
Tip-over hazard. Failure to
calibrate the primary boom sensor
could result in the machine tipping
over resulting in death or serious
injury.
4 - 40
June 2011
REV D
How to Calibrate the Primary
Boom Angle Sensor
Note: Perform this procedure on a firm, level
surface with the boom in the stowed position.
Note: A digital level will be required to perform this
procedure.
1 Pull out the red Emergency Stop button at the
platform controls. From the ground control box,
turn the key switch to ground control and pull
out the red Emergency Stop button while
holding the enter button (3 or 4 seconds)
until the engine symbol appears on the display
at the ground control box, then release.
2 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: .
3 Press the scroll button until RESET PRIMARY
BOOM ANGLE SENSOR is shown on the display.
4 Press the plus button to select yes, then
press and hold the enter button to accept.
5 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 to
accept.
Result: The alarm should sound.
Result: The alarm does not sound. Repeat this
procedure beginning with step 1.
Z-80/60 Part No. 88619
June 2011
REV D
6 Loosen the Primary Boom Angle Sensor
(PBAS) assembly bracket fasteners attached to
the primary boom. Loosen the wing nut and hex
nut on the threaded rod to allow the threaded
rod to move upward. Tighten the fasteners.
7 Set a digital level on top of the primary boom
mast on a level part of the tube so it is viewable
from the ground controls.
8 Start the engine.
9 Raise the boom until the digital level
displays 70°.
10 Loosen the wing nut from threaded rod and
move the threaded rod down until the engine
turns off.
11 Screw threaded rod into clevis yoke. Tighten
the wing nut to welded bracket. Tighten the jam
nut to welded bracket. Tighten the PBAS
fasteners to boom.
Result: The ground control box display should
read P9B & P11 FAULT.
12 Push in the red Emergency Stop button to the
off position. Wait until display turns off before
proceeding.
13 Pull out the red Emergency Stop button while
holding the enter button (3 or 4 seconds)
until the endgine symbol appears on the display
at the ground control box, then release.
Part No. 88619
Section 4 • Repair Procedures
BOOM COMPONENTS
14 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: .
15 Press the scroll button until PRIMARY BOOM
ANGLE = 70° is shown on the display.
16 Press the plus button to select yes, then
press the enter button to accept.
17 Press the scroll button until EXIT is shown on
the display. Press the plus button to select
yes, then press the enter button to accept.
18 At the ground controls, use auxiliary power and
lower the boom until the faults are no longer
shown on the display.
Result: The flashing arrow in the display at the
ground controls will turn off.
Result: The flashing arrow in the display at the
ground controls does not turn off. Repeat this
procedure beginning with step 1.
19 Start the engine and activate the primary boom
down function. Release the function enable
button when the digital level displays 40°. Push
in the red Emergency Stop button to the off
position.
20 Pull out the red Emergency Stop button while
holding the enter button (3 or 4 seconds)
until the endgine symbol appears on the display
at the ground control box, then release.
21 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: .
Z-80/60 4 - 41
Section 4 • Repair Procedures
BOOM COMPONENTS
22 Press the scroll button until PRIMARY BOOM
ANGLE = 40° is shown on the display.
23 Press the plus button to select yes, then
press the enter button to accept.
Result: The alarm should not sound.
Result: The alarm does sound. Repeat this
procedure beginning with step 1.
24 Press the scroll button until EXIT is shown on the
display. Press the plus button to select yes,
then press the enter button to accept.
25 Start the engine.
26 Activate the boom up function until the digital
level reads 65°.
Result: The primary boom should stop.
Result: The primary boom does not stop.
Immediately release the function enable button
and lower the boom. Repeat this procedure
beginning with step 1.
Tip-over hazard. If the boom does
not stop at 65°, immediately
release the function enable button
and lower the primary boom.
Failure to lower the boom could
cause the machine to tip over
resulting in death or serious injury.
4 - 42
June 2011
REV D
4-6
Secondary Boom Cable Track
The secondary boom cable track guides the cables
and hoses running up through the inside of the
secondary boom. It can be repaired link by link
without removing the cables and hoses that run
through it. Removal of the secondary boom cable
track is required to repair it.
How to Remove the Cable Track
Note: The secondary boom cable track must be
removed with the secondary boom extension
cylinder. See 4-9, How to Remove the Secondary
Boom Extension Cylinder.
How to Repair the Cable Track
Component damage hazard.
The boom cable track can be
damaged if it is twisted.
A cable track repair kit is available
through the Genie Industries
Service Parts Department.
1 Remove the secondary boom extension
cylinder.
Note: The secondary boom extension cylinder
must be removed as an assembly with the cable
tracks, cable track trays and cable track support
tubes from the platform end of the secondary
boom. See 4-9, How to Remove the Secondary
Boom Extension Cylinder.
2 Visually inspect the cable track and determine
which 4-link section needs to be replaced.
Z-80/60 Part No. 88619
June 2011
REV D
3 Carefully remove the snap rings from each end
of the damaged section of cable track.
4 Remove the retaining fasteners from the upper
black rollers from the 4-link section of cable
track to be replaced. Remove the rollers.
5 Lift up the hoses and cables and carefully
remove the damaged 4-link section of cable
track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
6 Remove the upper rollers from the replacement
section of cable track.
7 Lift up the hoses and cables and carefully insert
the new 4-link section of cable track.
Component damage hazard.
Hoses and cables can be
damaged if they are kinked or
pinched.
8 Connect the ends of the replacement cable
track section to the existing cable track using
the snap rings.
9 Install the rollers onto the new section of cable
track.
10 Re-assemble and install the extension cylinder
assembly into the secondary extension boom.
11 Operate the boom extend/retract function
through a full cycle to ensure smooth operation
of the cable track.
Part No. 88619
Section 4 • Repair Procedures
BOOM COMPONENTS
4-7
Secondary Boom
How to Disassemble the
Secondary Boom
Note: Complete disassembly of the secondary
boom is only necessary if the outer or inner
secondary boom tube must be replaced. The
secondary extension boom tube can be removed
with the secondary boom tube on the machine.
Note: The extension cylinder can be removed
without completely disassembling the boom. See
4-9, How to Remove the Secondary Boom
Extension Cylinder.
Bodily injury hazard. The
procedures in this section require
specific repair skills, lifting
equipment and a suitable
workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
Follow the disassembly steps to the point required
to complete the repair. Then re-assemble the
secondary boom by following the disassembly
steps in reverse order.
1 Remove the primary boom. See 4-2, How to
Remove the Primary Boom.
Z-80/60 4 - 43
Section 4 • Repair Procedures
BOOM COMPONENTS
2 Tag, disconnect and plug the hydraulic hoses at
the primary boom lift cylinder. Cap the fittings
on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
3 Attach a lifting strap from an overhead crane to
the lug on the barrel end of the primary boom
lift cylinder. Use the overhead crane to raise the
primary boom lift cylinder to a vertical position.
4 Remove the pin retaining fastener from the
primary boom rod end pivot pin.
5 Use a slide hammer to remove the pin. Remove
the primary boom lift cylinder and linkage arms
from the machine.
Crushing hazard. The primary
boom lift cylinder and linkage arms
could become unbalanced and fall
if not properly supported when the
pin is removed.
6 At the platform end, remove the secondary
boom access cover.
7 Tag, disconnect and plug the hydraulic hoses
from the turntable. Cap the fittings.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
4 - 44 Z-80/60
June 2011
REV D
8 Tag and disconnect the electrical cables from
the turntable.
9 Remove the hose protector bracket.
10 Working at the platform end, place blocks under
the barrel end of the secondary boom extension
cylinder for support.
11 Remove the barrel-end retaining fasteners.
12 Using a suitable lifting device, lift the extension
cylinder to clear the saddle blocks
13 Attach a lifting strap from an overhead crane to
the secondary extension boom assembly.
14 Slide the secondary extension boom assembly
out of the secondary boom tube approximately
two feet and remove the wear pads from the
secondary boom tube.
15 Support and slide the extension boom
assembly out of the secondary boom tube and
place it on a structure capable of supporting it.
Crushing hazard. The extension
boom tube could become
unbalanced and fall if not properly
supported when removed from the
primary boom tube.
Note: During removal, the overhead crane strap
will need to be adjusted for proper balancing.
16 To remove the secondary boom extension
cylinder, see 4-9, How to Remove the
Secondary Boom Extension Cylinder.
Part No. 88619
June 2011 Section 4 • Repair Procedures

REV D BOOM COMPONENTS

4-8 3 Remove the retaining fasteners securing the

upper and lower turntable covers from the
Secondary Boom Lift Cylinder turntable at the platform end. Remove the
covers.
How to Remove the Secondary 4 Remove the engine tray retaining fastener.
Boom Lift Cylinder Swing the engine tray out away from the
machine.
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or the
a engine tray anchor hole
hose end must be replaced. All connections must b engine tray retaining fastener
be torqued to specification during installation.
Refer to Section 2, Hydraulic Hose and Fitting 5 Locate the engine tray anchor hole at the pivot
Torque Specifications. end of the engine tray.

1 Lower the secondary boom to the stowed
position.
2 Tag, disconnect, secure and remove the battery
cables connecting the batteries. Remove
battery fasteners and hooks from battery tray.
Remove the batteries and store them in a safe
and secure location away from the machine.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
6 Install the bolt that was just removed into the
anchor hole to secure the engine tray from
moving.
Crushing hazard. Failure to install
the bolt into the engine tray to
secure it from moving could result
in death or serious injury.
7 Remove the fuel tank filler cap.

Part No. 88619 Z-80/60 4 - 45

Section 4 • Repair Procedures
BOOM COMPONENTS
8 Using an approved hand-operated pump, drain
the fuel tank into a suitable container. Refer to
Section 2, Specifications.
Explosion and fire hazard. Engine
fuels are combustible. Perform this
procedure in an open, well-
ventilated area away from heaters,
sparks, flames and lighted
tobacco. Always have an
approved fire extinguisher within
easy reach.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.
Note: Be sure to only use a hand-operated pump
suitable for use with gasoline and diesel fuels.
9 Tag and disconnect the wire harness from the
fuel level sending unit.
10 Tag, disconnect and plug the fuel hoses from
the fuel tank.
11 Clean up any fuel that may have spilled.
4 - 46 Z-80/60
June 2011
REV D
12 Remove the fuel tank mounting fasteners.
Carefully remove the fuel tank from the
machine.
Component damage hazard. The
fuel tank is plastic and may
become damaged if allowed to fall.
Note: Clean the fuel tank and inspect for cracks
and other damage before installing it onto the
machine.
13 Tag, disconnect and plug the hydraulic hoses
from the secondary boom lift cylinder. Cap the
fitings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
14 Place blocks under each end of the secondary
boom lift cylinder for support.
15 Remove the pin retaining fasteners from the
secondary boom lift cylinder rod-end pivot pin.
16 Use a soft metal drift to remove the pin.
17 Remove the pin retaining fastener from the
secondary boom lift cylinder barrel-end pivot
pin.
Part No. 88619
June 2011
REV D
18 Use a soft metal drift to remove the pin.
19 Remove the secondary boom lift cylinder from
the machine by pulling it through the platform
end of the secondary boom.
Crushing hazard. The secondary
boom lift cylinder could become
unbalanced and fall if not properly
supported when removed from the
machine.
Component damage hazard.
When removing the secondary
boom lift cylinder from the
machine, be careful not to damage
the counterbalance valves at the
barrel end of the cylinder.
Component damage hazard.
Cables and hoses can be
damaged if the cylinder is pulled
across them.
Part No. 88619
Section 4 • Repair Procedures
BOOM COMPONENTS
4-9
Secondary Boom Extension
Cylinder
The secondary boom extension cylinder extends
and retracts the secondary boom extension tube.
The secondary boom extension cylinder is
equipped with counterbalance valves to prevent
movement in the event of a hydraulic line failure.
How to Remove the Secondary
Boom Extension Cylinder
Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
Note: The secondary boom extension cylinder
must be removed as an assembly with the cable
tracks, cable track trays and cable track support
tubes from the platform end of the secondary
boom.
1 Raise the primary boom to a horizontal position.
2 Remove the access cover from the
counterweight end of the secondary boom.
Z-80/60 4 - 47
Section 4 • Repair Procedures June 2011

BOOM COMPONENTS REV D

3 Remove the fasteners securing the cable track
trays and cable track clamps to the secondary
extension boom.
4 Remove the external snap rings from the
extension cylinder rod-end pivot pin.
5 Use a soft metal drift to remove the pin.
6 Remove the access cover from the platform
end of the secondary boom.
7 Working at the platform end, place blocks under
the barrel end of the secondary boom extension
cylinder for support.
8 Remove the barrel-end retaining fasteners.
9 Using a suitable lifting device, lift the extension
cylinder to clear the saddle blocks
10 Support and slide the extension cylinder out of
the boom extension and place it on a structure
capable of supporting it.
11 Tag, disconnect and plug the secondary boom
extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
12 Remove the cable track fasteners and cable
track support tubes from the extension cylinder.
Component damage hazard. Be
careful not to damage the
secondary boom retract limit
switch when installing the cylinder
assembly into the secondary
boom. Secure the roller arm to the
switch body during assembly.

Crushing hazard. The secondary

boom extension cylinder could
become unbalanced and fall if not
properly supported when removed
from the machine.
Component damage hazard.
When removing the secondary
boom extension cylinder from the
machine, be careful not to damage
the counterbalance valves at the
barrel end of the cylinder.
Component damage hazard.
Cables and hoses can be
damaged if the cylinder is pulled
across them.

4 - 48 Z-80/60 Part No. 88619

June 2011 Section 4 • Repair Procedures

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REV DC
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Engines
5-1 How to Remove the Flex Plate
RPM Adjustment Note: Perform this procedure with the engine off
and cool to the touch.
Refer to Maintenance Procedure B-19, Check and
Adjust the Engine RPM. 1 Open the engine side turntable cover.
2 Tag and disconnect the battery cables from the
batteries.
5-2 Electrocution hazard. Contact with
electrically charged circuits could
Flex Plate result in death or serious injury.
Remove all rings, watches and
The flex plate acts as a coupler between the other jewelry.
engine and the pump. It is bolted to the engine
flywheel and has a splined center to drive the 3 Remove the engine tray retaining fastener.
pump. Swing the engine tray out away from the
machine.

a b c d e

a pump a engine tray anchor hole

b pump shaft
c pump coupler
d flex plate with raised spline
e engine flywheel
f 0.185 inch / 4.7 mm gap - Deutz Engines
0.15 inch / 3.8 mm gap - GM Engines
0.25 inch / 6.35 mm gap - Ford Engine
0.36 inch / 9.14 mm gap - Continental Engine
0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine
0.3 inch / 7.6 mm gap - Perkins 704-30 Engine
b engine tray retaining fastener
4 Tag and disconnect the wiring plug at the
electronic displacement controller (EDC),
located on the drive pump.
5 Locate the engine tray anchor hole at the pivot
end of the engine tray.
6 Install the bolt that was just removed into the
anchor hole to secure the engine tray from
moving.
Crushing hazard. Failure to install
the bolt into the engine tray to
secure it from moving could result
in death or serious injury.

Part No. 88619 Z-80/60 4 - 49

Section 4 • Repair Procedures
ENGINES
GM models:
7 Remove the fasteners securing the muffler to
the exhaust manifold.
Burn hazard. Hot engine parts can
cause severe burns.
8 Remove muffler mounting bracket fasteners.
Remove the muffler and bracket assembly from
the engine.
9 Remove the hose clamp securing the air filter
assembly to the air inlet tube.
10 Remove the air cleaner bracket fasteners.
Remove the air cleaner and bracket assembly
from the engine.
11 Support the drive pump with an appropriate
lifting device. Do not apply any lifting pressure.
12 Remove all of the remaining bell housing to
engine fasteners. Carefully pull the pump away
from the engine and secure it from moving.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
13 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine
flywheel.
Ford models:
7 Tag and disconnect the wire harness from the
oxygen sensor.
8 Remove the exhaust pipe heat shield fasteners
from the top of the muffler.
Burn Hazard. Hot engine parts can
cause severe burns.
4 - 50
June 2011
REV C
9 Remove the muffler retainer bracket fasteners.
10 Remove the muffler fasteners securing the
muffler to the exhaust manifold. Remove the
muffler from the bracket.
11 Remove the muffler bracket retaining fasteners.
Remove the muffler bracket from the engine.
12 Close the shutoff valve on the Liquid Petroleum
Gas (LPG) tank by turning it clockwise
(if equipped).
13 Tag and disconnect the wiring from the LPG
solenoid.
14 Remove the engine starter retaining fasteners
and remove the starter from the engine. Do not
disconnect the wiring.
15 Remove the dipstick tube bracket fasteners.
16 Attach a lifting strap from an overhead crane to
the lifting eyes on the engine.
17 Remove the bell housing engine tray fasteners.
18 Raise the engine slightly using the overhead
crane. Do not apply any lifting pressure.
19 Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell
housing engine fasteners.
20 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched
21 Remove the flex plate mounting fasteners.
Remove the flex plate from the engine fly
wheel.
Z-80/60 Part No. 88619
June 2011 Section 4 • Repair Procedures

REV C ENGINES

Continental models: Deutz F4L-913 models:

7 Tag and disconnect the wire harness from the 7 Tag and disconnect the wiring from the bell
oxygen sensor. housing.
8 Remove the exhaust pipe heat shield fasteners 8 Remove the exhaust tailpipe and air inlet tube
from the top of the muffler. U-bolts from the air cleaner mounting bracket.
Burn Hazard. Hot engine parts can Burn hazard. Hot engine parts can
cause severe burns. cause severe burns.
9 Remove the muffler retainer bracket fasteners. 9 Remove the fuel filter/water separator retaining
fasteners. Remove the filter/separator from the
10 Remove the muffler fasteners securing the
engine. Do not disconnect the fuel hoses.
muffler to the exhaust manifold. Remove the
muffler from the bracket. 10 Remove the air cleaner mounting bracket
fasteners. Remove the air cleaner and bracket
11 Remove the relay housing from the muffler
assembly from the engine.
mount. Do not disconnect the relays.
11 Support the drive pump with an appropriate
12 Disconnect and remove the ECM from the
lifting device. Remove all of the remaining bell
muffler mount.
housing to engine fasteners.
13 Close the shutoff valve on the Liquid Petroleum
12 Carefully pull the pump and bell housing
Gas (LPG) tank by turning it clockwise
assembly away from the engine and secure it
(if equipped).
from moving.
14 Unbolt the EPR valve from the muffler mount.
Component damage hazard.
Leave the hoses attached to the EPR valve.
Hoses can be damaged if they are
15 Remove the muffler mount. kinked or pinched.
16 Support the drive pump with an appropriate 13 Remove the flex plate mounting fasteners,
lifting device. Remove the pump plate mounting and remove the flex plate from the engine
fasteners. flywheel.
17 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
18 Remove the flex plate mounting fasteners.
Remove the flex plate from the engine flywheel.

Part No. 88619 Z-80/60 4 - 51

Section 4 • Repair Procedures
ENGINES
Deutz BF4L-2011 models:
7 Tag and disconnect the wiring from the bell
housing.
8 Remove the U-bolt from the exhaust flex pipe at
the muffler.
Burn hazard. Hot engine parts can
cause severe burns.
9 Remove the muffler bracket retaining fasteners
from bell housing. Remove the muffler and
bracket assembly from the engine.
10 Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell
housing engine fasteners.
11 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
12 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine
flywheel.
4 - 52
June 2011
REV C
Perkins 704-30 Models:
7 Remove the clamp securing the air intake elbow
to the air cleaner assembly. Remove the air
intake tube from the engine. Do not remove the
elbow from the air intake tube.
8 Support the drive pump with an appropriate
lifting device. Remove all of the bell housing to
engine fasteners.
9 Carefully pull the pump and bell housing
assembly away from the engine and secure it
from moving.
Component damage hazard.
Hoses can be damaged if they are
kinked or pinched.
10 Remove the flex plate mounting fasteners,
and remove the flex plate from the engine
flywheel.
Perkins 804C-33 Models:
7 Tag and disconnect the wiring from the bell
housing.
8 Remove the exhaust pipe clamp at the muffler.
Burn hazard. Hot engine parts can
cause severe burns.
9 Remove the muffler mounting bracket
fasteners. Remove the muffler and bracket
assembly from the engine.
10 Remove the hose clamps from the air cleaner
elbow and the engine intake manifold.
11 Remove the air cleaner mounting bracket
fasteners. Remove the air cleaner and bracket
assembly from the engine.
12 Support the drive pump with an appropriate
lifting device. Remove all of the remaining bell
housing to engine fasteners.
Z-80/60 Part No. 88619
June 2011 Section 4 • Repair Procedures

REV C ENGINES

13 Carefully pull the pump and bell housing GM models: Torque the flex plate mounting
assembly away from the engine and secure it bolts in sequence to 22 ft-lbs / 30 Nm. Then
from moving. torque the flex plate mounting bolts in sequence
to 31 ft-lbs / 42 Nm.
Component damage hazard.
Continental models: Torque the flex plate
Hoses can be damaged if they are
mounting bolts in sequence to 14 ft-lbs / 19 Nm.
kinked or pinched.
Then torque the flex plate mounting bolts in
14 Remove the flex plate mounting fasteners, sequence to 20.8 ft-lbs / 28 Nm.
and remove the flex plate from the engine Deutz models: Torque the flex plate mounting
flywheel. bolts in sequence to 26 ft-lbs / 35 Nm. Then
torque the flex plate mounting bolts in sequence
How to Install the Flex Plate to 37 ft-lbs / 51 Nm.
Perkins models: Torque the flex plate
1 Install the flex plate onto the engine flywheel
mounting bolts in sequence to 13 ft-lbs / 18 Nm.
with the raised spline towards the pump. Apply
Then torque the flex plate mounting bolts in
Loctite® removable thread sealant to the
sequence to 19 ft-lbs / 26 Nm.
mounting screws.
3 Install the pump coupler onto the pump shaft
2 Ford models: Torque the flex plate mounting
with the set screw toward the pump. Leave the
bolts in sequence to 14 ft-lbs / 19 Nm. Then
appropriate gap between coupler and pump
torque the flex plate mounting bolts in sequence
end plate for your engine.
to 20 ft-lbs / 27 Nm.
4 Apply Loctite® removable thread sealant to the
pump coupler set screw. Torque the set screw
to 61 ft-lbs / 83 Nm.
a b c d e
5 Install the pump onto the bell housing/mounting
plate and torque the pump retaining fasteners
to 57 ft-lbs / 77.3 Nm. Apply Loctite® removable
thread sealant to the mounting fasteners.
Component damage hazard. Do
not force the drive pump during
f installation or the flex plate teeth
a pump may become damaged.
b pump shaft
c pump coupler
d flex plate with raised spline
e engine flywheel
f 0.185 inch / 4.7 mm gap - Deutz Engines
0.15 inch / 3.8 mm gap - GM Engines
0.25 inch / 6.35 mm gap - Ford Engine
0.36 inch / 9.14 mm gap - Continental Engine
0.25 inch / 6.35 mm gap - Perkins 804C-33 Engine
0.3 inch / 7.6 mm gap - Perkins 704-30 Engine

Part No. 88619 Z-80/60 4 - 53

Section 4 • Repair Procedures June 2011

ENGINES REV C

1
1

6 1 3
6 3
4 3

2 5
4 5

4 5
2
GM models

6 Install the pump and mounting plate assembly

2 onto the engine. Apply Loctite® removable
Ford, Perkins, thread sealant to the mounting fasteners.
Deutz BF4L-2011 models and Perkins 704 models
Continental TME27 models Torque the pump mounting plate fasteners in
sequence to 14 ft-lbs / 19.1 Nm.
Deutz 913, Perkins 804 and GM models
1 Torque the pump mounting plate fasteners in
sequence to 28 ft-lbs / 38 Nm.
8 3 Deutz 2011 Models
Torque the pump mounting plate fasteners in
sequence to 46.7 ft-lbs / 63.3 Nm.
Ford Models
Torque the pump mounting plate fasteners in
6 5 sequence to 37 ft-lbs / 50.1 Nm.
Continental Models
Torque the pump mounting plate fasteners in
sequence to 23 ft-lbs / 31.2 Nm.
Component damage hazard.
4 7 When installing the pump, do not
force the pump coupler into the
2 flexplate or damage to the pump
shaft seal may occur.
Deutz F4L-913 models
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.

4 - 54 Z-80/60 Part No. 88619

June 2011 Section 4 • Repair Procedures

REV C ENGINES

6 1 6 1
10 8 10 8

4 3
4 3

11 12
11 12
7 5
2 9 7 5
Deutz F4L-913 and 2 9
Perkins 704-30 models
Deutz BF4L-2011 models

1 6
6 1
7 8 10 8

4 4 3
3

11 12

9 7 5
5 2
2 9
Ford models Perkins 804C-33 and
GM models
6 1

10 8

4 3

11 12

7 5

2 9

Continental models

Part No. 88619 Z-80/60 4 - 55

Section 4 • Repair Procedures
ENGINES
5-3
Engine Fault Codes -
Gasoline/LPG Models
How to Retrieve Engine Fault
Codes
When an engine malfunction is detected by the
Electronic Control Module (ECM), a fault code is
recorded and the check engine light will turn on at
the platform controls. Use the following procedure
to retrieve the engine fault code to determine the
engine malfunction.
Note: Perform this procedure with the key switch in
the off position.
1 Open the engine side turntable cover.
2 Locate the run/test toggle switch located on the
relay box cover.
3 Pull out the red Emergency Stop button to the
on position at the ground controls.
4 Hold the run/test toggle switch to the test
position and turn the key switch to the ground
controls position.
Result: The check engine light should turn on.
The check engine light should begin to blink.
Note: The check engine light will blink a "123" code
three times before blinking a fault code if one is
present.
4 - 56
June 2011
REV C
5 Continue to hold the run/test toggle switch in the
test position and count the blinks.
Note: If any fault codes are present, the ECM will
blink a three digit code. It will blink the first digit of a
three digit code, pause, blink the second digit,
pause, and then blink the third digit. For example:
the check engine light blinks 5 consecutive times,
blinks 3 times and then 1 time. That would indicate
code 531.
Note: Before the fault codes are displayed, the
check engine light will blink a code 123 times. After
the fault codes, the check engine light will blink a
code 123 three times again indicating the end of
the stored codes.
6 Refer to Section 5, Fault Codes for definition of
engine fault codes.
How to Clear Engine Fault Codes
from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1 Open the engine side turntable cover and locate
the battery.
2 Disconnect the negative battery cable from the
battery for a minimum of 5 minutes.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
3 Connect the negative battery cable to the
battery.
Z-80/60 Part No. 88619
June 2011 Section 4 • Repair Procedures

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REV B C
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6-1
Service Bypass/Recovery
Key Switch
The ground control box contains two key switches.
The main key switch towards the top of the control
box is for selection of ground or platform controls.
The key switch at the bottom of the control box is
the Service Bypass/Recovery key switch. Service
Bypass and Recovery modes are only intended for
certain circumstances and are not part of normal
machine operation. If either the Service Bypass or
the Recovery function is required, this indicates
there may be faults with the machine. Contact
trained personnel immediately.
Service Bypass is used for a platform out-of-
envelope condition and certain service situations.
Recovery is only to be used as a last attempt to
lower the platform when the operator in the
platform is unable to do so, system failure or in
emergency situations.
STOP
Ground Controls
How to Use the Service Bypass
Mode
Tip-over hazard. Operating the
machine outside of the operating
envelope while in Service Bypass
mode will result in death or serious
injury if proper operating
procedures and safety precautions
are not followed. Do not use this
mode if you are not trained and
familiar with the operating
envelope of the machine.
Note: Before using the Service Bypass mode,
make sure you understand the fault code or issue
affecting the operation of the machine to be sure
the use of service bypass is required.
The Service Bypass mode will allow the platform to
be manually leveled when an out-of-envelope
condition exists. In the event that the platform
angle is greater than 10° from level, the boom
angle and platform level functions are disabled.
Use of the Service Bypass mode will allow the
platform to be manually adjusted to within the
normal operating envelope, ±4.5°. Only auxiliary

power can be used to correct an out of level

platform fault.
00000

1 Turn the engine off.

2 Turn the main key switch to ground controls.
Remove the key from the main key switch and
insert the key into the service bypass/recovery
key switch.
Note: The main key switch must remain in the
Run ground control position.
Service 3 Turn the service bypass/recovery key switch to
Bypass
the service bypass position.
Recovery

Service Bypass/
Recovery Key Switch

Part No. 88619 Z-80/60 4 - 57

Section 4 • Repair Procedures
GROUND CONTROLS
4 Using auxiliary power, operate the platform
level toggle switch to level the platform.
Note: Only the auxiliary power unit can be used to
correct an out of level platform fault.
5 Turn the service bypass/recovery key switch to
the run position.
6 Remove the key from the service bypass/
recovery key switch and insert the key into the
main key switch.
Note: If the Service Bypass function has been
used, there may be faults with the machine. Check
the LCD screen on the ground control box for
machine faults, then contact trained service
personnel.
How to Use the Recovery Mode
Recovery is only to be used as a last attempt to
lower the platform when the operator in the
platform is unable to do so, system failure or in
emergency situations.
Bodily injury hazard. When using
recovery mode, the platform may
not fully lower to the ground when
the recovery mode is completed.
Failure to use only suitable
equipment and/or practices to
allow the operator to safely exit
the platform could result in death
or serious injury.
Bodily injury hazard. Platform
leveling is not active when using
recovery mode. The platform
could reach high out-of-level
conditions when using this mode.
The operator will need to secure
themself to the platform to prevent
falling injury.
4 - 58
June 2011
REV B
The Recovery mode allows the platform to be
lowered in the event the operator in the platform is
unable to lower the platform using the platform
controls, system failure or emergency situations.
The recovery sequence will automatically retract
the primary boom and then lower the primary boom
using the auxiliary power unit to allow the operator
at the platform controls to exit the platform.
1 Turn the main key switch to the off position.
Remove the key from the main key switch and
insert the key into the service bypass/recovery
key switch.
2 Turn and hold the service bypass/recovery key
switch to the recovery position. The switch must
be held in the recovery position.
Result: The auxiliary power unit will turn on and
the boom will begin the following recovery
sequence.
· The primary boom will retract
· The primary boom will lower
Note: The key switch must be held in the recovery
position until the recovery sequence is complete or
until the operator in the platform can safely exit the
platform.
Note: If any boom safety limit switches are faulty,
the boom will only retract and not lower and the
operator will need to be recovered from that point.
Note: If the Recovery function has been used, this
may indicate there may be faults with the machine.
Tag and remove the machine from service until the
fault has been corrected by trained personnel.
Z-80/60 Part No. 88619
June 2011
REV B
6-2
Circuit Boards
The ground control box (TCON) is the
communication and operations center for the
machine. The ground control box contains two key
switches. The key switch towards the top of the
control box is for selection of ground or platform
controls. The key switch at the bottom of the
control box is the Service Bypass key switch. It is
used to correct an out-of-level platform. If the
machine trips an envelope safety switch, the
operator at the ground controls can turn and hold
the Service Bypass key switch in the RECOVER
position, which will automatically retract the boom
and lower the platform to the ground.
The ground control box contains a replaceable
membrane decal with touch sensitive buttons for
various machine functions. The ground control box
also contains two printed circuit boards:
The LCD (Liquid Crystal Display) circuit board
is mounted to the inside of the control box lid which
controls the LCD display screen.
The ECM circuit board is the main circuit board
for the machine. There are relays on the ECM
circuit board that can be replaced. All operating
parameters and configuration of options for the
machine are stored in the ECM memory.
Note: The ECM circuit board inside the ground
control box (TCON) cannot be replaced by itself. If
the ECM circuit board is faulty and needs to be
replaced, contact the Genie Industries Service
Department.
Note: When an ECM circuit board is replaced, the
proportional valves will need to be calibrated.
See 1-3, How to Calibrate a Joystick.
Part No. 88619
Section 4 • Repair Procedures
GROUND CONTROLS
How to Determine the Revision
Level
1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the on
position at both platform and ground controls.
Result: The revision level of the ECM will
appear in the LCD display window.
How to Remove the LCD Display
Screen Circuit Board
1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the ground control box lid fasteners.
Open the control box lid.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
3 Carefully disconnect the ribbon cable from the
LCD display circuit board.
4 Remove the LCD display circuit board retaining
fasteners.
5 Carefully remove the LCD display circuit board
from the ground control box lid.
Z-80/60 4 - 59
Section 4 • Repair Procedures June 2011

GROUND CONTROLS REV B

6-3 5 Carefully remove the membrane decal from the

control box lid while guiding the ribbon cables
Membrane Decal out of the control box lid.

The membrane decal is a special decal that 6 Remove any decal adhesive from the control
consists of a decal with an electronic membrane box lid with a mild solvent.
on the backside. The membrane contains touch Component damage hazard.
sensitive areas that, when pushed, activates the Certain solvents can damage LCD
machine functions. The membrane buttons display. Do not allow any solvent
activate machine functions similar to toggle to come in contact with the LCD
switches, but do not have any moving parts. display screen.
How to Replace the Membrane 7 Install the new membrane decal onto the control
box lid while guiding the ribbon cables through
Decal the control box lid.
1 Turn the key switch at to the off position. 8 Connect the ribbon cables to the ECM circuit
2 Push in the red Emergency Stop button to the board.
off position at both the ground and platform 9 Close the control box lid and install the retaining
controls. fasteners.
3 Remove the ground control box lid fasteners.
Open the control box lid.
4 Tag and disconnect the two ribbon cables from
the membrane decal at the ECM circuit board.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.

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

June 2011 Section 4 • Repair Procedures

REV B
Hydraulic Pumps
7-1 2 Tag, disconnect and plug the hydraulic hoses at
the function pump. Cap the fittings on the
Function Pump pump.
Bodily injury hazard. Spraying
How to Remove the Function hydraulic oil can penetrate and
Pump burn skin. Loosen hydraulic
connections very slowly to allow
Note: When removing a hose assembly or fitting,
the oil pressure to dissipate
the O-ring on the fitting and/or hose end must be
gradually. Do not allow oil to
replaced and then torqued to specification during
squirt or spray.
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications. 3 Remove the pump mounting fasteners.
Carefully remove the pump.
1 Models without hydraulic tank shutoff
valves: Remove the drain plug from the Component damage hazard.
hydraulic tank and completely drain the tank Be sure to open the two hydraulic
into a suitable container. Refer to Section 2, tank valves (if equipped) and
Specifications. prime the pump after installing the
pump. See 7-2, How to Prime the
Models with hydraulic tank shutoff valves: Pump.
Close the two hydraulic tank valves located at
the hydraulic tank.
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.

open closed

Part No. 88619 Z-80/60 4 - 61

Section 4 • Repair Procedures
HYDRAULIC PUMPS
7-2
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), located on the pump. Any internal service
to the pump should only be performed at an
authorized Sauer-Danfoss service center. Contact
the Genie Industries Service Department to locate
your local authorized service center.
How to Remove the Drive Pump
Component damage hazard. The
work area and surfaces where this
procedure will be performed must
be clean and free of debris that
could get into the hydraulic system
and cause severe component
damage. Dealer service is
recommended.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Disconnect the wire harness at the electronic
displacement controller (EDC), located on the
drive pump.
4 - 62 Z-80/60
June 2011
REV B
2 Models without hydraulic tank shutoff
valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a suitable container. Refer to Section 2,
Specifications.
Models with hydraulic tank shutoff valves:
Close the two hydraulic tank valves located at
the hydraulic tank.
Component damage hazard. The
engine must not be started with
the hydraulic tank shutoff valves in
the closed position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.
open closed
3 Tag, disconnect and plug the hydraulic hoses at
the drive and function pumps. Cap the fittings
on the pumps.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Part No. 88619
June 2011
REV B
4 Support the pumps with a suitable lifting device
and remove the two drive pump mounting
fasteners.
5 Carefully pull the drive pump out until the pump
coupler separates from the flex plate.
6 Remove the drive pump assembly from the
machine.
Component damage hazard.
Be sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
Note: Before installing the pump, verify proper
pump coupler spacing. See 5-2, Flex Plate.
How to Prime the Pump
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2 Remove the engine tray retaining fastener.
Swing the engine tray out away from the
machine.
a engine tray anchor hole
b engine tray retaining fastener
3 Locate the engine tray anchor hole at the pivot
end of the engine tray.
Part No. 88619
Section 4 • Repair Procedures
HYDRAULIC PUMPS
4 Install the bolt removed in step 4 into the anchor
hole to secure the engine tray from moving.
Crushing hazard. Failure to install
the bolt into the engine tray to
secure it from moving could result
in death or serious injury.
5 Deutz and Perkins models: Tag and
disconnect the engine wiring harness from the
fuel shutoff solenoid at the injector pump.
GM and Ford models: Close the valve on the
LPG tank. Disconnect the hose from the tank.
Move the fuel select switch to the LPG position.
6 Have another person crank the engine with the
starter motor for 15 seconds, wait 15 seconds,
then crank the engine an additional 15 seconds
or until the pressure reaches 320 psi / 22 bar.
7 Deutz and Perkins models: Connect the
engine wiring harness to the fuel solenoid.
GM, Ford and Continental models: Connect
the LPG hose to the LPG tank and open the
valve on the tank.
8 Start the engine from the ground controls and
check for hydraulic leaks.
Z-80/60 4 - 63
Section 4 • Repair Procedures June 2011

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8-1
Function Manifold - View 1
The function manifold is located next to the ground control box.
Index Schematic
No. Description Item Function Torque

1 Differential sensing valve .................. A ........... Secondary boom

up/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

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 June 2011 Section 4 • Repair Procedures

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REVED MANIFOLDS
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1 2 3 4 5 6 7 8 9 10 11
A B C D E F G H I J K

L
12

M
O 13
15

N
14

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Section 4 • Repair Procedures June 2011

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8-2
Function Manifold - View 2
Index Schematic
No. Description Item Function Torque

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 auxiliary
pump #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 #1
to auxiliary pump #1 .......................... 20-25 ft-lbs / 27-34 Nm
17 Check valve, 5 psi / 0.34 bar ............. AF ......... Blocks flow from auxiliary
pump #2 to function pump #2 ........... 20-25 ft-lbs / 27-34 Nm
18 Relief valve, 3000 psi / 207 bar ......... AG ........ Oscillate and platform manifold
system relief ...................................... 20-25 ft-lbs / 27-34 Nm
19 Check valve, 5 psi / 0.34 bar ............. AH ........ Blocks flow from function pump #2
to 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

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June 2011 Section 4 • Repair Procedures

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1 2
P Q

R
3

S
4

T
5

U
6

V
7

W
8

X
9

Y
10

Z
11

AA
12

AB
13

AJ AI AH AG AF AE AD AC
21 20 19 18 17 16 15 14

Part No. 88619 Z-80/60 4 - 67

Section 4 • Repair Procedures
MANIFOLDS
8-3
Valve Adjustments -
Function Manifold
How to Adjust the System
Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Locate the boom retracted limit switch
(LSP1RO) limit switch on the outside of the
primary boom at the pivot end of the primary
boom.
2 Tag and disconnect the wire harness from the
limit switch, and install a wire jumper between
pins 1 and 2 of the limit switch connector. Place
another wire jumper between pins 3 and 4 of
the limit switch connector.
3 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the PTEST port on the function
manifold.
4 Start the engine from the ground controls.
5 Press and release the rpm select button until
the engine changes to high idle.
6 Simultaneously push and hold the function
enable/high speed button and the primary boom
retract button with the primary boom fully
retracted. Observe the reading on the pressure
gauge. Refer to Section 2, Specifications.
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7 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item AJ).
8 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
9 Repeat steps 4 through 8 confirm the relief
valve pressure.
10 Remove the pressure gauge.
11 Remove the wire jumpers from the limit switch
connector.
12 Securely install the LSP1RO pig tail into the
wire harness.
How to Adjust the Primary Boom
Down Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the LS port on the function manifold.
2 Start the engine from the ground controls.
3 Press and release the rpm select button until
the engine changes to high idle.
4 Raise the primary boom approximately
5 feet / 1.5 m.
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5 Place a 4 x 4 inch / 10 x 10 cm block on the
primary boom rest pad. Lower the primary
boom onto the block.
Crushing hazard. Keep hands
clear of the block when lowering
the primary boom.
6 Simultaneously push and hold the function
enable/high speed button and the primary boom
down button. Observe the pressure reading on
the pressure gauge. Refer to Section 2,
Specifications.
7 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item E).
8 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
9 Start the engine and repeat steps 6 through 8 to
confirm the relief valve pressure.
10 Start the engine and raise the primary boom
approximately 12 inches / 30 cm. Remove the
block and lower the primary boom to the
stowed position.
11 Turn the engine off and remove the pressure
gauge.
Part No. 88619
Section 4 • Repair Procedures
MANIFOLDS
How to Adjust the Primary Boom
Extend Relief Valve
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the LS port on the function manifold.
2 Start the engine from the ground controls.
3 Raise the boom to a horizontal position. Turn
the engine off.
4 Locate the boom extended limit switch
(LSP1EO) on the outside of the primary boom.
5 Remove the limit switch mounting bracket
retaining fasteners.
6 Pull the limit switch and bracket assembly out of
the boom tube and let it hang down.
7 Start the engine from the ground controls and
press and release the rpm select button until
the engine changes to high idle.
8 Simultaneously push and hold the function
enable/high speed button and the primary boom
extend button with the primary boom fully
extended. Observe the reading on the pressure
gauge. Refer to Section 2, Specifications.
9 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item U).
Z-80/60 4 - 69
Section 4 • Repair Procedures
MANIFOLDS
10 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
11 Repeat steps 7 through 8 to confirm relief valve
pressure.
12 Start the engine and fully retract the primary
boom. Turn the engine off.
13 Install the limit switch and bracket assembly to
the primary boom.
14 Remove the pressure gauge.
How to Adjust the Secondary
Boom Up Relief Valve
1 Remove the cover retaining fasteners from the
secondary boom end cover. Remove the cover
from the machine.
2 Locate the wire connector for secondary boom
limit switch LSS2AO. Disconnect the connector.
Note: The secondary boom limit switch LSS2AO is
the upper limit switch located on the inside of the
riser plate at the engine side of the machine.
3 Install a jumper wire between pins 3 and 4 of
the LSS2AO Deutsch connector on the wire
harness end.
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4 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the LS port on the function manifold.
5 Start the engine from the ground controls.
6 Simultaneously push and hold the function
enable/high speed button and the secondary
boom up/extend button and fully raise the
secondary boom.
7 Continue holding the function enable/high
speed button and the secondary boom up/
extend button while observing the reading on
the pressure gauge. Refer to Section 2,
Specifications.
8 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item B).
9 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
10 Repeat steps 5 through 7 to confirm relief valve
pressure.
11 Remove the pressure gauge.
12 Remove the jumper wire from LSS2AO limit
switch connector. Connect the limit switch to
the wire harness.
13 Install the secondary boom end cover and
tighten the retaining fasteners.
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How to Adjust the Secondary
Boom Down Relief Valve
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the LS port on the function manifold.
2 Start the engine from the ground controls.
3 Press and release the rpm select button until
the engine changes to high idle.
4 Raise the secondary boom approximately
12 inches / 30 cm.
5 Place a 4 x 4 inch / 10 x 10 cm block on the
secondary boom rest pad. Lower the secondary
boom onto the block.
Crushing hazard. Keep hands
clear of the block when lowering
the secondary boom.
6 Simultaneously push and hold the function
enable/high speed button and the secondary
boom down button. Observe the reading on the
pressure gauge. Refer to Section 2,
Specifications.
7 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item D).
Part No. 88619
Section 4 • Repair Procedures
MANIFOLDS
8 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
9 Start the engine and repeat step to confirm
relief valve pressure.
10 Start the engine and raise the secondary boom
approximately 12 inches / 30 cm. Remove the
block and lower the secondary boom to the
stowed position.
11 Turn the engine off and remove the pressure
gauge.
How to Adjust the Secondary
Boom Extend Relief Valve
Note: Perform this procedure with the secondary
boom fully raised.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the LS port on the function manifold.
2 Start the engine from the ground controls.
3 Simultaneously push and hold the function
enable/high speed button and the secondary
boom up/extend button with the secondary
boom fully raised and extended. Observe the
pressure reading on the pressure gauge. Refer
to Section 2, Specifications.
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4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item Q).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
6 Repeat steps 2 through 5 to confirm relief valve
pressure.
7 Remove the pressure gauge.
4 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item AG).
5 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Install the relief valve
cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
6 Repeat steps 2 through 3 to confirm relief valve
pressure.
7 Remove the pressure gauge.

How to Adjust the Platform

Manifold Relief Valve
Note: Perform this procedure with the boom in the
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the PTEST 2 port on the function
manifold.
2 Start the engine from the ground controls.
3 Simultaneously push and hold the function
enable/high speed button and the jib boom
down button with the jib boom fully lowered.
Observe the reading on the pressure gauge.
Refer to Section 2, Specifications.

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 June 2011 Section 4 • Repair Procedures

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MANIFOLDS REV E

8-4
Platform Manifold
The platform Manifold is mounted to the platform mounting weldment.

Index Schematic
No. Description Item Function Torque

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 differential
sensing circuit ................................... 23-25 ft-lbs / 31-34 Nm
6 Differential sensing valve, N.O. ......... GF ........ Platform level differential
sensing circuit ................................... 23-25 ft-lbs / 31-34 Nm
7 Differential sensing valve, N.O. ......... GH ........ Platform rotate differential
sensing 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
— 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)
16 Proportional solenoid valve,
3 position 4 way ................................. GQ ........ Platform level 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)
17 Check valve ....................................... GR ........ Platform rotate circuit

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June 2011 Section 4 • Repair Procedures

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1 2 3 4
GA GB GC GD

GR
17

GQ
16

GP
15

GO
14

GE
5

GF
6

GH
7

GI
8
GN GJ
13 9
GK
10

GM GL
12 11

Part No. 88619 Z-80/60 4 - 75

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MANIFOLDS REV E

8-5
Turntable Rotation Manifold
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index Schematic
No. Description Item Function Torque

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

1 2 3
KK LL MM

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8-6
Platform Rotate Manifold
The platform rotate manifold is mounted on the platform rotator.
Index Schematic
No. Description Item Function Torque

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

HB
2

HA
1

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MANIFOLDS REV E

8-7
Two Wheel Steer and Oscillate Manifold
(before serial number 990)

The Two Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the
machine.
Index Schematic
No. Description Item Function Torque

1 Solenoid valve, 3 position 4 way ....... BA ......... Steer left/right,

yellow side steer cylinder .................. 26-30 ft-lbs / 35-41 Nm
2 Solenoid valve, 3 position 4 way ....... BB ......... Steer left/right,
blue side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm
3 Solenoid valve, 2 position 3 way ....... BC ........ Oscillate cylinder, blue side .............. 26-30 ft-lbs / 35-41 Nm
4 Solenoid valve, 2 position 3 way ....... BD ........ Oscillate cylinder, yellow 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 ......... Blue side steer cylinder
extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm
7 Flow regulator valve,
1.2 gpm / 4.5 L/min
(before serial number 928)
1.5 gpm / 5.7 L/min ............................ BG ........ Blue side steer cylinder
(after serial number 927) retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
8 Check valve ....................................... BH ........ Load sensing circuit,
blue side steer cylinder retract ............ 8-10 ft-lbs / 11-14 Nm
9 Check valve ....................................... BI .......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
10 Check valve ....................................... BJ ......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
This list continues on the next page.

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1 2 3 4
BA BB BC BD

BQ
17
BP
16

BO
15
BN
14

BM
13

BE
5
BL
12 BF
6
BK
11
BG
7

BH
8

BJ BI
10 9

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MANIFOLDS REV E

Two Wheel Steer and Oscillate Manifold, continued

(before serial number 990)

Index Schematic
No. Description Item Function Torque

11 Flow regulator valve,

2.3 gpm / 8.7 L/min ............................ BK ......... Yellow side steer cylinder
extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm
12 Flow regulator valve,
1.2 gpm / 4.5 L/min
(before serial number 928)
1.5 gpm / 5.7 L/min ............................ BL ......... Yellow side steer cylinder
(after serial number 927) retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
13 Check valve, 65 psi / 4.5 bar ............. BM ........ Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
14 Check valve, 65 psi / 4.5 bar ............. BN ........ Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
15 Check valve ....................................... BO ........ Load sensing circuit,
yellow side steer cylinder retract ........ 8-10 ft-lbs / 11-14 Nm
16 Check valve ....................................... BP ......... Load sensing circuit,
yellow side steer cylinder extend ........ 8-10 ft-lbs / 11-14 Nm
17 Check valve ....................................... BQ ........ Load sensing circuit,
blue side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm

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1 2 3 4
BA BB BC BD

BQ
17
BP
16

BO
15
BN
14

BM
13

BE
5
BL
12 BF
6
BK
11
BG
7

BH
8

BJ BI
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MANIFOLDS REV E

8-8
Two Wheel Steer and Oscillate Manifold
(from serial number 990)

The Two Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the
machine.
Index Schematic
No. Description Item Function Torque

1 Solenoid valve, 3 position 4 way ....... JA ......... Steer left/right,

yellow side steer cylinder .................. 26-30 ft-lbs / 35-41 Nm
2 Solenoid valve, 3 position 4 way ....... JB ......... Steer left/right,
blue side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm
3 Solenoid valve, 2 position 3 way ....... JC ......... Oscillate cylinder, blue side .............. 26-30 ft-lbs / 35-41 Nm
4 Solenoid valve, 2 position 3 way ....... JD ......... Oscillate cylinder, yellow side ........... 26-30 ft-lbs / 35-41 Nm
5 Relief valve,
750 to 860 psi / 51.71 to 59.3 bar ..... JE ......... Oscillate circuit .................................. 20-25 ft-lbs / 27-34 Nm
6 Flow regulator valve,
1.5 gpm / 5.7 L/min ............................ JF ......... Blue side steer cylinder
extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm
7 Flow regulator valve,
1.0 gpm / 3.8 L/min ............................ JG ......... Blue side steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
8 Check valve ....................................... JH ......... Load sensing circuit,
blue side steer cylinder retract ............ 8-10 ft-lbs / 11-14 Nm
9 Check valve ....................................... JI ........... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
10 Check valve ....................................... JJ .......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm

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1 2 3 4
JA JB JC JD

JQ
17
JP
16

JO
15
JN
14

JM
13

JE
5
JL
12 JF
6
BK
11
JG
7

JH
8

JJ JI
10 9

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MANIFOLDS REV E

This list continues on the next page.

Two Wheel Steer and Oscillate Manifold, continued
(from serial number 990)

Index Schematic
No. Description Item Function Torque

11 Flow regulator valve,

1.5 gpm / 5.7 L/min ............................ JK ......... Yellow side steer cylinder
extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm
12 Flow regulator valve,
1.0 gpm / 3.8 L/min ............................ JL .......... Yellow side steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
13 Check valve, 65 psi / 4.5 bar ............. JM ......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
14 Check valve, 65 psi / 4.5 bar ............. JN ......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
15 Check valve ....................................... JO ......... Load sensing circuit,
yellow side steer cylinder retract ........ 8-10 ft-lbs / 11-14 Nm
16 Check valve ....................................... JP ......... Load sensing circuit,
yellow side steer cylinder extend ........ 8-10 ft-lbs / 11-14 Nm
17 Check valve ....................................... JQ ......... Load sensing circuit,
blue side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm

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1 2 3 4
JA JB JC JD

JQ
17
JP
16

JO
15
JN
14

JM
13

JE
5
JL
12 JF
6
BK
11
JG
7

JH
8

JJ JI
10 9

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MANIFOLDS REV E

How to Adjust the Oscillate 6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
Relief Valve decrease the pressure. Install the relief valve
Note: Perform this procedure with the boom in the cap.
stowed position. Tip-over hazard. Do not adjust
the relief valve higher than
Note: Perform this procedure with the engine
specified.
running at high RPM.
7 Repeat steps 3 through 4 to confirm relief valve
Note: This procedure will require two people. pressure.
1 Remove the drive chassis cover from the 8 Remove the pressure gauge.
square-end of the machine.
9 Install the drive chassis cover.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the two wheel steer
and oscillate manifold.
3 Start the engine from the platform controls.
4 Press down the foot switch and manually
activate one of the oscillate limit switches. Hold
the switch in the activated position and observe
the reading on the pressure gauge. Refer to
Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap (item BE,
before SN 1291 or JE, after SN 1290).

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8-9
Four Wheel Steer and Oscillate Manifold
(before serial number 990)

The Four Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the
machine.
Index Schematic
No. Description Item Function Torque

1 Solenoid valve, 3 position 4 way ....... CA ........ Steer left/right, square end
yellow side steer cylinder .................. 26-30 ft-lbs / 35-41 Nm
2 Solenoid valve, 3 position 4 way ....... CB ........ Steer left/right, square end
blue side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm
3 Check valve ....................................... CC ........ Load sensing circuit, circle end
yellow side steer cylinder retract ........ 8-10 ft-lbs / 11-14 Nm
4 Check valve, 65 psi / 4.5 bar ............. CD ........ Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
5 Solenoid valve, 2 position 3 way ....... CE ........ Oscillate cylinder, blue side .............. 26-30 ft-lbs / 35-41 Nm
6 Solenoid valve, 2 position 3 way ....... CF ......... Oscillate cylinder, yellow side ........... 26-30 ft-lbs / 35-41 Nm
7 Check valve, 65 psi / 4.5 bar ............. CG ........ Prevents steer cylinder from
moving 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, blue side steer cylinder
extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm
10 Flow regulator valve,
1.2 gpm / 4.5 L/min
(before serial number 928)
1.5 gpm / 5.7 L/min
(after serial number 927) ................... CJ ......... Circle end, blue side steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
11 Flow regulator valve,
1.2 gpm / 4.5 L/min
(before serial number 928)
1.5 gpm / 5.7 L/min
(after serial number 927) ................... CK ........ Circle end, yellow side steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
12 Flow regulator valve,
2.3 gpm / 8.7 L/min ............................ CL ......... Circle end, yellow side steer cylinder
extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm
This list continues on the next page.

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1 2 3 4 5 6
CA CB CC CD CE CF

CAE
31
CAD
30

CAC
29
CAB
28
CAA CG
27 7

CZ
26 CH
8
CY
25
CX CI
24 9

CJ
10
CW
23
CV CK
22 11

CU CL
21 12
CM
CT 13
20
CN
14
CS
19 CO
15

CR CQ CP
18 17 16

Part No. 88619 Z-80/60 4 - 89

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MANIFOLDS REV E

Four Wheel Steer and Oscillate Manifold, continued

Index Schematic
No. Description Item Function Torque

13 Check valve ....................................... CM ........ Load sensing circuit, circle end

blue side steer cylinder retract ............ 8-10 ft-lbs / 11-14 Nm
14 Check valve ....................................... CN ........ Load sensing circuit, circle end
blue side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm
15 Check valve ....................................... CO ........ Load sensing circuit, circle end
yellow side steer cylinder extend ........ 8-10 ft-lbs / 11-14 Nm
16 Solenoid valve, 3 position 4 way ....... CP ........ Steer left/right, circle end
blue side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm
17 Solenoid valve, 3 position 4 way ....... CQ ........ Steer left/right, circle end
yellow side steer cylinder .................. 26-30 ft-lbs / 35-41 Nm
18 Flow regulator valve,
1.2 gpm / 4.5 L/min
(before serial number 928)
1.5 gpm / 5.7 L/min
(after serial number 927) ................... CR ........ Square end, left side steer
cylinder retract circuit ........................ 26-30 ft-lbs / 35-41 Nm
19 Check valve ....................................... CS ........ Load sensing circuit, square end
blue side steer cylinder retract .......... 20-25 ft-lbs / 27-34 Nm
20 Check valve, 65 psi / 4.5 bar ............. CT ......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
21 Check valve, 65 psi / 4.5 bar ............. CU ........ Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
22 Flow regulator valve,
2.3 gpm / 8.7 L/min ............................ CV ........ Square end, yellow side steer
cylinder extend circuit ....................... 20-25 ft-lbs / 27-34 Nm
23 Flow regulator valve,
1.2 gpm / 4.5 L/min
(before serial number 928)
1.5 gpm / 5.7 L/min
(after serial number 927) ................... CW ....... Square end, yellow side steer
cylinder retract circuit ........................ 26-30 ft-lbs / 35-41 Nm
24 Flow regulator valve,
2.3 gpm / 8.7 L/min ............................ CX ........ Square end, blue side steer
cylinder extend circuit ....................... 20-25 ft-lbs / 27-34 Nm
25 Check valve ....................................... CY ........ Load sensing circuit, square end
yellow side steer cylinder retract ........ 8-10 ft-lbs / 11-14 Nm
26 Check valve, 65 psi / 4.5 bar ............. CZ ......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
27 Check valve, 65 psi / 4.5 bar ............. CAA ...... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
28 Check valve ....................................... CAB ...... Load sensing circuit, square end
yellow side steer cylinder extend ........ 8-10 ft-lbs / 11-14 Nm

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REV E MANIFOLDS

1 2 3 4 5 6
CA CB CC CD CE CF

CAE
31
CAD
30

CAC
29
CAB
28
CAA CG
27 7

CZ
26 CH
8
CY
25
CX CI
24 9

CJ
10
CW
23
CV CK
22 11

CU CL
21 12
CM
CT 13
20
CN
14
CS
19 CO
15

CR CQ CP
18 17 16

Part No. 88619 Z-80/60 4 - 91

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MANIFOLDS REV E

Four Wheel Steer and Oscillate Manifold, continued

Index Schematic
No. Description Item Function Torque

29 Check valve ....................................... CAC ...... Load sensing circuit, square end
blue side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm
30 Check valve, 65 psi / 4.5 bar ............. CAD ...... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
31 Check valve, 65 psi / 4.5 bar ............. CAE ...... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm

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REV E MANIFOLDS

1 2 3 4 5 6
CA CB CC CD CE CF

CAE
31
CAD
30

CAC
29
CAB
28
CAA CG
27 7

CZ
26 CH
8
CY
25
CX CI
24 9

CJ
10
CW
23
CV CK
22 11

CU CL
21 12
CM
CT 13
20
CN
14
CS
19 CO
15

CR CQ CP
18 17 16

Part No. 88619 Z-80/60 4 - 93

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MANIFOLDS REV E

8-10
Four Wheel Steer and Oscillate Manifold
(from serial number 990)

The Four Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the
machine.
Index Schematic
No. Description Item Function Torque

1 Solenoid valve, 3 position 4 way ....... KA ......... Steer left/right, square end
yellow side steer cylinder .................. 26-30 ft-lbs / 35-41 Nm
2 Solenoid valve, 3 position 4 way ....... KB ......... Steer left/right, square end
blue side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm
3 Check valve ....................................... KC ........ Load sensing circuit, circle end
yellow side steer cylinder retract ........ 8-10 ft-lbs / 11-14 Nm
4 Check valve, 65 psi / 4.5 bar ............. KD ........ Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
5 Solenoid valve, 2 position 3 way ....... KE ......... Oscillate cylinder, blue side .............. 26-30 ft-lbs / 35-41 Nm
6 Solenoid valve, 2 position 3 way ....... KF ......... Oscillate cylinder, yellow side ........... 26-30 ft-lbs / 35-41 Nm
7 Check valve, 65 psi / 4.5 bar ............. KG ........ Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
8 Relief valve,
750 to 860 psi / 51.71 to 59.3 bar ..... KH ........ Oscillate circuit .................................. 20-25 ft-lbs / 27-34 Nm
9 Flow regulator valve,
1.5 gpm / 5.7 L/min ............................ KI .......... Circle end, blue side steer cylinder
extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm
10 Flow regulator valve,
1.0 gpm / 3.8 L/min ............................ KJ ......... Circle end, blue side steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
11 Flow regulator valve,
1.0 gpm / 3.8 L/min ............................ KK ......... Circle end, yellow side steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
12 Flow regulator valve,
1.5 gpm / 5.7 L/min ............................ KL ......... Circle end, yellow side steer cylinder
extend circuit ..................................... 20-25 ft-lbs / 27-34 Nm
13 Check valve ....................................... KM ........ Load sensing circuit, circle end
blue side steer cylinder retract ............ 8-10 ft-lbs / 11-14 Nm
14 Check valve ....................................... KN ........ Load sensing circuit, circle end
blue side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm
15 Check valve ....................................... KO ........ Load sensing circuit, circle end
yellow side steer cylinder extend ........ 8-10 ft-lbs / 11-14 Nm
This list continues on the next page.

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1 2 3 4 5 6
KA KB KC KD KE KF

KAE
31
KAD
30

KAC
29
KAB
28
KAA KG
27 7

KZ
26 KH
8
KY
25
KX KI
24 9

KJ
10
KW
23
KV KK
22 11

KU KL
21 12
KM
KT 13
20
KN
14
KS
19 KO
15

KR KQ KP
18 17 16

Part No. 88619 Z-80/60 4 - 95

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MANIFOLDS REV E

Four Wheel Steer and Oscillate Manifold, continued

Index Schematic
No. Description Item Function Torque

16 Solenoid valve, 3 position 4 way ....... KP ......... Steer left/right, circle end
blue side steer cylinder ..................... 26-30 ft-lbs / 35-41 Nm
17 Solenoid valve, 3 position 4 way ....... KQ ........ Steer left/right, circle end
yellow side steer cylinder .................. 26-30 ft-lbs / 35-41 Nm
18 Flow regulator valve,
1.0 gpm / 3.8 L/min ............................ KR ........ Square end, left side steer
cylinder retract circuit ........................ 20-25 ft-lbs / 27-34 Nm
19 Check valve ....................................... KS ......... Load sensing circuit, square end
blue side steer cylinder retract .......... 20-25 ft-lbs / 27-34 Nm
20 Check valve, 65 psi / 4.5 bar ............. KT ......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
21 Check valve, 65 psi / 4.5 bar ............. KU ........ Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
22 Flow regulator valve,
1.5 gpm / 5.7 L/min ............................ KV ......... Square end, yellow side steer
cylinder extend circuit ....................... 20-25 ft-lbs / 27-34 Nm
23 Flow regulator valve,
1.0 gpm / 3.8 L/min ............................ KW ........ Square end, yellow side steer
cylinder retract circuit ........................ 26-30 ft-lbs / 35-41 Nm
24 Flow regulator valve,
1.5 gpm / 5.7 L/min ............................ KX ......... Square end, blue side steer
cylinder extend circuit ....................... 20-25 ft-lbs / 27-34 Nm
25 Check valve ....................................... KY ......... Load sensing circuit, square end
yellow side steer cylinder retract ........ 8-10 ft-lbs / 11-14 Nm
26 Check valve, 65 psi / 4.5 bar ............. KZ ......... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
27 Check valve, 65 psi / 4.5 bar ............. KAA ...... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
28 Check valve ....................................... KAB ...... Load sensing circuit, square end
yellow side steer cylinder extend ........ 8-10 ft-lbs / 11-14 Nm
29 Check valve ....................................... KAC ...... Load sensing circuit, square end
blue side steer cylinder extend ........... 8-10 ft-lbs / 11-14 Nm
30 Check valve, 65 psi / 4.5 bar ............. KAD ...... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
31 Check valve, 65 psi / 4.5 bar ............. KAE ...... Prevents steer cylinder from
moving when not steering ................. 20-25 ft-lbs / 27-34 Nm
This list continues on the next page.

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REV E MANIFOLDS

1 2 3 4 5 6
KA KB KC KD KE KF

KAE
31
KAD
30

KAC
29
KAB
28
KAA KG
27 7

KZ
26 KH
8
KY
25
KX KI
24 9

KJ
10
KW
23
KV KK
22 11

KU KL
21 12
KM
KT 13
20
KN
14
KS
19 KO
15

KR KQ KP
18 17 16

Part No. 88619 Z-80/60 4 - 97

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MANIFOLDS REV E

How to Adjust the Oscillate

Relief Valve
Note: Perform this procedure with the boom in the
stowed position.

Note: This procedure will require two people.

1 Remove the drive chassis cover from the
square-end of the machine.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the steer/oscillate
manifold.
3 Start the engine from the platform controls.
4 Press down the foot switch and manually
activate one of the oscillate limit switches. Hold
the switch in the activated position and observe
the reading on the pressure gauge. Refer to
Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold the
relief valve and loosen the jam nut. (item CH,
before SN 1301 or item KH, after SN 1300).
6 Adjust the stud with a hex wrench. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Repeat steps 3 through 4 to confirm relief valve
pressure.
8 Remove the pressure gauge.
9 Install the drive chassis cover.

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June 2011 Section 4 • Repair Procedures

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8-11
Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
No. Description Item Function Torque

1 Pilot Operated Directional valve,

2 position 3 way ............................ CBA .......... Activates generator ...................... 80-90 ft-lbs / 108-122 Nm
2 Orifice disc,
0.031 inch / 0.79 mm ..................... CBB .......... Delays shift to drive ......................... 35-40 ft-lbs / 47-54 Nm
3 Solenoid valve, 2 position 3 way .. CBC ......... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve,
280 psi @ 3.5 gpm / 19.3 bar @
13.2 L/min ...................................... CBD ......... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
5 Pressure switch 200 psi / 18.6 bar CBE .......... Generator relay switch ................................ 16 ft-lbs / 22 Nm
6 Connector fitting ...................................................................................................................... 11 ft-lbs / 15 Nm
7 Check valve ................................... CBF .......... Prevents oil flowing into generator .. 35-40 ft-lbs / 47-54 Nm

Part No. 88619 Z-80/60 4 - 99

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MANIFOLDS REV E

8-12
Traction Manifold, 2WD
The 2WD traction manifold is mounted inside the drive chassis at the circle-end of the machine.

Index Schematic
No. Description Item Function Torque
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 of
temporary 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 that
directs hot oil out of low pressure
side 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 motors
in forward and reverse ................ 90-100 ft-lbs / 122-136 Nm

4 - 100 Z-80/60 Part No. 88619

June 2011 Section 4 • Repair Procedures

REV E MANIFOLDS

1 2 3
EA EB EC

ED
4

EE
5
EJ
10

EI EF
9 6

EH
8

EG
7

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MANIFOLDS REV E

8-13 10 Press and hold the function enable/high rpm

select button (rabbit symbol) position.
Valve Adjustments, 2WD
11 Adjust the internal hex socket until the pressure
Traction Manifold reading on the gauge is 40 psi / 2.8 bar less
than the pressure reading taken in step 5. Turn
How to Adjust the Charge it clockwise to increase the pressure or
Pressure Relief Valve counterclockwise to decrease the pressure.
Install the valve cap.
Note: Perform this procedure with the hydraulic oil
12 Turn the engine off and remove the pressure
temperature from 100°F to 150°F / 38°C to 65.5°C.
gauge.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2 Use a wrench to hold the charge pressure relief
valve and remove the cap (item EG).
3 Turn the internal hex socket fully in a clockwise
direction until it stops. Install the cap.
4 Start the engine from the ground controls.
5 Press and hold the function enable/high rpm
select button (rabbit symbol) position. Note the
reading on the pressure gauge.
6 Turn the engine off.
7 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the drive manifold.
8 Use a wrench to hold the charge pressure relief
valve and remove the cap from the valve
(item EG).
9 Start the engine from the ground controls.

4 - 102 Z-80/60 Part No. 88619

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REV E MANIFOLDS
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MANIFOLDS REV E

8-14
Traction Manifold, 4WD
The 4WD traction manifold is mounted inside the drive chassis at the circle-end of the machine.

Index Schematic
No. Description Item Function Torque
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 of
temporary loss of charge pressure ... 20-25 ft-lbs / 27-34 Nm
5 Shuttle valve, 3 position 3 way .......... FE ......... Charge pressure circuit that
directs hot oil out of low pressure
side 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 end
drive motors in forward
and 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 end
drive motors in forward
and 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

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REV E MANIFOLDS

1 2 3 4 5
FA FB FC FD FE

FR
18

FQ
17

FF
6
FP
16

FO
15
FG
7
FN
14

FM
13 FH
8

FI
9

FJ
10

FL FK
12 11

Part No. 88619 Z-80/60 4 - 105

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MANIFOLDS REV E

8-15 10 Press and hold the function enable/high rpm

select button (rabbit symbol).
Valve Adjustments, 4WD
11 Adjust the internal hex socket until the pressure
Traction Manifold reading on the gauge is 40 psi / 2.8 bar less
than the pressure reading taken in step 5. Turn
How to Adjust the Charge it clockwise to increase the pressure or
Pressure Relief Valve counterclockwise to decrease the pressure.
Install the valve cap.
Note: Perform this procedure with the hydraulic oil
12 Turn the engine off and remove the pressure
temperature must be 100°F to 150°F / 38°C to
gauge.
65.5°C.

1 Connect a 0 to 600 psi / 0 to 50 bar pressure

gauge to the test port on the drive pump.
2 Use a wrench to hold the charge pressure relief
valve and remove the cap (item FF).
3 Turn the internal hex socket fully in a clockwise
direction until it stops. Install the cap.
4 Start the engine from the ground controls.
5 Press and hold the function enable/high rpm
select button (rabbit symbol) position. Note the
reading on the pressure gauge.
6 Turn the engine off.
7 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the drive manifold.
8 Use a wrench to hold the charge pressure relief
valve and remove the cap from the valve
(item FF).
9 Start the engine from the ground controls.

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June 2011
REV E
8-16
Valve Coils
How to Test a Coil
A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance or infinite resistance
indicates the coil has failed.
Since coil resistance is sensitive to temperature,
resistance values outside specification can
produce erratic operation. When coil resistance
decreases below specification, amperage
increases. As resistance rises above specification,
voltage increases.
While valves may operate when coil resistance is
outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to
be tested.
2 Test the coil resistance using a multimeter set
to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
Part No. 88619
Section 4 • Repair Procedures
MANIFOLDS
Valve Coil Resistance
Specifications
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / 20°C
that your air temperature increases or decreases
from 68°F / 20°C.
Valve coil resistance specifications
Proportional solenoid valve, 12V DC 4.8 Ω
(schematic items G, W and AB)
Proportional solenoid valve, 12V DC 9Ω
(schematic items R)
3 position 4 way solenoid valve, 12V DC 9Ω
(schematic items BA, BB, CA, CB, CP, CQ,
GB, GP and GQ)
3 position 4 way solenoid valve, 10V DC 6.3 Ω
(schematic items O and S)
2 position 2 way solenoid valve, 10V DC 3.3 Ω
(schematic items J)
2 position 2 way solenoid valve, 10V DC 6.3 Ω
(schematic items C and P)
2 position 3 way solenoid valve, 10V DC 6.3 Ω
(schematic items H, V, X, Z, AA, EE and EF)
2 position 3 way solenoid valve, 12V DC 9Ω
(schematic items BC, BD, CE, CF,
FB and FC)
Z-80/60 4 - 107
Section 4 • Repair Procedures June 2011

MANIFOLDS REV E

How to Test a Coil Diode COIL

a
Properly functioning coil diodes protect the MULTI
d METER
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current c -
to a coil. Faulty diodes can fail to protect the

+
b
electrical system, resulting in a tripped circuit 10 W 9V
breaker or component damage. RESISTOR BATTERY

Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
1 Test the coil for resistance. See 8-14, How to
Test a Coil.
2 Connect a 10Ω resistor to the negative terminal
of a known good 9V DC battery. Connect the
other end of the resistor to a terminal on the
coil.
Ω
Resistor, 10Ω
Genie part number
Note: The battery should read 9V DC or more
when measured across the terminals.
+
c - b
a multimeter
b 9V DC battery
c 10Ω resistor
d coil
Note: Dotted lines in illustration indicate a
reversed connection as specified in
step 6
3 Set a multimeter to read DC current.
Note: The multimeter, when set to read DC
current, should be capable of reading up to 800
mA.
27287
4 Connect the negative lead to the other terminal
on the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V DC
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.

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REV B E
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Turntable Rotation Components
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9-1 4 Attach a lifting strap from an overhead crane or

Turntable Rotation Assembly
How to Remove a Turntable
Rotation Assembly
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
Note: Perform this procedure with the platform
between the circle-end tires and with the machine
on a firm, level surface.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
unlocked locked
2 Remove the ground controls side fixed turntable
cover.
3 Tag, disconnect the hydraulic hoses from the
turntable rotation motor. Cap the fittings on the
motor.
other suitable lifting device to the lifting eye on
the turntable rotation assembly.
5 Remove the turntable rotator mounting bolts
and remove the turntable rotation assembly
from the machine.
6 Repeat steps 3 through 5 for the other turntable
rotation assembly.
Tip-over hazard. If the turntable
rotation lock pin is not properly
installed, machine stability is
compromised and the machine
could tip over when the drive hub
is removed from the machine,
which will result in death or
serious injury.
Crushing hazard. The drive hub
could become unbalanced and fall
if not properly supported by the
overhead crane or lifting device
when removed from the machine.
Note: When installing a turntable rotation
assembly, the rotation gear backlash must be
adjusted. See 9-1, Adjust the Turntable Rotation
Gear Backlash.

Part No. 88619 Z-80/60 4 - 109

Section 4 • Repair Procedures June 2011

TURNTABLE ROTATION COMPONENTS REV B

How to Adjust the Turntable 7 Rotate the backlash pivot plate away from the
turntable until it contacts the adjustment bolt.
Rotation Gear Backlash Torque the mounting fasteners on the backlash
The turntable rotation drive hub is mounted on an pivot plate to specification. Refer to Section 2,
adjustable plate that controls the gap between the Specifications.
rotation motor pinion gear and the turntable 8 Rotate the turntable through an entire rotation.
bearing ring gear. Check for tight spots that could cause binding.
Readjust if necessary.
Note: Perform this procedure with the platform
between the circle-end tires and with the machine
on a firm, level surface.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
2 Loosen the backlash pivot plate mounting
fasteners.
3 Push the backlash pivot plate towards the
turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
gear).
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
6 Turn the adjustment bolt 1/2 turn
counterclockwise. Tighten the lock nut on the
adjustment bolt.

4 - 110 Z-80/60 Part No. 88619

June 2011
REV B
10-1
Steer Sensors
The steer sensor measures steer angle and
communicates that information to the ground
controls ECM. The steer sensor on the ground
controls side of the machine at the square end acts
as the lead sensor. The other three sensors follow
the position, or steer angle, of the lead sensor.
There is a steer sensor mounted to the top of each
upper yoke pivot pin.
Note: If the square-end steering function becomes
inoperative, switch to circle-end steer mode and
the ground controls side circle-end steer sensor
will become the lead sensor.
Note: This procedure will require a minimum of two
people.
How to Measure the Tire
Alignment
1 Start the engine from the platform controls.
2 Press down the foot switch.
Measure the circle-end tires:
3 Press the square-end steer mode button.
Part No. 88619 Z-80/60
Section 4 • Repair Procedures
Axle Components
4 Measure the distance between the inside of one
circle-end tire and the chassis side plate on
both sides of the axle.
Result: Both measurements should be the
same to indicate that the tires are parallel with
the chassis.
Note: If the measurements are different or if a tire
is not parallel with the chassis, the steer sensor of
that tire will need to be adjusted. See How to
Adjust a Steer Sensor.
5 Repeat step 4 for the other circle-end tire.
Measure the square-end tires:
6 Press the circle-end steer mode button.
7 Measure the distance between the inside of one
square-end tire and the chassis side plate on
both sides of the axle.
Result: Both measurements should be the
same to indicate that the tires are parallel with
the chassis.
Note: If the measurements are different or if a tire
is not parallel with the chassis, the steer sensor of
that tire will need to be adjusted. See How to
Adjust a Steer Sensor.
8 Repeat step 4 for the other square-end tire.
4 - 111
Section 4 • Repair Procedures
AXLE COMPONENTS
How to Adjust a Steer Sensor
1 Start the engine from the platform controls.
2 Press down the foot switch and push the engine
idle select button until the engine switches to
high rpm.
Square-end steer sensors:
3 At the platform controls, press the circle-end
steer mode button.
4 Locate the steer sensor on top of the yoke pivot
pin.
5 Loosen the steer sensor cover retaining
fasteners. Do not remove them.
6 Rotate the steer sensor cover either clockwise
or counterclockwise. Measure the distance
between the inside of tire and the chassis side
plate on both sides of the axle.
7 Repeat step 4 until the tire is parallel with the
chassis.
8 Tighten the steer sensor cover fasteners.
9 Repeat steps 2 through 6 for the other square-
end steer sensor.
4 - 112
June 2011
REV B
Circle-end steer sensors:
10 At the platform controls, press the square-end
steer mode button.
11 Locate the steer sensor on top of the yoke pivot
pin.
12 Loosen the steer sensor cover retaining
fasteners. Do not remove them.
13 Rotate the steer sensor cover either clockwise
or counterclockwise. Measure the distance
between the inside of tire and the chassis side
plate on both sides of the axle.
14 Repeat step 4 until the tire is parallel with the
chassis.
15 Tighten the steer sensor cover fasteners.
16 Repeat steps 9 through 13 for the other circle-
end steer sensor.
17 At the platform controls, press the four-wheel
steer mode button. Measure the distance
between the inside of the tire and the chassis
side plate on both sides of the axle on each tire.
18 If any tire is not parallel, repeat the process
beginning with step 3.
Z-80/60 Part No. 88619
June 2011
REV B
How to Calibrate the Steer
Sensors
If a steer sensor reaches the limit of travel before a
tire is adjusted parallel to the chassis, the steer
sensor must be calibrated. This procedure will re-
establish a center position on the steer sensor.
Note: Perform this procedure with the machine in
the stowed position.
Note: This procedure will require two people.
1 Start the engine from the platform controls.
2 Press down the foot switch.
3 Choose a steer mode based on the tire that
needs alignment.
Note: If a circle-end tire cannot be aligned, press
the square-end steer mode button. If a square-end
tire cannot be aligned, press the circle-end steer
mode button.
4 Loosen the steer sensor cover retaining
fasteners. Do not remove them.
5 Rotate the steer sensor cover either clockwise
or counterclockwise to bring the tire as close to
alignment as possible.
6 Turn off the engine.
7 Press and hold the enter button on the
ground control panel while pulling out the
ground controls red Emergency Stop button to
the on position. Hold the enter button for
approximately 5 seconds and then release it.
8 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
sequence: .
Part No. 88619
Section 4 • Repair Procedures
AXLE COMPONENTS
9 Use the button to scroll through the menu
until the appropriate steer sensor is displayed.
Choose from:
RESET BLUE END BLUE SIDE STEER SENSOR
RESET YELLOW END BLUE SIDE STEER SENSOR
RESET YELLOW END YELLOW SIDE STEER SENSOR,
RESET BLUE END YELLOW SIDE STEER SENSOR.
Press the button to select YES, then press
the button.
10 Exit the sensor calibration mode and turn the
keyswitch to the off position.
11 Rotate the steer sensor to the opposite limit of
travel.
12 Using a voltmeter set to DC voltage, probe the
back of the steer sensor electrical connector at
pins B and C.
13 Turn the keyswitch on at the ground controls.
Rotate the sensor slowly until the voltage
reading is between 2.4 to 2.5V DC. The alarm
at the ground control box should sound.
14 Turn the keyswitch to platform controls. Start
the engine from the platform controls.
15 Press down the foot switch.
16 Rotate the steer sensor cover to adjust the tire
alignment. Measure the distance between the
inside of the tire and the chassis side plate on
both sides of the axle.
17 Repeat step 14 until the tire is parallel with the
chassis.
18 Tighten the steer sensor cover fasteners.
Z-80/60 4 - 113
Section 4 • Repair Procedures
AXLE COMPONENTS
10-2
Hub and Bearings, 2WD Models
How to Remove the
Hub and Bearings, 2WD Models
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steer wheels.
3 Center a lifting jack with a minimum capacity of
25,000 lbs / 12000 kg under the drive chassis
between the steer wheels.
4 Raise the machine 6 inches / 15 cm and place
blocks under the chassis for support.
Crushing hazard. The machine
may fall if not properly supported.
5 Remove the lug nuts. Remove the tire and
wheel assembly.
6 Remove the dust cap, cotter pin and
castle nut.
Note: Always use a new cotter pin when installing
a castle nut.
7 Pull the hub off the spindle. The washer and
outer bearing should fall loose from the hub.
8 Place the hub on a flat surface and gently pry
the bearing seal out of the hub.
9 Remove the rear bearing.
4 - 114
June 2011
REV B
How to Install the Hub and
Bearings, 2WD Models
Note: When replacing a wheel bearing, both the
inner and outer bearings including the pressed-in
races must be replaced.
1 Be sure that both bearings are packed
with clean, fresh grease.
2 Place the large inner bearing into the rear
of the hub.
3 Press the bearing seal evenly into the hub
until it is flush.
4 Slide the hub onto the yoke spindle.
Component damage hazard. Do
not apply excessive force or
damage to 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 158 ft-lbs / 214 Nm to
seat the bearing.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.
8 Loosen the castle nut one turn, and then torque
to 35 ft-lbs / 47 Nm.
9 Install a new cotter pin. Bend the cotter pin
to secure the castle nut.
Note: Always use a new cotter pin when installing
a castle nut.
10 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
specification. Refer to Section 2, Specifications.
Z-80/60 Part No. 88619
June 2011 Section 4 • Repair Procedures

REV B AXLE COMPONENTS

How to Adjust the Oscillate Limit
Switches
Tip-over hazard. Failure to
perform this procedure on a firm,
level surface could compromise
the stability of the machine and
could cause the machine to tip
over which will result in death or
serious injury.
Note: Perform this procedure with the machine on
a firm, level surface that is free of obstructions.
Use a digital level to confirm.
Note: This procedure will require two people.
1 Lower the boom to the stowed position.
2 Remove the drive chassis cover from the
circle-end of the machine.
6 Loosely install the limit switches. Using a feeler
gauge, establish a gap of 0.015 - 0.030 inches
/ 0.381 - 0.762 mm between the limit switch
plunger and the top of the axle.
7 Carefully hold the position of each limit switch
and 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 and
the top of the axle.
9 Measure the distance between the drive
chassis and the axle on both sides (from the
inside of the drive chassis).
Result: The measurements should be equal.
Note: If the distance is not equal and the
adjustment to the limit switches was completed
with the ground and drive chassis level, consult
Genie Industries Service Department.

3 Remove the oscillate axle limit switch mounting

fasteners. Remove the limit switches.
Note: The oscillate axle limit switches are located
inside the drive chassis above the axle.

4 Place a digital level on the turntable rotate

bearing plate.
5 Start the engine and level the drive chassis.
Press down the foot switch and manually
activate the oscillate limit switches until the
machine is completely level.

Part No. 88619 Z-80/60 4 - 115

Section 4 • Repair Procedures
AXLE COMPONENTS
10-3
Oscillating Axle Cylinders
The oscillating axle cylinders extend and retract
between the drive chassis and the oscillating axle.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a
hydraulic line failure. The valves are not
adjustable.
How to Remove an Oscillating
Axle Cylinder
Note: Perform this procedure on a firm, level
surface with the boom in the stowed position.
Note: When removing a hose assembly or fitting,
the O-ring on the fitting and/or hose end must be
replaced and then torqued to specification during
installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Rotate the boom until the turntable
counterweight is between the circle-end and
square-end tires.
4 - 116 Z-80/60
June 2011
REV B
2 Tag, disconnect and plug the oscillating axle
cylinder hydraulic hoses. Cap the fittings on the
oscillate cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
3 Remove the pin retaining fasteners from the
oscillate cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
4 Attach a lifting strap from an overhead crane to
the barrel end of the oscillating cylinder.
5 Remove the pin retaining fasteners from the
oscillate cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
Crushing hazard. The oscillate
cylinder may become unbalanced
and fall if not properly supported
when removed from the machine.
6 Remove the oscillate cylinder from the machine.
Part No. 88619
June 2011
REV B
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
· Machine parked on a firm, level surface
· 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
· All external AC power supply disconnected
from the machine
Part No. 88619 Z-80/60
Section 5 • Fault Codes
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Operator's Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Read each appropriate fault code thoroughly.
Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Crushing hazard. When testing
or replacing any hydraulic
component, always support
the structure and secure it
from movement.
Electrocution hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
Note: Two persons will be required to safely
perform some troubleshooting procedures.
5-1
Section 5 • Fault Codes June 2011

1234567890123456789012
1234567890123456789012
CONTROL SYSTEM FAULT CODES 1234567890123456789012
REV B C
1234567890123456789012

Fault Diagnostics -
Control System

How to Read Control System Fault

Codes
Note: Initial fault testing occurs at power-up.

Faults are abnormal conditions that exist due to

component failure or System misuse. CPU,
memory, LCD, LED, limited joystick and limited
operator switch testing is done on power-up. If
an operator switch is depressed on power-up,
the display should show and error and not allow
any machine functions.
Releasing the switch will clear the error and
allow all machine functions. The joystick
operates similarly.
All other fault testing is done continuously.
1 When a fualt is diagnosed, the PCON fault
indicator will flash and a fault message will be
displayed on the TCON LCD. The message will
contain the fault source and type.
2 Additional information, including the occurrence
counter and a time-stamp is available with a
PC, connected to one of the RS232 ports. Up
to 30 unique fault messages can be saved.
Each fault is saved with the device identity, fault
type, engine hour time-stamp and an 8-bit
occurrence counter.
3 The fault code table on the following pages lists
the functions or components monitored by the
system and recovery actions.

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

June 2011 Section 5 • Fault Codes

12345678901234567890123
12345678901234567890123
12345678901234567890123
REV C B CONTROL SYSTEM FAULT CODES
12345678901234567890123

Error Source Error Type Effects Recovery Actions

Normal func tion except thres hold for
Not c alibrated one or the other direc tion is z ero. Calibrate thres holds.
Dis play mess age on LCD.
Initiate one s ec ond beep of audible
Just c alibrated Self-c learing (trans ient)
PRIMARY BO O M EXT/RET warning dev ice.
FLO W VALVE Value at 5.0 V

Value Too High Limited speed and direc tion froz en Power up controller with the
at zero and neutral, alarm s ounds .. problem correc ted.
Value Too Low
Value at 0 V
PRI BO O M EXT VALVE
PRI BO O M RET VALVE Limited speed and direc tion froz en Power up controller with the
Fault c hec k
PRI BO O M UP VALVE at zero and neutral, alarm s ounds .. problem correc ted.
PRI BO O M DO WN VALVE
Stop all sec ondary boom functions,
Fault c hec k Power up controller with the
SEC BO O M LENG TH allow only s ec ondary boom retrac t.
(unknown length) problem correc ted.
Dis play mess age on LCD.
Stop all sec ondary boom functions,
allow only s ec ondary boom retrac t.
Fault c hec k Power up controller with the
SEC BO O M ANG LE O nce the boom is retrac ted allow
(unk nown angle) problem correc ted.
s econdary boom down. Display
mes sage on LCD.
SEC BO O M UP/DO WN Dis play mes sage on LCD and allow
Not c alibrated Perform auto calibrate procedure.
SPEED operation at default speed.
Normal func tion except thres hold for
Not c alibrated one or the other direc tion is z ero. Calibrate thres holds.
Dis play mess age on LCD.
SEC BO O M Initiate one s ec ond beep of audible
Just c alibrated Self-c learing (trans ient)
UP/DO WN/EXT/RET warning dev ice.
FLO W VALVE Value at 5.0 V
Value Too High Limited speed and direc tion froz en Power up controller with the
Value Too Low at zero and neutral, alarm s ounds .. problem correc ted.
Value at 0 V
SEC BO O M EXT VALVE
SEC BO O M RET VALVE
SEC BO O M UP VALVE
Limited speed and direc tion froz en Power up controller with the
Fault c hec k
SEC BO O M DO WN VALVE at zero and neutral, alarm s ounds .. problem correc ted.

SEC EXT SEQ VALVE

SEC DWN SEQ VALVE

Continued on next page

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

Section 5 • Fault Codes June 2011

CONTROL SYSTEM FAULT CODES REV C

Error Source Error Type Effects Recovery Actions

Range check
ENGINE SPEED
(underspeed)
Range check (low oil Power up controller with the problem
OIL PRESSURE Display message on LCD.
pressure) corrected.
Range check (high
WATER/OIL TEMP
temperature)
OIL PRESSURE SENSOR
Power up controller with the problem
Fault check Display message on LCD.
WATER/OIL TEMP SENSOR corrected.

Axle extend/retract disabled, display Power up controller with the problem

AXLE EXT/RET BUTTONS
message on LCD. corrected.
Power up controller with the problem
CAN BUS Fault check Display message on LCD.
corrected.
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
Value too low zero and neutral, alarm sounds. corrected.
PRIMARY BOOM UP/DOWN Value at 0 V
JOYSTICK
Joystick Speed and Direction frozen at
Not calibrated Calibrate joystick.
zero and neutral
Initiate one second beep of audible
Just calibrated Self-clearing (transient)
warning device.
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
Value too low zero and neutral, alarm sounds. corrected.
SECONDARY BOOM Value at 0 V
JOYSTICK
Joystick speed and direction frozen at
Not calibrated Calibrate joystick.
zero and neutral.
Initiate one second beep of audible
Just calibrated Self-clearing (transient)
warning device.
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
Value too low zero and neutral, alarm sounds. corrected.
PRIMARY
EXTEND/RETRACT Value at 0 V
JOYSTICK Joystick speed and direction frozen at
Not calibrated Calibrate joystick.
zero and neutral.
Initiate one second beep of audible
Just calibrated Self-clearing (transient)
warning device.

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

June 2011 Section 5 • Fault Codes

REV C CONTROL SYSTEM FAULT CODES

Error Source Error Type Effects Recovery Actions

Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
Value too low zero and neutral, alarm sounds. corrected.
STEER JOYSTICK Value at 0 V
Joystick speed and direction frozen at
Not calibrated Calibrate joystick.
zero and neutral.
Initiate one second beep of audible
Just calibrated Self-clearing (transient)
warning device.
PRIMARY BOOM UP/DOWN Fault Check, (both Primary boom up/down disabled, Power up controller with the problem
SWITCHES ON TCON buttons pressed) display message on LCD. corrected.
SEC BOOM Secondary boom up/extend and
Fault Check, (both Power up controller with the problem
UP/EXT/DWN/RET down/retract disabled, display message
buttons pressed) corrected
SWITCHES ON TCON on LCD.
PRIMARY BOOM EXT/RET Fault Check, (both Primary boom extend/retract disabled, Power up controller with the problem
SWITCHES ON TCON buttons pressed) display message on LCD. corrected.
Fault check Power up controller with the problem
PRIMARY BOOM LENGTH Display message on LCD.
(unknown length) corrected.
Fault check Allow only primary boom retract and Power up controller with the problem
PRIMARY BOOM ANGLE
(unknown angle) down. Display message on LCD. corrected.
Display message on LCD and allow
PRIMARY UP/DOWN SPEED Not calibrated Perform auto calibrate procedure.
operation at default speed.
PRIMARY Display message on LCD and allow
Not calibrated Perform auto calibrate procedure.
EXTEND/RETRACT SPEED operation at default speed.
Normal function except threshold for
Not calibrated one or the other direction is zero. Calibrate thresholds.
Display message on LCD.
Initiate one second beep of audible
PRIMARY BOOM UP/DOWN Just calibrated Self-clearing (transient)
warning device.
FLOW VALVE Value at 5.0 V
Value Too High Limited speed and direction frozen at Power up controller with the problem
Value Too Low zero and neutral, alarm sounds.. corrected.
Value at 0 V

Continued on next page

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

Section 5 • Fault Codes June 2011

CONTROL SYSTEM FAULT CODES REV C

Error Source Error Type Effects Recovery Actions

Display message on LCD.
SAFETY SWITCH P3
P3 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P6R1
P6R1 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P6R2
P6R2 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P7
P7 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P7R
P7R SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P9A
P9A SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P9B
P9B SAFETY SWITCH FAULT
Display message on LCD. Power up controller with the problem
SAFETY SWITCH P10 Fault check
P10 SAFETY SWITCH FAULT corrected.
Display message on LCD.
SAFETY SWITCH P11
P11 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P12
P12 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P14
P14 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P18
P18 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P22
P22 SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P22R
P22R SAFETY SWITCH FAULT
Display message on LCD.
SAFETY SWITCH P30
P30 SAFETY SWITCH FAULT
PLATFORM OVERLOAD
SENSOR
BOOM UP OVERLOAD Power up controller with the problem
Fault check (if active) Display message on LCD.
corrected.
BOOM DOWN OVERLOAD

SHUT DOWN MODE

5-6 Z-80/60 Part No. 88619

June 2011 Section 5 • Fault Codes

REV C CONTROL SYSTEM FAULT CODES

Error Source Error Type Effects Recovery Actions

Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
Value too low zero and neutral, alarm sounds. corrected.
TURNTABLE ROTATE Value at 0 V
JOYSTICK
Joystick speed and direction frozen at
Not calibrated Calibrate joystick.
zero and neutral.
Initiate one second beep of audible
Just calibrated Self-clearing (transient)
warning device.
TURNTABLE ROTATE Fault Check, (both Turntable rotate disabled, display Power up controller with the problem
BUTTONS buttons pressed) message on LCD. corrected.
TURNTABLE ROTATE Display message on LCD and allow
Not calibrated Perform auto calibrate procedure.
SPEED operation at default speed.
Normal function except threshold for
Not calibrated one or the other direction is zero. Calibrate thresholds.
Display message on LCD.
Initiate one second beep of audible
TURNTABLE ROTATE FLOW Just calibrated Self-clearing (transient)
warning device.
VALVE Value at 5.0 V
Value Too High Limited speed and direction frozen at Power up controller with the problem
Value Too Low zero and neutral, alarm sounds. corrected.
Value at 0 V
TURNTABLE ROTATE CW
VALVE Limited speed and direction frozen at Power up controller with the problem
Fault check
TURNTABLE ROTATE CCW zero and neutral, alarm sounds. corrected.
VALVE
TURNTABLE LEVEL
SENSOR X-DIRECTION
TURNTABLE LEVEL Display message on LCD and sound
Fault check Correct problem.
SENSOR Y-DIRECTION audible alarm.
PLATFORM LEVEL SENSOR
Y-DIRECTION

Continued on next page

Part No. 88619 Z-80/60 5-7

Section 5 • Fault Codes June 2011

CONTROL SYSTEM FAULT CODES REV C

Error Source Error Type Effects Recovery Actions

Sound audible warning and flash
primary boom down LED at the
medium rate and display message on
Value at 5.0 V LCD screen PRI BOOM ANG SENSOR Correct problem.
SHORTED HIGH. Primary boom up
inhibited. Primary boom velocity limited
to 50% of default value.

Sound audible warning and flash

primary boom down LED at the
medium rate and display message on
PRIMARY BOOM ANGLE
Value at 0 V LCD screen PRI BOOM ANG SENSOR Correct problem.
SENSOR
SHORTED LOW. Primary boom up
inhibited. Primary boom velocity limited
to 50% of default value.

Sound audible warning at the medium

rate and display message on LCD
Calibrate primary boom angle
Not calibrated screen PRI BOOM ANG SENSOR
sensor.
NOT CALIBRATED, inhibit primary
boom up from platform control.
Initiate one second beep of audible
Just calibrated Self-clearing (transient)
warning device.
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
Value too low zero and neutral, alarm sounds. corrected.
PROPEL JOYSTICK Value at 0 V
Joystick speed and direction frozen at
Not calibrated Calibrate joystick.
zero and neutral.
Initiate one second beep of audible
Just calibrated Self-clearing (transient)
warning device.
Normal function except threshold for
Not calibrated one or the other direction is zero. Calibrate thresholds.
Display message on LCD.
PROPEL VALVES FWD Initiate one second beep of audible
PROPEL VALVES REV Just calibrated Self-clearing, (transient)
warning device.
PROPEL EDC FWD Value at 5.0 V
PROPEL EDC REV
Value Too High Limited speed and direction frozen at Power up controller with the problem
Value Too Low zero and neutral, alarm sounds. corrected.
Value at 0 V

5-8 Z-80/60 Part No. 88619

June 2011 Section 5 • Fault Codes

REV C CONTROL SYSTEM FAULT CODES

Error Source Error Type Effects Recovery Actions

MOTOR SPEED VALVE
BRAKE VALVE
AUX PROPEL VALVE
PLAT LEV UP VALVE
Limited speed and direction frozen at Power up controller with the problem
PLAT LEV DN VALVE Fault check
zero and neutral, alarm sounds. corrected.
PLAT ROT CW VALVE
PLAT ROT CCW VALVE
JIB UP VALVE
JIB DN VALVE
JIB SWITCHES Fault Check, (both Affected functions disabled, display Power up controller with the problem
PLAT ROT SWITCHES contacts closed) message on LCD. corrected.
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
Value too low zero and neutral, alarm sounds. corrected.
STEERING JOYSTICK Value at 0 V
Joystick speed and direction frozen at
Not calibrated Calibrate joystick.
zero and neutral.
Initiate one second beep of audible
Just calibrated Self-clearing (transient)
warning device.
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
LF STR ANG SNSR
Value too low zero and neutral, alarm sounds. corrected.
Value at 0 V
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
RF STR ANG SNSR
Value too low zero and neutral, alarm sounds. corrected.
Value at 0 V
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
LR STR ANG SNSR
Value too low zero and neutral, alarm sounds. corrected.
Value at 0 V
Value at 5.0 V
Value too high Limited speed and direction frozen at Power up controller with problem
RR STR ANG SNSR
Value too low zero and neutral, alarm sounds. corrected.
Value at 0 V
LF STEER VALVE
RF STEER VALVE Limited speed and direction frozen at Power up controller with the problem
Fault check
LR STEER VALVE zero and neutral, alarm sounds. corrected.
RR STEER VALVE
FOOTSWITCH TIMEOUT Display message on LCD display. Recycle power.

Continued on next page

Part No. 88619 Z-80/60 5-9

Section 5 • Fault Codes June 2011

CONTROL SYSTEM FAULT CODES REV C

Control System Fault Codes Using the TCON LCD

Note: Take care when using this method to avoid
How to Clear Secondary Boom resetting threshold defaults.
Safety Switch Faults
1 With the key switch off, press and hold the
Note: Beginning with software release 2.0, the button and turn the key switch to the on
secondary boom envelope switches will latch and position. Release the button after five
faults must be reset in software or through the
seconds and press the buttons.
use of the TCON LCD. They will not clear by re-
powering the machine. 2 Press the button until CLEAR ALL SAFETY
SWITCH FAULTS appears.
Note: There are two methods to reset the faults,
by using Web GPI or through the menu available
3 Select YES, then press the button.
on the TCON LCD.
4 Press the button until EXIT appears.
Using Web GPI
1 Connect the device containing the WEB GPI 5 Select YES, then press the button.
software to the TCON with an RS-232 cable. Note: This clears all latching faults, not standard
2 Select the Secondary Boom, then the Safety faults.
Switch Status Flags screen.
3 Change any safety switch drop down menus
displaying FAULT to OK. Press SEND.
4 Exit Web GPI.

5 - 10 Z-80/60 Part No. 88619

June 2011
REV B
Engine Fault Codes -
Ford and Continental Models
How to Retrieve Ford and
Continental Engine Fault Codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also
uses signals from the sensors to initiate
sequential fuel injection and make constant and
instantaneous changes to ignition timing, fuel
delivery and throttle position to maintain the
engine's running condition at its highest
efficiency while at the same time keeping
exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code
in memory that relates to the appropriate sensor
and will turn on the Check Engine Light.
Note: Perform this procedure with the key switch
in the off position.
1 Open the ground controls side cover and
locate the run/test toggle switch on the side
of the ground control box.
2 Pull out the red Emergency Stop button to
the on position at both the ground and
platform controls.
3 Quickly activate and release the start toggle
switch/button. Do not start the engine.
4 Move and hold the run/test toggle switch to
the test position.
Result: The check engine light should turn
on. The check engine light should begin to
blink.
Part No. 88619
Section 5 • Fault Codes
ENGINE FAULT CODES
5 Continue to hold the run/test toggle switch in
the test position and count the blinks.
Note: Before the fault codes are displayed, the
check engine light will blink a code 123 three
times. After the fault codes, the check engine
light will blink a code 123 three times again
indicating the end of the stored codes.
Note: If any fault codes are present, the ECM
will blink a three digit code three times for each
code stored in memory. It will blink the first digit
of a three digit code, pause, blink the second
digit, pause, and then blink the third digit. For
example: the check engine light blinks 5
consecutive times, blinks 3 times and then 1
time. That would indicate code 531.
Note: Once a fault code has been retrieved and
the repair has been completed, the ECM
memory must be reset to clear the fault code
from the ECM. See How to Clear Engine Fault
Codes from the ECM.
How to Clear Engine Fault
Codes from the ECM
Note: Perform this procedure with the engine off
and the key switch in the off position.
1 Open the engine side turntable cover and
locate the battery.
2 Disconnect the negative battery cable from
the battery for a minimum of 5 minutes.
Electrocution hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings,
watches and other jewelry.
3 Connect the negative battery cable to the
battery.
Z-80/60 5 - 11
Section 5 • Fault Codes June 2011

Ford Engine ECM Fault Code Chart REV B

Code Problem Cause Solution

Heated Oxygen Sensor wiring and/or connections Repair wiring and/or connections OR replace
Closed Loop Multiplier High
111 (LPG)
open or shorted OR sensor is faulty OR there are sensor OR repair vacuum and exhaust
vacuum leaks or exhaust leaks. leaks.
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections Repair wiring and/or connections OR replace
112 (Bank 1) open or shorted OR sensor is faulty. sensor.
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections Repair wiring and/or connections OR replace
113 S(Bank 2) open or shorted OR sensor is faulty. sensor.
The post cat Heated Oxygen Sensor wiring
Post-cat oxygen sensor and/or connections are open or shorted OR Repair wiring and/or connections OR replace
114 open sensor is cold, non-responsive or inactive for 60 the post cat oxygen sensor.
seconds or longer.
Heated Oxygen Sensor wiring and/or connections
Repair wiring and/or connections OR replace
open or shorted OR sensor is faulty OR there are
Closed Loop Multiplier High sensor OR repair any vacuum and exhaust
121 (Gasoline)
vacuum leaks or exhaust leaks OR fuel pressure
leaks OR test the fuel pressure OR clean or
is low OR the fuel injectors need cleaning or
replace the fuel injectors.
replacing.
MAP, IAT or ECT sensors not in correct position
OR wiring and/or connections for sensors open or
Closed Loop Multiplier Low shorted OR sensor is faulty OR one or more fuel Adjust or replace sensors OR clean or repair
122 (Gasoline) injectors are stuck open OR there is electro- fuel injectors.
magnetic interference from a faulty crankshaft
and/or camshaft position sensor.
Heated Oxygen Sensor wiring and/or connections
Repair wiring and/or connections OR replace
Closed Loop Multiplier Low open or shorted OR sensor is faulty OR fuel
124 (LPG) quality is poor OR fuel system components may
sensor OR replace fuel OR test and repair
the fuel system components.
be faulty.
Repair exhaust leaks OR there is an
There are exhaust leaks OR the catalyst system
133 Gasoline cat monitor
efficiency is below the acceptable level.
emissions compliance issue. Contact Ford
Power Products for assistance.
Repair exhaust leaks OR there is an
There are exhaust leaks OR the catalyst system
134 LPG cat monitor
efficiency is below the acceptable level.
emissions compliance issue. Contact Ford
Power Products for assistance.
Repair exhaust leaks OR there is an
There are exhaust leaks OR the catalyst system
135 NG cat monitor
efficiency is below the acceptable level.
emissions compliance issue. Contact Ford
Power Products for assistance.
Heated Oxygen Sensor wiring and/or connections Repair heated oxygen sensor wiring and/or
open or shorted OR sensor is faulty OR there are connections OR replace sensor OR repair
Adaptive Lean Fault - High
141 Limit (Gasoline)
vacuum or exhaust leaks OR one or more fuel vacuum and exhaust leaks OR test the fuel
injectors faulty or stuck closed OR fuel quality is pressure OR clean or replace the fuel
poor OR fuel pressure is too low. injectors.
MAP, IAT or ECT sensors not in correct position
OR wiring and/or connections for sensors open or
Adaptive Rich Fault - Low shorted OR sensor is faulty OR one or more fuel Adjust or replace sensors OR clean or repair
142 Limit (Gasoline) injectors are stuck closed OR there is electro- fuel injectors.
magnetic interference from a faulty crankshaft
and/or camshaft position sensor.
Heated Oxygen Sensor wiring and/or connections Repair wiring and/or connections OR replace
open or shorted OR sensor is faulty OR there are sensor OR repair any vacuum and exhaust
143 Adaptive Learn High (LPG)
vacuum leaks or exhaust leaks OR fuel quality is leaks OR replace fuel OR test and repair the
poor OR fuel system components may be faulty. fuel system components.
Heated Oxygen Sensor wiring and/or connections Repair wiring and/or connections OR replace
Closed Loop Multiplier High
111 (LPG)
open or shorted OR sensor is faulty OR there are sensor OR repair vacuum and exhaust
vacuum leaks or exhaust leaks. leaks.
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections Repair wiring and/or connections OR replace
112 (Bank 1) open or shorted OR sensor is faulty. sensor.
HO2S Open/Inactive Heated Oxygen Sensor wiring and/or connections Repair wiring and/or connections OR replace
113 S(Bank 2) open or shorted OR sensor is faulty. sensor.
The post cat Heated Oxygen Sensor wiring
Post-cat oxygen sensor and/or connections are open or shorted OR Repair wiring and/or connections OR replace
114 open sensor is cold, non-responsive or inactive for 60 the post cat oxygen sensor.
seconds or longer.
Heated Oxygen Sensor wiring and/or connections
Repair wiring and/or connections OR replace
open or shorted OR sensor is faulty OR there are
Closed Loop Multiplier High sensor OR repair any vacuum and exhaust
121 (Gasoline)
vacuum leaks or exhaust leaks OR fuel pressure
leaks OR test the fuel pressure OR clean or
is low OR the fuel injectors need cleaning or
replace the fuel injectors.
replacing.

5 - 12 Z-80/60 Part No. 88619

June 2011 Section 5 • Fault Codes

REV B FORD ECM FAULT CODE CHART

Code Problem Cause Solution

Engine wire harness may have an intermittent
Repair short in engine wire harness OR test
144 Adaptive Learn Low (LPG) short to 5V DC or 12V DC OR fuel system
and repair the fuel system components.
components may be faulty.
Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR
161 System Voltage Low
battery supply wiring to ECM is open or shorted. repair battery supply wiring to ECM.
Alternator is overcharging the battery when
162 System Voltage High
engine RPM is greater than 1500 rpm.
Repair or replace the alternator.
IAT sensor wiring and/or connections are open or
Repair wiring and/or connections OR replace
211 IAT High Voltage shorted OR sensor is faulty OR engine intake air
sensor OR direct warmer air into air intake.
temperature is too cold.
IAT sensor wiring and/or connections are open or
Repair wiring and/or connections OR replace
212 IAT Low Voltage shorted OR sensor is faulty OR engine intake air
sensor OR direct cooler air into air intake.
temperature is too hot.
Air intake temperature is greater than 200° F with Check air intake system for damage and
IAT Higher Than Expected
213 (1)
the engine greater than 1000 rpm OR air intake proper routing of air intake components OR
system has leaks OR IAT sensor is faulty. replace the IAT sensor.
Air intake temperature is greater than 210° F with Check air intake system for damage and
IAT Higher Than Expected
214 (2)
the engine greater than 1000 rpm OR air intake proper routing of air intake components OR
system has leaks OR IAT sensor is faulty. replace the IAT sensor.
Faulty oil pressure sensor OR sensor wiring Replace oil pressure sensor OR repair
215 Oil Pressure Low and/or connections open or shorted OR engine oil sensor wiring and/or connections OR fill
level too low. engine oil level to specification.
Engine cooling system is malfunctioning OR Repair engine cooling system problems OR
221 CHT/ECT High Voltage sensor wires and/or connections open or shorted repair open or shorted wiring to sensor OR
OR sensor is faulty. replace sensor.
Engine cooling system is malfunctioning and Repair engine cooling system problems OR
overheating the engine OR sensor wires and/or repair open or shorted wiring to sensor OR
222 CHT/ECT Low Voltage
connections open or shorted OR sensor is faulty replace sensor OR fill engine coolant level to
OR coolant level is low. specification.
Coolant temperature at the cylinder head is 240°
Repair engine cooling system problems OR
F. Engine cooling system is malfunctioning and
CHT Higher Than Expected repair open or shorted wiring to sensor OR
223 (1)
overheating the engine OR sensor wires and/or
replace sensor OR fill engine coolant level to
connections open or shorted OR sensor is faulty
specification.
OR coolant level is low.
Coolant temperature at the cylinder head is 250°
Repair engine cooling system problems OR
F. Engine cooling system is malfunctioning and
CHT Higher Than Expected repair open or shorted wiring to sensor OR
224 (2)
overheating the engine OR sensor wires and/or
replace sensor OR fill engine coolant level to
connections open or shorted OR sensor is faulty
specification.
OR coolant level is low.
Open or shorted wiring and/or connections to Repair wiring and/or connections to sensor
231 MAP High Pressure
MAP sensor OR sensor is faulty. OR replace MAP sensor.
Open or shorted wiring and/or connections to Repair wiring and/or connections to sensor
232 MAP Low Voltage
MAP sensor OR sensor is faulty. 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.
Crankshaft position sensor wiring and/or Be sure system ground connections are in
242 Crank Sync Noise connections open or shorted OR there is a poor place and secure OR repair wiring and/or
system ground connection OR sensor is faulty. connections to sensor OR replace sensor.
Crankshaft position sensor wiring and/or Be sure system ground connections are in
Never Crank Synced At
243 Start
connections open or shorted OR there is a poor place and secure OR repair wiring and/or
system ground connection OR sensor is faulty. connections to sensor OR replace sensor.

Part No. 88619 Z-80/60 5 - 13

Section 5 • Fault Codes June 2011

FORD ECM FAULT CODE CHART REV B

Code Problem Cause Solution

Camshaft position sensor wiring and/or Be sure system ground connections are in
245 Camshaft Sensor Noise connections open or shorted OR there is a poor place and secure OR repair wiring and/or
system ground connection OR sensor is faulty. connections to sensor OR replace sensor.
Knock sensor wiring and/or connections open or Repair wiring and/or connections to knock
253 Knock Sensor Open
shorted OR sensor is faulty. sensor OR replace knock sensor.
Knock sensor wiring and/or connections open or Check for excessive engine vibration OR
254 Excessive Knock Signal shorted OR there is excessive engine vibration repair wiring and/or connections to knock
OR sensor is faulty. sensor OR replace knock sensor.
Repair wiring and/or connections to fuel
Open wiring and/or connections to fuel injector #1
311 Injector Driver #1 Open
OR fuel injector #1 is faulty OR ECM is faulty.
injector #1 OR replace fuel injector #1 OR
replace the ECM.
Wiring and/or connections to fuel injector #1 Repair wiring and/or connections to fuel
312 Injector Driver #1 Shorted shorted OR fuel injector #1 is faulty OR ECM is injector #1 OR replace fuel injector #1 OR
faulty. replace the ECM.
Repair wiring and/or connections to fuel
Open wiring and/or connections to fuel injector #2
313 Injector Driver #2 Open
OR fuel injector #2 is faulty OR ECM is faulty.
injector #2 OR replace fuel injector #2 OR
replace the ECM.
Wiring and/or connections to fuel injector #2 Repair wiring and/or connections to fuel
314 Injector Driver #2 Shorted shorted OR fuel injector #2 is faulty OR ECM is injector #2 OR replace fuel injector #2 OR
faulty. replace the ECM.
Repair wiring and/or connections to fuel
Open wiring and/or connections to fuel injector #3
315 Injector Driver #3 Open
OR fuel injector #3 is faulty OR ECM is faulty.
injector #3 OR replace fuel injector #3 OR
replace the ECM.
Wiring and/or connections to fuel injector #3 Repair wiring and/or connections to fuel
316 Injector Driver #3 Shorted shorted OR fuel injector #3 is faulty OR ECM is injector #3 OR replace fuel injector #3 OR
faulty. replace the ECM.
Repair wiring and/or connections to fuel
Open wiring and/or connections to fuel injector #4
321 Injector Driver #4 Open
OR fuel injector #4 is faulty OR ECM is faulty.
injector #4 OR replace fuel injector #4 OR
replace the ECM.
Wiring and/or connections to fuel injector #4 Repair wiring and/or connections to fuel
322 Injector Driver #4 Shorted shorted OR fuel injector #4 is faulty OR ECM is injector #4 OR replace fuel injector #4 OR
faulty. replace the ECM.
Open wiring and/or connections to fuel pump OR
Fuel Pump Loop Open or Repair wiring and/or connections to fuel
351 High Side Short To Ground
fuel pump power shorted to ground OR fuel pump
pump OR replace fuel pump.
is faulty.
Fuel Pump High Side Wiring and/or connections to fuel pump shorted to Repair wiring and/or connections to fuel
352 Shorted To Power power OR fuel pump is faulty. pump OR replace fuel pump.
Fuel pressure too high OR LPG lockoff not
Check fuel pressure OR repair LPG lockoff
MegaJector delivery sealing correctly OR the line between the
OR repair the line between the MegaJector
353 pressure higher than MegaJector and carburetor is kinked or restricted
and carburetor OR repair engine cooling
expected or is leaking OR engine cooling system is not
system OR replace MegaJector.
operating properly OR MegaJector is faulty.
Fuel pressure too low OR LPG lockoff not
Check fuel pressure OR repair LPG lockoff
Megajector delivery opening completely OR the line between the
OR repair the line between the MegaJector
354 pressure lower than MegaJector and carburetor is kinked or restricted
and carburetor OR repair engine cooling
expected or is leaking OR engine cooling system is not
system OR replace the MegaJector.
operating properly OR MegaJector is faulty.
Check CAN circuits for continuity and shorts
The ECM doesn’t get any response from the
MegaJector communication to power or ground and for continuity and
355 lost
MegaJector, or an incorrect response for 500ms
repair as necessary OR replace the
period or longer.
MegaJector.
The MegaJector detects voltage greater than 18
MegaJector voltage supply Repair charging system OR replace the
361 high
volts for 5 seconds anytime the engine is
MegaJector.
cranking or running.
Repair VBAT power or ground circuit to ECM
The MegaJector detects voltage less than 9.5
MegaJector voltage supply and MegaJector OR replace battery OR
362 low
volts for 5 seconds anytime the engine is
repair charging system OR replace the
cranking or running.
MegaJector.

5 - 14 Z-80/60 Part No. 88619

June 2011 Section 5 • Fault Codes

REV B FORD ECM FAULT CODE CHART

Code Problem Cause Solution

Megajector internal
363 actuator fault detection
Megajector internal circuitry
364 fault detection
MegaJector internal
365 communication fault
detection
411 Coil Driver #1 Open
412 Coil Driver #1 Shorted
413 Coil Driver #2 Open
414 Coil Driver #2 Shorted
511 FPP1 High Voltage
512 FPP1 Low Voltage
513 FPP1 Higher than IVS Limit
514 FPP1 Lower than IVS Limit
521 FPP2 High Voltage
522 FPP2 Low Voltage
531 TPS1 (Signal Voltage) High
532 TPS1 (Signal Voltage) Low
533 TPS2 (Signal Voltage) High
534 TPS2 (Signal Voltage) Low
Megajector internal
363 actuator fault detection
The MegaJector detects an internal fault. Open or
short in power, ground or CAN circuits.s
The MegaJector detects an internal circuitry
failure. Open or short in power, ground or CAN
circuits.
The MegaJector detects an internal
communications failure. Open or short in power,
ground or CAN circuits.
Open wiring and/or connections to ignition coil #1
OR ignition coil #1 is faulty.
Wiring and/or connections to ignition coil #1
shorted OR ignition coil #1 is faulty.
Open wiring and/or connections to ignition coil #2
OR ignition coil #2 is faulty.
Wiring and/or connections to ignition coil #2
shorted OR ignition coil #2 is faulty.
Not used.
Not used.
Not used.
Not used.
Not used.
Not used.
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.
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.
The #2 throttle position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR throttle position
sensor #2 is faulty.
The #2 throttle position sensor wiring and/or
connections open or shorted OR there is a poor
system ground connection OR throttle position
sensor #2 is faulty.
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.
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.
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.
Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
Repair wiring and/or connections to ignition
coil #1 OR replace ignition coil #1.
Repair wiring and/or connections to ignition
coil #2 OR replace ignition coil #2.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
If this fault appears on your machine, contact
Genie Industries Service Department.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace throttle
position sensor #1.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace throttle
position sensor #1.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace throttle
position sensor #2.
Be sure system ground connections are in
place and secure OR repair wiring and/or
connections to sensor OR replace throttle
position sensor #2.
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.

Continued on next
page

Part No. 88619 Z-80/60 5 - 15

Section 5 • Fault Codes June 2011

FORD ECM FAULT CODE CHART REV B

Code Problem Cause Solution

The throttle position sensor wiring and/or Be sure engine harness wiring and
connections for either TPS1 or TPS2 open or connections are in place and secure OR
535 TPS1 Higher than TPS2 shorted OR there is a poor system ground repair wiring and/or connections to one or
connection OR one or both throttle position both TPS sensors OR replace one or both
sensors are faulty. TPS sensors.
The throttle position sensor wiring and/or Be sure engine harness wiring and
connections for either TPS1 or TPS2 open or connections are in place and secure OR
536 TPS1 Lower than TPS2 shorted OR there is a poor system ground repair wiring and/or connections to one or
connection OR one or both throttle position both TPS sensors OR replace one or both
sensors are faulty. TPS sensors.
Governor actuator is stuck closed OR wiring
Repair wiring and/or connections to governor
537 Throttle Unable to Open and/or connections open or shorted OR governor
actuator OR replace the governor actuator.
actuator is faulty.
Governor actuator is stuck open OR wiring and/or
Repair wiring and/or connections to governor
538 Throttle Unable to Close connections open or shorted OR governor
actuator OR replace the governor actuator.
actuator is faulty.
Engine harness wiring and/or connections open
Repair wiring and/or connections in engine
545 Governor Interlock Failure or shorted OR there is a poor system ground
harness OR replace the ECM.
connection OR ECM is faulty.
ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle
Max Governor Speed
551 Override
sticking open OR there are air leaks between the operation OR repair any air leaks between
throttle body and cylinder head. the throttle body and cylinder head.
ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle
552 Fuel Rev Limit sticking open OR there are air leaks between the operation OR repair any air leaks between
throttle body and cylinder head. the throttle body and cylinder head.
ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle
553 Spark Rev Limit sticking open OR there are air leaks between the operation OR repair any air leaks between
throttle body and cylinder head. the throttle body and cylinder head.
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
611 COP Failure
faulty.
damage or shorts to ECM to be sure they
are secure OR replace ECM.
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
612 Invalid Interrupt
faulty.
damage or shorts to ECM to be sure they
are secure OR replace ECM.
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
613 A/D Loss
faulty.
damage or shorts to ECM to be sure they
are secure OR replace ECM.
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
614 RTI 1 Loss
faulty.
damage or shorts to ECM to be sure they
are secure OR replace ECM.
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
615 Flash Checksum Invalid
faulty.
damage or shorts to ECM to be sure they
are secure OR replace ECM.
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
616 RAM Failure
faulty.
damage or shorts to ECM to be sure they
are secure OR replace ECM.
Locate and repair any engine harness wiring
Engine harness wiring and/or connections open
External 5V DC Ref Lower damage or shorts OR locate and
631 than Expected
or shorted to ground OR there is a faulty engine
troubleshoot or repair faulty engine sensor
sensor OR ECM is faulty.
OR replace ECM.
Locate and repair any engine harness wiring
Engine harness wiring and/or connections open
External 5V DC Ref Higher damage or shorts OR locate and
632 than Expected
or shorted to ground OR there is a faulty engine
troubleshoot or repair faulty engine sensor
sensor OR ECM is faulty.
OR replace ECM.
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
655 RTI 2 Loss
faulty.
damage or shorts to ECM to be sure they
are secure OR replace ECM.
Locate and repair any engine harness wiring
Loose wire connections to ECM OR ECM is
656 RTI 3 Loss
faulty.S
damage or shorts to ECM to be sure they
are secure OR replace ECM.

5 - 16 Z-80/60 Part No. 88619

June 2011 Section 5 • Fault Codes

REV B
Continental Engine ECM Fault Code Chart

Adaptive Learn KC*

Power Derate 1
Power Derate 2
Adaptive Learn

Low Rev Limit

Shutdown
System Code Fault Name Fault Conditions
MAP 108 MAP Pressure High Y Y MAP pressure > 16 psi and TPS < 10%
and RPM > 1800
To Unlatch, MAP pressure must be < 10
psi
107 MAP Voltage Low Y Y MAP voltage < 0.05 vdc and TPS > 2%
and RPM < 7000
To Unlatch, MAP voltage must be > 0.5
vdc

ECT/ 118 ECT Voltage High Y ECT voltage > 4.95 vdc
CHT 117 ECT Voltage Low Y ECT voltage < 0.05 vdc
ECT higher than expected
116 Y Y Y ECT > 210° F and RPM > 600
1
ECT higher than expected
217 Y ECT > 230° F and RPM > 600
2

IAT 113 IAT Voltage High Y IAT voltage > 4.95 vdc
112 IAT Voltage Low Y IAT voltage < 0.05 vdc
111 IAT higher than expected 1 Y Y IAT > 200° F and RPM > 1000
127 IAT higher than expected 2 Y IAT > 210° F and RPM > 1000

BP 2229 BP Pressure High Y Y BP pressure > 16 psi

129 BP Pressure Low Y Y BP pressure < 8.3 psi

Battery 563 Voltage High Y Y Voltage > 18 vdc

Voltage 562 Voltage Low Y Y Voltage < 9.5 vdc and RPM > 1500

5V 643 5VE1 High Voltage Y 5VE1 > 5.4 vdc

External 642 5VE1 Low Voltage Y 5VE1 < 4.6 vdc

TPS 123 TPS1 High Voltage Y TPS1 voltage > 4.8 vdc
122 TPS1 Low Voltage Y TPS1 voltage < 0.2 vdc
223 TPS2 High Voltage Y TPS2 voltage > 4.8 vdc
222 TPS2 Low Voltage Y TPS2 voltage < 0.2 vdc
221 TPS1 > than TPS2 Y (TPS1 percent - TPS2 percent) > 20%
121 TPS1 < than TPS2 Y (TPS1 percent - TPS2 percent) < -20%
2112 Unable to reach > TPS Y (target TPS - actual TPS) > 20%
2111 Unable to reach < TPS Y (target TPS - actual TPS) < -20%
2135 TPS1/2 simultaneous Y Uses same parameters as individual
voltages out of range TPS1/2 voltage fault detection above

Part No. 88619 Z-80/60 5 - 17

Section 5 • Fault Codes June 2011

CONTINENTAL ECM FAULT CODE CHART REV B

Adaptive Learn KC*

Power Derate 1
Power Derate 2
Adaptive Learn

Low Rev Limit

Shutdown
System Code Fault Name Fault Conditions
FPP 2122 FPP1 High Voltage Y FPP1 voltage > 4.8 vdc
2123 FPP1 Low Voltage Y FPP1 voltage < 0.2 vdc

Max Govern Speed

Engine 219 RPM > 3400
Override
Speed 1111 Rev Fuel Limit RPM > 3600
1112 Spark Rev Limit Y RPM > 3800

Oil 524 Oil Pressure Low Y Oil pressure pulled-up input with a
Pressure threshold voltage of 2.5 vdc and
RPM > 500 and run-time > 30 s

Adaptive 171 AL High Gasoline Bank 1 AL_BM > 30% and RPM between 0-9999
Learn and MAP between 0-99 psi
172 AL Low Gasoline Bank 1 AL_BM < -30% and RPM between 0-9999
and MAP between 0-99 psi
1161 AL High LPG AL_BM > 30% and RPM between 0-9999
and MAP between 0-99 psi
1162 AL Low LPG AL_BM < -30% and RPM between 0-9999
and MAP between 0-99 psi

Closed 1155 CL High Gasoline Bank 1 CL_BM > 40% and RPM between 0-9999
Loop and MAP between 0-99 psi
1156 CL Low Gasoline Bank 1 CL_BM <-40% and RPM between 0-9999
and MAP between 0-99 psi
1151 CL High LPG CL_BM > 35% and RPM between 0-9999
and MAP between 0-99 psi
1152 CL Low LPG CL_BM < -35% and RPM between 0-9999
and MAP between 0-99 psi

Catalyst 420 Gasoline Cat Monitor Y Y EGO2 RMS > 0.005 phi and EGO2
Monitor RMS > EGO1 RMS* 50% and
EGO2 RMS > CL waveform RMS* 50%
1165 LPG Cat Monitor Y Y EGO2 RMS > 0.005 phi and EGO2
* Adaptive Learn Key Cycle RMS > EGO1 RMS* 50% and
EGO2 RMS > CL waveform RMS* 50%

5 - 18 Z-80/60 Part No. 88619

June 2011 Section 5 • Fault Codes

REV B CONTINENTAL ECM FAULT CODE CHART

Adaptive Learn KC*

Power Derate 1
Power Derate 2
Adaptive Learn

Low Rev Limit

Shutdown
System Code Fault Name Fault Conditions
EGO 134 EGO Open/Lazy Pre-cat 1 Y Y EGO cold persistently > 120 seconds
Sensors 154 EGO Open/Lazy Post-cat 1 Y Y EGO cold persistently > 120 seconds

Injectors 261 Injector Loop Open or Injector off-state low-side < 4 vdc
Low-Side Short to Ground Y Y Y and battery voltage > 9 vdc
262 Injector Coil Shorted Y Y Y Injector on-state low-side > 4 vdc
and battery voltage < 16 vdc

Relay Control Ground

Power 686
Short
Relay 685 Relay Coil Short
Control 687 Relay Coil Short to Pwr
Coil

Tach 2618 Tach Output Ground Short Does not turn on MIL
Output 2619 Tach Output Short to Pwr Does not turn on MIL

EPR 1171 EPR Delivery Pressure Y Y MJ actual-commanded press > 4 in. H20
Diagnostics > than expected
LPG 1172 EPR Delivery Pressure Y Y MJ actual-commanded press < 4 in. H20
< than expected
1173 EPR Comm Lost Y Y No MJ packets received within 500 ms
1174 EPR Voltage Supply High Y Y
1175 EPR Voltage Supply Low Y Y
1176 EPR Internal Actuator Y Y
fault detection
1177 EPR Internal Circuitry Y Y
fault detection
1178 EPR Internal Comm Y Y
fault detection

* Adaptive Learn Key Cycle

Continued on next
page

Part No. 88619 Z-80/60 5 - 19

Section 5 • Fault Codes June 2011

CONTINENTAL ECM FAULT CODE CHART REV B

Adaptive Learn KC*

Power Derate 1
Power Derate 2
Adaptive Learn

Low Rev Limit

Shutdown
System Code Fault Name Fault Conditions
No cam pulse in 4 cycles and RPM >
Cam 342 Cam Loss Y Y
1000
Crank 337 Crank Loss Cam pulses without crank activity
Sensors > 6 cam pulses
341 Cam Sync Noise Y Y Number of invalid cam re-syncs = 1
within a time window of <= 700 ms
336 Crank Sync Noise Y Y Number of invalid crank re-syncs = 1
within a time window of <= 800 ms
16 Never Crank Synced Cranking revs without sync < 4 revs
at Start and RPM > 90 rpm

Internal 606 COP Failure Y Y

Processor 1612 RTI 1 Loss Y Y
Diagnostics 1613 RTI 2 Loss Y Y
1614 RTI 3 Loss Y Y
1615 A/D Loss Y Y
1616 Invalid Interrupt Y Y
601 Flash Checksum Invalid Y Y
604 RAM Failure Y Y

J1939 1625 Shutdown Request Number of shutdown requests >= 1

Network 1626 CAN Tx Failure TX error counter > 100
1627 CAN Rx Failure Rx error counter > 100
CAN Address Conflict
1628 Address conflict counter > 5
Failure

* Adaptive Learn Key Cycle

5 - 20 Z-80/60 Part No. 88619

June 2011 Section 6 • Schematics

Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics

Electrocution hazard. Contact with

Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rules and
operating instructions printed in the
Operator's Manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
Hydraulic Schematics
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
General Repair Process
Malfunction Identify
discovered symptoms Troubleshoot

problem
still exists

Return to Inspect Perform

service problem and test repair
solved

Part No. 88619 Z-80/60 6-1

Section 6 • Schematics June 2011

Wire Circuit Legend

REV B

Circuit numbering Circuit suffix

1 Circuit numbers consist of three parts: the circuit Definition Suffix
prefix, circuit number and circuit suffix. The AC Generator GEN
circuit prefix indicates the type of circuit. The Alternator Field AF
circuit number describes the function of the Angle ANG
circuit. The circuit suffix provides an Auxiliary Boom Valve ABV
abbreviation for the number or may be used to Auxiliary Forward Valve AFV
further define the function of this portion of the Auxiliary Hydraulic Pump AH
circuit. It also may be used to indicate the final Auxiliary Platform Valve APV
end of the circuit, i.e., LS or limit sw. Auxiliary Reverse Valve ARV
Auxiliary Steer/Drive Valve ASV
2 The circuit number may be used more than once
Axle Extend Valve AXE
in a circuit.
Axle Oscillate AXO
Axle Retract Valve AXR
For Example: Axle Front Position FAP
C 74 PL – This is the circuit for the lockout
Axle Rear Position RAP
valve #1. C stands for control, 74 is the number of the circuit Battery BAT
for the primary #1 lock out valve. Boom Extended BEX
PL stands for Primary Lockout. Boom Stowed BST
S 62 BST – This is the circuit that communicates to the onboard Brake BRK
computers of the machine that the boom is fully stowed. S Bypass Valves BV
stands for safety, 62 is the number of the circuit for boom Calibrate CAL
stowed and BST stands for Boom Stowed.
CAN Signal CAN
P 48 LP – P stands for power. 48 is the circuit number for work CAN Shield SHD
lamps and LP stands for Lamp. CATS Module CAT
R 48 LP – R stands for relay. In this case it is the wire that Chain Break CNK
feeds the relay coil for the work lamp. All other numbers remain Data High DTH
the same. Data Low DTL
Drive Chassis Controller DCN
Circuit prefix Drive Enable DE
C ..... Control Drive Enable Left DEL
D ..... Data
Drive Enable Right DER
Electrical Displacement Control EDC
E ...... Engine
Envelope Light ENV
G ..... Gauges Engine Speed Select ESP
N ..... Neutral Engine Status Lamp ESL
Envelope Lockout ENL
P ...... Power
Extend/retract Lockout ERL
R ..... Relay Output Filter Restricted FLR
S ...... Safety Filter Switch FLT
V ...... Valve Flashing Beacon FB
Float Switch FS
Footswitch Signal FTS
Forward FWD
Fuel Pump FP
Fuel Select (gas/LP) FL
Fuel Solenoid FSL

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

June 2011 Section 6 • Schematics

REV B WIRE CIRCUIT LEGEND

Definition Suffix Definition Suffix

Function Enable FE Pressure Comp Enable PCE
Ground Control TCN Pressure Sender PSR
Ground GND Pressure Switches PS
Horn HRN Primary Boom Angle Sensor PBS
High RPM HS Primary Boom Down PBD
Hydraulic Generator HG Primary Boom Ext/Ret Lockout Valve PBL
Ignition IGN Primary Boom Extend PBE
Jib Bellcrank Down JBD Primary Boom Extend/Retract Flow Control PER
Jib Bellcrank Up JBU Primary Boom Retract PBR
Jib Sensor JBS Primary Boom Angle Sensor PBS
Jib U/D Control JUD Primary Boom Down PBD
Jib Down JD Primary Boom Ext/Ret Lockout Valve PBL
Jib Up/Down Flow Control JFC Primary Boom Extend PBE
Jib Select Valve JSV Primary Boom Extend/Retract Flow Control PER
Jib Up JU Primary Boom Retract PBR
Jib E/R Control JER Primary Boom Up PBU
Jib Ext JBE Primary Boom Up/Dwn Flow Control PUD
Jib Ret JBR Primary Boom Extend/Retract Signal PLS
Jib Rotate Left (CCW) JRL Primary Boom Up/Down Signal PES
Jib Rotate Right (CW) JRR Primary Lockout PL
Joystick 5 VDC Power JPW Primary Length Sensor PSL
Lamps LPS Propel Signal JPL
Left Front LF Program Setup Enable PSE
Left Front Steer Sensor LFS Propel Lockout PLL
Left Rear LR Proportional Valve PRV
Left Rear Steer Sensor LRS Proximity Sensor PXS
Limit Switch LS Receptacle REC
Lift Speed Reduction LSR Recovery RCV
Load Sensor LDS Retract Lockout RL
Lockout LO Return RET
Low RPM LS Reverse REV
Low fuel LOF Right Front RF
Motor Shift (Speed) MS Right Front Steer Sensor RFS
Multi Function Valve MFV Right Rear RR
Platform Control PCN Right Rear Steer Sensor RRS
Primary Ext/Ret Lockout PEL RPM RPM
Platform Level Down PLD Secondary Boom Angle Sensor SBS
Platform Level Flow Control PLF Secondary Boom Elevated SBL
Platform Level Up PLU Sec Boom Down SBD
Platform Rotate Flow Control PRF Sec Boom Extend SBE
Platform Rotate Control PRC Sec Boom Extend/Retract Flow Control SER
Platform Rotate Left (CCW) PRL Sec Boom Retract SBR
Platform Rotate Right (CW) PRR Sec Boom Up SBU
Power PWR Sec Boom Up/Dwn Flow Control SUD
Power to Length Sensor PSL Secondary Boom SB
Platform Tilt Alarm PTA This list continues on the next page.
Platform Tilt Sensor PTS

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

Section 6 • Schematics June 2011

WIRE CIRCUIT LEGEND REV B

Definition Suffix Wire Coloring

Secondary Boom Lockout Valve (Extend) SLE
Secondary Boom Lockout Valve (Riser Down) SLD 1 All cylinder extension colors are solid and all
Sensor SEN retract functions are striped black. When using
Spare SP black wire, the stripe shall be white.
Speed Sensor SS
2 All rotations that are LEFT or CW are solid,
Start Aid (Glow Plug or choke) SA
RIGHT or CCW are striped and black. When the
Starter STR
wire is black, the stripe is white.
Steer Control Signal STC
Steering Valve Clockwise SCW 3 All proportional valve wiring is striped.
Steering Valve Counter Clockwise SCC
Temp Sender TSR
Temp Switches TS Wire Color Legend
Tether TET
BL Blue
Tilt Alarm X axis TAX
BL/BK Blue/Black
Tilt Alarm Y axis TAY
BL/RD Blue/Red
Turntable or Ground Control Panel TCN
BL/WH Blue/White
Turntable Rotate Flow Control TRF
BK Black
Turntable Rotate Right (CW) TRR
BK/RD Black/Red
Turntable Rotate Signal TRS
BK/WH Black/White
Turntable Tilt Alarm TTA
BR Brown
Turntable Tilt Sensor TTS
GR Green
Test Switch TSW
GR/BK Green/Black
GR/WH Green/White
RD Red
RD/BK Red/Black
RD/WH Red/White
OR Orange
OR/BL Orange/Blue
OR/BK Orange/Black
OR/RD Orange/Red
WH White
WH/BK White/Black
WH/RD White/Red
YL Yellow

6-4 Z-80/60 Part No. 88619

June 2011 Section 6 • Schematics

REV B WIRE CIRCUIT LEGEND

Color, Circuit #, and Primary function Color, Circuit #, and Primary function
RD 1 Primary boom up drive WH/BK 31 Reverse/EDC-B
RD/BK 2 Primary boom down drive WH/RD 32 Brake
RD/WH 3 Primary boom up/dwn FC BK 33 Start
proportional valve drive BK/WH 34 Start aid (glow plug or choke)
WH 4 Turntable rotate left valve drive BK/RD 35 High engine speed select
WH/BK 5 Turntable rotate right valve drive BL 36 Steer clockwise
WH/RD 6 Turntable rotate FC proportional BL/BK 37 Steer counterclockwise
valve drive BL/WH 38 Gas
BK 7 Primary boom extend BL/RD 39 LP
BK/WH 8 Primary boom retract OR 40 Limit switch signal stowed
BK/RD 9 Primary boom Extend/Retract OR/BK 41 RPM signal
proportional valve drive OR/RD 42 Boom retracted signal
BL 10 Secondary boom up valve drive GR 43 Jib up
BL/BK 11 Secondary boom down valve drive GR/BK 44 Jib down
BL/WH 12 Secondary boom up/dwn FC GR/WH 45 AC Generator
proportional valve drive WH 46 Drive horn
BL/RD 13 Drive enable WH/BK 47 Output power enable
OR 14 Platform level up valve WH/RD 48 Work lamp
OR/BK 15 Platform level down valve WH/BK 49 Motion lamp
OR/RD 16 Platform up/dwn FC proportional BL 50 Auxiliary boom
valve drive BL/WH 51 Auxiliary steer
GR 17 Platform rotate left valve driver BL/RD 52 Auxiliary platform
GR/BK 18 Platform rotate right valve driver WH/BK 53 Boom envelope safety valve cutoff
GR/WH 19 Jib select valve driver circuit BK/WH 54 Power to safety interlock switches
RD 20 12 battery supply (engine)
WH 21 12 ignition supply GR/BK 55 Axle oscillation
BK 22 Keyswitch power to platform RD 56 Foot switch/TCON estop power
ESTOP RD/WH 57 Boom down safety interlock
WH 23 Power to platform RD/BK 58 Safety interlock to engine
RD 24 Power to warning senders GR/WH 59 Chain break circuit
WH/BK 25 Power to oil pressure sender GR/WH 60 Axle extend
WH/RD 26 Power to temp sender GR 61 Axle retract
RD 27 Auxiliary power OR 62 Boom stowed (safety)
RD/BK 28 Platform level alarm OR/RD 63 Power to boom envelope safety
RD/WH 29 Drive motor shift (speed) switch
WH 30 Forward/EDC-A This list continues on the next page.

Part No. 88619 Z-80/60 6-5

Section 6 • Schematics June 2011

WIRE CIRCUIT LEGEND REV B

Color, Circuit #, and Primary function Color, Circuit #, and Primary function
OR/BK 64 Power for operational switches BK 99 J1708 - (low)
BL/WH 65 Low fuel indication WH/RD 100 Outrigger lowered
BL 66 Drive enable WH/BK 101 Outrigger raised
BL 67 Secondary boom not stowed OR 102 Pothole protector up
RD 68 Primary boom lowered OR/RD 103 Pothole protector down
(operational) BK/WH 104 Proprietary data buss –
BL 69 Primary boom #1 extended (i.e. ITT or AP)
BL/WH 70 Primary boom #2 retracted BK/RD 105 Proprietary data buss +
BL/BK 71 Primary boom #2 extended (i.e. ITT or AP)
GN 72 Secondary boom extend GR 106 Spare
GN/BK 73 Secondary boom retract RD 107 Alternator field
RD 74 Primary #1 Lockout BL/WH 108 Engine status
RD/WH 75 Primary #2 Lockout GR/WH 109 Sensor pwr
BL 76 Pri boom #3 extended BK 110 Sensor return
WH 77 Lower angle #1 operational OR 111 Steer signal
WH/BK 78 Upper angle #2 operational RD 112 Steer signal to solenoid valve
BK 79 power from TCON ESTOP OR/RD 113 Multi function valve
N/A 80 Can 2.0/J1939 Shield BK/RD 114 Load moment overweight
GR 81 Can 2.0/J1939 Low RD/BK 115 Load moment underweight
YL 82 Can 2.0/J1939 High OR 116 Hydraulic oil cooler
GR/WH 83 Tilt signal x axis RD 117 Flashing beacon
GR/BK 84 Tilt signal y axis OR 118 Lift speed reduction
GR 85 Tilt sensor power BL 119 Hydraulic pressure sensor output
OR 86 Hydraulic filter restricted OR 120 Oil cooler fan
RD 87 Platform level safety power GR 121 Axle oscillate LEFT
RD/BK 88 Platform level safety output GR/BK 122 Axle oscillate RIGHT
BR 89 Platform level safety ground RD/BK 123 Primary boom angle signal
RD/BK 90 Proximity kill operational
RD/WH 91 Gate Interlock RD/WH 124 Secondary boom angle signal
WH/BK 92 Motor speed (LO/HI) operational
WH/RD 93 Motor bypass WH/RD 125 Secondary boomlockout
WH 94 Load sensor (Ext Enable)
OR 95 Tether ESTOP return WH/BK 126 Secondary boom lockout
RD 96 Tether power (Riser Down Enable)
BK 97 Tether ESTOP power GR 127 ECU test switch
WH 98 J1708 + (high) OR/RD 128 Low engine speed

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

June 2011 Section 6 • Schematics

REV B WIRE CIRCUIT LEGEND

Color, Circuit #, and Primary function Color, Circuit #, and Primary function
RD/BK 129 Descent alarm BL/WH 163 Pri extend/retract signal
WH/RD 130 Travel alarm RD/WH 164 Pri up/down signal
BL 131 Motion alarm WH/RD 165 TT Rotate signal
GR 132 Platform load input OR 166 Boom length signal safety
GR/WH 133 Platform load alarm OR/BK 167 Boom length signal operational
GR/BK 134 Key switch power BL/RD 168 Primary boom hydraulic valve
BL/WH 135 Fuel pump lockout
RD 136 Power to safety module GN 169 Envelope active LED
RD/WH 137 Propel power (P_38) WH/RD 170 Load sense relay source
RD/BK 138 Pri boom up/sec boom dwn-Ext WH/BK 171 Load sense relay sink
(P_11/30) BL 172 UP/DN flow control ground
WH/RD 139 Turntable rot FC safety (P_39) BK 173 Ext/Ret flow control ground
OR/RD 140 Boom envelope safety WH 174 Key switch power, ground position
RD 141 Primary boom angle signal safety WH/BK 175 Load sensor signal operational
OR 142 Secondary boom angle signal GN/WH 176 Secondary extend/retract FC
safety BL/RD 177 Extend/retract lockout
BL/RD 143 Drive enable left BK 178 Control module status light
BL/WH 144 Drive enable right GN 179 Drive power relay
RD/WH 145 Calibrate BK 180 Lift power relay
BL 146 Jib bellcrank up FC OR 181 48 Volt alternator field (or battery)
BL/BK 147 Jib bellcrank down FC RD 182 24 Volt battery
BL/WH 148 Jib bellcrank sensor BL 183 Envelope or load sense recovery
GR/WH 149 Jib Up/Down FC WH 184 Program setup enable
GR/BK 150 Hydraulic generator bypass WH 185 Encode A
GR 151 Hydraulic EDCoutput BL 186 Encode B
BK 152 Injector retard BL 187 Bootstrap or program enable
BK 153 Jib extend GR 188 Safety cross check
BK/WH 154 Jib retract BK 189 Data receive
OR/RD 155 Pressure comp enable BK/WH 190 Data transmit
GN/WH 156 Jib Up/Down WH/RD 191 Multi-Function pressure relief
BK/RD 157 Jib Ext/Ret WH/BK 192 Jib rotate left
BL/RD 158 Spare WH/RD 193 Jib rotate right
BL/WH 159 Steer joystick signal WH/RD 194 Speed select input
WH/RD 160 Propel joystick signal OR/RD 195 Electric brake source
WH/BK 161 Sec boom joystick signal YL 196 2.5V Sensor power
OR 162 Joystick 5 VDC power BR N/A Ground or return

Part No. 88619 Z-80/60 6-7

Section 6 • Schematics June 2011

Limit Switches and Angle Sensors

REV C

Types of Limit Switches Limit Switch Numbering

There are two types of limit switches, found in LSP1AO Primary boom angle stowed
various locations throughout the machine: LSP1RO Primary boom length retracted
LSP1EO Primary boom length fully extended
mechanical-type operational or safety switches. LSS1AO Secondary boom angle, fully stowed
As in aircraft, which features redundant safety LSS2AO Secondary boom angle, fully raised
systems, each mechanical operational switch is LSS3AO Secondary boom angle, 25° to 30°
backed up with a separate, independently LSS2AS Secondary boom angle safety
LSS1RO Secondary boom fully retracted
functioning safety switch. LSS1RS Secondary boom fully retracted, safety
LSJ1EO Platform level fully extended
The mechanical-type operational or safety LST1O Drive enable mechanical
switches are used to sense a positive displacement LSA1OS Oscillate axle, right side
or movement of the limit switch actuator, or arm, as LSA2OS Oscillate axle, left side
the machine moves through its range of operational
functions. Included in this group are envelope limit
switches which sense the extended length and
angle of the booms and rotational position of the
Numbering Legend
turntable. Switch number
J Jib boom D Down
For example, when the secondary boom is fully P Primary Boom A Angle
raised and the operational switch is activated, it S Secondary Boom E Extend
T Turntable R Retract
tells the ECM at the ground controls to start LS Limit switch O Operational
S Safety
extending the secondary boom.

Another example is the drive enable limit switch,

which disables the drive function anytime the boom
is rotated past the rear axles, indicated by the
LS P 1 R O
'circle' end of the drive chassis.
In some cases, the engine will be stopped if safety
parameters are exceeded.

6-8 Z-80/60 Part No. 88619

June 2011 Section 6 • Schematics

REV C LIMIT SWITCHES AND ANGLE SENSORS

Limit Switch and Angle Sensor Legend

PRIMARY
BOOM ANGLE
SENSOR

LSP1RO LSS2AO LSP1EO

LSP1AO
LSS1RO LSJ1EO

PRIMARY
BOOM

LSS2AS
JIB
SECONDARY
LSS3AO BOOM
BOOM

TURNTABLE
ANGLE SENSOR PLATFORM
ANGLE
LSS1RS LSA2OS SENSOR

LSS1AO
DRIVE CHASSIS
CONTROL BOX
LSA1OS
LST1O

LSA1OS: Limit switch, Axle #1 Oscillating Operational. LSS1RO: Limit switch, Secondary Boom #1 Retract
Activates the axle oscillate circuit on the right side. Operational Switch. Secondary boom fully retracted
(secondary boom down allowed).
LSA2OS: Limit switch, Axle #2 Oscillating Operational.
Activates the axle oscillate circuit on the left side. LSS1RS: Limit switch, Secondary Boom #1 Retract Safety
Switch. Secondary boom fully retracted
LST1O: Limit switch, Operational. Activates the drive enable (secondary boom down allowed). Backup switch for LSS1RO.
zone.
LSS1AO: Limit switch, Secondary Boom #1 Angle Operational
Turntable Angle Sensor: Measures the X axis and Y axis of Switch. Open when the secondary boom is fully lowered, closes
the turntable. The alarm sounds at 4.5 degrees. when the boom is raised out of the stowed position. This switch
limits the drive speed and disables the drive motor destroke.
Primary Boom Angle Sensor (PBS): Measures the Y axis
The other contacts close when the boom is fully lowered
angle of the primary boom. The operational range shall be +33
allowing the platform to be tucked underneath the mast for
degrees to +73 degrees. The safety cutouts are set at +70
transport.
degrees and will disable boom up and stop the engine.
LSP1AO: Limit Switch, Primary Boom #1 Angle Operational.
Platform Angle Sensor: Measures the angle of the platform.
One side closes when the primary boom is raised from the
The range of measurement is +/- 20 degrees. The safety cutout
stowed position, disabling the drive motor destroke and limiting
is set at +/- 10 degrees from gravity and will disable the primary
the drive speed. The other side of the switch closes when the
and secondary boom up/down functions and the platform level
boom is fully lowered allowing the platform to be tucked
up/down functions.
underneath the mast for transport.
LSS2AO: Limit switch, Secondary Boom #2 Angle Operational
LSJ1EO: Limit Switch, Jib Boom #1. Closes when the platform
Switch. Secondary boom angle full extension, angle up all the
leveling cylinder is fully extended, disabling the primary boom
way (secondary boom extend allowed).
down function.
LSS3AO: Limit switch, Secondary Boom #3 Angle Operational
LSP1EO: Limit Switch, Primary Boom #1 Extend Operational.
Switch. Secondary boom elevated to 30-35 degrees. Used to
Switch closes as the primary boom extends the last 6 to 12
switch platform/primary boom leveling parameters.
inches signaling the computer.
LSS2AS: Limit switch, Secondary Boom #2 Angle Safety
LSP1RO: Limit Switch, Primary Boom #1 Retract Operational.
Switch. Secondary boom angle full extension, angle up all the
Switch closes when the primary boom is fully retracted.
way (secondary boom extend allowed).
Backup switch for LSS2AO.

Part No. 88619 Z-80/60 6-9

Section 6 • Schematics June 2011

Drive Chassis and Platform Controller Pin Legend

REV C
B

6 - 10 Z-80/60 Part No. 88619

June 2011 Section 6 • Schematics

Engine Relay and Fuse Panel Legend

REV D
B

DEUTZ F4L 913

5 6 7 8
F16 F20 (before serial number 339)
LABEL DESCRIPTION GENIE P/N
CR2 CR17
CR1 START RELAY 61225
F17 F7 CR2 IGNITION/FUEL RELAY 34052
1 2 3 4
CR5 HORN RELAY 34052
CR17 HYDRAULIC OIL COOLER FAN RELAY 34052
F7 FUSE, 20A, HYDRAULIC OIL COOLER FAN 60536
OPTION F16 FUSE, 70A, ENGINE RPM AND COLD START 88151
CR5 CR1 PR2
RELAY F17 FUSE, 20A, STARTER AND ALTERNATOR 60536
F20 FUSE, 20A, ENGINE RPM 60536
PR2 STARTING AID RELAY 61225

5 6 7 8
PERKINS 704-30
F16 (before serial number 329)
LABEL DESCRIPTION GENIE P/N
CR2 CR17
CR1 START RELAY 34052
F17 F7
1 2 3 4 CR2 IGNITION/FUEL RELAY 34052
CR4 RPM RELAY 34052
CR5 HORN RELAY 34052
CR17 HYDRAULIC OIL COOLER FAN RELAY 34052
OPTION CR5 CR1 CR4 F7 FUSE, 20A, HYDRAULIC OIL COOLER FAN 60536
RELAY F16 FUSE, 20A, ENGINE RPM AND COLD START 60536
F17 FUSE, 20A, STARTER AND ALTERNATOR 60536

GM 3.0L
5 6 7 8

LABEL DESCRIPTION GENIE P/N

CR17 CR2 IGNITION/FUEL RELAY 34052
F17 F7 CR5 HORN RELAY 34052
1 2 3 4 CR17 HYDRAULIC OIL COOLER FAN RELAY 34052
F7 FUSE, 20A, HYDRAULIC OIL COOLER FAN 60536
F17 FUSE, 20A, STARTER AND ALTERNATOR 60536

CR5 CR2 OPTION

RELAY

Part No. 88619 Z-80/60 6 - 11

Section 6 • Schematics June 2011

ENGINE RELAY AND FUSE PANEL LEGEND REV D

B

DEUTZ 2011
(after serial number 338)
5 6 7 8
LABEL DESCRIPTION GENIE P/N
F20 F23 B1
CR1 START RELAY 61225
CR28 CR17 CR28 ENGINE RUN/ALTERNATOR FIELD RELAY 34052
F22 F7 CR5 HORN RELAY 34052
1 2 3 4 B2
CR15 GLOW PLUG RELAY 61225
CR17 HYDRAULIC OIL COOLER FAN RELAY 34052
R21 F7 FUSE, 20A, HYDRAULIC OIL COOLER FAN 60536
F20 FUSE, 20A, ENGINE RPM 60536
CR5 CR1 CR15
F22 FUSE, 60A, GLOW PLUG 101340
GND F23 FUSE, 30A, ENGINE 94327

PERKINS 804
5 6 7 8
(after serial number 328)
F16 F17 B1 LABEL DESCRIPTION GENIE P/N

CR28 CR17 CR1 START RELAY 61225

CR2 IGNITION POWER RELAY 34052
F22 F7 B2
1 2 3 4 CR5 HORN RELAY 34052
CR15 GLOW PLUG RELAY 61225
CR17 HYDRAULIC OIL COOLER FAN RELAY 34052
R21
CR4 RPM RELAY 34052
CR4 CR5 CR1 CR15 F17 FUSE, 20A, ENGINE 60536
F7 FUSE, 30A, OIL COOLER, RPM 94327
GND 60536
F16 FUSE, 20A, STARTER
F22 FUSE, 70A, GLOW PLUG 88151

CONTINENTAL TME27
5 6 7 8
F17 P20 PWR

CR17
F7 B2 BAT
1 2 3 4 LABEL DESCRIPTION GENIE P/N
CR1 START RELAY 34052
CR5 HORN RELAY 34052
C21 IGN CR17 HYDRAULIC OIL COOLER FAN RELAY 34052
CR5 CR1 F7 FUSE, 30A, HYDRAULIC OIL COOLER 94327
F17 FUSE, 30A, STARTER 94327
GND

5 6 7 8

FORD LRG 425

F16 F20 B1

CR2 CR17
F17 F7 B2
(after serial number 262)
1 2 3 4
LABEL DESCRIPTION GENIE P/N
CR1 START RELAY 61255
R21 CR5 HORN RELAY 34052
CR5 CR1 CR17 HYDRAULIC OIL COOLER FAN RELAY 34052
CR4 RPM RELAY 34052
GND F7 FUSE, 20A, HYDRAULIC OIL COOLER 60536
F17 FUSE, 20A, STARTER AND ALTERNATOR 60536

6 - 12 Z-80/60 Part No. 88619

June 2011 Section 6 • Schematics

REV B
D ENGINE RELAY AND FUSE PANEL LEGEND

CONTINENTAL TME27 ENGINE

FUSE PANEL

STARTER
RELAY

EPR
RELAY
(LPG ONLY)

POWER
RELAY
COILS
INJECTORS F1 MAIN 20A
02 SENSORS BAT+

F2 5A
ECM

F3 15A
POWER
FUEL
PUMP F4 FUEL 15A
PUMP
RELAY
F5 EPR 15A
(LPG)

Part No. 88619 Z-80/60 6 - 13

Section 6 • Schematics June 2011

Turntable Controller Pin Legend

REV C
B

6 - 14 Z-80/60 Part No. 88619

June 2011 Section 6 • Schematics

Electrical Symbols Legend

REV B

FS1
BLK
BLK

P3
WHT LS3 Foot switch
N.O.H.C N.C.H.O
Quick disconnect
terminal Limit switch Horn button
Coil normally open
solenoid or relay
P1
KS1
WHT #21 TB21
PLATFORM
OTS2
GROUND N.O.
T-circuits connect H1 Emergency Stop
at terminal button normally
Oil temperature
switch closed
Horn or alarm Key switch normally open
T-circuits
connect FAN
FB PR1
CTS1
N.O.
Hydraulic oil
Flashing beacon Power relay cooling fan
Connection Coolant temperature
no terminal switch
normally open Aux
G1 TS2 Pump
ENGINE
START

Gauge Auxiliary pump

OPS1
Circuits crossing N.C.
no connection
510
HM Toggle switch SPDT Oil pressure switch
normally closed Resistor with
ohm value

Diode Hour meter

TS6
DOWN
UP

L3
PLATFORM LEVEL

-
Gauge sending unit Tilt sensor
LED
Battery
Toggle switch DPDT
F1

25A A B C
PULL IN

Fuse
HOLD
AUX MAIN

CR4
with amperage N.O.

Battery separator Control relay contact Fuel or RPM

normally open solenoid

CB1

15A
Starting aid:
glow plug or
Circuit breaker flame ignitor
with amperage Coil

Part No. 88619 Z-80/60 6 - 15

Section 6 • Schematics June 2011

Hydraulic Symbols Legend

REV B

25 psi
(1.7 bar)

Accumulator

Differential
Filter with sensing valve Directional valve
bypass valve .035" pilot operated
(0.89 mm) 2 position, 2 way
relief setting
Orifice with size

Shut off valve Solenoid operated

proportional valve Solenoid operated 3 position,
Pump
fixed displacement 4 way, directional valve

Check valve

200 psi
(13.8 bar)
2 position, 3 way, shuttle valve
Pump
bi-directional, Priority
variable displacement flow regulator valve
Relief valve
with pressure setting

o
Hydraulic oil cooler
Solenoid operated 2 position,
3 way, directional valve
Motor
bi-directional
Directional valve 3000 psi
(mechanically activated) (206.8 bar)
3:1

Brake

Motor Pilot operated 3 position,

2-speed, 3 way, shuttle valve Counterbalance valve
bi-directional with pressure and pilot ratio

E
Pump prime mover 50% 50%
(engine or motor)
Flow divider/combiner valve
with pressure balancing orifice
and flow percentages
2 position, 2 way
solenoid valve

Double acting
cylinder

6 - 16 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

REV D
Electrical Schematic Layout
(before serial number 2511)

Part No. 88619 Z-80/60 6 - 17

June 2011 Section 6 • Schematics

Electrical Schematic Layout

(before serial number 2511)

6 - 17
6 - 18
 June 2011 Section 6 • Schematics

Electrical Schematic - View 1

Drive Chassis Controller (DCON) (before serial number 2511)

6 - 20
6 - 19
 8
7
6
5
4
3
2
1

6 - 20
A
VLVRET-BRN P2-01 VALVE RTN1

P2-02
Section 6 • Schematics

P2-03

V29MS-RD/WH P2-04 MOTOR SPEED

DCON EN7
B

P2-05 OSCILLATE STOWED

P2-06 AUX FORWARD

P2-07 AUX REVERSE

V36RRS-BL P2-08 RR STEER RIGHT

Electrical Schematic - View 1

V37RRS-BL/BK P2-09 RR STEER LEFT

C

Z-80/60
C111RRS-OR P2-10 RR STEER SNSR

C111LRS-OR P2-11 LR STEER SNSR

C111RFS-OR P2-12 RF STEER SNSR

C111LFS-OR P2-13 LR STEER SNSR

VLVRET2-BRN P2-14 VALVE RTN2

D

V32BRK-WH/RD P2-15 BRAKE

V36LRS-BL P2-16 LR STEER RIGHT

V37LRS-BL/BK P2-17 LR STEER LEFT

V36RFS-BL P2-18 RF STEER RIGHT

Drive Chassis Controller (DCON) (before serial number 2511)

P110RT-BK P2-19 STEER SNSR GND

E

P109ANG-GR/WH P2-20 STEER SNSR PWR

V37RFS-BL/BK P2-21 RF STEER LEFT

June 2011

Part No. 88619

V36LFS-BL P2-22 LF STEER RIGHT

V37LFS-BL/BK P2-23 LF STEER LEFT

F

HARNESS
J32 23 PIN
DRIVE CHASSIS
G

Continued on View 7
H

HARNESS
J31 23 PIN
DRIVE CHASSIS

GND-DCN-BR P1-01 DCON ECU GND

P21DCN-WH P1-02 DCON ECU PWR

P53LS-RD P1-03 P_6R1

I

P1-04

S56PRV-RD P1-05 P_7R

S56PRV-RD P1-06 P12

P1-07
J

P1-08 DIGIN AXLE RET GND

P1-09 AXLE NOT RET RTN

P1-10 CAN SHIELD

P1-11 RS232 RXD

P1-12 RS232 TXD

K

P1-13 BOOT

P1-14

P1-15 AXLE NOT EXT SIG

P1-16

D81CAN- -GR P1-17 CAN -

L

D82CAN+ -YL P1-18 CAN +

P1-19 RS232 GND

P1-20

P1-21
Continued on View 2

P1-22
M

P1-23 AXLE NOT EXT PWR

N
REV C
 N
REV D

View 1

Pin 6
Pin 5
Pin 4
Pin 3
Pin 2
Pin 1
GND12-BR
PCON

ALARM+ RD/BK
ALARM

P20

PWR
GND

YOUT
XOUT
1

RKOUT
PLAT ROT L-GN

Continued on
2
M

GND16-BR
3
ROTATE

PLAT ROT R-GN/BK

Pin1

Pin 7
Pin 6
Pin 5
Pin 4
Pin 3
Pin 2

Joystick Adaptor Harness

4
5 PLAT LVL UP-OR
6 GND6-BR GND6-BR
LEVEL

7 PLAT LVL UP-OR PLAT LVL DN-OR/BK

PLATFORM PLATFORM

8 PLAT LVL DN-OR/BK

JIB UP-GN
9
JIB

GND13-BR
10 ESTOP RET-BK
JIB DN-GN/BK
11
L

12 GND12-BR ESTOP RET-BK

13 GND13-BR
14 JIB UP-GN
PCON

15 JIB DN-GN/BK
16 GND16-BR ESTOP PWR-RD/BK
E-STOP (P2)

17 PLAT ROT L-GN

18 PLAT ROT R-GN/BK
VLVRET-BRN P1-01 VLV RTN
19 ALARM+ RD/BK
P1-02
20 ESTOP PWR-RD/BK
C17PRL-GR P1-03 ON/OFF VLV3_A
K

C18PRR-GR/BK P1-04 ON/OFF VLV3_B

C43JU-GR P1-05 PROP VLV2_A
C44JD-GR/BK P1-06 PROP VLV2_B
C14PLU-OR P1-07 PROP VLV1_A
C15PLD-OR/BK P1-08 PROP VLV1_B
J27
P1-09 1
R90PXS-RD/BK P1-10 PROX KILL GND H1_GND-BR 2
ESTOP PWR-RD/BK

C90PXS-RD/BK P1-11 PROX KILL CMD H1_PWR-OR 3

J

GN P1-12 LOAD SNSR GND H1_XOUT-RD 4

WH P1-13 LOAD SNSR IN H1_YOUT-BK 5
JOYSTICK (JC1)
BOOM UP/DWN &

BK P1-14 LOAD SNSR PWR 6

TURNTABLE ROTATE

C88PTS-RD/BK P1-15 SAFE PL TILT OUT 7

1 H3_GND-BR
P56FTS-RD P1-16 FOOT SW PWR J26
2 H2_GND-BR 1
C56FTS-RD P1-17 FOOT SW RTN
3 H3_PWR-OR H2_GND-BR 2
P6

S14PLU-OR P1-18 PL LVL CYL EXT

4 H2_PWR-OR H2_PWR-OR 3
PLATRET-BR P1-19 PL TILT SNSR GND
5 4
C84TAY-GR/BK P1-20 PL TILT SNSR
6 5
JOYSTICK (JC2)

H4_STEER-BL
I

H2_YOUT-YL
P85PTS-GR P1-21 PL TILT SNSR PWR
7 H4_XOUT-PR 6
PRI BOOM EXT/RET

PTSRET-BR P1-22 SAFE PL TILT GND U20

8 H4_YOUT-WH 7
P87PTS-RD P1-23 SAFE PL TILT PWR
9 H3_YOUT-GN J28
1
10 H2_YOUT-YL
H3_GND-BR 2
11 H1_YOUT-BK
H3_PWR-OR 3
12 H1_XOUT-RD
4
13 H1_PWR-OR
JOYSTICK (JC5)

H3_YOUT-GN 5
14 H4_PWR-OR

PCON MANIFOLD
J22 WHITE 23 PIN
6
SEC BOOM UP/DWN
H

15 H1_GND-BR
7
16 H4_GND-BR
J25
1
H4_GND-BR 2
H4_PWR-OR 3
H4_XOUT-PR 4
H4_YOUT-WH 5
JOYSTICK (JC3)

H4_STEER-BL 6
DRIVE & STEERING

7
G

ECU

P6
P22
P7R

P7
SLP_MODE

P1
1
F

Continued on View 8

P1
5
4

1
2

2 HORN
DB9 CONNECTOR
ON CIRCUIT BOARD

P1
3
6

74HC08
74HC08

3 AC GENERATOR
P5
P3
P2
PIN

P1
4 AUXILIARY
June 2011

CKT #

P1
5 START ASSIST
RS232_TXD
RS232_RXD

RS232_GND
E

P1
Part No. 88619
PCON MEMBRANE PANEL (MS1)

6 START
1
GNDPCON-BR P1-01 PCON GND P1
2 7 DRIVE ENABLE
P52PCON-WH P1-02 PCON PWR
J23 10PIN

3
P1-03 P1
4 8 SPARE 1
S56PRV-RD P1-04 P7
5
IS
IN
P6

P1-05
Vbb

P1
IN2
P7R

GND

6 9 AXLE RETRACT
P1-06
OUT
BTS650

7
ST OUT 2
IN1 OUT 1
VbbBTS621

P56PRV-RD/WH P1-07 P22 P1

U21
U22
D

J24A 10PIN

8 10
P1-08
9
P1-09
10 P2
P1-10 1 ENGINE SPEED
P1-11
P2
P1-12 2 AXLE EXTEND
J24B 10PIN

P1-13
P2
P1-14 3 DRIVE SPEED
C47OUT-WHT/BLK P1-15 OUT PWR ENBL
P2
C46HN-WH P1-16 HRN RLY CNTRL 4 FRONT STEER
C

D81CAN- -GR P1-17 CAN-

Z-80/60

P2
D82CAN+ -YL P1-18 CAN+ 5 REAR STEER
P1-19
P2
P1-20 6 CRAB STEER
P1-21
P2
P1-22 7 COORD STEER
P23PCON-BK P1-23 PWR-PCON ESTOP
MEMBRANE/LED INTERFACE CARD

P2
8 SPARE 2
B

P2
9 FUEL TYPE

P2
BOOM HARN

10
J21 BLACK 23 PIN
A

Continued on View 3
Electrical Schematic - View 2
Platform Controls (PCON) (before serial number 1167)

6 - 21
Section 6 • Schematics

8
7
6
5
4
3
2
1
June 2011 Section 6 • Schematics

Electrical Schematic - View 2

Platform Controls (PCON) (before serial number 1167)

6 - 21
6 - 22
 June 2011 Section 6 • Schematics

REV A Electrical Schematic - View 2

Platform Controls (PCON) (from serial number 1167 to 2510)
N M L K J I H G F E D C B A

8
Pin1
Pin 1 GND Pin 2
Pin 2 PWR Pin 3
Pin 3 XOUT Pin 4
Pin 4 YOUT Pin 5
Pin 5 RKOUT Pin 6
Pin 6 Pin 7

Joystick Adaptor Harness

Part No. 88619 Z-80/60 6 - 23

June 2011 Section 6 • Schematics

Electrical Schematic - View 2

Platform Controls (PCON) (from serial number 1167 to 2510)

6 - 23
6 - 24
 June 2011 Section 6 • Schematics

Electrical Schematic - View 3

Ground Controls (TCON)(before serial number 2511)

6 - 26
6 - 25
Section 6 • Schematics June 2011

Electrical Schematic - View 3 REV D

Ground Controls (TCON) (before serial number 2511)
A B C D E F G H I J K L M N

6 - 26 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

REV C Electrical Schematic - View 4

(before serial number 2511)
N M L K J I H G F E D C B A

Part No. 88619 Z-80/60 6 - 27

June 2011 Section 6 • Schematics

Electrical Schematic - View 4

(before serial number 2511)

6 - 27
6 - 28
 June 2011 Section 6 • Schematics

Electrical Schematic - View 5

(before serial number 2511)

6 - 30
6 - 29
Section 6 • Schematics June 2011

Electrical Schematic - View 5 REV C

(before serial number 2511)
A B C D E F G H I J K L M N

1 AUXILIARY HYD RECOVERY SIGNAL

MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL

BOOM UP/DWN FC RECOVERY SIGNAL

2
(P15)+(ECU POWER) (P15)+(ECU POWER)
P_30
TO HORN BUTTON
AUXILIARY HYD RECOVERY SIGNAL
U95 MULTI FUNCTION VLV RECOVERY SIGNAL
PWR TO TCON ESTOP
BOOM RET RECOVERY SIGNAL
P_22 P_22
BOOM DWN RECOVERY SIGNAL
3 P_9B BOOM EXT/RET FC RECOVERY SIGNAL
OUT PWR ENABLE OUT PWR ENABLE (OE)
BOOM UP/DWN FC RECOVERY SIGNAL
P_6R2 (SM)+(AH) TO MICRO P_30
Vbb BTS621
IN1 OUT 1 P22R P22R
IN2
ST OUT 2
Vbb BTS621 P22R P_22R
P_6R2

IN1 OUT 1 GND 14 12

IN2 ((~SM)+(AH))(P_22) 13 P7R
ST OUT 2 BTS650 74HC08
GND Vbb P10
P7R
OUT
IN
4 9 IS 9

(P15)+(ECU POWER)
8 (~SM)+(AH) ((~SM)+(AH))(P_7) 8 P_7
((~SM)+(AH))(BM STOWED) 10 10
(BM STOWED)

TO HORN BUTTON
BTS650
Vbb 74HC08
74HC08
OUT

(SM)+(AH)
IN
IS

P7R
P_7
P_6R2
BTS650
Vbb
Continued on View 6
OUT
IN (OE)
IS 4
6 4
((~SM)+(AH))(OE) 5 (~SM)+(AH) ~SLP MODE (~SM)
5 Vbb BTS621 74HC08
5
AUX HYD (AH)
IN1 OUT 1 2
IN2 3
(TM)(FE) 1
ST OUT 2

P6R1
FUNC ENABLE (FE)
P_7

BOOM STOWED GND 74HC08

TCON MODE TCON MODE(TM)
P_7 P_7 P9A
P7R P7R P6R1
P10 P10 P_11

TO MICRO

TO MICRO
U32
6 14

PCON POWER 5V12V

PCON POWER GND
74HC08 7
P_1

P9A

P6R1
P_11
TO MICRO
TO MICRO

TO MICRO TO MICRO
7
20A
CB

Continued on View 4

TT_TILT_SNSR_PWR
TT_TILT_SNSR_GND

ALTERNATOR RPM
OIL/WATER_TEMP
STARTER RELAY

AC GENERATOR

AC GENERATOR
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
OIL_PRESSURE
SYS_BAT_PWR

SERVICE HRN
BATECU-PWR

BATECU-PWR
SYS BAT GND

VALVE RTN#1

VALVE RTN_2
BATECU GND

VALVE_RTN3
THROTTLE

EDC FWD
IGN/FUEL

EDC REV

8 Continued on View 11
FWD
REV

J15 BLACK 4 PIN J13 WHITE 23 PIN

P1-01
P1-02
P1-03
P1-04

P1-01
P1-02
P1-03
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-10

P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
P1-11

POWER HARN ENGINE HARN

6 - 30 Z-80/60 Part No. 88619

 N
REV C

M
L
K
J
I

P7R
P10
P_30

P9A

P11
P_22R

P6R1
Continued on View 5

J10
P10
START
15
STRT ASST
14
SCROLL R
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
H

13
AUXILIARY HYD RECOVERY SIGNAL

SCRL F/ENT
BOOM UP/DWN FC RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL

12
MULTI FUNCTION VLV RECOVERY SIGNAL

- BUTTON
11
+ BUTTON
10
GAS/LP
9
G

ENG SPEED
8
AUXILIARY
7
SEC. UP
6
BOOM UP
5
F

4
TO PLD
Continued on View 12

TO MICRO 3
MANIFOLD HARN

TO PLD 2
J14 WHITE 35 PIN

TO MICRO
VLVRET4-BR P4-01 VALVE_RTN4 1
June 2011

C03PBF-RD/WH P4-02 BOOM_UP/DOWN_VLV

TO MICRO

C09PERF-BK/RD P4-03 BOOM_EXT/RET_VLV

E

Part No. 88619

C06TRF-WH/RD P4-04 TURNTABLE_ROTATE_VLV

P4-05
TO MICRO TO MICRO
C12SBFC-BL/WH P4-06 SEC. BOOM F.C.
C01PBU-RD P4-07 PRI_UP_VLV J11
P11 ROOM RET
C02PBD-RD/BK P4-08 PRI_DOWN_VLV
15
C07PBE-BK P4-09 PRI_EXTEND_VLV
BOOM DOWN
C08PBR-BK/WH P4-10 PRI_RET_VALVE TO MICRO
14
P4-11 TO PLD
BOOM EXT
D

SEC_DWN_VLV
TCON MEMBRANE PANEL

C11SBD-BL/BK P4-12 13
R49LP - WT/BK P4-13 DRIVE LIGHTS RELAY RABBIT
P_30

VLVRET5-BR P4-14 VALVE_RTN5 TO MICRO

TO MICRO 12
P4-15 HYD_FILTER1
TO MICRO SEC. DOWN
P4-16 HYD_FILTER2
TO PLD 11
VLVRET5-BR P4-17 BOOM REVERSE LOAD TURTLE
VLVRET5-BR P4-18 BOOM OVERLOAD
10
C10SBU-BL P4-19 SEC_UP_VLV TO MICRO BOOM CCW
C73SBR-BL/RD P4-20 SEC_RET_VLV TO PLD 9
C

C72SBE-BL/WH P4-21 SEC_EXT_VLV TO MICRO PLTFRM CCW

Z-80/60

P4-22 8
P4-23 MULTI_FUNCT_VLV
JIB UP
P4-24 TO MICRO
7
C04TRL-WH P4-25 ROTATE_CW_VLV
PLTFRM UP
C05TRR-WH/BK P4-26 ROTATE_CCW_VLV TO MICRO 6
VALVE RTN7 P4-27 VALVE_RTN7
PLTFRM DOWN
P4-28 5
P4-29 TO PLD JIB DOWN
B

VALVE RTN6 P4-30 VALVE_RTN6 TO MICRO 4

P4-31
PLTFRM CW
C27AUX-RD P4-32 AUX_RELAY
3
P125SBLE-WH/RD P4-33 SEC BOOM EXT SEQ #1 VLV TO MICRO
BOOM CW
P126SBLD-WH/BK P4-34 SEC BOOM DOWN SEQ #2 VALVE
2
P4-35 TO MICRO

1
A
Ground Controls (TCON) (before serial number 2511)

6 - 31
Electrical Schematic - View 6
Section 6 • Schematics

8
7
6
5
4
3
2
1
June 2011 Section 6 • Schematics

Electrical Schematic - View 6

Ground Controls (TCON) (before serial number 2511)

6 - 31
6 - 32
 June 2011 Section 6 • Schematics

Electrical Schematic - View 7

(before serial number 2511)

6 - 34
6 - 33
 8
7
6
5
4
3
2
1

6 - 34
Y27-TWO SPEED MOTOR STROKE (J87)

A
VLVRET-BRN P2-01
Y2-BRAKE RELEASE (J106)
P2-02
P2-03
Section 6 • Schematics

V29MS-RD/WH P2-04

A
S11-RR STEER RIGHT SNSR RD P2-05
P2-06

J107

B
BL P2-07

C
BK V36RRS-BL P2-08
B

V37RRS-BL/BK P2-09
(before serial number 2511)

A
RD C111RRS-OR P2-10
S12-LR STEER RIGHT
C111LRS-OR P2-11

J108

B
BL C111RFS-OR P2-12

C
BK C111LFS-OR P2-13
VLVRET2-BRN P2-14
Electrical Schematic - View 7

A
RD V32BRK-WH/RD P2-15
S13-RF STEER RIGHT
V36LRS-BL P2-16

J109
C

Z-80/60
BL

B
V37LRS-BL/BK P2-17
BK P2-18

C
V36RFS-BL
P110RT-BK P2-19

A
RD P109ANG-GR/WH P2-20
S14-LF STEER RIGHT P2-21
V37RFS-BL/BK

J110

B
BL V36LFS-BL P2-22

C
BK V37LFS-BL/BK P2-23

Y55-RR STEER RIGHT (J91)

D

Y56-RR STEER LEFT (J92)

Y57-LR STEER RIGHT (J93)
Y58-LR STEER LEFT (J94)
J32 23 PIN DRIVE
CHASSIS HARNESS

Y59-RF STEER RIGHT (J95)

Y60-RF STEER LEFT (J96)
Y61-LF STEER RIGHT (J97)
Y62-LF STEER LEFT (J98)
E

J31 23 PIN DRIVE

CHASSIS HARNESS

GND-DCN-BR P1-01
P21DCN-WH P1-02
June 2011

Part No. 88619

P53LS-RD P1-03
P1-04
S56PRV-RD P1-05
S56PRV-RD P1-06
F

P1-07
WH S56PRV(A)-RD
14
22

BK S56PRV-RD P1-08
LSA1OS
AXLE LS
NC

BR V121AXO-GR
NO

P1-09

OSCILLATE
RD S56PRV(B)-RD
21

13
4 3 2 1

P1-10

LIMIT SWITCH
(STOWED POS)
J104

P1-11
Y57 OSCILLATE RIGHT (J86) V121AXO-GR P1-12
P1-13
P1-14
Y56 OSCILLATE LEFT (J85)
G

V122AXO-GR/WH P1-15
P1-16
WH S56PRV(B)-RD
14

D81CAN- -GR P1-17

22

BK S56PRV-RD
NC

BR V122AXO-GR/WH
NO

P1-18
LSA2OS

D82CAN+ -YL
AXLE RS

RD S56PRV(A)-RD
21
4 3 2 1

13

OSCILLATE

P1-19
LIMIT SWITCH
(STOWED POS)

P1-20
J105

P1-21
P1-22
P1-23
H

S56PRV-RD

P21DCN-WH
GNDDCN-BR
D82CAN+ -YL

P53LS-WH/BK
D81CAN- -GR
I

Continued on View1
J
K

Continued on View 8
L
M
REV C

N
 June 2011 Section 6 • Schematics

REV C Electrical Schematic - View 8

(before serial number 2511)
N M L K J I H G F E D C B A

PWR-PCON ESTOP
PL TILT SNSR PWR
PL TILT SNSR GND

SAFE PL TILT PWR

SAFE PL TILT GND
SAFE PL TILT OUT
LOAD SNSR PWR
LOAD SNSR GND

HRN RLY CNTRL

PROX KILL CMD
ON/OFF VLV3_A
ON/OFF VLV3_B

PROX KILL GND

OUT PWR ENBL

PL LVL CYL EXT
FOOT SW PWR
FOOT SW RTN
LOAD SNSR IN
PROP VLV2_A
PROP VLV2_B
PROP VLV1_A
PROP VLV1_B
ON CIRCUIT BOARD

PL TILT SNSR
PIN CKT #P

PCON PWR
DB9 CONNECTOR

PCON GND
P2 RS232_RXD

VLV RTN
P3 RS232_TXD

CAN+
Continued on View 2

CAN-
P5 RS232_GND

P22
P7
P1-01
P1-02
P1-03
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-10

P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23

P1-01
P1-02
P1-03
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-10

P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
P1-11

P1-11
J22 WHITE 23 PIN J21 BLACK 23 PIN
PCON MANIFOLD BOOM HARN 2

WH
C18PRR-GR/BK

GN
C15PLD-OR/BK

R90PXS-RD/BK
C90PXS-RD/BK

BK
C88PTS-RD/BK

C84TAY-GR/BK

C47OUT-WHT/BLK
C44JD-GR/BK
VLVRET-BRN

PLATRET-BR
C17PRL-GR

C14PLU-OR

PTSRET-BR
S14PLU-OR

P85PTS-GR

P87PTS-RD
C56FTS-RD

P56PRV-RD/WH
P56FTS-RD
C43JU-GR

GNDPCON-BR
P52PCON-WH

D81CAN- -GR
D82CAN+ -YL

P23PCON-BK
S56PRV-RD

C46HN-WH
3

1 2 3 4 5 6 J55
1. PLAT SNSR GND
2. TILT SNSR SIG OUT
3. TILT SNSR PWR
4. TILT SW GND

PLAT TILT SENSOR

+
Continued on View 9

0-20DEG Y AXIS -
WH
GN

BK
5. PWR TO TILT SW
4

+
PLAT ROT CW (J76)

-
PLAT ROT CCW (J77)

6. OUTPUT FROM TILT SW

POWER FET
JIB DOWN (J79)

PLAT LEVEL DN (J81)

SAFETY CUTOUT
PLAT LEVEL UP (J80)
JIB UP (J78)

10 DEG
C56FTS-RD

C23PTS-WH
R56FTS-RD

C56PTS-RD
Continued on View 7

POWER FET
-
SAFETY CUTOUT
NOT USED

10 DEG
PLATFORM OPTIONAL SWING
TILT SENSOR
GATE WIRING 3
5
J82 ASSEMBLY C46HN-WH
4 3 21 J84 S56PRV-RD 1
WH

RD
BR
BK

4 3 2 1 1 2 P56PRV-RD/WH 2
WH

WH
RD

RD
BR
BK

BK

4 3 2 1 1 2

WH
FOOTSW (FS1)

RD
BR
BK
22 21
NC 22 21 FOOTSWITCH
LSP1 PROX J119
14 13 PROXIMITY NC 6
KILL SWITCH 14 13 NO 22 21 P23PCON-BK
NO 2 1 2 1 NC 3
OPTIONAL NO GNDPCON-BR 6
WH
WH

BR
RD

NC
RD
BR
BK

BK
SWING GATE 4
14 13 INTERLOCK
NORMAL SWITCH POSITION P52PCON-WH
OVERLOAD NO 5
SHOWN FOR: LSA1OS C47OUT-WH/BK
LIMIT SW
LSA2OS 22 21 22 21 1
LSP1OLS D81CAN- -GR
PROX KILL NC NC 2
WH
RD

SWING GATE
BK

D82CAN+ -YL
14 13 14 13
NO NO

LSJ1EO NORMAL SWITCH POSITION

OVERLOAD LIMIT SW PLATFORM LEVEL
NO SHOWN FOR: LSJ1EO
LSP1OLS (SHOWN IN
OVERLOADED CONDITION)
CYL FULLY EXT SWITCH 7
(STOWED POS)
NC

J16-DRIVE CHASSIS HARN J33-BOOM HARN

A A A A
D82CAN+ -YL YEL CAN HIGH YEL D82CAN+ -YL
B B B B
D81CAN- -GR GRN CAN LOW GRN D81CAN- -GR

P RING
J18-DRIVE CHASSIS HARN J34-LIMIT SW HARN
1 1 1 1
S56PRV-RD S56PRV-RD
2 2
WH P7R WH
2 2
GNDDCN-BR
8
GNDDCN-BR BK DCON GND BK

J17-DRIVE CHASSIS HARN J35-LIMIT SW HARN

1 1 1 1 P21DCN-WH
P21DCN-WH RD DCON PWR RD
2 2 2 2
P53LS-WH/BK WH/BK P6R1 WH/BK P53LS-WH/BK

Part No. 88619 Z-80/60 6 - 35

June 2011 Section 6 • Schematics

Electrical Schematic - View 8

(before serial number 2511)

6 - 35
6 - 36
 June 2011 Section 6 • Schematics

Electrical Schematic - View 9

(before serial number 2511)

6 - 38
6 - 37
Section 6 • Schematics June 2011

Electrical Schematic - View 9 REV D

(before serial number 2511)
A B C D E F G H I J K L M N

U30

TETHER FUNC ENBL

FLASHING BEACON

DIAG/TETHER PWR
PWR-PCON ESTOP

DIAG/TETHER GND
HORN RELAY COIL

TET ESTOP PWR

OUT PWR ENBL

TET ESTOP RET

PCON POWER

CAN SHIELD

CAL FREQ 1

CAL FREQ 2

RS232 GND
RS232 RXD
PCON GND

RS232 TXD
Continued on View 3

CAN HIGH
CAN LOW
WORK LT
TCON

BOOT
P_22
P_7
J11 BLACK 23 PIN

P1-01
P1-02
P1-03
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-10

P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
P1-11
2 BOOM HARN

C47OUT-WH/BK

P56PRV-RD/WH
GNDPCON-BR

R48LP-WH/RD
P52PCON-WH

R49LP-WH/BK

D81CAN- -GR
P23PCON-BK

D82CAN+ -YL
S56PRV-RD
C46HN-WH

4 Continued on View 8

5 B1ENG (12 VOLT)

C46HN-WH
S56PRV-RD
P56PRV-RD/WH Continued on View 10
TO WORK LIGHTS 87a
RED 87 30
R48LP-WH/RD GND-BR
86 85
6 P23PCON-BK
GNDPCON-BR TO FLASHING BEACON 87a
P52PCON-WH RED 87 30
C47OUT-WH/BK C117FB-RD GND-BR
86 85
D81CAN- -GR
D82CAN+ -YL

D82CAN+ -YL

D81CAN- -GR

8
S56PRV-RD S56PRV-RD
GNDDCN-BR GNDDCN-BR

P21DCN-WH P21DCN-WH
P53LS-WH/BK P53LS-WH/BK

6 - 38 Z-80/60 Part No. 88619

 N
REV C

M
L
K

S56PRV-RD

P21DCN-WH
GNDDCN-BR

P53LS-WH/BK
Continued on View 9
J

18/19

J114
CABLE

J20A

12 WAY
GN GN SNSR GND-BR
GN/BK GN/BK SNSR GND-BR
SNSR GND-BR

3 7 11
GN/WH GN/WH SNSR GND-BR
TILT SNSR
S56PRV-RD
P21DCN-WH
GNDDCN-BR

P53LS-WH/BK

J20B

70 TO 35 DEG Y-AXIS
+
- BL/BK BL/BK C123PBD RD/BK
SAFETY CUTOUTS
4 WAY 1 2 3 12 WAY 9 8

BL BL P109PBTS-GR/WH P109PBTS-GR/WH

10 12
J12 BLACK 35 PIN
I

LIMIT SWITCH HARN

+ + 18/19
80 DEG - 80 DEG - CABLE
BK/WH BK/WH P54ENG-BK/WH GNDDCN-BR P2-01
OR/BK OR/BK SJ1-WH/RD P21DCN-WH P2-02
POWER FET POWER FET

4 2 6
1 12 2

RD RD S59SBE-GR/WH P53LS-WH/BK P53LS-WH/BK P2-03 P_6R1

RD/WH RD/WH
RD/BK RD/BK P54ENG-BK/WH P54ENG-BK/WH P2-04 P_6R2

PRI BOOM ANG SENSOR

POWER FET POWER FET
S56PRV-RD P2-05 P_7R

8
3

WH WH S12SBL-BL/WH
WH/RD WH/RD P53LS-WH/BK P2-06 P_9A
WH/BK WH/BK P_9B
P58LS RD/BK P58LS RD/BK P2-07
P54ENG-BK/WH P54ENG-BK/WH P2-08 P_10
LSP1EO LSP1EO
WH WH BL/WH C64LS-OR/BK P_11

21
3' FROM FULLY 3' FROM FULLY S12SBL-BL/WH S12SBL-BL/WH P2-09

WHT
4 7

BK BK
21

BK BK C71PBE-BL/BK
EXTENDED BR EXTENDED BR P53LS-WH/BK P2-10
H

22 21

22 21

14 13
14 13

RD RD

NC
NC

J44 J44

NO
WHT NO

P53LS-WH/BK P2-11
18/19

P54ENG-BK/WH P54ENG-BK/WH P2-12

CABLE

C64LS-OR/BK C64LS-OR/BK P2-13

LSP1RO WH LSP1RO WH OR/RD C65LOF-BL/WH C65LOF-BL/WH P2-14
14

WHT
WHT

BK BK BK/RD
3' EXTENDED BR 3' EXTENDED BR OR C70PBR-BL/WH C66DREN-BL C66DREN-BL P2-15
4321

22 21
4321

14 13
13
22 21

J45 RD J45 RD BL/RD C64LS-OR/BK

NC
5 611 10

NC

WHT NO
WHT NO

C73SBR-BL/RD C73SBR-BL/RD P2-16

SJ1-WH/RD
P58LS-RD/BK

P53LS-WH/BK

C68PBD-RD C68PBD-RD P2-17 LSP1AO

S59SBE-GR/WH

C64LS-OR/BK P2-18 LSB2RO

C70PBR-BL/WH P2-19 LSP1RO
C64LS-OR/RD C64LS-OR/BK C71PBE-BL/BK P2-20 LSP1EO
C124SBL RD/WH C124SBL RD/WH C67SBD-BL P2-21
G

C77SBU-WH P2-22
P2-23 P1-SEQ
P2-24 P2-SEQ
LSS1RS WH S59SBE-GR/WH S59SBE-GR/WH
LSS1RS WH BK P53LS-WH/BK P53LS-WH/BK SNSR GND-BR P2-25
BK 3' EXTENDED P58LS-RD/BK
C68PBD-RD

3' EXTENDED BR BR P58LS-RD/BK

C66DREN-BL

P109PBS-GR/WH P2-26
12 11
4321

J46 RD SJ1-WH/RD SJ1-WH/RD

NC
22 21

12 11
YEL NC

NC
4321

J46 RD
S12SBL-BL/WH

22 21
C73SBR-BL/RD

YEL NC

P2-27
C124SBL RD/WH

C124SBL RD/WH P2-28

P2-29
WH LSS2AS WH S59SBE-GR/WH S59SBE-GR/WH
LSS2AS
C64LS-OR/BK

BK RAISED BK P53LS-WH/BK P53LS-WH/BK P2-30

RAISED BR BR P58LS-RD/BK P58LS-RD/BK
SAFETY P2-31 BM STWD
12 11

12 11
22 21

22 21

RD
NC

SJ1-WH/RD
4321

NC

SAFETY RD SJ1-WH/RD
4321
PUR NC

PUR NC

J47
F

J47 C123PBD RD/BK P2-32

FST1S C65LOFL-BL/WH C65LOFL-BL/WH P2-33
LOW FUEL FS C64LS-OR/BK C64LS-OR/BK S12SBL-BL/WH P2-34 P_30
P2-35
WH
ALL SWITCHES ARE SHOWN IN THE BOOM STOWED POSITION

ALL SWITCHES ARE SHOWN IN THE "OUT OF BOX" POSITION

BK LST1O WH C66DREN-BL
21

LST1O BK C64LS-OR/BK C64LS-OR/BK

21

BR DRV ENABLE BR
DRV ENABLE
22 21

14 13

RD
NC
22 21

J48
14 13

ORN NO

RD
NC

ORN NO

J48

WH LSS1RO WH C64LS-OR/BK C64LS-OR/BK

June 2011

LSS1RO BK BK C73SBR-BL/RD C73SBR-BL/RD

SEC RET OPER BR SEC RET OPER BR V126SBLD-WH/BK V126SBLD-WH/BK
14 13
4321
14 13
4321

RD
NO
24 23

J49 RD P126SBLD-WH/BK
24 23

P126SBLD-WH/BK
NO

RED NO
RED NO

J49
E

Part No. 88619

WH LSS1AO WH
LSS1AO BK BK
5 DEG BR 5 DEG BR C64LS-OR/BK C64LS-OR/BK
22 21
22 21

14 13
14 13

4321
4321

C67SBD-BL
NC

RD J50 RD C67SBD-BL C67SBD-BL

NC
BLU NO

BLU NO

J50

WH WH C64LS-OR/BK C64LS-OR/BK
LSS2AO BK LSS2AO C77SBU-WH C77SBU-WH
BK C77SBU-WH
RAISED OPER BR RAISED OPER BR V125SBLE-WH/RD V125SBLE-WH/RD
22 21

14 13
4321
22 21

14 13

RD
4321

NC

RD
NC

J51 P125SBLE-WH/RD P125SBLE-WH/RD

GRN NO

J51

WH LSP1AO WH
GRN NO BRN
22

14

LSP1AO
C64LS-OR/BK

BK BK
C68PBD-RD

> 5 DEG BR > 5 DEG BR C64LS-OR/BK

D

22 21
21

4321

RD
4321

RD J43
NC

NC

C68PBD-RD
14 13
13
NO

BRN NO

J43
Continued on View 4
C

Z-80/60
V125SBLE-WH/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
P125SBLE-WH/RD
B
A

Continued on View 11
Limit Switches (before serial number 2511)
Electrical Schematic - View 10

6 - 39
Section 6 • Schematics

8
7
6
5
4
3
2
1
June 2011 Section 6 • Schematics

Electrical Schematic - View 10

Limit Switches (before serial number 2511)

6 - 39
6 - 40
 June 2011 Section 6 • Schematics

Electrical Schematic - View 11

Deutz F4L-913 Engine (before serial number 339)

6 - 42
6 - 41
Section 6 • Schematics June 2011

Electrical Schematic - View 11 REV B

Deutz F4L-913 Engine (before serial number 339)
A B C D E F G H I J K L M N

TT_TILT_SNSR_PWR
TT_TILT_SNSR_GND

ALTERNATOR RPM
OIL/WATER_TEMP
STARTER RELAY

AC GENERATOR

AC GENERATOR
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
OIL_PRESSURE
SYS_BAT_PWR
1

SERVICE HRN
BATECU-PWR

BATECU-PWR
SYS BAT GND

VALVE RTN#1

VALVE RTN_2
BATECU GND

THROTTLE

EDC FWD
IGN/FUEL

EDC REV
FWD
REV
J15 BLACK 4 PIN J13 WHITE 23 PIN

P1-01
P1-02
P1-03
P1-04

P1-01
P1-02
P1-03
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-10

P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
P1-11
POWER HARNESS ENGINE HARNESS
Continued on View 5 TURNTABLE TILT
SENSOR

1 +
C84TAY-GN/BK C84TAY-GN/BK
-

C31EDC-WH/BK

C26TSR-WH/RD
C25PSR-WH/BK

C41RPM-OR/BK
C35RPM-BK/RD
2

C34SA-BK/WH
C83TAX-GN/WH C83TAX-GN/WH +

VLVRET2-BR
C46HRN-WH

C30EDC-WH
-

C21IGN-WH

C33STR-BK
3
2

B1BAT-RD

B1BAT-RD
P85TTSR-GR P85TTSR-GR

GND-BR
GND-BR
4
RET85TTSR-BR RET85TTSR-BR
5 0-20 DEGREE
SENSOR ALARM
6 SET AT 4.5 DEGREES

P31-ENG HARNESS
J31-TILT SNSR
CB 87a 3 DETAIL "B"
OPTIONAL 120VAC W/REGULATOR
J32-ENG HARNESS P32-GENERATOR 30A 1 30 4 RD/12VDC RED
HARNESS 87

REGULATOR
C45GEN-GR/WH 1 WT BR/R45GEN(A) BRN
3 2 86 85 5

110 VAC
2 GR YL/BAT GND YEL
3 BK RD BR/P45GEN(B) BRN
PURPLE/F45GEN PURPLE

WHT-NEUTRAL
AUX MAIN

120V AC
BATTERY
Continued on View 10 SEPARATOR

BLK-120VAC
AUTO
RESET CB
SEE DETAIL C FOR 220VAC GENERATOR
W/REGULATOR AND DETAIL D FOR 120VAC
GENERATOR W/O REGULATOR.
Continued on View 12
15A
C33STR-BK

4
B2BAT-RD

B1BAT-RD

C26TSR-WT/RD
C25PSR-WT/BK
B1ENG-RD B1ENG-RD
P125SBLE-WH/RD P125SBLE-WH/RD P125SBLE-WH/RD P125SBLE-WH/RD
P126SBLD-WH/BK P126SBLD-WH/BK P126SBLD-WH/BK P126SBLD-WH/BK
V125SBLE-WH/RD V125SBLE-WH/RD V125SBLE-WH/RD V125SBLE-WH/RD
5 V126SBLD-WH/BK V126SBLD-WH/BK V126SBLD-WH/BK V126SBLD-WH/BK
C21IGN-WH
F7
20 A P33STR-BK P33STR-BK P33STR-BK
F16 F17 F17 TO J3 WHITE
70 A 20 A 20 A C35RPM-BK/RD 23 PIN ENGINE
HARNESS
P1-22
CB DETAIL "D"
87a 3
OPTIONAL 120VAC W/O REGULATOR
P116HYD-OR P116HYD-OR J32-ENG HARNESS P32-GENERATOR 30A 1 30 4
HARNESS 87
B1STAID-RD B1STAID-RD C45GEN-GR/WH 1 WT

P116HYD-OR
C21IGN-WH
2 86 85 5
6 TROMBETTA WH-PULL IN 2 GR SEE DETAIL "C"

C21IGN-WH
B1ENG-RD
MOM N.O.
1 2 3 BK RD FOR 220VAC GENERATOR

GR
TIME DELAY
30 86 W/REGULATOR AND

C34SA-BK/WH
CR1
STARTER +BAT DETAIL "B"
RELAY 87a 87 85 FOR 120VAC
RD-HOLD 1 2
4 5

C107AF-RD
2 1 2 1 WHT-NEUTRAL GENERATOR W/ REGULATOR.
C107AF-RD

30 86 PR2
HORN CR17 86 86 CR2
30
+AUX -BAT START AID 30
P33STR-BK

RELAY ENGINE

BATGND(A) - BK
OIL COOLER
87a 87 85 RELAY 2 1 87a 120V AC
COM RELAY 85 87 87a 87 85 ALTERNATOR
5 CR5
WH-PULL IN
4 86 30 AUTO
5 RELAY
C41RPM-OR/BK

S-500 5 4 4
RD-HOLD

87a RESET CB

C116HYD-WH
C31EDC-WH/BK
85 87 BLK-120VAC
15A
C30EDC-WH
5 4

C26TSR-WT/RD
C25PSR-WT/BK
R116HYD-OR
FAN BREAK
P46HRN(A)-WH

TO J3 WHITE
7 SWITCH
VLVRET2-BR

VLVRET2-BR
J57 23 PIN ENGINE
ALTERNATOR HARNESS
1 2 3 P1-22
EXCT. OTS1

R34SA-BK/WH
N.O. J32-ENGINE DETAIL "C"

VLVRET-BR
WH

P32-GENERATOR HARNESS
RD

BK

HARNESS
87a 3
BAT. BAT. OPT 220VAC W/REGULATOR
+ - B1BAT-RD RD
1 30 4
C27AUX-RD

30A RD/12VDC RD
PR1

REGULATOR
87

C45GEN-GR/WH WH WH/R45GEN(A) WH

220 V AC
+ + STA. 2 86 85 5
BR BR GND
BAT GND-BR

FAN BATGND-BR BR
PULL IN
HOLD

J120 J56
STARTER AUX. BR BK P45GEN(B) BK
A B C D A B C
PUMP GR BK/WH F45GEN BK/WH
BAT GND-BR

BAT GND-BR
BAT GND-BR

BAT GND-BR
REGULATOR IND.
TO J4-32
WHITE 35 PIN

- -

PULL IN
8

HOLD
H1 WH-NEUTRAL
B2 B1
220VAC
AUTO
TEMPERATURE
RESET CB SEE DETAIL B FOR 120VAC GENERATOR
SWITCH

HYDRAULIC
OIL COOLER FAN
HORN
AUXILIARY PUMP
CONTACTOR

FLAME START
FLAMMABLE
START IGNITOR

FUEL VALVE

OIL PRESSURE
AUXILIARY PUMP

FUEL SOLENOID
DUAL COIL EDC
STARTER

ALTERNATOR

FLAMMABLE
START RELAY

OIL TEMP.
SENDER
AUX HYD
ELECTRONICS
BATTERY

START BATTERY

STARTER RELAY

COOLER RELAY
ENGINE BLOCK

HORN
RELAY

W/REGULATOR AND DETAIL D FOR 120VAC

HI/LO SPEED
SOLENOID

HYDRAULIC OIL

IGNITION/
ALTERNATOR
RELAY
TROMBETTA

BK-220VAC
10A GENERATOR W/O REGULATOR.

6 - 42 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

REV C Electrical Schematic - View 11

Deutz BF4L-2011 & TD2011L04i Engine (from serial number 339 to 2316)
N M L K J I H G F E D C B A

P1-15 TT_TILT_SNSR_PWR
P1-14 TT_TILT_SNSR_GND

P1-18 ALTERNATOR RPM

P1-13 OIL/WATER_TEMP
P1-09 STARTER RELAY

P1-17 AC GENERATOR

P1-22 AC GENERATOR
P1-20 TT_TILT_X_AXIS
P1-21 TT_TILT_Y_AXIS
P1-12 OIL_PRESSURE
P1-01 SYS_BAT_PWR

P1-07 SERVICE HRN

P1-04 BATECU-PWR

P1-04 BATECU-PWR
P1-02 SYS BAT GND

P1-01 VALVE RTN#1

P1-16 VALVE RTN_2

P1-03 BATECU GND

P1-19 VALVE_RTN3
P1-02 THROTTLE

P1-10 EDC FWD

P1-03 IGN/FUEL

P1-11 EDC REV

P1-05 FWD
Continued on View 5

P1-06 REV
J15 BLACK 4 PIN J13 WHITE 23 PIN

P1-08

P1-23
POWER HARN ENGINE HARN

2
1 +

B1BAT-RD

B1BAT-RD

C31EDC-WH/BK

C26TSR-WH/RD
C25PSR-WH/BK

C41RPM-OR/BK
C35RPM-BK/RD
C84TAY-GN/BK C84TAY-GN/BK -

GND-BR
GND-BR

C34SA-BK/WH
2 +

VLVRET2-BR
C46HRN-WH

C30EDC-WH
C83TAX-GN/WH C83TAX-GN/WH

C21IGN-WH
-

C33STR-BK
3
P85TTSR-GR P85TTSR-GR

SENSOR ALARM
4
RET85TTSR-BR RET85TTSR-BR
5

0 DEGREE

SET AT 4.5
DEGREES
Continued on View 10 6

P31-ENG HARN
J31-TILT SNSR
DETAIL "C" OPT 120VAC W/REGULATOR
P32-GEN HARN 87a 3
B1BAT RD 4
J32-ENG HARN
30A 1 30
87
RD/12VDC TURNTABLE 3
C45GEN GN/WH TILT

REGULATOR
C45GEN-GR/WH 2 86 85 5 NEUTRAL WH

VOLTAGE
SENSOR
GND BR BR GND
BR BR LINE BK
GN FIELD BK/WH
WH WH

LINE BK
AUX MAIN

AUTO
RESET CB BK NEUTRAL WH

BK BK FIELD BK/WH
4
C33STR-BK

15A

SEE DETAIL D FOR 220VAC GENERATOR W/REGULATOR.

B2BAT-RD

B1BAT-RD
RD
RD

C26TSR-WH/RD
C25PSR-WH/BK
B1ENG-RD B1ENG-RD B1ENG-RD B1ENG-RD P34 J34
1
P125SBLE-WH/RD
P126SBLD-WH/BK
P125SBLE-WH/RD
P126SBLD-WH/BK
P125SBLE-WH/RD
P126SBLD-WH/BK
P125SBLE-WH/RD
P126SBLD-WH/BK
2 Continued on View 12 5
V125SBLE-WH/RD V125SBLE-WH/RD V125SBLE-WH/RD 3
V125SBLE-WH/RD
4
V126SBLD-WH/BK V126SBLD-WH/BK V126SBLD-WH/BK V126SBLD-WH/BK
B1ENG-RD

F7 OIL COOLER C21IGN-WH

C21IGN-WH
F20 HI/LO COOLER

B1ENG-RD
F22

F20

F23
20 A
F7

60 A

20 A

20 A

F22 GLOW PLUG

C34SA-BK/WH
F23 ENG/ST/ALT
P35RPM-BK/RD

30 86 CR28
ENG ALT
DUETZ BF4L2011 OR TD2011L04i ENGINE
RD
RD

87a 87 85 RELAY
C35RPM-BK/RD

P116HYD-OR P116HYD-OR
6

P116HYD-OR
P34SA-BK/WH P34SA-BK/WH

R21IGN-WH
C21IGN-WH
TROMBETTA WH-PULL IN
TIME DELAY RD-HOLD TO
MOM N.O. J13 WHITE 23 PIN
CR1
30 86 B ENG HARNESS
STARTER
R21IGN-WH P1-22
RELAY 87a 87 85
A 86 CR5 30
BATGND(A) - BK

AUX+ HORN CR17 OIL 86 30

C107AF-RD

87a 87 85 RELAY

C26TSR-WT/RD
C25PSR-WT/BK
COOLER DETAIL "D" OPT 220VAC W/REGULATOR
GND- C
WH-PULL IN

85 87 87a 87a 3
CR15 86 RELAY P32-GEN HARN
S-500 30
RD-HOLD

C116HYD-WH
ST AID B1BAT RD 4
C31EDC-WH/BK
30A 1 30 RD/12VDC
RELAY 85 87 87a
C41RPM-OR/BK

87
C30EDC-WH

J32-ENG HARN
P46HRN(A)-WH

C45GEN GN/WH 7

REGULATOR
R116HYD-OR
NEUTRAL WH

VOLTAGE
C45GEN-GR/WH 2 86 85 5
VLVRET2-BR
P33STR-BK

GND04-BR

GND04-BR

J57 GND BR BR GND

D2
1 2 3
R34SA-BK/WH
OTS1 BR BR LINE BK
D7
N.O.
VLVRET-BR

ALTERNATOR
GN
WH

FIELD BK/WH
RD

BK

D5 D3
RD

EXCT.
WH
C27AUX-RD

WH
PR1

BAT. BAT. FAN

+ -
BAT GND-BR

+ +
D1 J120 D8 LINE BK
PULL IN
HOLD

AUTO
AUX. STA. A B C D RESET CB BK NEUTRAL WH
BAT GND-BR

PUMP
BAT GND-BR

BAT GND-BR
BAT GND-BR
WHITE 35 PIN

BK BK FIELD BK/WH
8
- -
12.5 A
H1
TO J4-32

B2 REGULATOR IND.
B1 SEE DETAIL C FOR 120VAC GENERATOR W/REGULATOR.

OIL PRESSURE

OIL TEMP
SENDER
ENGINE BLOCK
ELECTRONICS

START BAT

CONTACTOR

ALTERNATOR

OIL COOLER

SOLENOID
DUAL
SOLENOID

TEMP SW
SERVICE
AUX HYD

RELAY
STARTER
STARTER

HYDRAULIC
BATTERY

GLOW

GLOW
AUX HYD

COIL

COOLER
RELAY

EDC

PLUG

PLUG
HORN

RELAY
HORN
RELAY

PUMP

AUX HYD

SPEED

FUEL
HI/LO

FAN

Part No. 88619 Z-80/60 6 - 43

June 2011 Section 6 • Schematics

Electrical Schematic - View 11

Deutz BF4L-2011 & TD2011L04i (from serial number 339 to 2316)

6 - 43
6 - 44
 June 2011 Section 6 • Schematics

Electrical Schematic - View 11

Deutz BF4L-2011 & TD2011L04i Engine
(from serial number 2317 to 2510)

6 - 46
6 - 45
Section 6 • Schematics June 2011

Electrical Schematic - View 11 REV A

Deutz BF4L-2011 & TD2011L04i
(from serial number 2317 to 2510)
A B C D E F G H I J K L M N
1

P1-15 TT_TILT_SNSR_PWR
P1-14 TT_TILT_SNSR_GND

P1-18 ALTERNATOR RPM

P1-13 OIL/WATER_TEMP
P1-09 STARTER RELAY

P1-17 AC GENERATOR

P1-22 AC GENERATOR
P1-20 TT_TILT_X_AXIS
P1-21 TT_TILT_Y_AXIS
P1-12 OIL_PRESSURE
P1-01 SYS_BAT_PWR

P1-07 SERVICE HRN

P1-04 BATECU-PWR

P1-04 BATECU-PWR
P1-02 SYS BAT GND

P1-01 VALVE RTN#1

P1-16 VALVE RTN_2

P1-03 BATECU GND

P1-19 VALVE_RTN3
P1-02 THROTTLE

P1-10 EDC FWD

P1-03 IGN/FUEL

P1-11 EDC REV

P1-05 FWD
Continued on View 5

P1-06 REV
J15 BLACK 4 PIN J13 WHITE 23 PIN

P1-08

P1-23
POWER HARN ENGINE HARN
2

B1BAT-RD 1 +

B1BAT-RD

C31EDC-WH/BK

C26TSR-WH/RD
C25PSR-WH/BK

C41RPM-OR/BK
C35RPM-BK/RD
C84TAY-GN/BK C84TAY-GN/BK -
GND-BR
GND-BR

C34SA-BK/WH
2 +

VLVRET2-BR
C46HRN-WH

C30EDC-WH
C83TAX-GN/WH C83TAX-GN/WH

C21IGN-WH
-

C33STR-BK
3
P85TTSR-GR P85TTSR-GR

SENSOR ALARM
4
RET85TTSR-BR RET85TTSR-BR
5

0 DEGREE

SET AT 4.5
DEGREES
Continued on View 10 6

P31-ENG HARN
J31-TILT SNSR
DETAIL "C" OPT 120VAC W/REGULATOR
3 P32-GEN HARN 87a 3
B1BAT RD 1 30 4
30A RD/12VDC TURNTABLE
87
J32-ENG HARN C45GEN GN/WH TILT

REGULATOR
C45GEN-GR/WH 2 86 85 5 NEUTRAL WH

VOLTAGE
SENSOR
GND BR BR GND
BR BR LINE BK
GN FIELD BK/WH
WH WH

4 LINE BK
AUX MAIN

AUTO
RESET CB BK NEUTRAL WH

BK BK FIELD BK/WH
C33STR-BK

15A

SEE DETAIL D FOR 220VAC GENERATOR W/REGULATOR.

B2BAT-RD

B1BAT-RD
RD
RD

C26TSR-WH/RD
C25PSR-WH/BK
P34 J34
5 B1ENG-RD B1ENG-RD B1ENG-RD B1ENG-RD
1
P125SBLE-WH/RD
P126SBLD-WH/BK
P125SBLE-WH/RD
P126SBLD-WH/BK
P125SBLE-WH/RD
P126SBLD-WH/BK
P125SBLE-WH/RD
P126SBLD-WH/BK
2 Continued on View 12
V125SBLE-WH/RD V125SBLE-WH/RD V125SBLE-WH/RD 3
V125SBLE-WH/RD
4
V126SBLD-WH/BK V126SBLD-WH/BK V126SBLD-WH/BK V126SBLD-WH/BK
B1ENG-RD

F7 OIL COOLER C21IGN-WH

C21IGN-WH
F20 HI/LO RPM

B1ENG-RD
F22

F20

F23
20 A
F7

60 A

20 A

30 A

F22 GLOW PLUG

C34SA-BK/WH
F23 ENG/ST/ALT
P35RPM-BK/RD

6 30 86 CR28
ENG ALT
DUETZ BF4L2011 OR TD2011L04i ENGINE
RD
RD

87a 87 85 RELAY
C35RPM-BK/RD

P116HYD-OR P116HYD-OR

P116HYD-OR
P34SA-BK/WH P34SA-BK/WH

R21IGN-WH
C21IGN-WH
TROMBETTA WH-PULL IN
TIME DELAY RD-HOLD TO
MOM N.O. J13 WHITE 23 PIN
CR1
30 86 B ENG HARNESS
STARTER
R21IGN-WH P1-22
RELAY 87a 87 85
A 86 CR5 30
BATGND(A) - BK

AUX+ HORN CR17 OIL 86 30

C107AF-RD

87a 87 85 RELAY

C26TSR-WT/RD
C25PSR-WT/BK
COOLER DETAIL "D" OPT 220VAC W/REGULATOR
GND- C
WH-PULL IN

85 87 87a 87a 3
CR15 86 RELAY
7 S-500 30 P32-GEN HARN
RD-HOLD

C116HYD-WH
ST AID B1BAT RD 4
C31EDC-WH/BK

30A 1 30 RD/12VDC
RELAY 85 87 87a
C41RPM-OR/BK

87
C30EDC-WH

J32-ENG HARN
P46HRN(A)-WH

C45GEN GN/WH

REGULATOR
R116HYD-OR
NEUTRAL WH

VOLTAGE
C45GEN-GR/WH 2 86 85 5
VLVRET2-BR
P33STR-BK

GND04-BR

GND04-BR

J57 GND BR BR GND

D2
1 2 3
R34SA-BK/WH

OTS1 BR BR LINE BK
D7
BK

N.O.
VLVRET-BR

ALTERNATOR
GN
CB7-15A
WH

FIELD BK/WH
RD

D5 D3
RD

EXCT.
WH
C27AUX-RD

WH
PR1

BAT. BAT. FAN

+ -
BAT GND-BR

+ +
D1 J120 D8 LINE BK
PULL IN
HOLD

8 AUX. STA. A B C D
AUTO
RESET CB BK NEUTRAL WH
BAT GND-BR

PUMP
BAT GND-BR

BAT GND-BR
BAT GND-BR
WHITE 35 PIN

- - BK BK FIELD BK/WH
12.5 A
H1
TO J4-32

B2 REGULATOR IND.
B1 SEE DETAIL C FOR 120VAC GENERATOR W/REGULATOR.

OIL PRESSURE

OIL TEMP
SENDER
ENGINE BLOCK
ELECTRONICS

START BAT

CONTACTOR

ALTERNATOR

OIL COOLER

SOLENOID
DUAL
SOLENOID

TEMP SW
SERVICE
AUX HYD

RELAY
STARTER
STARTER

HYDRAULIC
BATTERY

GLOW

GLOW
AUX HYD

COIL

COOLER
RELAY

EDC

PLUG

PLUG
HORN

RELAY
HORN
RELAY

PUMP

AUX HYD

SPEED

FUEL
HI/LO

FAN

6 - 46 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

Electrical Schematic - View 12

(before serial number 2511)

6 - 48
6 - 47
 8
7
6
5
4
3
2
1

6 - 48
A
Section 6 • Schematics

V125SBLE-WH/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
P125SBLE-WH/RD
(before serial number 2511)

Continued on View 11
Electrical Schematic - View 12

Z-80/60
(DWN ENABLE) SEC BM DN SEQ #2
D

V126SBLD-WH/BK P125SBLE-WH/RD
Continued on View 6

JXX
(EXT ENABLE) SEC BM EXT SEQ #1 V125SBLE-WH/RD P126SBLD-WH/BK

JXX
MANIFOLD HARN
J14 WHITE 35 PIN

VLVRET4-BR VLVRET4-BR P4-01 VALVE_RTN4

E

PRI BM UP/DN F.C. (J58) C03PBF-RD/WH C03PBF-RD/WH P4-02 BOOM_UP/DOWN_VLV

PRI BM EXT/RET F.C. (J61) C09PERF-BK/RD C09PERF-BK/RD P4-03 BOOM_EXT/RET_VLV
TT ROT CW/CCW F.C. (J69) C06TRF-WH/RD C06TRF-WH/RD P4-04 TURNTABLE_ROTATE_VLV

P P P
P4-05
SEC. BM F.C. (J64) C12SBFC-BLU/WT C12SBFC-BL/WH P4-06 SEC. BOOM F.C.

P
PRI UP VLV (J59) C01PBU-RD C01PBU-RD P4-07 PRI_UP_VLV
June 2011

Part No. 88619

PRI DWN VLV (J60) C02PBD-RD/BK C02PBD-RD/BK P4-08 PRI_DOWN_VLV
PRI EXT VLV (J62) C07PBE-BK C07PBE-BK P4-09 PRI_EXTEND_VLV
PRI RET VLV (J63) C08PBR-BK/WH C08PBR-BK/WH P4-10 PRI_RET_VALVE
VLVRET5-BR P4-11
C11SBD-BL/BK C11SBD-BL/BK P4-12 SEC_DWN_VLV
F

R49LP - WT/BK R49LP - WT/BK P4-13 DRIVE LIGHTS RELAY

12 VOLT VLVRET5-BR P4-14 VALVE_RTN5 TO MICRO
SEC DWN VLV (J68)
SEC UP VLV (J67) P4-15 HYD_FILTER1
P4-16 HYD_FILTER2
SEC RET VLV (J66)
VLVRET5-BR P4-17 BOOM REVERSE LOAD
1 30 87 4
87a 3

SEC EXT VLV (J65) 2 86 85 5

VLVRET5-BR P4-18 BOOM OVERLOAD
C10SBU-BL P4-19 SEC_UP_VLV TO MICRO
LAMPS
P125SBLE-WH/RD
P126SBLD-WH/BK

C73SBR-BL/RD P4-20 SEC_RET_VLV

TO DRIVE

C10SBU-BL C10SBU-BL C72SBE-BL/WH P4-21 SEC_EXT_VLV

C73SBR-BL/RD C73SBR-BL/RD
C72SBE-BL/WT C72SBE-BL/WH P4-22
P4-23 MULTI_FUNCT_VLV
G

P4-24
TT ROT CW VLV (J70) C04TRL-WH C04TRL-WH P4-25 ROTATE_CW_VLV
TT ROT CCW VLV (J71) C05TRR WH/BK C05TRR-WH/BK P4-26 ROTATE_CCW_VLV
VALVE RTN7 VALVE RTN7 P4-27 VALVE_RTN7
P4-28
P4-29
VALVE RTN6 VALVE RTN6 P4-30 VALVE_RTN6
P4-31
C27AUX-RD C27AUX-RD P4-32 AUX_RELAY
P125SBLE-WH/RD P4-33 SEC BOOM EXT SEQ #1 VLV
SEC BOOM DOWN SEQ #2 VALVE
H

P126SBLD-WH/BK P4-34
P4-35
I
J
K
L
M
REV C

N
 June 2011 Section 6 • Schematics

Electrical Schematic
Perkins 704-30 Engine (before serial number 329)

6 - 50
6 - 49
Section 6 • Schematics June 2011

Electrical Schematic REV A

Perkins 704-30 Engine (before serial number 329)
A B C D E F G H I J K L M N

BATECU-PWR
SYS BAT GND
BATECU GND

THROTTLE

EDC FWD
IGN/FUEL

EDC REV
1

FWD
REV
J15 BLACK 4 PIN J13 WHITE 23 PIN

P1-01

P1-02

P1-03

P1-04

P1-01

P1-02

P1-03

P1-04

P1-05

P1-06

P1-07

P1-08

P1-09

P1-10

P1-12

P1-13

P1-14

P1-15

P1-16

P1-17

P1-18

P1-19

P1-20

P1-21

P1-22

P1-23
P1-11
POWER HARNESS ENGINE HARNESS

Continued on View 5

C31EDC-WH/BK

C26TSR-WH/RD
C25PSR-WH/BK

C41RPM-OR/BK
C35RPM-BK/RD

C34SA-BK/WH
TURNTABLE TILT

VLVRET2-BR
C46HRN-WH

C30EDC-WH
BATGND-BR
BATGND-BR
BATECU-RD

C21IGN-WH
SENSOR

C33STR-BK
BATVLV-RD
1 +
C84TAY-GN/BK -

2 C83TAX-GN/WH
P85TTSR-GR
2

3
+
-

4
RET85TTSR-BR
Continued on View 10 J32-ENG HARNESS P32-GENERATOR
HARNESS
CB 87a 3 DETAIL "B"
5

6
0-20 DEGREE
OPT 120VAC W/REGULATOR SENSOR ALARM SET
RD
30A 1 30 4 RD 12VDC
AT 4.5 DEGREES
RED

REGULATOR
87

P31-ENG HARN

J31-TILT SNSR
C45GEN-GR/WH WT WH R45GEN(A) WH
2 86 85 5

110 VAC
BR BR BAT GND BR

BR BK P45GEN(B) BK

GR BK/WH F45GEN BK/WH

3
WH-NEUTRAL

120V AC
AUTO
RESET CB SEE DETAIL "C" FOR 220VAC GENERATOR
BATTERY
AUX MAIN

BK-120VAC W/REGULATOR AND DETAIL "D" FOR 120VAC

SEPARATOR 15A
GENERATOR W/O REGULATOR.
C33STR-BK
B2BAT-RD

B1BAT-RD

4 C26TSR-WT/RD
C25PSR-WT/BK

B1ENG-RD B1ENG-RD
Continued on View 12
P33STR-BK P33STR-BK
C21IGN-WH
F7
5 20 A
F16
20 A
F17
20 A

B1BAT-RD
C107AF-WH

TO J3 WHITE
P116HYD-OR
23 PIN ENGINE

P116HYD-OR
B1STAID-RD HARNESS

C21IGN-WH
1 2 P1-22

B1ENG-RD
CR1 30 86 CB DETAIL "D"
87a 3
STARTER OPTIONAL 120VAC W/O REGULATOR
RELAY 87a 85 J32-ENG HARNESS P32-GENERATOR 1 30 4
B1STAID-RD

87 C35RPM-BK/RD
30A

P33STR-BK
4 5 HARNESS 87
6 2 1
C45GEN-GR/WH 1 WT
2 86 85 5

C34SA-BK/WH
R33STR-BK

1 2
C107AF-WH
P33STR-BK

86 30 CR17 2
2 1 GR SEE DETAIL "C"

R33STR-BK
30 86 CR5 OIL COOLER
87a

B1BAT-RD
HORN RELAY CR2 86 30 3 BK RD FOR 220VAC GENERATOR

GR
85 87
RELAY ENG/FUEL
87a 87 85
5 4 RELAY
87a W/REGULATOR AND
87
C41RPM-OR/BK

85
4 5 DETAIL "B"
STARTING AID 5 4
FOR 120VAC
C31EDC-WH/BK
1 2
RELAY MODULE
30 86 WHT-NEUTRAL GENERATOR W/ REGULATOR.

C26TSR-WT/RD
CR4

C25PSR-WT/BK
VLVRET2-BR
C30EDC-WH

TEMPERATURE CONTROL
P46HRN(A)-WH

STARTING

R116HYD-OR
TIME DELAY
AID RELAY

C116HYD

C107AF-WH
87 85
BATGND BR

87a 7 6 120V AC
4 5
ALTERNATOR 5 AUTO
RESET CB

R34SA-BK/WH
EXCT.
J57 BLK-120VAC
3 15A
7 BAT. BAT.
C27AUX-RD

+ -
BK

BK

OTS1
4
N.O.
PR1

A
PR2 1
STA.
BAT GND-BR

+ +
FAN
PULL IN
HOLD

J120

WH

RD
BK
STARTER
B2 B1
AUX. A B C D
BAT GND-BR

BAT GND-BR

BAT GND-BR
PUMP REGULATOR

BAT GND-BR
H1
- - IND.
WHITE 35 PIN

PULL IN
HOLD
J56
TO J4-32

ENGINE BLOCK
8
HORN

GLOW PLUG

OIL PRESSURE
SENDER

COOLANT
TEMPERATURE
SENDER
TEMPERATURE
SWITCH
ALTERNATOR

HI/LO SPEED
AUXILIARY PUMP

SOLENOID

FUEL SOLENOID
STARTER

AUXILIARY PUMP
CONTACTOR

DUAL COIL EDC

IGNITION-
ALTERNATOR/
FUEL RELAY
STARTING AID
RELAY

HYDRAULIC OIL
COOLER FAN
START BATTERY

HORN
STARTER RELAY

RELAY

HYDRAULIC OIL
COOLER RELAY
TROMBETTA
AUXILIARY PUMP /
ELECTRONICS
BATTERY

6 - 50 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

REV C Electrical Schematic

Perkins 804C-33 & 804D-33 Engine (from serial number 329 to 2316)
N M L K J I H G F E D C B A

P1-04 BATECU-PWR
P1-02 SYS BAT GND
P1-03 BATECU GND

P1-02 THROTTLE

P1-10 EDC FWD

P1-03 IGN/FUEL

P1-11 EDC REV

Continued on View 5

P1-05 FWD
P1-06 REV
P1-01

P1-01

P1-04

P1-07
P1-08
P1-09

P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
J15 BLACK 4 PIN J13 WHITE 23 PIN
POWER HARN ENGINE HARN

C31EDC-WH/BK

C26TSR-WH/RD
1

C25PSR-WH/BK

C41RPM-OR/BK
C35RPM-BK/RD
C84TAY-GN/WH -

C34SA-BK/WH

VLVRET2-BR
+

C46HRN-WH
2

C30EDC-WH
BATGND-BR
BATGND-BR
BATECU-RD

C21IGN-WH
C83TAX-GN/WH

C33STR-BK
BATVLV-RD
-

TURNTABLE TILT
3

AT 4.5 DEGREES
SENSOR ALARM
P85TTSR-GR

0-20 DEGREE
RET85TTSR-BR 4

SENSOR
5
6
DETAIL "C" OPT 120VAC W/REGULATOR
87a 3

P31-ENG HARN
P32-GEN HARN
Continued on View 10 B1BAT RD 4

J31-TILT SNSR
30A 1 30 RD/12VDC
87
J32-ENG HARN

REGULATOR
C45GEN GN/WH NEUTRAL WH

VOLTAGE
C45GEN-GR/WH 2 86 85 5
GND BR BR GND
BR BR LINE BK
GN FIELD BK/WH
WH WH

LINE BK
AUTO
RESET CB BK NEUTRAL WH
AUX MAIN

BK BK FIELD BK/WH
15A

SEE DETAIL D FOR 220VAC GENERATOR W/REGULATOR.

C33STR-BK
B2BAT-RD

B1BAT-RD

FUSE INFO C26TSR-WT/RD

F7 HYD CLR/RPM
F16 START C25PSR-WT/BK
F17 ENGINE
F22 GLOW PLUGS
P21IGN-WH
C34SA-BK/WH
P21IGN-WH Continued on View 12

P21IGN-WH
30 A

20 A

70 A

20 A
F16

F22

F17
F7

C21IGN-WH
CR2
86 30
ENG/FUEL
RELAY 85 87 87a
P34SA-BK/WH
R21IGN-WH
P46HN-WH
P116HYD-OR
P35RPM-RD

C34SA-BK/WH

P116HYD-OR
TO

C21IGN-WH
CR1 J13 WHITE 23 PIN
STARTER 30 86
ENG HARNESS

C35RPM-BK/RD
P35RPM-RD
RELAY 87a 87 85 P1-22
1 2 CR5
CR17
R33STR-BK

30 86 HORN
86 30 86 30 OIL COOLER DETAIL "D" OPT 220VAC W/REGULATOR
RELAY 87a 3
87a 87 85 85 87 87a CR15 85 87 87a RELAY P32-GEN HARN
C107AF-RD
C41RPM-OR/BK

B1BAT RD 4
4 5 CR4 30A 1 30 RD/12VDC

R21IGN-WH

R21IGN-WH
GLOW PLUG 87

C31EDC-WH/BK
J32-ENG HARN

REGULATOR
RELAY C45GEN GN/WH NEUTRAL WH

VOLTAGE
C45GEN-GR/WH 2 86 85 5

C26TSR-WT/RD
C25PSR-WT/BK
VLVRET2-BR
86

C30EDC-WH
30
P46HRN(A)-WH

R116HYD-OR
GND BR BR GND

C116HYD
87a 87 85
BATGND BR

BR BR LINE BK
ALTERNATOR
GN FIELD BK/WH

R34SA-BK/WH

C
EXCT.

A
J57 WH WH
BAT. BAT.
C27AUX-RD

+ - OTS1

RD
BK
RD
BK

LINE BK
PR1

N.O. J56 AUTO

FAN RESET CB BK NEUTRAL WH
STA.
BAT GND-BR

+ +

HOLD
J120 BK BK FIELD BK/WH
B2 B1 12.5 A
AUX. A B C D

BAT GND-BR
BAT GND-BR
BAT GND-BR
BAT GND-BR

PUMP H1
WHITE 35 PIN

SEE DETAIL C FOR 120VAC GENERATOR W/REGULATOR.

- - REGULATOR IND.
TO J4-32P
ELECTRONICS

START BAT

OIL TEMP SENDER

OIL PRESSURE
BATTERY
AUX HYD

HI/LO SPEED
CONTACTOR

TROMBETTA
ALTERNATOR

OIL COOLER

SOLENOID
GLOW PLUG

FUEL PUMP
SERVICE

DUAL
STARTER

HYDRAULIC
RELAY
STARTER

START AID
AUX HYD

TEMP SW
COIL
HORN

SOLENOID

COOLER
EDC
RELAY

HORN
AUX HYD

RELAY
PUMP

RELAY

FUEL
ENGINE BLOCK

FAN
Part No. 88619 Z-80/60 6 - 51
June 2011 Section 6 • Schematics

Electrical Schematic
Perkins 804C-33 & 804D-33 Engine (from serial number 329 to 2316)

6 - 51
6 - 52
 June 2011 Section 6 • Schematics

Electrical Schematic
Perkins 804D-33 Engine (from serial number 2317 to 2510)

6 - 54
6 - 53
Section 6 • Schematics June 2011

Electrical Schematic REV A

Perkins 804D-33 Engine (from serial number 2317 to 2510)
A B C D E F G H I J K L M N

6 - 54 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

REV A Electrical Schematic

Perkins 804D (from serial number 2511)
N M L K J I H G F E D C B A

Part No. 88619 Z-80/60 6 - 55

June 2011 Section 6 • Schematics

Electrical Schematic
Perkins 804D (from serial number 2511)

6 - 55
6 - 56
 June 2011 Section 6 • Schematics

Electrical Schematic
Continental TME27 Engine (before serial number 2511)

6 - 58
6 - 57
 8
7
6
5
4
3
2
1

6 - 58
A

POWER HARN
J15 BLACK 4 PIN
Section 6 • Schematics

AUX HYD &

AUX MAIN
ELECTRONICS B2BAT-RD

-
BATTERY + P1-01
F7 30 A

ENGINE BLOCK
P1-02 SYS BAT GND
B1BAT-RD
P1-03 BATECU GND
B
Electrical Schematic

F17 30 A P1-04 BATECU-PWR

START BAT

-
+

STARTER

STARTER
C

Continued on View 10

Z-80/60
STARTER
SOLENOID

Fuse F7 20 Amp
AUX HYD PUMP

AUX.
PUMP
after Serial Number 2339
AUX HYD
CONTACTOR

PAGE 6
PR1

TO P4-32
B1BAT-RD
B2BAT-RD

WHITE 35 PINS
P20PWR-RD

P116HYD-RD
D

+
Continued on View 5

BAT.
Continental TME27 Engine (before serial number 2511)

ALTERNATOR
J13 WHITE 23 PIN
ENGINE HARN

REGULATOR
-
ALTERNATOR

BAT.

STA.
R1

IND.
P1-01 VALVE RTN#1

EXCT.
C35RPM-BK/RD P1-02 THROTTLE

510 OHM
E

C107AF-RD C21IGN-WH P1-03 IGN/FUEL

P1-04 BATECU-PWR

P1-05 FWD

87a

4
1
P1-06 REV

30
June 2011

Part No. 88619

R46HRN-WH
SERVICE BAT GND-BR C46HRN-WH P1-07 SERVICE HRN

H1
HORN
C39LP-BL/RD P1-08 LP/GAS SELECT

86 CR5
HORN
C33STR-BK P1-09 STARTER RELAY

87 85 RELAY
F

C30EDC-WH P1-10 EDC FWD

C31EDC-WH/BK P1-11 EDC REV

C30EDC-WH
C25PSR-WH/BK P1-12 OIL_PRESSURE
DUAL COIL
EDC C26TSR-WH/RD P1-13 OIL/WATER_TEMP
C31EDC-WH/BK

A B C D
RET85TTSR-BR P1-14 TT_TILT_SNSR_GND

P85TTSR-GN P1-15 TT_TILT_SNSR_PWR

CR17

C127RET-BR P1-16 VALVE RTN_2

G

RELAY

P1-17 AC GENERATOR
OIL COOLER

N.O.
OTS1
C41RPM-OR/BK P1-18 ALTERNATOR RPM
TEMP. SW
5
2

COOLER RLY C116HYD-OR

P1-19 VALVE_RTN3
4
86 30
1

HYDRAULIC C83TAX-GN/WH P1-20 TT_TILT_X_AXIS

85 87 87a

R116HYD-OR
COOLER FAN
C84TAY-GN/BK P1-21 TT_TILT_Y_AXIS
FAN

P1-22 AC GENERATOR
C33STR-BK
H

C21IGN-WH

P20PWR-RD

P1-23
6
5
4
3
2
1

C39LP-BL/RD

C35RPM-BK/RD
C25PSR-WH/BK
C41RPM-OR/BK
C26TSR-WH/RD

DETAIL B CONTINENTAL TME27 ENGINE

-
-

87a

0-20 DEGREE
+
+

4
1

SENSOR ALARM
30

STARTER SET AT 4.5

J31-TILT SNSR

DEGREES
2

RELAY
87 85
86 CR1

5
TO 120VAC OR 220VAC

R33STR-BK
RELAY
HYDRAULIC GENERATOR

C45GEN-GN/WH
R45GEN-GN/WH

8
STARTER

C35RPM-BK/RD
RD-12GA

WH-14GA
I

C21IGN-WH
86
87
87a
CR15

11

C39LP-BL/RD
30
85

6
GND-BR

C41RPM-OR/BK
HARNESS
12

CONTINENTAL BK-12GA
10 A
GENERATOR RELAY

ENGINE
HARNESS
1

VSW-RD
9

VEHICLE INTERFACE 1
J

C108ESL-BL/WH
C47 OUT
TO TCON

10

C127TSW-GN
B1 BAT-RD
KEYSWITCH

CONTINENTAL TME27 ENGINE

3

C38RET-BL
4
TO BATTERY POST

C38FP-BL/WH
R2
1 KOHM

C38FP-BL/WH
LED
K

ENGINE STATUS

FUEL
C38RET-BL
PUMP
FUEL
PUMP

OIL
PRESSURE C25PSR-WH/BK
C47OUT-WH/BK

C108ESL-BL/WH

COOLANT
TEMP C26TSR-WH/RD

C108ESL-BL/WH PIN-1
L

VSW-RD PIN-2
1

C21IGN-WH PIN-3
3

C127TSW-GN PIN-4
4
5

C127RET-BR PIN-5
6

PIN-6
TEST
SWITCH
M

TCON-ENGINE
J113 DEUTSCH 6 PIN
N

Continued on View 12
REV B
 June 2011 Section 6 • Schematics

REV A Electrical Schematic - Engine Options

Continental TME27 Engine (from serial number 2510)
N M L K J I H G F E D C B A

Part No. 88619 Z-80/60 6 - 59

June 2011 Section 6 • Schematics

Electrical Schematic - Engine Options

Continental TME27 Engine (from serial number 2510)

6 - 59
6 - 60
 June 2011 Section 6 • Schematics

Electrical Schematic
Ford LRG 425 Engine

6 - 62
6 - 61
Section 6 • Schematics June 2011
REV A

Electrical Schematic
Ford LRG 425 Engine
A B C D E F G H I J K L M N
1

P1-04 BATECU-PWR
P1-03 BATECU GND
P1-02 SYS BAT GND

THROTTLE

EDC FWD
IGN/FUEL

EDC REV
FWD
REV
P1-01
P1-02
P1-03
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-10

P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
P1-11
P1-01
J13 WHITE 23 PIN
ENGINE HARN Continued on View 5

C31EDC-WH/BK

C26TSR-WH/RD
C25PSR-WH/BK

C41RPM-OR/BK
C35RPM-BK/RD
C84TAY-GN/BK 1 +

C39LP-BL/RD
-

VLVRET2-BR
C46HRN-WH

C30EDC-WH
C21IGN-WH
J15 BLACK 4 PIN 2 +

C33STR-BK
2 POWER HARN C35RPM-BK/RD
C83TAX-GN/WH
3
-

DEGREES
P85TTSR-GR
RET85TTSR-BR 4
5

4.5
6

BATGND-BR
BATGND-BR
BATECU-RD
BATVLV-RD
J31-TILT SNSR

DETAIL "C" OPT 120VAC W/REGULATOR

P32-GEN HARN 87a 3
3 B1BAT RD
30A 1 30
87
4
RD/12VDC
J32-ENG HARN

REGULATOR
C45GEN GN/WH NEUTRAL WH

VOLTAGE
C45GEN-GR/WH 2 86 85 5
GND BR BR GND
BR BR LINE BK
GN FIELD BK/WH
WH WH
AUXMAIN

LINE BK
AUTO
4 RESET CB BK NEUTRAL WH

BK BK FIELD BK/WH
15A
B2BAT-RD

B1BAT-RD

SEE DETAIL D FOR 220VAC GENERATOR W/REGULATOR.

20 A
20 A

F17

Continued on View 10 Continued on View 12

F7

C41RPM-OR/BK
5 C26TSR-WT/RD
C25PSR-WT/BK
C33STR-BK
C39LP-BL/RD
C35RPM-BK/RD
C21IGN-WH
B1BAT-RD B1BAT-RD

TO
6 J13 WHITE 23 PIN
ENG HARNESS
P1-22
P116HYD-OR P116HYD-OR
P20PWR-RD

P116HYD-OR
C21IGN-WH
R33STR-BK

DETAIL "D" OPT 220VAC W/REGULATOR

P32-GEN HARN 87a 3
B1BAT RD 1 30 4
30A RD/12VDC
C107AF-RD

87
1 2 2 CR51 J32-ENG HARN

REGULATOR
2 1 C45GEN GN/WH NEUTRAL WH

VOLTAGE
30 86 30 86 CR17 C45GEN-GR/WH 2 86 85 5
HORN 86 30
OIL COOLER
87a 87 85 87a 87 85 RELAY 85 87 87a RELAY
GND BR BR GND
C31EDC-WH/BK

4 5 5
7 4 5 4 BR BR LINE BK

C26TSR-WT/RD
C25PSR-WT/BK
C30EDC-WH

C116HYD-WH
P46HRN(A)-WH
500

GN
R116HYD-OR

FUEL FIELD BK/WH

BAT GND-BR

VLVRET2-BR

R16

C108ESL-BL/WT
PUMP

C41RPM-OR/BK

C35RPM-BK/RD
WH WH

C127TSW-GR
C39LP-BL/RD

C38FP-BL/WT
ALTERNATOR

R21IGN-WH
R33STR-BK

C21IGN-WH
C33STR-BK
B1BAT-RD
EXCT.
LINE BK
C27AUX-RD

AUTO

BATT -
BAT. BAT. OTS1 BK
+ - RESET CB NEUTRAL WH
PR1
BAT GND-BR

N.O.
+ + STA. FAN BK BK FIELD BK/WH
A 12.5 A
BAT GND-BR

AUX. AB CD
PUMP IND. H1 SEE DETAIL C FOR 120VAC GENERATOR W/REGULATOR.
13 9 7 15 1 2 18 6 24 23 5 34
8 - - TO J4-32
WHITE 35 PIN
REGULATOR

FORD 42 PIN CONNECTOR

ENGINE BLOCK
STARTER RELAY

AUX HYD PUMP

SERVICEPHORN

COOLER RELAY
TEMP SW
HORNPRELAY

COOLANT TEMP
DUAL

OIL PRESSURE
TROMBETTA

ALTERNATOR
ELECTRONICS

COIL
CONTACTOR

HYDRAULIC OIL
EDC
BATTERY

STARTER
AUX HYD

START BAT

COOLER FAN
AUX HYD

6 - 62 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics
REV C

Electrical Schematic
GM 3.0L Engine
N M L K J I H G F E D C B A 1

BATECU-PWR
SYS BAT GND
BATECU GND

THROTTLE

EDC FWD
IGN/FUEL

EDC REV
FWD
REV
J15 BLACK 4 PIN J13 WHITE 23 PIN

P1-01
P1-02
P1-03
P1-04

P1-01
P1-02
P1-03
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-10

P1-12
P1-13
P1-14
P1-15
P1-16
P1-17
P1-18
P1-19
P1-20
P1-21
P1-22
P1-23
P1-11
POWER HARN ENGINE HARN

Continued on View 5 TURNTABLE TILT

SENSOR
2

C31EDC-WH/BK

C26TSR-WH/RD
C25PSR-WH/BK

C41RPM-OR/BK
C35RPM-BK/RD

C34SA-BK/WH

C39LP-BL/RD

VLVRET2-BR
C46HRN-WH

C30EDC-WH
+

BATGND-BR
BATGND-BR
1

BATECU-RD

C21IGN-WH

C33STR-BK
BATVLV-RD
C84TAY-GN/BK -
2 +
C83TAX-GN/WH -
3
P85TTSR-GR
4
RET85TTSR-BR
5
0-20 DEGREE
6 SENSOR ALARM SET
AT 4.5 DEGREES

J31-TILT SNSR
J32-ENGINE P32-GENERATOR HARNESS DETAIL "C"
HARNESS 87a 3
B1BAT-RD RD OPT 220VAC W/REGULATOR
30A 1 30
87
4 RD/12VDC RD 3

REGULATOR
C45GEN-GR/WH WH WH/R45GEN(A) WH
2 86 85 5

220 V AC
BATGND-BR BR BR GND BR
BR BK P45GEN(B) BK
GR BK/WH F45GEN BK/WH

WH-NEUTRAL

AUX MAIN
220VAC
BATTERY
AUTO
SEPARATOR SEE DETAIL "B" FOR 120VAC GENERATOR
BK-220VAC
RESET CB
W/REGULATOR AND DETAIL "D" FOR 120VAC 4
B2BAT-RD 10A GENERATOR W/O REGULATOR.

B1BAT-RD
C41RPM-OR/BK

C26TSR-WT/RD
C25PSR-WT/BK

Continued on View 10 C33STR-BK

C39LP-BL/RD
Continued on View 12
F7
20 A
F17
20 A C35RPM-BK/RD 5
C21IGN-WH

B1ENG-RD B1ENG-RD

C27AUX-RD

B1ENG-RD

C21IGN-WH
FUEL

C35RPM-BK/RD
PUMP

C39LP-BL/RD
P116HYD-OR P116HYD-OR

C27AUX-RD
6

R21IGN-WH

R21IGN-WH
C33STR-BK
1 2

P116HYD-OR
30

C21IGN-WH
CR2 86
ENGINE
RELAY 87a 87 85
SEE ES0185 4 5

C41RPM-OR/BK
MED SPD REQ
FOR GM DETAIL

PUMP+ BL/WT
BATGND BR
NOT USED
NOT USED

NOT USED
1 2

P33STR-BK
30 2 1

C107AF-RD
86 CR5
HORN 86 30 CR17
85 RELAY 87a OIL COOLER
87a 87
85 87 RELAY
4 5 1 2 3 4 5 6 7 8 9 10 11 12

C41RPM-OR/BK
5 4

C31EDC-WH/BK

C116HYD-WH
C30EDC-WH

C26TSR-WT/RD
C25PSR-WT/BK
SEE ES0185 FOR GM DETAIL

R116HYD-OR
P46HRN(A)-WH
BAT GND-BR

VLVRET2-BR
ALTERNATOR
EXCT. TO J3 WHITE
23 PIN ENGINE
HARNESS
BAT. BAT. OTS1 P1-22
+ - N.O.
DETAIL "D"
C27AUX-RD

CB
PR1

87a 3
OPTIONAL 120VAC W/O REGULATOR
+ + STA. J32-ENG HARNESS P32-GENERATOR 30A 1 30 4
FAN
HARNESS 87
J120 C45GEN-GR/WH 1 WT
STARTER AUX.
B2 B1 D C B A 2 86 85 5
REGULATOR 2
PUMP
H1
GR SEE DETAIL "C"
8
BAT GND-BR

BAT GND-BR

BAT GND-BR
BAT GND-BR

BAT GND-BR
IND. 3 FOR 220VAC GENERATOR
WHITE 35 PIN

BK RD

GR
- -
W/REGULATOR AND
TO J4-32

DETAIL "B"
FOR 120VAC
WHT-NEUTRAL GENERATOR W/ REGULATOR.
ENGINE BLOCK
120V AC
AUXILIARY PUMP
STARTER RELAY
START BATTERY

DUAL COIL EDC

ALTERNATOR
TROMBETTA
STARTER

HORN

TEMPERATURE AUTO
SWITCH

HYDRAULIC
AUXILIARY PUMP
CONTACTOR

OIL COOLER FAN

OIL PRESSURE
SENDER

COOLANT
TEMPERATURE
SENDER
HORN
RELAY

HYDRUALIC OIL
COOLER RELAY

IGNITION/
ALTERNATOR
RELAY
AUXILIARY PUMP /
ELECTRONICS
BATTERY

RESET CB
BLK-120VAC
15A

Part No. 88619 Z-80/60 6 - 63

June 2011 Section 6 • Schematics

Electrical Schematic
GM 3.0L Engine

6 - 63
6 - 64
 June 2011 Section 6 • Schematics

REV A Electrical Schematic

Safety Circuits
N M L K J I H G F E D C B A

Part No. 88619 Z-80/60 6 - 65

June 2011 Section 6 • Schematics

Electrical Schematic
Safety Circuits

6 - 65
6 - 66
 June 2011 Section 6 • Schematics

Electrical Schematic - Generator Options

6 - 68
6 - 67
Section 6 • Schematics June 2011

Electrical Schematic - Generator Options REV A

A B C D E F G H I J K L M N

1 MTE Hydraulic Generator Option

Belt Driven Generator Option

6 - 68 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

REV A Electrical Schematic

Welder Generator Option

Part No. 88619 Z-80/60 6 - 69

June 2011 Section 6 • Schematics

Electrical Schematic
Welder Generator Option

6 - 69
6 - 70
 June 2011 Section 6 • Schematics

Hydraulic Schematic
2 Wheel Drive (2 and 4 Wheel Steer)
(before serial number 990)

6 - 72
6 - 71
Section 6 • Schematics June 2011

Hydraulic Schematic REV D

2 Wheel Drive (2 and 4 Wheel Steer)
(before serial number 990)
A B C D E F G H I J K L M N

1
Note: 'alpha' callouts refer to
components shown in the
manifold illustrations.
Refer to the Repair Section.

6 - 72 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

Hydraulic Schematic
2 Wheel Drive (2 and 4 Wheel Steer)
(from serial number 990 to 2674)

6 - 74
6 - 73
Section 6 • Schematics June 2011

Hydraulic Schematic REV D

2 Wheel Drive (2 and 4 Wheel Steer)
(from serial number 990 to 2674)
A B C D E F G H I J K L M N

1
Note: 'alpha' callouts refer to
components shown in the
manifold illustrations.
Refer to the Repair Section.

6 - 74 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

REV A Hydraulic Schematic

2 Wheel Drive (2 and 4 Wheel Steer)
(serial number 1543 and from serial number 2675)
N M L K J I H G F E D C B A
1

Note: 'alpha' callouts refer to

components shown in the
manifold illustrations.
Refer to the Repair Section.
2

Part No. 88619 Z-80/60 6 - 75

June 2011 Section 6 • Schematics

Hydraulic Schematic
2 Wheel Drive (2 and 4 Wheel Steer)
(serial number 1543 and from serial number 2675)

6 - 75
6 - 76
 June 2011 Section 6 • Schematics

Hydraulic Schematic
4 Wheel Drive (2 and 4 Wheel Steer)
(before serial number 990)

6 - 78
6 - 77
Section 6 • Schematics June 2011

Hydraulic Schematic REV D

4 Wheel Drive (2 and 4 Wheel Steer)
(before serial number 990)
A B C D E F G H I J K L M N

Note: 'alpha' callouts refer to

components shown in the
manifold illustrations.
Refer to the Repair Section.
2

6 - 78 Z-80/60 Part No. 88619

 June 2011 Section 6 • Schematics

Hydraulic Schematic
4 Wheel Drive (2 and 4 Wheel Steer)
(from serial number 990 to 2674)

6 - 80
6 - 79
Section 6 • Schematics June 2011

Hydraulic Schematic REV D

4 Wheel Drive (2 and 4 Wheel Steer)
(from serial number 990 to 2674)
A B C D E F G H I J K L M N

1
Note: 'alpha' callouts refer to
components shown in the
manifold illustrations.
Refer to the Repair Section.

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

 June 2011 Section 6 • Schematics

REV A Hydraulic Schematic

4 Wheel Drive (2 and 4 Wheel Steer)
(serial number 1543 and from serial number 2675)
N M L K J I H G F E D C B A

1
Note: 'alpha' callouts refer to
components shown in the
manifold illustrations.
Refer to the Repair Section.

Part No. 88619 Z-80/60 6 - 81

June 2011 Section 6 • Schematics

Hydraulic Schematic
4 Wheel Drive (serial number 1543 and from serial number 2675)

6 - 81
6 - 82
 June 2011 Section 6 • Schematics

REV A Hydraulic Schematic

Hydraulic Generator Options
N M L K J I H G F E D C B A

Continental Engine Only Deutz Engine 3

Perkins Engine
Continental Engine

Part No. 88619 Z-80/60 6 - 83

June 2011 Section 6 • Schematics

Hydraulic Schematic
Hydraulic Generator Options

6 - 83
6 - 84
 9
8
7
6
5
4
3
2
1

11

13
12
10
Y27-TWO SPEED MOTOR STROKE (J87)

VLVRET-BR P2-01 VALVE RTN1

Y2-BRAKE RELEASE (J106)
P2-02
P2-03
V29MS-RD/WH P2-04 MOTOR SPEED

A
S11-RR STEER RIGHT SNSR RD P2-05 OSCIL;ATE STOWED
P2-06 AUX FORWARD

J107
BL P2-07 AUX REVERSE
A

B C
BK V36RRS-BL P2-08 RR STEER RIGHT
V37RRS-BL/BK P2-09 RR STEER LEFT

A
S12-LR STEER RIGHT RD C111RRS-OR P2-10 RR STEER SNSR
C111LRS-OR P2-11 LR STEER SNSR

J108
BL C111RFS-OR P2-12 RF STEER SNSR

B C
BK C111LFS-OR P2-13 LR STEER SNSR
VLVRET2-BR P2-14 VALVE RTN2

A
S13-RF STEER RIGHT RD V32BRK-WH/RD P2-15 BRAKE
V36LRS-BL P2-16 LR STEER RIGHT

J109
BL V37LRS-BL/BK P2-17 LR STEER LEFT

B C
BK V36RFS-BL P2-18 RF STEER RIGHT
P110RT-BK P2-19 STEER SNSR GND

A
S14-LF STEER RIGHT RD P109ANG-GR/WH P2-20 STEER SNSR PWR
V37RFS-BL/BK P2-21 RF STEER LEFT

J110
BL V36LFS-BL P2-22 LF STEER RIGHT

B C
BK V37LFS-BL/BK P2-23 LF STEER LEFT
B

Y55-RR STEER RIGHT (J91)

Y56-RR STEER LEFT (J92)
ES0508 Rev B

HARNESS
Y57-LR STEER RIGHT (J93)
Y58-LR STEER LEFT (J94)

J32 23 PIN
(from S/N 2511)

DRIVE CHASSIS
Y59-RF STEER RIGHT (J95)
Genie Z-80

Y60-RF STEER LEFT (J96)

Y61-LF STEER RIGHT (J97)

DCON EN7
Y62-LF STEER LEFT (J98)
Genie Part Number 227794 Rev A

GND-DCN-BR P1-01 DCON ECU GND

Electrical Schematic

P21DCN-WH P1-02 DCON ECU PWR

P53LS-RD P1-03 P_6R1
P1-04
S56PRV-RD P1-05 P_7R
S56PRV-RD P1-06 P12
P1-07
WH S56PRV(A)-RD P1-08 DIGIN AXLE RET GND
BK S56PRV-RD
C

BR V121AXO-GN

NO
NC
P1-09 AXLE NOT RET RTN

AXLE RS
22 21
RD S56PRV(B)-RD

43 2 1

14 13

LSA1OS

OSCILLATE
P1-10 CAN SHIELD

LIMIT SWITCH
P1-11 RS232 RXD

(STOWED POS)
J104
Y57 OSCILLATE V121AXO-GR P1-12 RS232 TXD
RIGHT (J86)
P1-13 BOOT
P1-14
Y56 OSCILLATE V122AXO-GR/WH P1-15 AXLE NOT EXT SIG
LEFT (J85)
P1-16
WH S56PRV(B)-RD
BK S56PRV-RD D81CAN- -GR P1-17 CAN -
BR V122AXO-GN/WH

NO
NC
D82CAN+ -YL P1-18 CAN +

AXLE LS
22 21
S56PRV(A)-RD

4321
RD

14 13

LSA2OS

OSCILLATE
P1-19 RS232 GND

LIMIT SWITCH
P1-20

(STOWED POS)
J105
P1-21
GND12-BR
P1-22
ALARM+ RD/BK
PCON
ALARM

P1-23 AXLE NOT EXT PWR P20

1
PLAT ROT L-GN
2
GND16-BR
3
D

ROTATE

PLAT ROT R-GN/BK

HARNESS
4
5 PLAT LVL UP-OR

J31 23 PIN
DRIVE CHASSIS
6 GND6-BR GND6-BR
LEVEL

7 PLAT LVL UP-OR PLAT LVL DN-OR/BK

PLATFORM PLATFORM

8 PLAT LVL DN-OR/BK

JIB UP-GN
9
JIB

GND13-BR
10 ESTOP RET-BK
JIB DN-GN/BK
11
12 GND12-BR ESTOP RET-BK

S56PRV-RD
GNDDCN-BR

P53LS-WH/BK
P21DCN-WH
D81CAN- -GR
D82CAN+ -YL
13 GND13-BR
14 JIB UP-GR
PCON

15 JIB DN-GR/BK
WH 16 GND16-BR ESTOP PWR-RD/BK
E-STOP (P2)

22
BK 17 PLAT ROT L-GR

NO
NC
BR

21
RD 18 PLAT ROT R-GR/BK

4 3 21

14 13

SHOWN FOR: LSA1OS

LSA2OS
19 ALARM+ RD/BK

PROX KILL
20 ESTOP PWR-RD/BK

SWING GATE
NORMAL SWITCH POSITION
E

VLVRET-BRN P1-01 VLV RTN

P1-02
C17PRL-GR P1-03 ON/OFF VLV3_A J27
PLAT ROT CCW (J77)
JSGND1-BR 1
PLAT ROT CW (J76) C18PRR-GR/BK P1-04 ON/OFF VLV3_B

OPTIONAL
PROXIMITY
LSP1 PROX
P162JPW-OR 2

KILL SWITCH
JIB UP (J78) C43JU-GR P1-05 PROP VLV2_A
C165TRS-WH/RD 3
WH JIB DOWN (J79) C44JD-GR/BK P1-06 PROP VLV2_B
C164PES-RD/WH 4

22
BK PLAT LEVEL UP (J80) C14PLU-OR P1-07 PROP VLV1_A
BR 5

LS18
21

LS18A
C15PLD-OR/BK P1-08 PROP VLV1_B

14 13
JOYSTICK (JC1)

RD PLAT LEVEL DN (J81)

4 3 2 1

NO
NC
6
BOOM UP/DWN &

J82

LIMIT SW
P1-09 1 JSGND3-BR

(SHOWN IN
OVERLOAD
TURNTABLE ROTATE

CONDITION)
R90PXS-RD/BK P1-10 PROX KILL GND 2 JSGND2-BR

OVERLOADED
J26
C90PXS-RD/BK P1-11 PROX KILL CMD 3 P162JPW-OR JSGND2-BR 1
GR/YL P1-12 LOAD SNSR GND 4 P162JPW-OR P162JPW-OR 2

LS18
OR P1-13 LOAD SNSR SIG 5 3

LS18A
BK RD P1-14 LOAD SNSR PWR 6 C159STC-BL/WH C163PLS-BL/WH 4

Genie Part Number 227794 Rev A

LIMIT SW
RD

OVERLOAD
C88PTS-RD/BK P1-15 SAFE PL TILT OUT 7 C159STC-BL/WH 5
JOYSTICK (JC2)

R56FTS-RD P56FTS-RD P1-16 FOOT SW PWR 8 C160JPL-WH/RD 6

1
PRI BOOM EXT/RET

P1-17 FOOT SW RTN 9

J84

C56FTS-RD C56FTS-RD C161SB-WH/BK

J28
P6

S14PLU-OR P1-18 PL LVL CYL EXT 10 C163PLS-BL/WH

F

JSGND3-BR 1
J119
1

WH 0-20DEG Y AXIS PLATRET-BR P1-19 PL TILT SNSR GND 11 C164PES-RD/WH

2

FOOTSW (FS1)

Genie Z-80 (from S/N 2511) ES0508B

22
+ P162JPW-OR
2

LSJ1EO
BK

21
C84TAY-GR/BK P1-20 PL TILT SNSR 12 C165TRS-WH/RD
BR - 3
3

21

14 13
RD P85PTS-GR P1-21 PL TILT SNSR PWR 13 P162JPW-OR

NC

NO
SAFETY CUTOUTS 4
+ + C161SB-WH/BK
4

(STOWED POS)
- PTSRET-BR P1-22 SAFE PL TILT GND U20 14 P162JPW-OR
10 DEG - 10 DEG 5

PLATFORM LEVEL
JOYSTICK (JC5)

P87PTS-RD P1-23 SAFE PL TILT PWR 15 JSGND1-BR

POWER FET POWER FET 6
SEC BOOM UP/DWN

16 JSGND4-BR

CYL FULLY EXT SWITCH

6 J55

ASSEMBLY
PLATFORM

J25
TILT SENSOR

JSGND4-BR 1

S56PRV-RD
WH

P21DCN-WH
GNDDCN-BR
P162JPW-OR 2

D82CAN+ -YL
22

D81CAN- -GR

P53LS-WH/BK
BK
2 1
ECU

BR C159STC-BL/WH 3
21

14 13

RD
NC

NO

C160JPL-WH/RD 4
PCON MANIFOLD

4. TILT SW GND
P6
P22

5
3. TILT SNSR PWR
P7R

C159STC-BL/WH
1. PLAT SNSR GND
P7

5. PWR TO TILT SW
JOYSTICK (JC3)

6
2. TILT SNSR SIG OUT
J22 WHITE 23 PIN
DRIVE & STEERING

SHOWN FOR: LSJ1EO

6. OUTPUT FROM TILT SW

NORMAL SWITCH POSITION

SLP_MODE

WH C23PTS-WH P1
22

14

BK 1
C56PTS-RD
G

BR
21

13
4 3 21

RD
NO
NC

P1
5
4

2 HORN
DB9 CONNECTOR

5
3
2
ON CIRCUIT BOARD

P1
3
6

J17-DRIVE CHASSIS HARN

J18-DRIVE CHASSIS HARN
3 AC GENERATOR
J16-DRIVE CHASSIS HARN
74HC08

WH
2 74HC08

2
1
GATE WIRING

2
P1

1
B
INTERLOCK
SWING GATE

4 AUXILIARY
PIN CKT #

2
OPTIONAL SWING

1
A

2
B
FOOTSWITCH

P1
RS232_TXD
RS232_RXD

RS232_GND

5 START ASSIST
2
1
PCON MEMBRANE PANEL (MS1)

YL
GR

BK

RD
WH

P1
6 START
WH/BK
1
GNDPCON-BR P1-01 PCON GND P1
2 7 DRIVE ENABLE
P52PCON-WH P1-02 PCON PWR
3
J23 10PIN

P1-03 P1
P7R

4 8 SPARE 1
P6R1

S56PRV-RD P1-04 P7
SLIP RING

5
CAN LOW
IS
IN

CAN HIGH

P1-05
ST

P1
P6

Vbb

Vbb

6 AXLE RETRACT
P7R

9
GND

P1-06
OUT

7
DCON GND BK

DCON PWR RD
WH
YL

P56PRV-RD/WH P1-07 P22 P1

GR
IN1 OUT 1
IN2 OUT 2

BTS650 U21
BTS621 U22

8 10
J24A 10PIN

WH/BK
H

P1-08
2
1
2
1

9
B
A

P1-09
10 P2
2
1
2
1
B
A

P1-10 1 ENGINE SPEED

P1-11
P2
P1-12 2 AXLE EXTEND
P1-13
J24B 10PIN

P2
P1-14 3 DRIVE SPEED
C47OUT-WHT/BLK P1-15 OUT PWR ENBL
P2
C46HN-WH P1-16 HRN RLY CNTRL 4 FRONT STEER
J33-BOOM HARN

D81CAN- -GR P1-17 CAN-

J34-LIMIT SW HARN

J35-LIMIT SW HARN

P2
D82CAN+ -YL P1-18 CAN+ 5 REAR STEER
P1-19
P2
P1-20 6 CRAB STEER
P1-21
P2
P1-22 7 COORD STEER
P23PCON-BK P1-23 PWR-PCON ESTOP
MEMBRANE/LED INTERFACE CARD

P2
8 SPARE 2
I

P2
9 FUEL TYPE

P2
BOOM HARN

10
S132LDS-BL/WH
C46HN-WH
GNDPCON-BR

D81CAN- -GR
P23PCON-BK
P52PCON-WH

C47OUT-WH/BK

D82CAN+ -YL
S56PRV-RD
P56PRV-RD/WH
2
1

1
2

P21DCN-WH
4
3
2
1

D82CAN+ -YL

P53LS-WH/BK
S56PRV-RD
D81CAN- -GR
B
A

GND DCN-BR
J21 BLACK 23 PIN

S56PRV-RD

C46HN-WH
P23PCON-BK

D81CAN- -GR
D82CAN+ -YL
P52PCON-WH
GNDPCON-BR

P56PRV-RD/WH

C47OUT-WH/BK

S132LDS-BL/WH

GNDPCON-BR P1-01 PCON GND

ALM-GND-BR
P52PCON-WH P1-02 PCON POWER
ALM PWR-RD
5
3
2
DB9 CONNECTOR

C46HN-WH P1-03 HORN RELAY COIL

ON CIRCUIT BOARD

C47OUT-WH/BK P1-04 OUT PWR ENBL P_15-OR/BK

P23PCON-BK P1-05 PWR-PCON ESTOP C47OUT WH/BK
J

S56PRV-RD P_7 PLAT-GN/WH

PIN CKT #

P1-06 P_7
U30
P56PRV-RD/WH P1-07 P_22 S1 PBU-OR
RS232_TXD
RS232_RXD

RS232_GND

R48LP-WH/RD P1-08 WORK LT

RUN

RECOVERY
SERV BYPASS

2
2
4
4
4
2

C117FB-RD P1-09 FLASHING BEACON ALARM GND 16

P1-10 CAN SHIELD ALARM PWR 15 RD
Z

V
Y
X
U

P1-11 RS232 RXD TCON MODE 14 RD/WH

W

1
1
3
3
3
1

P1-12 RS232 TXD P11 13 OR

P1-13 BOOT P7-GR/WH 12 GR/WH
S132LDS-BL/WH P1-14 LOAD SENSR INPUT OPER. REC. 11 OR/BK BL/WH
P1-15 TET ESTOP PWR P22 10 P56PRV-RD
P1-16 SPARE P15 SERV. OR OPER. REC. 9 SRV REC-WH
D81CAN- -GR P1-17 CAN LOW P7R 8 S56PRV-RD/BK
D82CAN+ -YL P1-18 CAN HIGH P6R1 7 P53LS-BK/WH
P1-19 RS232 GND OUTPUT PWR ENABLE 6 C47OUT WH/BK TCON MODE
P1-20 TETHER FUNC ENBL PCON MODE 5 P23PCON-BK P23PCON-BK
P1-21 DIAG/TETHER GND ECU POWER 4 C47OUT GN/BK C47OUT WH/BK
P1-22 DIAG/TETHER PWR TETHER ESTOP-BL/RD 3
K

GROUND
OFF
OFF
OFF
OFF
OFF
BL/WH

GROUND

2
1
2
2
2

GROUND
GROUND

PLAT
PLAT
PLAT
PLAT
PLAT

GROUND

P1-23 TET ESTOP RET TCON ESTOP-BL/WH 2

TO WORK LIGHTS

PWR TO TCON ESTOP-BL/BK 1 B

A
E

D
C

1
2
1
1
1

TO FLASHING BEACON
RED
RED

WH/BK
J17

G-P MODE GR/BK

P15

C117FB-RD
BOOM HARN

R48LP-WH/RD

BL/BK
87
86

86
87
87a

87a
P3 - TO MICRO
TCON

J11 BLACK 23 PIN

ESTOP

85
30

30
85

PRI LO#1 O
SERV. OR
BM 100' I
OPER. REC.
B1ENG (12 VOLT)

GND-BR
GND-BR

BM 3' I
BM DWN ST I
AUX HYD O
MLT FNC VLV O
L

TCON

BM RET O
BM DWN O
BM E/R FC O
P15
ECU POWER
TO MICRO
SERVICE OR RECOVERY MODE

BM U/D FC O
PLD
1

LED

S56PRV-RD
2

P21DCN-WH
P11

GNDDCN-BR
P_7

P7R

P53LS-WH/BK
P_22

P6R1
RED ALARM
J127 LOADSENSE LED

TCON MODE

PCON POWER
TO HORN BUTTON

OUT PWR ENABLE

(P15)+(ECU POWER)

PWR TO TCON ESTOP

M

S56PRV-RD

P21DCN-WH
GNDDCN-BR

P53LS-WH/BK
P_7
P7R

P11
P_22

P6R1
TCON MODE

PCON POWER
TO HORN BUTTON

OUT PWR ENABLE

(P15)+(ECU POWER)

PWR TO TCON ESTOP

N
LOCKOUT VALVE #1 SIG

PRI BOOM DOWN STATUS

18/19
PRI BOOM LENGTH 3' STATUS

J114

CABLE
J20A
BOOM RET RECOVERY SIGNAL

12 WAY
PRI BOOM LENGTH 100' STATUS

4 WAY
BOOM DWN RECOVERY SIGNAL

GR SNSR GND-BR
AUXILIARY HYD RECOVERY SIGNAL

GR
2
BOOM UP/DWN FC RECOVERY SIGNAL

GR/BK SNSR GND-BR

BOOM EXT/RET FC RECOVERY SIGNAL

GR/BK
MULTI FUNCTION VLV RECOVERY SIGNAL

7 11

GR/WH GR/WH SNSR GND-BR SNSR GND-BR

S56PRV-RD
P21DCN-WH
GNDDCN-BR

P53LS-WH/BK

J20B

70 TO 35 DEG Y-AXIS
+
3 12 WAY 9

- BL/BK BL/BK C123PBD RD/BK C123PBD RD/BK

SAFETY CUTOUTS
8

P109PBTS-GR/WH P109PBTS-GR/WH
10 12

BL BL
LIMIT SWITCH HARN

+ 80 DEG + 80 DEG 18/19

J12 BLACK 35 PIN

- - CABLE
4

BK/WH BK/WH P54ENG-BK/WH GNDDCN-BR P2-01 DCON ECU GND

2

OR/BK OR/BK SJ1-WH/RD P21DCN-WH P2-02 DCON ECU PWR

POWER FET POWER FET
6
1 12 2

RD RD S59SBE-GR/WH P53LS-WH/BK P2-03 P_6R1

PRI BOOM ANG SENSOR

P53LS-WH/BK U30
RD/WH RD/WH
RD/BK RD/BK P54ENG-BK/WH P54ENG-BK/WH P2-04 P_6R2
POWER FET POWER FET U31
S56PRV-RD P2-05 P_7R
8
3

WH WH S12SBL-BL/WH U32
WH/RD WH/RD P53LS-WH/BK P2-06 P_9A
O

WH/BK WH/BK
P58LS RD/BK P58LS RD/BK P2-07 P_9B
P54ENG-BK/WH P54ENG-BK/WH P2-08 P_10
LSP1EO
WH WH BL/WH C64LS-OR/BK
21

LSP1EO 3' FROM FULLY S12SBL-BL/WH S12SBL-BL/WH P2-09 P_11

WHT
4 7

21

BK BK BK BK C71PBE-BL/BK
3' FROM FULLY BR EXTENDED BR P53LS-WH/BK P2-10 P_12
22 21

EXTENDED J44
22 21

14 13
14 13

RD RD
NC
NC

NO
WHT NO

J44 P53LS-WH/BK P2-11 P_14

18/19
P10

P54ENG-BK/WH
P11
P_7

P2-12 P_18
P7R

CABLE

P54ENG-BK/WH
P9A
P6R1
P_22

C64LS-OR/BK C64LS-OR/BK P2-13 OPER SW PWR

TCON MODE

PCON POWER

WH LSP1RO WH OR/RD C65LOF-BL/WH C65LOF-BL/WH P2-14 FST1S

14

LSP1RO
WHT
WHT
22

BK BK BK/RD TO PLD
3' EXTENDED 3' EXTENDED C70PBR-BL/WH C66DREN-BL C66DREN-BL P2-15 LST10
BR
4321

BR OR
J45
22 21

J45 TO PLD
14 13
13
21

NC

RD
4321

RD BL/RD C64LS-OR/BK
5 611 10

NC
TO

SJ1-WH/RD

NO
NO

C73SBR-BL/RD C73SBR-BL/RD P2-16 LSS1RO

P58LS-RD/BK

P53LS-WH/BK
TO

MICRO

C68PBD-RD C68PBD-RD P2-17 LSP1AO

S59SBE-GR/WH
MICRO

C64LS-OR/BK P2-18 LSB2RO

.
TO PLD
C70PBR-BL/WH P2-19 LSP1RO
TO

C64LS-OR/RD C64LS-OR/BK C71PBE-BL/BK P2-20 LSP1EO

MICRO

C124SBL RD/WH C124SBL RD/WH C67SBD-BL P2-21 LSS1AO

C77SBU-WH P2-22 LSS2AO
OR
BL P2-23 P1 SEQ
YEL

OR S73SLD-GR/BK
P

12

WH TO PLD
BL P2-24 P2 SEQ
YEL

LSS1RS BK S59SBE-GR/WH TO MICRO

12

WH
22

LSS1RS S59SBE-GR/WH
BR
11

3' EXT P53LS-WH/BK SNSR GND-BR P2-25 SNSR GND

NC
22 21

BK P53LS-WH/BK
13 14
NC

NO

3' EXT
C68PBD-RD

654321

J46 RD BR P58LS-RD/BK P58LS-RD/BK

11
C66DREN-BL
TO

NC
21

P109PBS-GR/WH
13 14

J46 P2-26 SNSR PWR

NC

NO
654321

RD
S12SBL-BL/WH

SJ1-WH/RD SJ1-WH/RD
C73SBR-BL/RD
C124SBL RD/WH
MICRO

P2-27 PRESSURE GA
OR
BL C124SBL RD/WH P2-28 DIGITAL IN
OR
PUR

S10SLE-BL
12

LSS2AS WH BL P2-29 LSB13AO

PUR

RAISED LSS2AS
12

BK
22

WH S59SBE-GR/WH S59SBE-GR/WH
C64LS-OR/BK

11

BR RAISED P2-30 LSB14AO

NC
22 21

SAFETY
13 14
NC

P53LS-WH/BK
NO

BK P53LS-WH/BK
654321

RD SAFETY
11

J47 BR P58LS-RD/BK P58LS-RD/BK

NC
21

13 14
NC

P2-31 BOOM STOWED

NO

J47
654321

RD SJ1-WH/RD SJ1-WH/RD
C123PBD RD/BK P2-32 PRI ANG INPUT

C65LOFL-BL/WH P2-33 SEC ANG INPUT

FST1S C65LOFL-BL/WH
LOW FUEL FS S12SBL-BL/WH P2-34 P_30
C64LS-OR/BK C64LS-OR/BK
P2-35 VLV RET
ALL SWITCHES ARE SHOWN IN THE "OUT OF BOX" POSITION

WH
ALL SWITCHES ARE SHOWN IN THE BOOM STOWED POSITION

LST1O WH C66DREN-BL
22

BK
21
22

LST1O BK C64LS-OR/BK
DRV ENABLE C64LS-OR/BK
21

BR DRV ENABLE
J48 BR
21

14 13
NC

RD
21

ORN NO
14 13

J48 RD
NC

ORN NO

WH WH C64LS-OR/BK C64LS-OR/BK
RED

LSS1RO LSS1RO
BK BK C73SBR-BL/RD C73SBR-BL/RD
Q

SEC RET OPER BR SEC RET OPER BR V126SBLD-WH/BK V126SBLD-WH/BK

J49
14 13
4321

J49
NO
14 13

24 23

RD RD
24 23

P126SBLD-WH/BK
NO

P126SBLD-WH/BK
4321

NO
RED NO

WH WH
BK LSS1AO BK
LSS1AO
BR 5 DEG BR C64LS-OR/BK C64LS-OR/BK
5 DEG
22 21
22 21

14 13
14 13
NC

J50 C67SBD-BL
4321

RD RD
4321

NC

C67SBD-BL C67SBD-BL
BLU NO

BLU NO

J50

WH WH C64LS-OR/BK C64LS-OR/BK
22

LSS2AO
22

BK LSS2AO BK C77SBU-WH C77SBU-WH

RAISED OPER C77SBU-WH
BR RAISED OPER BR V125SBLE-WH/RD V125SBLE-WH/RD
21

14 13

J51
21

14 13

4321

RD J51
NC
4321

NC

RD P125SBLE-WH/RD P125SBLE-WH/RD
GRN NO
GRN NO
IN2
IN1

GND

WH WH
LSP1AO
22
22

LSP1AO BK BK
ST OUT 2
OUT 1

> 5 DEG > 5 DEG C64LS-OR/BK

Vbb BTS621

BR BR
21
21

J43 J43 RD
TCON

RD
NC

NC
14 13
14 13

4321

C68PBD-RD
4321

BRN NO

BRN NO
P128 J128
P_7

P10
P7R

P9A
((~SM)+(AH))(BM STOWED)

P_11
P_22
P_30

P_9B

P6R1
P_6R2

8
R

TCON MODE

S10SLE-BL
74HC08

PCON POWER
9

10

S73SLD-GR/BK
BOOM STOWED
OUT PWR ENABLE
TO HORN BUTTON

V125SBLE-WH/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
P125SBLE-WH/RD
(P15)+(ECU POWER)

PWR TO TCON ESTOP

(BM STOWED)
(~SM)+(AH)

AUX HYD RD RD RD
BOOM RET RECOVERY SIGNAL

U95
BOOM DWN RECOVERY SIGNAL

ELECTRONICS AUX MAIN

B2

RD RD P_6R2
U32

F7
-
+

BATTERY
AUXILIARY HYD RECOVERY SIGNAL

B2BAT-RD
BOOM UP/DWN FC RECOVERY SIGNAL

20 A
BOOM EXT/RET FC RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL

IS

IS
IN

IS

IN
IN

F22
Vbb

IN2
Vbb

IN1

START BAT
Vbb
IN2
IN1

B1
GND
GND

-
+
POWER HARN

B1BAT-RD
60 A
OUT

OUT
OUT

P_6R2
BTS650

BTS650
BTS650

F20
ST OUT 2

J15 BLACK 4 PIN

ST OUT 2

OUT 1
OUT 1

Vbb BTS621
Vbb BTS621

CB
BLOCK

P35RPM-BK/RD
CR1

ENGINE

20 A B1BAT-RD P1-01 SYS_BAT_PWR P_1 P_7

RELAY

F23 20A
GND-BR P1-02 SYS BAT GND
STARTER

STARTER 30 A GND-BR P1-03 BATECU GND

TO
S

B1ENG-RD
STARTER
(TM)(FE)

P33STR-BK B1BAT-RD P1-04 BATECU-PWR

P7R
P22R

MICRO
P_22

C33STR-BK
OUT PWR ENABLE (OE)

87a 87 85
30 86
((~SM)+(AH))(OE)

STARTER RELAY BAT GND-BR

3
6
((~SM)+(AH))(P_7) 8

74HC08
((~SM)+(AH))(P_22) 11

7
14
74HC08
74HC08

74HC08
1
2
4
9

5
(~SM)+(AH)

10
12

74HC08 13

AUX HYD PUMP

F20 HI/LO RPM

C35RPM-BK/RD
AUX.
PUMP
F23 ENG/ST/ALT
F7 OIL COOLER

F22 GLOW PLUG

PR1
(OE)

AUX HYD
GND
5V 12V
P10
P_7
P7R
(~SM)+(AH)

CONTACTOR
BAT+

GND-
AUX+
TO MICRO

(~SM)+(AH)
ENGINE HARN
4

J13 WHITE 23 PIN

C27AUX-RD
S-500
TCON MODE(TM)

P1-01 VALVE RTN#1

MOM N.O.
TIME DELAY
TROMBETTA

C35RPM-BK/RD P1-02 THROTTLE

C
A
B
FUNC ENABLE (FE)
P_7

+
P116HYD-OR
P34SA-BK/WH

BAT.

C21IGN-WH P1-03 IGN/FUEL

P22R

C34SA-BK/WH P1-04 START ASSIST P6R1

5 AUX HYD (AH)
~SLP MODE (~SM)
TO

ALTERNATOR P1-05 FWD P_7

P1-06 REV
MICRO

P7R
-
ALTERNATOR

C46HRN-WH P1-07 SERVICE HRN

T

BAT.

STA.

REGULATOR IND.
EXCT.

P1-08
D2
RD-HOLD

C107AF-RD C33STR-BK P1-09 STARTER RELAY

D1
WH-PULL IN

TO HORN BUTTON
C41RPM-OR/BK C30EDC-WH P1-10 EDC FWD
(P15)+(ECU POWER)
BAT GND-BR C31EDC-WH/BK P1-11 EDC REV
TO

HORN C25PSR-WH/BK P1-12 OIL_PRESSURE

MICRO

P46HRN(A)-WH
30

RELAY C26TSR-WH/RD P1-13 OIL/WATER_TEMP

VLVRET2-BR
P1-14 TT_TILT_SNSR_GND
H1

SERVICE
P1-15 TT_TILT_SNSR_PWR
TO

HORN
86 CR5

VLVRET2-BR P1-16 VALVE RTN_2

MICRO

HORN
87a 87 85 RELAY
TO

P1-17 AC GENERATOR
MICRO

1
J57

C41RPM-OR/BK P1-18 ALTERNATOR RPM

RD RD-HOLD
TROMBETTA HOLD P1-19
2

HI/LO SPEED WH WH-PULL IN

S10SLE-BL

PULL IN
3

P1-20 TT_TILT_X_AXIS
TO

B1ENG-RD

SOLENOID BK BATGND(A) - BK
S73SLD-GR/BK

CB7 P1-21 TT_TILT_Y_AXIS

MICRO

P116HYD-OR
P34SA-BK/WH
P22R

15A
V125SBLE-WH/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
P125SBLE-WH/RD

GND04-BR P1-22 AC GENERATOR

P1-23 VALVE_RTN3
C30EDC-WH
DUAL COIL GND04-BR
U

EDC
C31EDC-WH/BK
A B C D
C45GEN-GR/WH
J32-ENG HARN
P85TTSR-GR

J120
C84TAY-GR/BK

ST AID
RET85TTSR-BR
C83TAX-GR/WH

RELAY 85
CR15 86

GLOW PLUG VLVRET-BR C34SA-BK/WH

RELAY

R34SA-BK/WH
30

GLOW PLUG
87 87a
C21IGN-WH
C25PSR-WH/BK
C26TSR-WH/RD

R21IGN-WH

OTS1N.O.
85
86

TEMP SW BAT GND-BR C116HYD-WH C21IGN-WH

COOLER
RELAY P116HYD-OR
HYDRAULIC BAT GND-BR R116HYD-OR
OIL COOLER FAN
30 OIL
GENERATOR OPTIONS- SEE 6-68

FAN
CR17
V

RELAY
87 87a COOLER
PERKINS 804D ENGINE- SEE 6-55

J10
D7

P10
D8

B1ENG-RD START
FUEL SOLENOID BAT GND-BR R21IGN-WH
15
CONTINENTAL TME27 ENGINE- SEE 6-59

C21IGN-WH
DUETZ TD2011L04i ENGINE SHOWN

STRT ASST
P85TTSR-GR

14
C84TAY-GR/BK

RET85TTSR-BR
C83TAX-GR/WH

SCROLL R
30 86 CR28
87a 87 85 RELAY
TCON

13
D5
ENG ALT
2

4
3
1

6
5

OIL PRESSURE C25PSR-WT/BK SCRL F/ENT

12
D3
-
-
+
+

0-20 DEGREE - BUTTON

OIL TEMP SENDER C26TSR-WT/RD SENSOR ALARM SET
11
AT 4.5 DEGREES
C27AUX-RD
TURNTABLE
J31-TILT SNSR

TILT SENSOR

+ BUTTON
P9A

P_11
P_30

P10

P6R1
P7R
P_22R
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL

P31-ENG HARN
BOOM UP/DWN FC RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL

BOOM EXT/RET FC RECOVERY SIGNAL

MULTI FUNCTION VLV RECOVERY SIGNAL

10
GAS/LP
S10SLE-BL

9
S73SLD-GR/BK

ENG SPEED
8
W

V125SBLE-WH/RD
V126SBLD-WH/BK
P126SBLD-WH/BK
P125SBLE-WH/RD

AUXILIARY
7
SEC. UP
4
3
2
1
P34 J34

(DWN ENABLE) SEC BM DN SEQ #2 V126SBLD-WH/BK BOOM UP

5

(EXT ENABLE) SEC BM EXT SEQ #1 V125SBLE-WH/RD

4
TO PLD
TO

3
S10SLE-BL
MICRO

S73SLD-GR/BK

2
MANIFOLD HARN

TO PLD
J14 WHITE 35 PIN

P125SBLE-WH/RD
P126SBLD-WH/BK
TO

VLVRET4-BR VLVRET4-BR P4-01 VALVE_RTN4 1

MICRO

PRI BM UP/DN F.C. (J58) C03PBF-RD/WH C03PBF-RD/WH P4-02 BOOM_UP/DOWN_VLV

TO MICRO

PRI BM EXT/RET F.C. (J61) C09PERF-BK/RD C09PERF-BK/RD P4-03 BOOM_EXT/RET_VLV

X

TT ROT CW/CCW F.C. (J69) C06TRF-WH/RD C06TRF-WH/RD P4-04 TURNTABLE_ROTATE_VLV

P P P
TO

P4-05
TO MICRO
MICRO

SEC. BM F.C. (J64) C12SBFC-BLU/WT C12SBFC-BL/WH P4-06 SEC. BOOM F.C.

P

PRI UP VLV (J59) C01PBU-RD C01PBU-RD P4-07 PRI_UP_VLV J9

P9 ROOM RET
PRI DWN VLV (J60) C02PBD-RD/BK C02PBD-RD/BK P4-08 PRI_DOWN_VLV
15
TO

PRI EXT VLV (J62) C07PBE-BK C07PBE-BK P4-09 PRI_EXTEND_VLV

BOOM DOWN
MICRO

PRI RET VLV (J63) C08PBR-BK/WH C08PBR-BK/WH P4-10 PRI_RET_VALVE

14
VLVRET5-BR P4-11 TO PLD
BOOM EXT
C11SBD-BL/BK C11SBD-BL/BK P4-12 SEC_DWN_VLV
13
R49LP - WT/BK R49LP - WT/BK P4-13 DRIVE LIGHTS RELAY
TO

RABBIT
TO
P_30

12 VOLT VLVRET5-BR P4-14 VALVE_RTN5

MICRO

12
TO

SEC DWN VLV (J68)

MICRO

S73SLD-GR/BK P4-15 LSS1RS MONITOR INPUT

SEC UP VLV (J67) SEC. DOWN
MICRO

1 30

P4-16 SPARE
SEC RET VLV (J66) TO PLD 11
87

S10SLE-BL P4-17 LSS2AS MONITOR INPUT TURTLE

2 86 85 5

SEC EXT VLV (J65)

4
87a 3

P4-18 SPARE
10
TO

TO DRIVELAMPS C10SBU-BL P4-19 SEC_UP_VLV

BOOM CCW
P125SBLE-WH/RD
P126SBLD-WH/BK

SEC_RET_VLV
MICRO

C73SBR-BL/RD P4-20 TO PLD 9

Y

C10SBU-BL C10SBU-BL C72SBE-BL/WH P4-21 SEC_EXT_VLV

TO

C73SBR-BL/RD C73SBR-BL/RD PLTFRM CCW

C72SBE-BL/WT C72SBE-BL/WH P4-22 8
P4-23 MULTI_FUNCT_VLV
JIB UP
TO

P4-24 7
TT ROT CW VLV (J70) C04TRL-WH C04TRL-WH P4-25 ROTATE_CW_VLV
PLTFRM UP
TO

TT ROT CCW VLV (J71) C05TRR WH/BK C05TRR-WH/BK P4-26 ROTATE_CCW_VLV

6
MICRO MICRO MICRO

VALVE RTN7 VALVE RTN7 P4-27 VALVE_RTN7

PLTFRM DOWN
P4-28 5
P4-29 TO PLD JIB DOWN
VALVE RTN6 VALVE RTN6 P4-30 VALVE_RTN6
4
TO
TCON MEMBRANE PANEL

P4-31 PLTFRM CW
MICRO

C27AUX-RD C27AUX-RD P4-32 AUX_RELAY

3
TO

P125SBLE-WH/RD P4-33 SEC BOOM EXT SEQ #1 VLV

BOOM CW
P126SBLD-WH/BK P4-34 SEC BOOM DOWN SEQ #2 VALVE
2
TO

P4-35
MICRO MICRO

1
Z