Part No. 110284Rev A1March 2006
Service ManualRefer to inside cover for additional serial number information
IC Power(from serial number 100)
Z-51/30J Part No. 110284
September 2005
ii
Introduction
Important
Read, understand and obey the safety rules andoperating instructions in the Genie Z-51/30JOperator's Manual before attempting anymaintenance or repair procedure.
This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting faultcodes and repair procedures for qualified serviceprofessionals.
Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealer servicecenter.
Technical Publications
Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specifications aresubject to change without notice.
Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.
Contact Us:
http://www.genieindustries.come-mail: [email protected]
Serial Number Information
Genie Industries offers the following ServiceManuals for these models:
Title Part No.
Copyright © 2005 by Genie Industries
110284 Rev A September 2005First Edition, First Printing
"Genie" and "Z" are registered trademarks ofGenie Industries in the USA and many othercountries.
Printed on recycled paper
Printed in U.S.A.
Introduction
Part No. 110284 Z-51/30J
March 2006
Serial Number Legend
INTRODUCTION
iii
Z5130 05 - 12345
Model
Model year
Sequencenumber
PN - 77055
Country of manufacture: USA
This machine complies with:
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
EN 280:2001
Model: Z-51/30
Serial number: Z513005-12345
Electrical schematic number: E0384
Rated work load (including occupants): 500 lb / 227 kg
Maximum allowable inclination of the chassis:
4.5°
Nominal Power: 48 hp / 61 kW
Maximum allowable side force : 90 lb / 400 N
Maximum number of platfrm occupants: 2
Model year: Manufacture date: 04/12/052005
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 51 ft 3 in/ 15.6 m
Maximum platform reach : 30 ft 4 in/ 9.2 m
Machine unladen weight: 15,882 lbs / 7,204 kg
05
Gradeability: 45%
Serial numberstamped on chassis
Serial label(located under cover)
Part No. 110284 Z-51/30J
September 2005
v
Safety Rules
Section 1 • Safety Rules
DangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-51/30J Operator'sManual will result in death or serious injury.
Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.
Do Not Perform MaintenanceUnless:
You are trained and qualified to performmaintenance on this machine.
You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksite
regulations- applicable governmental regulations
You have the appropriate tools, liftingequipment and a suitable workshop.
Z-51/30J Part No. 110284
September 2005
SAFETY RULES
vi
Section 1 • Safety Rules
Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.
Read each procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.
Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Used to indicate operation ormaintenance information.
Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.
Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or
placing loads. Always wear approved steel-toedshoes.
Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammableand combustible materials like battery
gases and engine fuels. Always have an approvedfire extinguisher within easy reach.
Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free
of debris that could get into machine componentsand cause damage.
Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the
weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.
Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.
Be sure that your workshop or work areais properly ventilated and well lit.
Part No. 110284 Z-51/30J
March 2006
Table of Contents
vii
Introduction
Important Information .................................................................................................. ii
Serial Number Information ........................................................................................... ii
Serial Number Legend................................................................................................ iii
Section 1 Safety Rules
General Safety Rules ................................................................................................. v
Section 2 Rev Specifications
B Machine Specifications .......................................................................................... 2 - 1
B Performance Specifications ................................................................................... 2 - 1
A Hydraulic Specifications ........................................................................................ 2 - 2
A Manifold Component Specifications ...................................................................... 2 - 3
A Deutz F3L-2011 Engine Specifications .................................................................. 2 - 4
A Machine Torque Specifications.............................................................................. 2 - 5
A Hydraulic Hose and Fitting Torque Specifications ................................................. 2 - 6
A SAE and Metric Fastener Torque Chart ................................................................ 2 - 7
Z-51/30J Part No. 110284
March 2006
TABLE OF CONTENTS
viii
Section 3 Rev Scheduled Maintenance Procedures
Introduction ........................................................................................................... 3 - 1
Pre-Delivery Preparation ....................................................................................... 3 - 3
Maintenance Inspection Report ............................................................................. 3 - 5
A Checklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................ 3 - 7
A-2 Perform Function Tests ............................................................................... 3 - 7
A-3 Perform Engine Maintenance ...................................................................... 3 - 8
A-4 Check the High Pressure Hydraulic Filter Condition Indicator ...................... 3 - 8
A-5 Test the Oscillate Axle ................................................................................. 3 - 9
A-6 Perform 30 Day Service ............................................................................... 3 - 9
A-7 Inspect the Fuel Filter/Water Separator ..................................................... 3 - 10
A-8 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 11
B Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 12
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 12
B-3 Test the Key Switch ................................................................................... 3 - 13
B-4 Check the Exhaust System........................................................................ 3 - 14
B-5 Check the Oil Cooler and Cooling Fins ...................................................... 3 - 14
B-6 Check the Tires and Wheels (including lug nut torque) .............................. 3 - 15
B-7 Confirm the Proper Brake Configuration .................................................... 3 - 16
B-8 Check the Oil Level in the Drive Hubs ....................................................... 3 - 16
B-9 Check and Adjust the Engine RPM ............................................................ 3 - 17
B-10 Test the Ground Control Override .............................................................. 3 - 18
B-11 Check the Directional Valve Linkage ......................................................... 3 - 18
B-12 Test the Platform Self-leveling ................................................................... 3 - 19
Part No. 110284 Z-51/30J
March 2006
TABLE OF CONTENTS
ix
Section 3 Rev Scheduled Maintenance Procedures, continued
B-13 Test the Engine Idle Select ........................................................................ 3 - 19
B-14 Test the Drive Brakes ................................................................................ 3 - 20
B-15 Test the Drive Speed - Stowed Position .................................................... 3 - 20
B-16 Test the Drive Speed - Raised or Extended Position ................................. 3 - 21
B-17 Test the Alarm Package (if equipped) ........................................................ 3 - 22
B-18 Perform Hydraulic Oil Analysis .................................................................. 3 - 23
B-19 Perform Engine Maintenance .................................................................... 3 - 23
B Checklist C Procedures
C-1 Perform Engine Maintenance .................................................................... 3 - 24
C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 24
C-3 Test the Platform Overload Mechanism (if equipped) ................................ 3 - 25
B Checklist D Procedures
D-1 Check the Boom Wear Pads ..................................................................... 3 - 27
D-2 Check the Free-wheel Configuration .......................................................... 3 - 27
D-3 Replace the Drive Hub Oil ......................................................................... 3 - 29
D-4 Replace the Hydraulic Filters ..................................................................... 3 - 29
D-5 Perform Engine Maintenance .................................................................... 3 - 31
D-6 Calibrate the Platform Overload System (if equipped) ............................... 3 - 31
D-7 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 33
D-8 Inspect for Turntable Bearing Wear ........................................................... 3 - 34
A Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 36
E-2 Perform Engine Maintenance .................................................................... 3 - 38
E-3 Perform Engine Maintenance .................................................................... 3 - 38
Z-51/30J Part No. 110284
September 2005
Section 4 Rev Repair Procedures
Introduction ........................................................................................................... 4 - 1
A Platform Controls
1-1 ALC-500 Circuit Board ................................................................................. 4 - 2
1-2 Joysticks ...................................................................................................... 4 - 3
A Platform Components
2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 7
2-2 Platform Rotator ........................................................................................... 4 - 8
A Jib Boom Components
3-1 Jib Boom.................................................................................................... 4 - 10
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 11
A Primary Boom Components
4-1 Cable Track ............................................................................................... 4 - 13
4-2 Primary Boom ............................................................................................ 4 - 15
4-3 Primary Boom Lift Cylinder ........................................................................ 4 - 18
4-4 Primary Boom Extension Cylinder ............................................................. 4 - 19
4-5 Platform Leveling Master Cylinder ............................................................. 4 - 20
A Secondary Boom Components
5-1 Secondary Boom ....................................................................................... 4 - 23
5-2 Secondary Boom Lift Cylinders .................................................................. 4 - 28
A Engines
6-1 RPM Adjustment ........................................................................................ 4 - 29
6-2 Flex Plate ................................................................................................... 4 - 29
A Hydraulic Pumps
7-1 Lift/Steer Pump .......................................................................................... 4 - 31
7-2 Drive Pump ................................................................................................ 4 - 32
x
TABLE OF CONTENTS
Part No. 110284 Z-51/30J
March 2006
Section 4 Rev Repair Procedures, continued
A Manifolds
8-1 Function Manifold Components ................................................................. 4 - 34
8-2 Valve Adjustments - Function Manifold ...................................................... 4 - 38
8-3 Jib Boom / Platform Rotate Manifold Components ..................................... 4 - 39
8-4 Turntable Rotation Manifold Components .................................................. 4 - 40
8-5 Directional Valve Manifold Components .................................................... 4 - 41
8-6 Traction Manifold Components .................................................................. 4 - 44
8-7 Valve Adjustments, Traction Manifold ........................................................ 4 - 46
8-8 Valve Coils ................................................................................................. 4 - 46
. A Turntable Rotation Components
9-1 Turntable Rotation Assembly ..................................................................... 4 - 48
A Axle Components
10-1 Oscillate Lock-out Cylinders ...................................................................... 4 - 49
Section 5 Rev Fault Codes
Introduction ........................................................................................................... 5 - 1
A Fault Codes - Control System ............................................................................... 5 - 2
Section 6 Rev Schematics
Introduction ........................................................................................................... 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Hydraulic Symbols Legend .................................................................................... 6 - 3
B Electrical Schematic .............................................................................................. 6 - 5
A Ground Control Box Terminal Strip Wiring Diagram .............................................. 6 - 7
A Ground Control Box Switch Panel Wiring Diagram ................................................ 6 - 8
A Platform Control Box Terminal Strip Wiring Diagram ............................................. 6 - 9
A Platform Control Box Switch Panel Wiring Diagram ............................................ 6 - 10
A Hydraulic Schematic ............................................................................................ 6 - 11
xi
TABLE OF CONTENTS
Part No. 110284 Z-51/30J 2 - 1
Section 2 • SpecificationsMarch 2006
REV B Specifications
Machine Specifications
Tires and wheels
Tire size 355/55 D625
Tire ply rating 14
Overall tire diameter 36.9 in93.7 cm
Wheel diameter 24.5 inches62.2 cm
Wheel width 11.75 inches29.8 cm
Wheel lugs 9 @ 5/8 -18
Lug nut torque, lubricated 94 ft-lbs127.4 Nm
Fluid capacities
Fuel tank 17 gallons64.4 liters
Hydraulic tank 24 gallons91 liters
Hydraulic system 30 gallons(including tank) 113.6 liters
Drive hubs - Steer end 17 fl oz0.5 liters
Drive hubs with brake, 57:1, 24 fl ozNon-steer end 0.7 liters
Performance Specifications
Drive speed, maximum
Stowed position 5 mph8 km/h
40 ft/5.5 sec12.2 m/5.5 sec
Raised or extended position 0.6 mph1 km/h
40 ft/45 sec12.2 m/45 sec
Braking distance, maximum
High range on paved surface 3 to 6 ft0.9 to 1.8 m
Gradeability See Operator's Manual
Boom function speeds, maximumfrom platform controls
Jib boom up 48 to 52 seconds
Jib boom down 28 to 32 seconds
Primary boom up 36 to 40 seconds
Primary boom down 36 to 40 seconds
Secondary boom up 24 to 28 seconds
Secondary boom down 24 to 28 seconds
Primary boom extend 20 to 24 seconds
Primary boom retract 20 to 24 seconds
Turntable rotate, 355° 82 to 88 secondsprimary boom retracted
For operational specifications, refer to theOperator's Manual.
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
2 - 2 Z-51/30J Part No. 110284
Section 2 • Specifications September 2005
REV ASPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalentISO viscosity grade Multi-viscosityViscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and have a minimum viscosity indexof 150. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Premium ECO 46Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046Quintolubric 822
Mineral based Shell Tellus T32Shell Tellus T46
Chevron Aviation A
Use Chevron Aviation A hydraulicoil when in ambient temperaturesconsistently below 0°F / -18°C.
Use Shell Tellus T46 hydraulic oilwhen oil temperatures consistentlyexceed 205°F / 96°C.
Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.
Drive pump
Type: bi-directional, variabledisplacement piston pump
Flow rate @ 2500 rpm 32 gpm121 L/min
Drive pressure, maximum 3500 psi241 bar
Charge pump
Type: gear
Displacement 0.84 cu in13.76 cc
Flow rate @ 2500 rpm 9.1 gpm34.4 L/min
Charge pressure @ 2500 rpm 315 psi21.7 bar
Function pump
Type: gear
Displacement 0.67 cu in11 cc
Flow rate @ 2500 rpm 7.25 gpm27.4 L/min
Auxiliary pump
Type: gear, fixed displacement
Displacement per revolution 0.067 cu in1.1 cc
Auxiliary pump relief pressure 3200 psi220.6 bar
Part No. 110284 Z-51/30J 2 - 3
Section 2 • SpecificationsSeptember 2005
REV A
Function manifold
System relief valve pressure 3200 psi220.6 bar
Secondary boom down 2100 psirelief valve pressure 145 bar
Platform level relief valve pressure 2500 psi172 bar
Steer flow regulator 1.5 gpm5.7 L/min
Boom extend flow regulator 2 gpm7.6 L/min
Jib boom / platform rotate flow regulator 0.4 gpm1.5 L/min
Drive manifold
Hot oil relief pressure 250 psi17.2 bar
Steer end drive motors
Displacement 1.53 cu inper revolution 25 cc
Non-steer end drive motors
Displacement per revolution, variable 0.01 to 1.83 cu in(2 speed motor) 1.61 to 30 cc
Hydraulic filters
High pressure filter Beta 3 200
High pressure filter 100 psibypass pressure 6.89 bar
Medium pressure filter Beta 3 200
Medium pressure filter 50 psibypass pressure 3.4 bar
Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass
Manifold ComponentSpecifications
Plug torque
SAE No. 2 36 in-lbs / 4 Nm
SAE No. 4 10 ft-lbs / 13 Nm
SAE No. 6 14 ft-lbs / 19 Nm
SAE No. 8 38 ft-lbs / 51 Nm
SAE No. 10 41 ft-lbs / 55 Nm
SAE No. 12 56 ft-lbs / 76 Nm
Valve coil resistance specifications
Proportional directional solenoid valve, 10V DC 6 to 8Ω(schematic items BP, BU and BY)
3 position 4 way directional valve, 10V DC 6 to 8Ω(schematic items BF, BM and CG)
2 position 3 way solenoid valve, 10V DC 6 to 8Ω(schematic items CA, CC, G, AF and AG)
SPECIFICATIONS
2 - 4 Z-51/30J Part No. 110284
Section 2 • Specifications September 2005
REV ASPECIFICATIONS
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C 5W-30(synthetic)
-4°F to 90°F / -20°C to 32°C 10W-40
Above 23°F / -5°C 20W-50
Engine oil should have minimum properties of APIclassification CC/SG or CD/SG grades.Units ship with 10W-40 CH-4
Oil temperature switch specifications
Torque 8-18 ft-lbs11-24 Nm
Temperature switch point 220° F104° C
Oil pressure switch specifications
Torque 8-18 ft-lbs11-24 Nm
Oil pressure switch point 15 psi1 bar
Fuel injection system
Injection pump make Bosch
Injector opening pressure 3046 psi210 bar
Fuel requirement diesel number 2-D
Alternator output 60A, 14V DC
Starter motor
Normal engine cranking speed 200 to 250 rpm
Current draw, normal load 140-200A
Battery
Type 12V DC, Group 34/78
Quantity 1
Cold cranking ampere 900A
Reserve capacity @ 25A rate 200 minutes
Fan belt deflection 3/8 to 1/2 inch9 to 12 mm
Deutz F3L 2011 Engine
Displacement 142.2 cu in2.33 liters
Number of cylinders 3
Bore and stroke 3.7 x 4.4 inches94 x 112 mm
Horsepower
Gross intermittent @ 2800 rpm 48Continuous @ 2800 rpm 46Horsepower @ 2500 rpm 40
Firing order 1 - 2 - 3
Low idle 1500 rpm
High idle 2500 rpm
Compression ratio 19:1
Compression pressure (approx.)Pressure (psi or bar) of lowest cylinder must beat least 75% of highest cylinder.
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in0.3 mm
Exhaust 0.020 in0.5 mm
Lubrication system
Oil pressure 40 to 60 psi(operating temp. @ 2000 rpm) 2.75 to 4.1 bar
Oil capacity 8.5 quarts(including filter) 8 liters
Part No. 110284 Z-51/30J 2 - 5
Section 2 • SpecificationsSeptember 2005
REV A
Machine Torque Specifications
Platform rotator
1-8 center bolt, GR 5 480 ft-lbs651 Nm
3/8 -16 bolts, GR 8 44 ft-lbs60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm
Drive motor/brake mounting bolts, dry 110 ft-lbs149 Nm
Drive motor/brake mounting bolts, lubricated 80 ft-lbs108 Nm
Drive motor and hubs
Drive hub mounting bolts, lubricated 180 ft-lbs244 Nm
Drive motor mounting bolts, lubricated 55 ft-lbs75 Nm
SPECIFICATIONS
2 - 6 Z-51/30J Part No. 110284
Section 2 • Specifications September 2005
REV ASPECIFICATIONS
Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.
SAE O-ring Boss Port(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 40 ft-lbs / 54.2 Nm
-10 69 ft-lbs / 93.6 Nm
-12 93 ft-lbs / 126.1 Nm
-16 139 ft-lbs / 188.5 Nm
-20 172 ft-lbs / 233.2 Nm
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm
Seal-Lok® Fittings(hose end)
SAE Dash size Torque
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 40 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 80 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Seal-Lok® fittings
1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.
The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield service kit (Genie partnumber 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated andretained properly.
4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.
5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.
6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.
Part No. 110284 Z-51/30J 2 - 7
Section 2 • SpecificationsSeptember 2005
REV A SPECIFICATIONS
SIZE THREAD
in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m20 100 11.3 80 9 140 15.8 110 12.4 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8
f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYLUBED
• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide Bolts
Grade 8
LUBED
1/4
LUBED DRY LUBED DRY
1 1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
5/16
3/8
7/16
1/2
Size
(mm)in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m f t -lbs N m8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Class 12.9Class 4.6
DRYLUBED
METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •
LUBED DRY
Class 10.9Class 8.8
DRY
10.9 12.98.84.6
2 - 8 Z-51/30J Part No. 110284
Section 2 • Specifications September 2005
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Part No. 110284 Z-51/30J 3 - 1
September 2005 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.
Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every 2 years as specified on theMaintenance Inspection Report.
Failure to perform each procedureas presented and scheduled maycause death, serious injury orsubstantial damage.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating machine.
Keep records on all inspections for three years.
Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom betweenthe non-steer wheels
· Turntable secured with the turntablerotation lock
· Key switch in the off position with thekey removed
· Wheels chocked
· All external AC power disconnectedfrom the machine
About This Section
This section contains detailed procedures for eachscheduled maintenance inspection.
Each procedure includes a description, safetyinformation and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Used to indicate operation ormaintenance information.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
3 - 2 Z-51/30J Part No. 110284
September 2005Section 3 • Scheduled Maintenance Procedures
Maintenance Symbols Legend
The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.
Indicates that tools will be required toperform this procedure.
Indicates that new parts will be requiredto perform this procedure.
Indicates that a cold engine will berequired to perform this procedure.
Indicates that a warm engine will berequired to perform this procedure.
Indicates that dealer service is requiredto perform this procedure.
Pre-delivery Preparation Report
The pre-delivery preparation report containschecklists for each type of scheduled inspection.
to use for each inspection. Store completed formsas required.
Maintenance Schedule
There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, six months, annual, and two years.The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Report have beendivided into five subsections—A, B, C, D and E.Use the following chart to determine which group(s)of procedures are required to perform a scheduledinspection.
Inspection Table or Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Six months or every 500 hours A + B + C
Annual or every 1000 hours A + B + C + D
Two years or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report containschecklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.
SCHEDULED MAINTENANCE PROCEDURES
Part No. 110284 Z-51/30J 3 - 3
September 2005 Section 3 • Scheduled Maintenance Procedures
Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev B
Genie UKThe Maltings, Wharf Road
Grantham, LincolnshireNG31- 6BH England
(44) 1476-584333
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.
Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.
If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin the R box.
LegendY = yes, completedN = no, unable to completeR = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform thePre-delivery Preparation.
The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anythingis apparently wrong with a machine before it is put intoservice.
A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removed fromservice.
Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.
Scheduled maintenance inspections shall be performed byqualified service technicians, according to themanufacturer's specifications and the requirements listed inthe responsibilities manual.
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September 2005Section 3 • Scheduled Maintenance Procedures
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Part No. 110284 Z-51/30J 3 - 5
March 2006 Section 3 • Scheduled Maintenance Procedures
Checklist A - Rev A Y N R
A-1 Pre-operationinspection
A-2 Functions tests
A-3 Engine maintenance
A-4 Filter condition indicator
A-5 Oscillate axle
Perform after 50 hours:
A-6 30 day service
Perform every 100 hours:
A-7 Fuel filter/separator
A-8 Rotation bearing
Instructions· Make copies of both pages to use
for each inspection.
· Select the appropriate checklist(s)for the type of inspection to beperformed.
Daily or 8 hourInspection: A
Quarterly or 250 hourInspection: A+B
Six Month or 500 hourInspection: A+B+C
Annual or 1000 hoursInspection: A+B+C+D
2 Year or 2000 hourInspection: A+B+C+D+E
· Place a check in the appropriate boxafter each inspection procedure iscompleted.
· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.
LegendY = yes, acceptableN = no, remove from service
R = repaired
Comments
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Checklist B - Rev B Y N R
B-1 Battery
B-2 Electrical wiring
B-3 Key switch
B-4 Exhaust system
B-5 Oil cooler and fins
B-6 Tires and wheels
B-7 Brake configuration
B-8 Drive hub oil level
B-9 Engine RPM
B-10 Ground control override
B-11 Directional valve
B-12 Platform leveling
B-13 Engine idle select
B-14 Drive brakes
B-15 Drive speed -stowed position
B-16 Drive speed -raised position
B-17 Alarm package
B-18 Hydraulic oil analysis
Perform every 400 hours:
B-19 Engine maintenance
Maintenance Inspection Report
3 - 6 Z-51/30J Part No. 110284
March 2006Section 3 • Scheduled Maintenance Procedures
Checklist C - Rev B Y N R
C-1 Engine maintenance
C-2 Grease platformoverload (if equipped)
C-3 Test platform overload(if equipped)
Checklist D - Rev B Y N R
D-1 Boom wear pads
D-2 Free-wheelconfiguration
D-3 Drive hub oil
D-4 Hydraulic filters
D-5 Engine maintenance
D-6 Calibrate platformoverload system(if equipped)
D-7 Turntable bearing bolts
D-8 Turntable bearing wear
MAINTENANCE INSPECTION REPORT
Checklist E - Rev A Y N R
E-1 Hydraulic oil
Perform every 3000 hours:
E-2 Engine maintenance
Perform every 12,000 hours:
E-3 Engine maintenance
Instructions· Make copies of both pages to use
for each inspection.
· Select the appropriate checklist(s)for the type of inspection to beperformed.
Daily or 8 hourInspection: A
Quarterly or 250 hourInspection: A+B
Six Month or 500 hourInspection: A+B+C
Annual or 1000 hoursInspection: A+B+C+D
2 Year or 2000 hourInspection: A+B+C+D+E
· Place a check in the appropriate boxafter each inspection procedure iscompleted.
· If any inspection receives an “N”, tagand remove the machine fromservice, repair and re-inspect it. Afterrepair, place a check in the “R” box.
LegendY = yes, acceptableN = no, remove from service
R = repaired
Comments
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Part No. 110284 Z-51/30J 3 - 7
September 2005 Section 3 • Scheduled Maintenance Procedures
REV A
A-1Perform Pre-operationInspectionCompleting a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparently wrongwith a machine before the operator performs thefunction tests. The pre-operation inspection alsoserves to determine if routine maintenanceprocedures are required.
Complete information to perform this procedure isavailable in the Genie Z-51/30J Operator's Manualon your machine.
Checklist A Procedures
A-2Perform Function TestsCompleting the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.
Complete information to perform this procedure isavailable in the Genie Z-51/30J Operator's Manualon your machine.
3 - 8 Z-51/30J Part No. 110284
September 2005Section 3 • Scheduled Maintenance Procedures
REV ACHECKLIST A PROCEDURES
A-3Perform Engine Maintenance
Engine specifications require thatthis procedure be performed dailyor every 10 hours, whichevercomes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929).
Deutz FL 2011 Operation ManualGenie part number 84794
To access the engine:
1 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
A-4Check the High PressureHydraulic Filter ConditionIndicatorMaintaining the high pressure hydraulic filter ingood condition is essential to good systemperformance and safe machine operation. The filtercondition indicator will show when the hydraulic flowis bypassing a clogged filter. If the filter is notfrequently checked and replaced, impurities willremain in the hydraulic system and causecomponent damage.
1 Open the engine side turntable cover.
2 Start the engine from the ground controls.
3 Change the engine idle to high rpm (rabbitsymbol).
4 Visually inspect the filter condition indicator.
Result: The filter condition indicator should beoperating with the plunger in the green area.
Result: If the indicator displays the plunger inthe red area, this indicates that the hydraulicfilter is being bypassed and the filter should bereplaced. See D-4, Replace the HydraulicFilters.
Part No. 110284 Z-51/30J 3 - 9
September 2005 Section 3 • Scheduled Maintenance Procedures
REV A CHECKLIST A PROCEDURES
A-5Test the Oscillate Axle
Proper axle oscillation is essential to safe machineoperation. If the axle oscillation system is notoperating correctly, the stability of the machine iscompromised and it may tip over.
1 Start the engine from the platform controls.
2 Drive the right steer tire up onto a6 inch / 15 cm block or curb.
Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.
3 Drive the left steer tire up onto a6 inch / 15 cm block or curb.
Result: The three remaining tires should stay infirm contact with the ground and the chassisshould remain level at all times.
4 Drive both steer tires up onto a6 inch / 15 cm block or curb.
Result: The non-steer tires should stay in firmcontact with the ground.
If the chassis does not remainlevel during test, refer to RepairProcedure 8-5, How to Set Up theDirectional Valve Linkage.
A-6Perform 30 Day Service
The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 50 hours of usage, whichevercomes first. After this interval, refer to themaintenance checklist for continued scheduledmaintenance.
1 Perform the following maintenance procedures:
• A-8 Grease the Turntable Rotation Bearingand Rotate Gear
• B-6 Check the Lug Nut Torque(including tires and wheels)
• B-8 Check the Oil Level in the Drive Hubs
• C-1 Perform Engine Maintenance
• D-4 Replace the Hydraulic Filters
• D-7 Check the Turnable Rotation BearingBolts
3 - 10 Z-51/30J Part No. 110284
September 2005Section 3 • Scheduled Maintenance Procedures
REV A
A-7Inspect the Fuel Filter/ WaterSeparator
Engine specifications require thatthis procedure be performed every100 hours.
Proper maintenance of the fuel filter/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and component damage.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.
Perform this procedure with theengine off.
1 Put on protective clothing and eye wear.
2 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
3 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
4 Locate the fuel filter/water separator next to theoil filter.
5 Loosen the drain plug located at the bottom ofthe filter. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.
Do not completely drain the filter.
a fuel filter/water separatorb drain valve
6 Clean up any fuel that may have spilled.
7 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.
8 Swing the engine back to its original positionand close the engine pivot plate latch.
9 Install the engine pivot plate safety pin.
CHECKLIST A PROCEDURES
a
b
Part No. 110284 Z-51/30J 3 - 11
September 2005 Section 3 • Scheduled Maintenance Procedures
REV A
A-8Grease the Turntable RotationBearing and Rotate Gear
Genie specifications require thatthis procedure be performed every100 hours of operation. Performthis procedure more often if dustyconditions exist.
Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.
1 Open the ground controls side turntable coverand locate the grease fitting near the groundcontrol box.
2 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches / 10 to 13 cm at a time and repeat thisstep until the entire bearing has been greased.
3 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
CHECKLIST A PROCEDURES
3 - 12 Z-51/30J Part No. 110284
March 2006Section 3 • Scheduled Maintenance Procedures
REV B
B-1Inspect the Battery
Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions.
Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.
Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections arefree of corrosion.
3 Be sure that the battery retainer and cableconnections are tight.
The battery is a maintenance freebattery and does not require thereplenishing of electrolyte.
Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.
Checklist B Procedures
B-2Inspect the Electrical Wiring
Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.
Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.
1 Open the engine side turntable cover.
2 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
3 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
4 Inspect the following areas for burnt, chafed,corroded and loose wires:
· Engine wiring harness
· Hydraulic manifold wiring
5 Open the ground controls side turntable cover.
Part No. 110284 Z-51/30J 3 - 13
March 2006 Section 3 • Scheduled Maintenance Procedures
REV B
6 Inspect the following areas for burnt, chafed,corroded and loose wires:
· Ground control box wire harnesses
· Inside of the ground control box
· Hydraulic manifold wiring
7 Inspect for a liberal coating of dielectric greaseat the following location:
· All wire harnesses connectors to theground control box
8 Start the engine from the ground controls andraise the secondary boom above the turntablecovers.
9 Remove the center turntable cover retainingfasteners. Remove the center turntable coverfrom the machine.
10 Inspect the turntable area for burnt, chafed andpinched cables.
11 Lower the boom to the stowed position and turnthe engine off.
12 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
· Cable track on the primary boom
· Cables on the primary, and jib booms
· Jib boom/Platform rotate manifold
· Inside of the platform control box
13 Inspect for a liberal coating of dielectric greaseat the following location:
· All wire harnesses connectors to theplatform control box
14 Swing the engine back to its original positionand close the engine pivot plate latch.
15 Install the engine pivot plate safety pin.
16 Install the center turntable cover and tighten theretaining fasteners.
B-3Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could cause ahazardous operating situation.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to ground control, start theengine and then turn the key switch to platformcontrol.
3 Check all machine function from the groundcontrols.
Result: All machine functions should notoperate.
4 Turn the key switch to ground control.
5 Check all machine function from the platformcontrols.
Result: All machine functions should notoperate.
6 Turn the key switch to the off position.
Result: The engine should stop and no functionsshould operate.
CHECKLIST B PROCEDURES
3 - 14 Z-51/30J Part No. 110284
March 2006Section 3 • Scheduled Maintenance Procedures
REV B
B-4Check the Exhaust SystemMaintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.
Bodily injury hazard. Do notinspect while the engine is running.Remove the key to secure fromoperation.
Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.
1 Be sure that all nuts and bolts are tight.
2 Inspect all welds for cracks.
3 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.
B-5Check the Oil Cooler andCooling Fins
Maintaining the oil cooler in good condition isessential for good engine performance. Operating amachine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.
Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.
Burn hazard. Beware of hot enginecomponents. Contact with hotengine components may result insevere burns.
Oil cooler
1 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
3 Remove the fasteners from the engine sidecover, then remove the cover.
CHECKLIST B PROCEDURES
Part No. 110284 Z-51/30J 3 - 15
March 2006 Section 3 • Scheduled Maintenance Procedures
REV B
4 Inspect the oil cooler for leaks and physicaldamage.
a oil coolerb cylinder head cooling finsc fan blower fins
5 Clean the oil cooler of debris and foreignmaterial.
Cooling and fan blower fins
6 Inspect the fan blower fins for physical damage.
7 Clean the fan blower fins of debris and foreignmaterial.
8 Inspect the head cooling passages and fins forphysical damage or foreign material, using aflashlight.
9 Clean the cylinder head cooling passages ofdebris and foreign material.
10 Install the engine side cover.
11 Swing the engine back to its original positionand close the engine pivot plate latch.
12 Install the engine pivot plate safety pin.
B-6Check the Tires and Wheels(including lug nut torque)
Maintaining the tires and wheels, including properwheel fastener torque, is essential to safe operationand good performance. Tire and/or wheel failurecould result in a machine tip-over. Componentdamage may also result if problems are notdiscovered and repaired in a timely fashion.
The tires are foam-filled and do notneed air added to them.
1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.
2 Check each wheel for damage, bends andcracked welds.
3 Check each lug nut for proper torque.Refer to Section 2, Specifications.
CHECKLIST B PROCEDURES
cba
3 - 16 Z-51/30J Part No. 110284
March 2006Section 3 • Scheduled Maintenance Procedures
REV B
B-7Confirm the ProperBrake Configuration
Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.
1 Check each drive hub disconnect cap to be sureit is in the engaged position.
2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).
a drive pumpb free-wheel valvec lift pumpd screwdriver
The free-wheel valve is located onthe side of the drive pump.
The free-wheel valve shouldalways remain closed.
B-8Check the Oil Levelin the Drive Hubs
Failure to maintain proper drive hub oil levels maycause the machine to perform poorly and continueduse may cause component damage.
1 Drive the machine to rotate the hub until theplugs are located one on top and the other at90 degrees.
a drive hub plugs
2 Remove the plug located at 90 degrees andcheck the oil level.
Result: The oil level should be even with thebottom of the side plug hole.
3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.
4 Install the plug(s) into the drive hub.
5 Repeat this procedure for each drive hub.
6 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.
CHECKLIST B PROCEDURES
a
b
c
d
brake disengaged position
brake engaged position
a
Part No. 110284 Z-51/30J 3 - 17
March 2006 Section 3 • Scheduled Maintenance Procedures
REV B
B-9Check and Adjust theEngine RPM
Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.
This procedure will require twopeople.
1 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
3 Connect a tachometer to the engine, and thenstart the engine from the ground controls.
Result: Low idle should be 1500 rpm.
Skip to step 5 if the low idle rpm is correct.
4 Loosen the low idle lock nut, then turn the lowidle adjustment screw clockwise to increase therpm or counterclockwise to decrease the rpm.Tighten the low idle lock nut and recheck therpm.
a solenoid bootb high idle adjustment nutc yoke lock nutd yokee low idle adjustment screwf low idle lock nut
5 Move the function enable toggle switch to thehigh idle (rabbit symbol) position at the groundcontrols.
Result: High idle should be 2500 rpm.
If high idle rpm is correct, disregard adjustmentstep 6.
6 Loosen the yoke lock nut, then turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.
Be sure the solenoid fully retractswhen activating high idle.
7 Swing the engine back to its original positionand close the engine pivot plate latch.
8 Install the engine pivot plate safety pin.
CHECKLIST B PROCEDURES
f
e
c dba
3 - 18 Z-51/30J Part No. 110284
March 2006Section 3 • Scheduled Maintenance Procedures
REV B
B-10Test the Ground ControlOverrideA properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allow groundpersonnel to operate the machine from the groundcontrols whether or not the red Emergency Stopbutton on the platform controls is in the on or offposition. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.
1 Push in the platform red Emergency Stop buttonto the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boomfunction through a partial cycle.
Result: All boom functions should operate.
B-11Check the Directional ValveLinkage
Perform this test only on modelsequipped with an oscillating axle.
Proper axle oscillation is essential to safe machineoperation. If the directional valve linkage is notoperating correctly, the stability of the machine iscompromised and it may tip over.
1 Remove the drive chassis cover and the axlecovers from the non-steer end of the drivechassis.
2 Locate the directional valve inside of the non-steer axle and inspect the linkage for thefollowing:
· Lock nut is tight against yoke
· Yoke clevis pins are installed
· Cotter pins are installed through clevis pins
· Linkage is properly attached todirectional valve
CHECKLIST B PROCEDURES
Part No. 110284 Z-51/30J 3 - 19
March 2006 Section 3 • Scheduled Maintenance Procedures
REV B
B-12Test the Platform Self-leveling
Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which operates in a closedloop hydraulic circuit with the master cylinderlocated at the base of the boom.A platform self-leveling failure creates an unsafeworking condition for platform andground personnel.
1 Start the engine from the ground controls andlower the boom into the stowed position.
2 Hold the function enable toggle switch to eitherside and adjust the platform to a level positionusing the platform level toggle switch.
3 Raise and lower the primary boom througha full cycle.
Result: The platform should remain level atall times to within ±5 degrees.
B-13Test the Engine Idle SelectA properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are two settings.
Foot switch activated low idle (turtle symbol)allows the operator to control individual boomfunctions. Drive functions will operate at low idle,but at reduced performance.
Foot switch activated high idle (rabbit symbol)should be used for normal machine operation. Thisselection activates high idle only when the footswitch is pressed down.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Start the engine from the ground controls thenmove the function enable toggle switch to thehigh idle (rabbit symbol) position and hold in theon position.
Result: The engine should change to high idle.
3 Release the function enable toggle switch.
Result: The engine should return to low idle.
4 Turn the key switch to platform controls.
5 Move the engine idle control switch to footswitch activated high idle (rabbit symbol).
Result: The engine should not change tohigh idle.
6 Press down the foot switch.
Result: The engine should change to high idle.
6 Move the engine idle control switch to footswitch activated low idle (turtle symbol).
Result: The engine should change to low idle.
CHECKLIST B PROCEDURES
3 - 20 Z-51/30J Part No. 110284
March 2006Section 3 • Scheduled Maintenance Procedures
REV B
B-14Test the Drive Brakes
Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when they are actually not fullyoperational.
Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-7, Confirm the ProperBrake Configuration.
Select a test area that is firm, leveland free of obstructions.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
3 Move the engine idle control switch tofoot switch activated high idle (rabbit andfoot switch), then lower the boom into thestowed position.
4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.
5 Bring the machine to top drive speed beforereaching the test line. Release the drive joystickwhen your reference point on the machinecrosses the test line.
6 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.
The brakes must be able to holdthe machine on any slope it is ableto climb.
B-15Test the Drive Speed -Stowed Position
Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.
Select a test area that is firm, leveland free of obstructions.
1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Move the engine idle control switch tofoot switch activated high idle (rabbit and footswitch), then lower the boom into the stowedposition.
4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.
5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.
CHECKLIST B PROCEDURES
Part No. 110284 Z-51/30J 3 - 21
March 2006 Section 3 • Scheduled Maintenance Procedures
REV B
B-16Test the Drive Speed -Raised or Extended Position
Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.
Select a test area that is firm, leveland free of obstructions.
1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Move the engine idle select switch to foot switchactivated high idle (rabbit and foot switch).Press down the foot switch and raise theprimary boom above horizontal.
4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.
5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
6 Continue at full speed and note the time whenthe machine reference point crosses the finishline.
7 Press down the foot switch and lower the boomto the stowed position.
8 Extend the boom 1 foot / 30 cm.
9 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.
10 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
11 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.
CHECKLIST B PROCEDURES
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B-17Test the Alarm Package(if equipped)The alarm package includes:
· Travel alarm
· Descent alarm
· Flashing beacon
Alarms and a beacon are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theturntable covers.
The alarms and beacon willoperate with the enginerunning or not running.
1 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
Result: The flashing beacon should be on andflashing.
2 Move the function enable switch to either sideand activate the primary boom toggle switch inthe down position, hold for a moment and thenrelease it.
Result: The descent alarm should sound whenthe switch is held down.
3 Move the function enable switch to either sideand activate the secondary boom toggle switchin the down position, hold for a moment andthen release it.
Result: The descent alarm should sound whenthe switch is held down.
4 Move the function enable toggle switch to eitherside and activate the jib boom toggle switch inthe down position, hold for a moment and thenrelease it.
Result: The descent alarm should sound whenthe switch is held down.
5 Turn the key switch to platform control.
Result: The flashing beacon should be onand flashing.
6 Press down the foot switch. Move the primaryboom control handle to the down position, holdfor a moment and then release it.
Result: The descent alarm should sound whenthe control handle is held down.
7 Press down the foot switch. Move thesecondary boom control handle to the downposition, hold for a moment and then release it.
Result: The descent alarm should sound whenthe control handle is held down.
8 Press down the foot switch. Activate the jibboom toggle switch in the down position, holdfor a moment and then release it.
Result: The descent alarm should sound whenthe switch is held down.
9 Press down the foot switch. Move the drivecontrol handle off center, hold for a moment andthen release it. Move the drive control handle offcenter in the opposite direction, hold for amoment and then release it.
Result: The travel alarm should sound when thedrive control handle is moved off center in eitherdirection.
CHECKLIST B PROCEDURES
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REV B
B-18Perform Hydraulic Oil Analysis
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction strainermay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.
Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.See E-1, Test or Replace theHydraulic Oil.
B-19Perform Engine Maintenance
Deutz engine specifications requirethat this procedure be performedevery 400 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929).
Deutz FL 2011 Operation ManualGenie part number 84794
To access the engine:
1 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
CHECKLIST B PROCEDURES
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C-1Perform Engine Maintenance
Deutz engine specifications requirethat this procedure be performedevery 500 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929).
Deutz FL 2011 Operation ManualGenie part number 84794
To access the engine:
1 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
Checklist C Procedures
C-2Grease the Platform OverloadMechanism (if equipped)
Genie specifications requirethat this procedure be performedevery 500 hours or 6 months,whichever comes first. Performthis procedure more often if dustyconditions exist.
Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.
1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.
2 Thoroughly pump grease into each greasefitting.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent
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C-3Test the Platform OverloadSystem (if equipped)
Genie specifications require thatthis procedure be performed every500 hours or six months.
Testing the platform overload system regularly isessential to safe machine operation. Continued useof an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.
Perform this procedure with themachine on a firm, level surface.
1 Turn the key switch to platform control. Start theengine from the platform controls.
2 Level the platform.
3 Determine the maximum platform capacity.Refer to the machine serial plate.
4 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity in one of thelocations shown.
Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.
5 Carefully move the test weight to eachremaining location.
Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.
6 Add an additional 10 lbs / 4.5 kg of weight tooverload the platform.
Result: The alarm should be sounding.The platform overload indicator light should beflashing at both the ground and platformcontrols.
Result: If the alarm does not sound and theplatform overload indicator light does not comeon with the test weights in any of the platformlocations, the platform overload system needsto be calibrated. See D-6, Calibrate the PlatformOverload System (if equipped).
There may be an approximate 2second delay before the overloadindicator light turns on and thealarm sounds.
CHECKLIST C PROCEDURES
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7 Carefully move the test weights to eachremaining location in the platform.
Result: The alarm should be sounding.The platform overload indicator light should beflashing at both the ground and platformcontrols.
Result: If the alarm does not sound and theplatform overload indicator light does not comeon with the test weights in any of the platformlocations, the platform overload system needsto be calibrated. See D-6, Calibrate the PlatformOverload System (if equipped).
There may be an approximate 2second delay before the overloadindicator light turns on and thealarm sounds.
8 Test all machine functions from the platformcontrols.
Result: All platform control functions should notoperate.
9 Turn the key switch to ground control.
10 Test all machine functions from the groundcontrols.
Result: All ground control functions should notoperate.
Machine functions should stilloperate with auxiliary power at theground controls.
11 Lift the test weights off the platform floor using asuitable lifting device.
Result: The platform overload indicator light andalarm should turn off at both the ground andplatform controls.
There may be an approximate 2second delay before the overloadindicator light and alarm turn off.
12 Test all machine functions from the groundcontrols.
Result: All ground control functions shouldoperate normally.
13 Turn the key switch to platform control.
14 Test all machine functions from the platformcontrols.
Result: All platform control functions shouldoperate.
If the platform overload system isnot operating properly, see D-6,Calibrate the Platform OverloadSystem (if equipped).
CHECKLIST C PROCEDURES
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REV BChecklist D Procedures
D-1Check the Boom Wear Pads
Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.
1 Measure each wear pad. Replace the wear padonce it reaches the minimum allowablethickness. If the wear pad is still withinspecification, shim as necessary to obtainminimum clearance with zero binding.
2 Extend and retract the primary boom through theentire range of motion to check for tight spotsthat may cause binding or scraping of the boom.
Always maintain squarenessbetween the outer and innerboom tubes.
Primary boom wearpad specifications New Minimum
Top, bottom and side wear pads 3/4 inch 5/8 inch(platform end of boom) 19 mm 15.9 mm
Side and bottom wear pads 5/8 inch 1/2 inch(pivot end of boom) 15.9 mm 12.7 mm
Top wear pads 3/4 inch 5/8 inch(pivot end of boom) 19 mm 15.9 mm
D-2Check the Free-wheelConfiguration
Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily for towing.A machine configured to free-wheel without operatorknowledge may cause death or serious injury andproperty damage.
Collision hazard. Select a work sitethat is firm and level.
Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.
Non-steer wheels:
1 Chock the steer wheels to prevent the machinefrom rolling.
2 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the non-steer tires.
3 Lift the wheels off the ground and then placejack stands under the drive chassis for support.
4 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachnon-steer wheel hub.
disengaged position
engaged position
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5 Manually rotate each non-steer wheel.
Result: Each non-steer wheel should rotate withminimum effort.
6 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Lift the machine andremove the jack stands.
Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.
Steer wheels:
7 Chock the non-steer wheels to prevent themachine from rolling.
8 Center a lifting jack of ample capacity(20,000 lbs / 10,000 kg) under the drive chassisbetween the steer tires.
9 Lift the wheels off the ground and then placejack stands under the drive chassis for support.
10 Disengage the drive hubs by turning over thedrive hub disconnect caps on eachsteer wheel hub.
11 Manually rotate each steer wheel.
Result: Each steer wheel should rotate withminimum effort.
12 Re-engage the drive hubs by turning overthe hub disconnect caps. Rotate each wheel tocheck for engagement. Raise the machine andremove the jack stands.
Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.
13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).
a drive pumpb free-wheel valvec lift pumpd screwdriver
The free-wheel valve is located onthe side of the drive pump.
The free-wheel valve shouldalways remain closed.
CHECKLIST D PROCEDURES
disengaged position
engaged position
a b
c
d
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a
D-3Replace the Drive Hub Oil
Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly and continueduse may cause component damage.
1 Select the drive hub to be serviced. Then drivethe machine until one of the two plugs is at thelowest point.
2 Remove both plugs and drain the oil.
3 Drive the machine until one plug is at the topand the other is at 90 degrees.
a drive hub plugs
4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Install the plugs.
5 Repeat steps 1 through 4 for all the other drivehubs.
D-4Replace the Hydraulic Filters
Genie requires that this procedurebe performed yearly or every 1000hours, whichever comes first.Perform this procedure more oftenif dusty conditions exist.
Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filters be replaced more often.
Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.
Perform this procedure with theengine off.
Hydraulic return filter
1 Open the ground controls side turntable coverand locate the hydraulic return filter housing ontop of the hydraulic tank.
2 Remove the cap from the filter housing.
3 Lift the handle on the filter element and rotatethe element counterclockwise to release theelement from the housing.
4 Remove the filter element from the filterhousing.
CHECKLIST D PROCEDURES
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5 Install the new filter element into the filterhousing.
6 Push the filter element down to be sure the o-ring on the element is fully seated into thehousing.
7 Rotate the filter element clockwise to lock it inplace.
8 Install the filter housing cap.
9 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housing.
Medium and high pressure filters
The medium pressure filter is forthe charge pump and the highpressure filter is for all machinefunctions except the drive circuitand oscillating axle circuit.
10 Open the engine side turntable cover and locatethe medium and high pressure filters.
The medium pressure filter ismounted near the pump. The highpressure filter, with filter conditionindicator, is mounted to thebulkhead.
11 Place a suitable container under each filter.
12 Remove the filter housings by using a wrench onthe nut provided on the bottom of the housings.
13 Remove the filter elements from the housings.
14 Inspect the housing seals and replace them ifnecessary.
15 Install the new filter elements into the housingsand tighten them securely.
The medium and high pressurefilters use the same elements.
16 Clean up any oil that may have spilled during theinstallation procedure.
17 Use a permanent ink marker to write the dateand number of hours from the hour meter on theoil filter housings.
18 Start the engine from the ground controls.
19 Inspect the filter housings and relatedcomponents to be sure that there are no leaks.
CHECKLIST D PROCEDURES
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D-5Perform Engine Maintenance
Deutz engine specifications requirethat this procedure be performedevery 1000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929).
Deutz FL 2011 Operation ManualGenie part number 84794
To access the engine:
1 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
D-6Calibrate the Platform OverloadSystem (if equipped)
Genie specifications require thatthis procedure be performed every1000 hours of operation or yearly.
Yearly calibration of the platform overload systemis essential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.
Perform this procedure with themachine on a firm, level surface.
1 Level the platform.
2 Determine the maximum platform capacity.Refer to the machine serial plate.
3 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity at the center of theplatform floor.
CHECKLIST D PROCEDURES
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Determine the limit switch trigger point:
4 Gently move the platform up and down by hand,so it bounces approximately 2.5 to 5 cm. Allowthe platform to settle.
Result: The overload indicator light and thealarm is on. Slowly tighten the load springadjustment nut by turning it clockwise just untilthe overload indicator light and alarm turns off.
The platform will need to be movedup and down and allowed to settlein between adjustments.
There may be an approximate 2second delay before the overloadindicator light turns on and thealarm sounds.
Result: The overload indicator light andalarm is off. Slowly loosen the load springadjustment nut by turning it counterclockwisejust until the overload indicator light and alarmturn on.
There may be an approximate 2second delay before the overloadindicator light turns on and thealarm sounds.
The platform will need to be movedup and down and allowed to settlein between adjustments.
CHECKLIST D PROCEDURES
Confirm the setting:
5 Turn the key switch to platform control. Start theengine from the platform controls.
6 Lift the test weight off the platform floor using asuitable lifting device.
7 Place the test weight back onto the center of theplatform floor using a suitable lifting device.
Result: The alarm should be off. The platformoverload indicator light should be off at both theground and platform controls.
There may be an approximate 2second delay before the overloadindicator light and alarm turn off.
8 Add an additional 10 lb / 4.5 kg test weight tothe original test weight to overload the platform.
Result: The alarm should be sounding.The platform overload indicator light should beflashing at both the ground and platformcontrols.
There may be an approximate 2second delay before the overloadindicator light turns on and thealarm sounds.
9 Test all machine functions from the platformcontrols.
Result: All platform control functions should notoperate.
10 Turn the key switch to ground control.
11 Test all machine functions from the groundcontrols.
Result: All ground control functions should notoperate.
If the platform overload system isnot operating properly, repeatsteps 1 through 4.
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REV B
D-7Check the Turntable RotationBearing Bolts
Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.
1 Raise the primary boom and place a safetychock on the lift cylinder rods. Carefully lowerthe boom onto the lift cylinder safety chock.
Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering theboom.
The lift cylinder safety chock isavailable through the GenieService Parts Department.
2 Turn the engine off.
3 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
4 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
5 Remove the center turntable cover retainingfasteners. Remove the center turntable coverfrom the machine.
CHECKLIST D PROCEDURES
6 Be sure that each turntable mounting bolt istorqued in sequence to specification. Refer toSection 2, Specifications.
Bolt torque sequence
7 Start the engine from the ground controls.
8 Raise the primary boom and remove the safetychock.
9 Lower the boom to the stowed position.
10 Remove drive chassis covers from both thesteer end and the non-steer end of the machine.
11 Remove the lower chassis cover mountingfasteners from inside of the drive chassis (ifequipped).
12 Remove the lower chassis cover to access thelower turntable bearing bolts under the drivechassis.
13 Check to ensure that each lower bearingmounting bolt under the drive chassis is torquedin sequence to specification. Refer to Section 2,Specifications.
Bolt torque sequence
15
1013618
311
8
16
2
914 5 17
412
7
1
Counterweight
115
7
12
4
5
14
9216
8
3
11
6
1310
Counterweight
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a
b
c
d
CHECKLIST D PROCEDURES
D-8Inspect for Turntable BearingWear
Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.
Perform this procedure with themachine on a firm, level surfaceand the boom in the stowedposition.
1 Grease the turntable bearing. See A-8, Greasethe Turntable Bearing and Rotate Gear.
2 Torque the turntable bearing bolts tospecification. See D-7, Check the TurntableRotation Bearing Bolts.
3 Start the machine from the ground controls andraise the primary and secondary booms to fullheight. Do not extend the primary boom.
4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no more than1 inch / 2.5 cm from the bearing.
To obtain an accuratemeasurement, place the dialindicator no more than 1 inch /2.5 cm from the turntable rotationbearing.
a turntableb dial indicatorc drive chassisd turntable rotation bearing
5 At the dial indicator, adjust it to "zero" theindicator.
6 Lower the secondary boom to the stowedposition and lower the primary boom to ahorizontal position. Fully extend the primaryboom.
7 Note the reading on the dial indicator.
Result: The measurement is less than0.055 inch / 1.4 mm. The bearing is good.
Result: The measurement is more than0.055 inch / 1.4 mm. The bearing is worn andneeds to be replaced.
8 Fully retract the primary boom. Raise theprimary and secondary booms to full height.Visually inspect the the dial indicator to be surethe needle returns to the "zero" position.
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REV B
9 Remove the dial indicator and rotate theturntable 90°.
10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.
11 Lower the primary and secondary booms to thestowed position and turn the machine off.
12 Remove the dial indicator from the machine.
CHECKLIST D PROCEDURES
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REV A
1 Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.
Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
3 Remove the drain plug from the hydraulic tankand completely drain the tank into a container ofsuitable capacity. Refer to Section 2,Specifications.
4 Tag, disconnect and plug the two suction hosesand supply hose for the auxiliary pump from thehydraulic tank. Cap the fittings on the tank.
The hoses can be accessedthrough the access hole under theturntable.
5 Disconnect and plug the return filter hydraulichose at the return filter. Cap the fitting on thefilter housing.
E-1Test or Replace the HydraulicOil
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction straineror hydraulic filters may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften.
Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.
Perform this procedure with theboom in the stowed position.
Checklist E Procedures
open closed
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REV A
6 Remove the ground controls side turntablecover.
7 Support the hydraulic tank with an appropriatelifting device.
8 Remove the hydraulic tank mounting fasteners.
9 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulictank could become unbalancedand fall if not properly supportedwhen removed from the machine.
10 Remove the hydraulic return filter housingmounting fasteners. Remove the hydraulicreturn filter housing from the hydraulic tank.
11 Remove the suction strainers from the tank andclean them using a mild solvent.
12 Rinse out the inside of the tank using a mildsolvent.
13 Install the suction strainers into the hydraulictank
14 Install the drain plug using a thread sealant onthe threads.
15 Install the hydraulic return filter housing onto thehydraulic tank.
16 Install the hydraulic tank onto the machine.
17 Install the two suction hoses to the suctionstrainers.
18 Install the supply hose for the auxiliary powerunit and the return filter hose.
19 Open the two hydraulic tank valves at thehydraulic tank.
20 Fill the tank with the proper hydraulic oil for yourmachine until the level is within the top2 inches / 5 cm of the sight gauge. Do notoverfill. Refer to Section 2, Specifications.
21 Clean up any oil that may have spilled.
22 Prime the pump. Refer to Repair Procedure 7-2,How to Prime the Pump.
CHECKLIST E PROCEDURES
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E-2Perform Engine Maintenance
Deutz engine specifications requirethat this procedure be performedevery 3000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929).
Deutz FL 2011 Operation ManualGenie part number 84794
To access the engine:
1 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
E-3Perform Engine Maintenance
Deutz engine specifications requirethat this procedure be performedevery 12,000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz FL 2011 Operation Manual(Deutz part number 0297-9929).
Deutz FL 2011 Operation ManualGenie part number 84794
To access the engine:
1 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
2 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
CHECKLIST E PROCEDURES
Part No. 110284 Z-51/30J 4 - 1
September 2005 Section 4 • Repair Procedures
Repair Procedures
Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in the Genie Z-51/30JOperator’s Manual on your machine.
Be sure that all necessary tools and parts areavailable and ready for use.
Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom between the non-steer wheels
· Turntable secured with the turntable rotation lock
· Key switch in the off position with the key removed
· Wheels chocked
· All external AC power disconnectedfrom the machine
About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.
Perform disassembly procedures to the pointwhere repairs can be completed. To re-assemble,perform the disassembly steps in reverse order.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Used to indicate operation ormaintenance information.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
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The platform control box contains one printedcircuit board. The ALC-500 circuit board inside theplatform control box controls all proportionalmachine functions from the platform. The joystickcontrollers at the platform controls utilize HallEffect technology and require no adjustment. Theoperating parameters of the joysticks are stored inmemory at the ECM circuit board at the platformcontrols. If a joystick error occurs or if a joystick isreplaced, it will need to be calibrated before thatparticular machine function will operate. See 1-2,How to Calibrate a Joystick.
Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.
a ALC-500 circuit boardb drive/steer joystick controllerc secondary boom up/down
joystick controllerd primary boom up/down and
turntable rotate left/rightjoystick controller
1-1ALC-500 Circuit Board
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
When the ALC-500 circuit board isreplaced, the joystick controllerswill need to be calibrated. See 1-2,How to Calibrate a Joystick.
How to Remove the ALC-500Circuit Board1 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 retainingfasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to theinside of the platform control box.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Platform Controls
bcd
a
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REV A
1-2Joysticks
How to Calibrate a JoystickThe joysticks on this machine utilize digital HallEffect technology for proportional control. If ajoystick is disconnected or replaced, it must becalibrated before that particular machine functionwill operate.
The joystick must be calibratedbefore the threshold, max-out orramp rate can be set.
Perform this procedure with theengine off.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Select a joystick to calibrate.
4 Move the joystick full stroke in either directionand hold for 5 seconds.
5 Return the joystick to the neutral position, pausefor a moment, then move the joystick full strokein the opposite direction. Hold for 5 seconds andreturn the joystick to the neutral position.
Result: The alarm should sound indicatingsuccessful joystick calibration.
6 Repeat this procedure for each joystickcontrolled machine function including the thumbrocker steer switch.
No machine fuction should operatewhile performing the joystickcalibration procedure.
4 Attach a grounded wrist strap to the groundscrew inside the platform control box.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.
5 Carefully disconnect the wire connectors fromthe circuit board.
6 Remove the ALC-500 circuit board mountingfasteners.
7 Carefully remove the ALC-500 circuit board fromthe platform control box.
PLATFORM CONTROLS
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REV APLATFORM CONTROLS
How to Adjust the JoystickMax-out SettingThe max-out setting of a joystick controls themaximum speed of a joystick-controlled machinefunction. Whenever a hydraulic cylinder, drivemotor or hydraulic pump is replaced, the max-outsetting should be adjusted to maintain optimumperformance. The max-out settings on the joystickcan be changed to compensate for hydraulic pumpwear to maintain peak performance from themachine.
Perform this procedure with theboom in the stowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the platform controls red EmergencyStop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
7 Momentarily activate the drive enable toggleswitch in the right direction 4 times.
Result: There should be a pause and the alarmshould sound 4 times indicating that themachine is in max-out calibration mode.
8 Start the engine from the platform controls andpress down the foot switch.
9 Start a timer and activate the machine functionthat needs to be adjusted. Record the time ittakes for that function to complete a full cycle(ie; boom up).
10 Compare the machine function time withspecifications and determine whether thefunction time needs to increase or decrease.
Refer to Section 2, Specificationsfor function speeds.
11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycletime. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.
Each time the drive enable toggleswitch is momentarily moved, thetime will change in 2% increments.
12 Repeat steps 9 through 11 for each joystickcontrolled machine function.
13 Return the joystick to the neutral position andwait for approximately 10 seconds.
Result: The alarm should sound indicating thatthe settings have been saved in memory.
Do not operate any machinefunction during the 10 secondwaiting time.
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REV A PLATFORM CONTROLS
How to Adjust the JoystickRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.
Perform this procedure with theboom in the stowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the platform controls red EmergencyStop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
7 Momentarily activate the drive enable toggleswitch in the right direction 6 times.
Result: There should be a pause and the alarmshould sound 6 times indicating that themachine is in ramp rate calibration mode.
8 Start the engine from the platform controls andpress down the foot switch.
9 Start a timer and simultaneously move thejoystick in either direction full stroke. Note howlong it takes the function to reach maximumspeed. This is the ramp rate.
10 Compare the function ramp rate time with thetable below and determine whether the ramprate time needs to increase or decrease.
11 While the joystick is activated, set the ramprate. Momentarily move the drive enable toggleswitch in the right direction to increase the timeor momentarily move the drive enable toggleswitch in the left direction to decrease the time.
Each time the drive enable toggleswitch is momentarily moved, thetime will change in 10%increments.
12 Repeat steps 9 through 11 for each joystickcontrolled machine function.
13 Return the joystick to the neutral position andwait for approximately 10 seconds.
Result: The alarm should sound indicating thatthe settings have been saved in memory.
Do not operate any machinefunction during the 10 secondwaiting time.
Ramp rate (factory settings)
Primary boom up/downaccelerate 4 secondsdecelerate 0.5 second
Secondary boom up/downaccelerate 2 secondsdecelerate 0.5 second
Turntable rotateaccelerate 2 secondsdecelerate 0.5 second
Driveaccelerate 3 secondsdecelerate to neutral 0.5 seconddecelerate, change of direction 0.5 seconddecelerate, coasting 0.75 seconddecelerate, braking 1 seconddecelerate, shift from low to high speed 1 seconddecelerate, shift from high to low speed 2 seconds
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How to Adjust the JoystickThreshold SettingThe threshold setting of a joystick is the minimumoutput at which a function proportional valve canopen and allow the function to operate.
Perform this procedure with theboom in the stowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Turn the key switch to platform control. Do notstart the engine.
3 Push in the platform controls red EmergencyStop button to the off position.
4 Do not press down the foot switch.
5 Move and hold the drive enable toggle switch inthe right position and pull out the redEmergency Stop button to the on position.
6 When the alarm sounds, release the driveenable toggle switch.
7 Momentarily activate the drive enable toggleswitch in the right direction 8 times.
Result: There should be a pause and the alarmshould sound 8 times indicating that themachine is in threshold calibration mode.
8 Start the engine from the platform controls andpress down the foot switch.
9 Select a boom function joystick to set thethreshold.
10 Slowly move the joystick off center in eitherdirection just until the function begins to move.
11 Slowly move the joystick back to the neutralposition. Just before the function stops moving,move the drive enable toggle switch to eitherside to set the threshold.
Result: The alarm should sound indicating asuccessful calibration.
12 Repeat steps 9 through 11 for each boomjoystick controlled machine function (boom up/down, boom extend/retract and turntable rotate).
13 Return the joystick to the neutral position andwait for approximately 10 seconds.
Result: The alarm should sound indicating thatthe settings have been saved in memory.
Do not operate any machinefunction during the 10 secondwaiting time.
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REV APlatform Components
2-1Platform Leveling Slave Cylinder
The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of boom motion. It operates in aclosed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.
How to Remove the PlatformLeveling Slave Cylinder
Before cylinder removal isconsidered, bleed the slavecylinder to be sure there is noair in the closed loop.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Extend the primary boom until the slave cylinderbarrel-end pivot pin is accessible.
2 Raise the primary boom slightly and placeblocks under the platform for support.
3 Lower the primary boom until the platform isresting on the blocks just enough to support theplatform.
Do not rest the entire weight of theboom on the blocks.
4 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder at the unions andconnect them together using a connector.Connect the hoses from the cylinder togetherusing a connector.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
5 Remove the pin retaining fastener from the slavecylinder rod-end pivot pin. Do not remove thepin.
6 Remove the external snap rings from the slavecylinder barrel-end pivot pin. Do not remove thepin.
7 Place a block under the slave cylinder forsupport. Protect the cylinder rod from damage.
8 Use a soft metal drift to drive the rod-end pivotpin out.
Crushing hazard. The platformcould fall when the slave cylinderrod-end pivot pin is removed if notproperly supported.
Component damage hazard. Theslave cylinder rod may becomedamaged if it is allowed to fall ifnot properly supported by the liftingdevice.
9 Use a soft metal drift and drive the barrel-endpin out.
10 Carefully pull the cylinder out of the primaryboom.
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How to Bleed the Slave CylinderDo not start the engine. Useauxiliary power for this procedure.
1 Raise the primary boom to a horizontal position.
2 Move the platform level toggle switch up anddown through two platform leveling cycles toremove any air that might be in the system.
2-2Platform Rotator
How to Bleed the PlatformRotator
This procedure will require twopeople. Do not start the engine.Use auxiliary power for thisprocedure.
1 Move the function enable toggle switch to eitherside and activate the platform rotate toggleswitch to the right then the left through twoplatform rotation cycles, then hold the switch tothe right position until the platform is fullyrotated to the right.
2 Place a suitable container underneath theplatform rotator.
3 Open the top bleed screw on the rotator, but donot remove it.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the left position until the platform is fullyrotated to the left. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.
Crushing hazard. Keep clear of theplatform during rotation.
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REV A PLATFORM COMPONENTS
5 Open the bottom bleed screw on the rotator, butdo not remove it.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
6 Move the function enable toggle switch to eitherside and hold the platform rotate toggle switchto the right position until the platform is fullyrotated to the right. Continue holding the toggleswitch until air stops coming out of the bleedscrew. Close the bleed screw.
Crushing hazard. Keep clear of theplatform during rotation.
7 Clean up any hydraulic oil that may have spilled.
8 Rotate the platform fully in both directions andinspect the bleed screws for leaks.
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3-1Jib Boom
How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Remove the platform.
2 Disconnect the electrical connector from the jibboom/platform rotate select valve manifoldmounted to the platform support.
3 Tag, disconnect and plug all of the hydraulichoses from the jib boom/platform rotate selectvalve manifold. Cap the fittings on the manifoldand pull the hoses out through the platformrotator.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Remove the platform mounting weldment.
5 Attach a lifting strap from an overhead crane tothe platform rotator for support.
6 Remove the pin retaining fastener from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.
7 Remove the pin retaining fasteners from bothplatform rotator pivot pins. Do not remove thepins.
8 Use a soft metal drift to remove the leveling armpivot pin and let the leveling arms hang down.
9 Use a soft metal drift to remove the platformrotator pivot pin and remove the platform rotatorfrom the machine.
10 Slide both of the jib boom leveling arms off ofthe jib boom cylinder rod-end pivot pin.
11 Remove the hose and cable cover from the sideof the jib boom. Remove the hose and cableseparators.
12 Attach a lifting strap from an overhead crane tothe jib boom.
13 Support the barrel end of the jib boom liftcylinder with a suitable lifting device.
14 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
Jib Boom Components
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REV A JIB BOOM COMPONENTS
15 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin.
16 Use a soft metal drift to remove the pin and letthe cylinder hang down.
Crushing hazard. The jib boomcould fall when when the barrel-endpivot pin is removed if not properlysupported by the overhead crane.
17 Remove the pin retaining fastener from the jibboom pivot pin. Use a soft metal drift to removethe pin, then remove the jib boom from thebellcrank.
Crushing hazard. The jib boomcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.
18 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.
19 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, then remove the jibboom lift cylinder from the bellcrank.
Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.
3-2Jib Boom Lift Cylinder
How to Remove the Jib BoomLift Cylinder
Perform this procedure with theboom in the stowed position.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks just enough to support theplatform.
Do not rest the entire weight of theboom on the blocks.
2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
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REV A
3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.
4 Use a soft metal drift to tap the jib boom liftcylinder rod-end pivot pin half way out. Thenlower one of the leveling arms to the ground.Tap the pin the other direction and lower theopposite leveling arm. Do not remove the pin.
5 Support the jib boom lift cylinder with a suitablelifting device.
6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pin andlet the cylinder hang down.
Crushing hazard. The jib boomcould fall when the barrel-end pivotpin is removed if not properlysupported by the overhead crane.
7 Attach a lifting strap from an overhead crane tothe lug on the rod end of the jib boom liftcylinder.
8 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the jib boom liftcylinder from the machine.
Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.
JIB BOOM COMPONENTS
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4-1Cable Track
The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.
How to Remove the Cable TrackWhen removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Locate the cables from the primary boom cabletrack to the platform control box. Number eachcable and its entry location at the platformcontrol box.
2 Disconnect the cables from the platform controlbox.
3 Remove the hose and cable cover from the sideof the jib boom. Remove the hose and cableseparators.
4 Remove the hose clamp on the primary boombellcrank.
5 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.
Primary Boom Components
6 Tag, disconnect and plug the hydraulic hosesfrom the "V1" and "V2" ports on thecounterbalance valve manifold located on theplatform rotator. Cap the fittings on themanifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
7 Tag and disconnect the hydraulic hoses fromthe platform leveling slave cylinder at the unionand connect them together using a connector.Connect the hoses from the cylinder togetherusing a connector.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
8 Tag, disconnect and plug the hydraulic hosesfrom the jib boom/platform rotate manifold. Capthe fittings on the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
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REV APRIMARY BOOM COMPONENTS
9 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union located above theprimary boom lift cylinder. Cap the fittings onthe unions.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
10 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling master cylinder. Capthe fittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
11 Raise the boom to a horizontal position.
12 Place blocks between the upper and lower cabletracks and secure the upper and lower trackstogether.
Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.
13 Attach a lifting strap from an overhead 5 ton /5,000 kg capacity crane to the platform end ofthe primary boom for support. Do not lift it.
14 Remove all hose and cable clamps from theunderside of the primary boom.
15 Support the rod end of the primary boom liftcylinder with a suitable lifting device.
16 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Donot remove the pin.
17 Raise the primary boom slightly with theoverhead crane to relieve the pressure on theprimary boom lift cylinder rod-end pivot pin.
18 Use a soft metal drift to remove the primaryboom lift cylinder rod-end pivot pin.
Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported by the lifting device.
19 Lower the rod end of the primary boom liftcylinder approximately 12 inches / 30 cm.
20 Pull all of the hoses and cables out and awayfrom the mounting ears for the rod end of theprimary boom lift cylinder.
21 Raise the rod end of the primary boom liftcylinder back into position and install the rod-end pivot pin. Install the pin retaining fasteners.
22 Attach a strap from an overhead crane to thecable track.
23 Remove the mounting fasteners from the uppercable track at the platform end of the extensionboom.
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REV A
24 Remove the cable track mounting fasteners thatattach the lower cable track to the primaryboom.
25 Remove the cable track from the machine andplace it on a structure capable of supporting it.
Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.
Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.
How to Repair the Primary BoomCable Track
Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.
A 7 link repair section of cabletrack is available throughthe Genie Industries Service PartsDepartment.
a link separation pointb lower clip
1 Use a slotted screwdriver to pry down on thelower clip.
2 To remove a single link, open the lower clipand then use a screw driver to pry the link to theside.
3 Repeat steps 1 and 2 for each link.
4-2Primary Boom
How to Remove the PrimaryBoom
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Perform this procedure with theboom in the stowed position.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Remove the platform.
2 Remove the jib boom. See 3-1, How to Removethe Jib Boom.
3 Remove the cable track. See 4-1, How toRemove the Cable Track.
4 Raise the primary boom to a horizontal position.
5 Remove the hose and cable cover from theupper pivot.
PRIMARY BOOM COMPONENTS
a
b
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6 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin. Use a softmetal drift to remove the pin. Then lower thecylinder and let it hang down.
Component damage hazard.When lowering the master cylinderdown, be sure not to damage themaster cylinder hoses or fittings.
7 Locate the primary boom drive speed limitswitch inside of the upper pivot.
8 Remove the primary boom drive speed limitswitch mounting fasteners. Do not disconnectthe wiring.
9 Locate the primary extension boom drive speedlimit switch inside of the extension boom.
10 Remove the primary extension boom drivespeed limit switch mounting fasteners. Do notdisconnect the wiring.
11 Pull the limit switch and the wiring out of theextension tube and move it out of the way.
12 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
13 Remove the hose clamp at the pivot end of theboom.
14 Attach a 5 ton / 5,000 kg overhead crane to thecenter point of the primary boom.
15 Attach a similar lifting device to the primaryboom lift cylinder.
16 Place support blocks under the primary boom liftcylinder.
17 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.
Crushing hazard. The boom liftcylinder and primary boom will fallif not properly supported.
18 Lower the rod end of the primary boom liftcylinder onto support blocks. Protect thecylinder rod from damage.
19 Remove the pin retaining fasteners from theprimary boom pivot pin.
20 Remove the primary boom pivot pin with a softmetal drift, then carefully remove the primaryboom from the machine and place it on astructure capable of supporting it.
Crushing hazard. The primaryboom could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.
PRIMARY BOOM COMPONENTS
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REV A PRIMARY BOOM COMPONENTS
How to Disassemble the PrimaryBoom
Complete disassembly of theboom is only necessaryif the outer or inner boom tubemust be replaced. The extensioncylinder can be removed withoutcompletely disassembling theboom. See 4-4, How to Removethe Primary Boom ExtensionCylinder.
1 Remove the primary boom. See How to Removethe Primary Boom.
2 Place blocks under the barrel end of the primaryboom extension cylinder for support.
3 Remove the pin retaining fastener from theextension cylinder barrel-end pivot pin at thepivot end of the primary boom. Use a soft metaldrift to remove the pin.
4 Remove and label the location of the wear padsfrom the platform end of the primary boom.
Pay careful attention to thelocation and amount of shims usedwith each wear pad.
5 Support and slide the extension tube andextension cylinder assembly out of the boomtube.
Crushing hazard. The primaryboom extension tube couldbecome unbalanced and fall whenremoved from the primary boomtube if not properly supported.
During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.
6 Remove the external snap rings from theextension cylinder rod-end pivot pin at theplatform end of the extension tube. Use a softmetal drift to remove the pin.
7 Support and slide the extension cylinder out ofthe base end of the extension tube. Place theextension cylinder on blocks for support.
Crushing hazard. The extensioncylinder could become unbalancedand fall when removed fromprimary boom extension tube if notproperly supported.
During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.
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REV APRIMARY BOOM COMPONENTS
4-3Primary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers theprimary boom. The primary boom lift cylinder isequipped with a counterbalance valve to preventmovement in the event of a hydraulic line failure.
How to Remove the PrimaryBoom Lift Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Raise the primary boom to a horizontal position.
2 Raise the secondary boom until the primaryboom lift cylinder barrel-end pivot pin is abovethe turntable covers.
3 Attach a 5 ton / 5000 kg overhead crane to theprimary boom for support.
4 Raise the primary boom with the overhead craneslightly to take the pressure off the primaryboom lift cylinder pivot pins.
5 Support the rod end and the barrel end of theprimary boom lift cylinder with a secondoverhead crane or similar lifting device.
6 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
7 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.
Crushing hazard. The primaryboom will fall if not properlysupported when the primary boomrod-end pivot pin is removed.
8 Place a support block across both turntablecovers under the primary boom lift cylinder.
9 Lower the rod end of the lift cylinder onto theblock. Protect the cylinder rod from damage.
Crushing hazard. The primaryboom lift cylinder could fall if notproperly supported.
10 Remove the primary boom lift cylinder barrel-endpivot pin retaining fasteners. Do not remove thepin.
11 Use a slide hammer to remove the barrel-endpivot pin. Carefully remove the primary boom liftcylinder from the machine.
Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported andsecured to the lifting device.
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REV A PRIMARY BOOM COMPONENTS
4-4Primary Boom ExtensionCylinder
The primary boom extension cylinder extends andretracts the primary boom extension tube.Theprimary boom extension cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.
How to Remove the PrimaryBoom Extension Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Raise the primary boom to a horizontal position.
2 Extend the primary boom until the primary boomextension cylinder rod-end pivot pin isaccessible in the primary boom extension tube.
3 Remove the hose and cable guard from theupper pivot.
4 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
5 At the platform end of the boom, remove theexternal snap rings from the extension cylinderrod-end pivot pin. Use a soft metal drift toremove the pin.
6 Remove the barrel-end pivot pin retainingfasteners.
7 Place a rod through the barrel-end pivot pin andtwist to remove the pin.
8 Support and slide the extension cylinder out ofthe upper pivot.
Crushing hazard. The extensioncylinder could fall when removedfrom the extension boom if notproperly supported.
Component damage hazard. Becareful not to damage thecounterbalance valves on theprimary boom extension cylinderwhen removing the cylinder fromthe primary boom.
Component damage hazard. Hosesand cables can be damaged if theprimary boom extension cylinder isdragged across them.
Note the length of the cylinder afterremoval. The cylinder must be atthe same length for installation.
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REV A
4-5Platform LevelingMaster Cylinder
The master cylinder acts as a pump for the slavecylinder. It’s part of the closed circuit hydraulic loopthat keeps the platform level through the entirerange of boom motion. The master cylinder islocated at the base of the primary boom.
How to Remove the PlatformLeveling Master Cylinder
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Raise the secondary boom until both the rod-endand barrel-end pivot pins on the master cylinderare accessible.
2 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
PRIMARY BOOM COMPONENTS
3 Attach overhead crane or similar lifting device tothe master cylinder.
4 Remove the pin retaining fasteners from themaster cylinder barrel-end pivot pin.
5 Place a rod through the barrel-end pivot pin andtwist to remove the pin.
6 Remove the pin retaining fastener from the rod-end pivot pin.
7 Place a rod through the rod-end pivot pin andtwist to remove the pin.
8 Remove the master cylinder from the machine.
Crushing hazard. The mastercylinder could become unbalancedand fall if not properly attached tothe overhead crane.
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September 2005Section 4 • Repair Procedures
REV ASecondary Boom Components
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Secondary Boom components
a upper secondary boom(number 1 arm)
b upper tension link(number 2 arm)
c lower tension link(number 3 arm)
d mid-pivote compression linkf secondary boom lift cylinder (2)g lower secondary boom
(number 4 arm)h turntable pivoti boom restj upper pivot
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September 2005 Section 4 • Repair Procedures
REV A SECONDARY BOOM COMPONENTS
5-1Secondary Boom
How to Disassemble theSecondary Boom
Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.
Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Remove the platform.
2 Remove the jib boom. See 3-1, How to Removethe Jib Boom.
3 Remove the primary boom. See 3-2, How toRemove the Primary Boom.
4 Remove the master cylinder. See 4-5, How toRemove the Master Cylinder.
5 Attach a lifting strap from an overhead crane toto the lug on the rod end of the primary boom liftcylinder. Then raise the primary boom liftcylinder with the crane, to a vertical position.
6 Tag, disconnect and plug the hydraulic hoses atthe primary boom lift cylinder. Cap the fittingson the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
7 Remove the pin retaining fastener from theprimary boom lift cylinder barrel-end pivot pin.
8 Use a slide hammer to remove the pin. Removethe primary boom lift cylinder from the machine.
Crushing hazard. The primaryboom lift cylinder could becomeunbalanced and fall if not properlysupported by the overhead crane.
9 Tag, disconnect and plug the hydraulic hoseson both of the secondary boom lift cylinders.Cap the fittings on the cylinders.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
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REV A
10 Remove the pin retaining fasteners from bothsides of the secondary boom lift cylinder rod-end pivot pin and barrel-end pivot pin. Do notremove the pins.
11 Attach a strap from an overhead crane to the lugon the rod end of one of the secondary boom liftcylinders for support. Do not apply any liftingpressure.
12 Use a soft metal drift to drive the barrel-endpivot pin half way out. Lower the barrel end ofthe secondary boom lift cylinder and let it hangdown.
13 Use a soft metal drift to drive the rod-end pivotpin half way out.
14 Remove the secondary boom lift cylinder fromthe machine.
15 Repeat steps 11 through 14 for the othersecondary boom lift cylinder.
Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlyattached to the overhead crane.
Component damage hazard. Whenremoving a secondary boom liftcylinder from the machine, becareful not to damage thecounterbalance valve at the barrelend of the cylinder.
16 Attach a lifting strap from an overhead crane tothe upper pivot for support. Do not lift it.
17 Attach a lifting strap from a second overheadcrane to the number 1 arm at the mid-pointbetween the upper pivot and mid-pivot.
18 Remove the pin retaining fasteners from thenumber 1 arm pivot pins at the mid-pivot andthe upper pivot. Do not remove the pins.
19 Use a soft metal drift to drive both pins out.
20 Remove the number 1 arm from the machine.
Crushing hazard. The number 1arm could become unbalanced andfall when removed from themachine if not properly attached tothe overhead crane.
Crushing hazard. The upper pivotcould fall when the number 1 armis removed from the machine if notproperly supported by the overheadcrane.
21 Using the overhead crane attached to the upperpivot, raise the secondary boom assemblyapproximately 30 inches / 76 cm.
22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm blockbetween the number 2 arm and the boom rest.Then lower the secondary boom assembly ontothe block.
Crushing hazard. The secondaryboom assembly could fall if notproperly supported by the4 x 4 x 11 inch / 10 x 10 x28 cm block.
SECONDARY BOOM COMPONENTS
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REV A
23 Pull all of the cables and hoses out through theupper pivot.
Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.
24 Remove the hose and cable covers from the topof the number 2 arm.
25 Pull all of the hoses and cables out of the upperpivot and out through the mid-pivot. Lay thehoses and cables on the ground.
Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.
26 Remove the pin retaining fastener from thenumber 2 arm pivot pin at the upper pivot. Use asoft metal drift to remove the pin.
27 Remove the upper pivot from the machine.
Crushing hazard. The upper pivotcould become unbalanced and fallwhen removed from the machine ifnot properly attached to theoverhead crane.
28 Attach the lifting strap from an overhead craneto the number 2 arm at the upper pivot end.
29 Raise the number 2 arm slightly and remove the4 x 4 x 11 inch / 10 x 10 x 28 cm block.
30 Lower the number 2 arm onto the boom rest pad.
31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cmblock between the number 3 arm and thenumber 4 arm at the mid-pivot end.
32 Attach a lifting strap from the overhead crane tothe mid-pivot for support. Do not lift it.
33 Remove the pin retaining fasteners from thenumber 2, 3 and 4 arm pivot pins at themid-pivot. Do not remove the pins.
34 Use a soft metal drift to drive each pin out. Thenremove the mid-pivot from the secondary boomassembly.
Crushing hazard. The mid-pivotcould become unbalanced and fallwhen removed from the secondaryboom assembly if not properlysupported by the overhead crane.
35 Attach the lifting strap from an overhead craneto the center point of the number 2 arm forsupport. Do not lift it.
36 Remove the pin retaining fasteners from bothcompression link pivot pins. Do not remove thepins.
37 Use a soft metal drift to remove the lowercompression link pivot pin at the number 3 arm.
38 Support the compression link with an appropriatelifting device.
SECONDARY BOOM COMPONENTS
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REV A
43 Open the ground controls side turntable cover.
44 Remove the fuel tank filler cap.
45 Using an approved hand-operated pump, drainthe fuel tank into a container of suitablecapacity. Refer to Section 2, Specifications.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.
Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or contrainer.
Be sure to only use a hand-operated pump suitable for usewith gasoline and diesel fuel.
46 Tag, disconnect and plug the fuel hoses fromthe fuel tank. Clean up any fuel that may havespilled.
47 Remove the fuel tank mounting fasteners.Carefully remove the fuel tank from themachine.
Component damage hazard. Thefuel tank is plastic and maybecome damaged if allowed to fall.
Clean the fuel tank and inspect forcracks and other damage beforeinstalling it onto the machine.
39 Use a soft metal drift to remove the uppercompression link pivot pin from the number 2arm. Remove the compression link from themachine.
Crushing hazard. The number 2arm could fall when thecompression link is disconnectedfrom the number 2 arm if notproperly supported by the overheadcrane.
Crushing hazard. The compressionlink may fall if not properlysupported when removed from thesecondary boom assembly.
40 Remove the number 2 arm from the machine.
Crushing hazard. The number 2arm could become unbalanced andfall when removed from thesecondary boom assembly if notproperly supported by the overheadcrane.
41 Remove the upper and lower hose and cablecovers from the number 3 arm.
42 Pull all of the cables and hoses from the number3 arm and lay them over the turntablecounterweight.
Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.
SECONDARY BOOM COMPONENTS
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REV A
57 Remove the pin retaining fasteners from thenumber 4 arm at the turntable riser. Do notremove the pin.
58 Attach a lifting strap from the overhead crane tothe center point of the number 4 arm. Do notlift it.
59 Use a slide hammer to remove the number 4arm from the turntable riser through the groundcontrols side bulkhead.
60 Remove the number 4 arm from the machine.
Crushing hazard. The number 4arm could become unbalanced andfall when removed from themachine if not properly supportedby the overhead crane.
SECONDARY BOOM COMPONENTS
48 Remove the retaining fastener from the groundcontrol box and function manifold pivot plate.
49 Lower the ground control box and functionmanifold pivot plate to access the number 3 armpivot pin.
50 Attach the lifting strap from the overhead craneto the centerpoint of the number 3 arm forsupport. Do not lift it.
51 Remove the mounting fasteners from the coverlocated in the boom storage area to access thenumber 3 and number 4 arm pivot pin retainingfasteners at the turntable riser.
52 Remove the pin retaining fasteners from thenumber 3 arm at the turntable riser. Do notremove the pin.
53 Use a slide hammer to remove the number 3arm pivot pin from the turntable pivot throughthe access hole behind the ground control box.
54 Remove the number 3 arm from the machine.
Crushing hazard. The number 3arm could become unbalanced andfall when removed from themachine if not properly supportedby the overhead crane.
55 Remove the upper and lower hose and cablecovers from the number 3 arm.
56 Remove the secondary boom drive speed limitswitch mounting fasteners from the number 4arm at the mid-pivot end. Do not disconnect thewiring.
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REV A
5-2Secondary Boom Lift Cylinders
There are two secondary boom lift cylindersincorporated in the structure of the secondary boomassembly. These cylinders operate in parallel andrequire hydraulic pressure to extend and retract.Each secondary boom lift cylinder is equipped witha counterbalance valve to prevent movement in theevent of a hydraulic line failure.
How to Remove a SecondaryBoom Lift Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Lower the secondary boom to the stowedposition.
2 Raise the primary boom so that it is above thesecondary boom lift cylinder rod-end pivot pin.
SECONDARY BOOM COMPONENTS
3 Tag, disconnect and plug the hydraulic hoseson the secondary boom lift cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
4 Remove the pin retaining fasteners from thesecondary boom lift cylinder rod-end pivot pinand barrel-end pivot pin. Do not remove thepins.
5 Attach a strap from an overhead crane to the lugon the rod end of the secondary boom liftcylinder for support. Do not apply any liftingpressure.
6 Use a soft metal drift to drive the barrel-endpivot pin half way out. Lower the barrel end ofthe secondary boom lift cylinder and let it hangdown.
7 Use a soft metal drift to drive the rod-end pivotpin half way out.
8 Remove the secondary boom lift cylinder fromthe machine.
Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlyattached to the overhead crane.
Component damage hazard. Whenremoving a secondary boom liftcylinder from the machine, becareful not to damage thecounterbalance valve at the barrelend of the cylinder.
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REV A
6-1RPM Adjustment
Refer to Maintenance Procedure B-9, Check andAdjust the Engine RPM.
6-2Flex Plate
The flex plate acts as a coupler between the engineand the pump. It is bolted to the engine flywheeland has a splined center to drive the pump.
How to Remove the Flex Plate1 Disconnect the positive battery cable from the
battery.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
2 Disconnect the electrical connectors at theelectrical proportional controller, located on thedrive pump.
3 Support the drive pump with an appropriatelifting device. Then remove all of the bellhousing to engine mounting bolts. Leave thepump connected to the bell housing.
4 Carefully pull the pump and bell housing awayfrom the engine and secure it from moving.
Component damage hazard. Hosescan be damaged if they are kinkedor pinched.
5 Remove the flex plate mounting fasteners,then remove the flex plate from the engineflywheel.
How to Install the Flex Plate1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Torque the flex plate mounting bolts in sequenceto 28 ft-lbs / 38 Nm.
3 Torque the flex plate mounting bolts in sequenceto 40 ft-lbs / 54 Nm.
Engines
1
2
3
4 5
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September 2005Section 4 • Repair Procedures
REV AENGINES
4 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.
a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 7/16 inch / 11 mm gap
5 Apply Loctite® removable thread sealant to thepump coupler set screw. Torque the set screwto 61 ft-lbs / 83 Nm.
6 Install the pump and bell housing assembly.Torque the bell housing mounting bolts labeled"C" in sequence to 28 ft-lbs / 38 Nm.
Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay occur.
Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.
7 Torque the bell housing mounting bolts labeled"C" in sequence to 40 ft-lbs / 54 Nm.
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September 2005 Section 4 • Repair Procedures
REV AHydraulic Pumps
7-1Lift/Steer Pump
How to Remove theLift/Steer Pump
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.
Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
2 Tag, disconnect and plug the lift/steer pumphydraulic hoses. Cap the fittings on the pump.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Remove the pump mounting bolts. Carefullyremove the pump.
Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.
open closed
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September 2005Section 4 • Repair Procedures
REV AHYDRAULIC PUMPS
7-2Drive Pump
The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electrical proportional controller,located on the pump. The only adjustment that canbe made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould only be performed at an authorized servicecenter. Call Genie Industries Service Department tolocate your local authorized service center.
How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Disconnect the electrical connectors at theelectrical proportional controller located on thedrive pump.
2 Locate the two hydraulic tank valves at thehydraulic tank through the access holeunderneath the turntable. Close the valves.
Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
3 Tag and disconnect and plug the hydraulichoses from the drive and lift/steer pumps. Capthe fittings on the pumps.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Support the pump with a lifting device andremove the two drive pump mounting fasteners.
open closed
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REV A
a
5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.
6 Remove the drive pump from the machine.
Component damage hazard. Thehydraulic pump may becomeunbalanced and fall if not properlysupported.
Component damage hazard. Wheninstalling the pump, do not forcethe pump coupler into the flexplateor damage to the pump shaft sealmay occur.
Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.
HYDRAULIC PUMPS
How to Prime the Pump1 Connect a 0 to 600 psi / 0 to 41 bar pressure
gauge to the test port on the drive pump.
2 Remove the safety pin (if equipped) from theengine pivot plate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
3 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
4 Hold the manual fuel shutoff valve clockwise tothe closed position.
a manual fuel shutoff valve
5 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches 320 psi / 22 bar.
6 Release the manual fuel shutoff valve.
7 Start the engine from the ground controls andcheck for hydraulic leaks.
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8-1Function Manifold Components
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 3 position 4 way ...... BM ........ Platform level up/down ................................ 25 ft-lbs / 34 Nm
2 Solenoid valve, 3 position 4 way ...... CG ........ Platform rotate left/right andjib boom up/down ........................................ 25 ft-lbs / 34 Nm
3 Flow regulator valve,2 gpm / 7.6 L/min ............................... BZ ......... Boom extend/retract circuit .......................... 20 ft-lbs / 27 Nm
4 Solenoid valve, 2 position 3 way ...... CA ........ Primary boom extend .................................. 20 ft-lbs / 27 Nm
5 Proportional directionalsolenoid valve, 3 position 4 way ....... BY ......... Primary boom up/down .................... 16-20 ft-lbs / 22-27 Nm
6 Differential sensing valve160 psi / 11 bar ................................. BG ........ Meters flow to functions ............................... 25 ft-lbs / 34 Nm
7 Proportional directionalsolenoid valve, 3 position 4 way ....... BP ......... Turntable rotate left/right .................. 16-20 ft-lbs / 22-27 Nm
8 Proportional directionalsolenoid valve, 3 position 4 way ....... BU ........ Secondary boom up/down ............... 16-20 ft-lbs / 22-27 Nm
9 Solenoid valve, 3 position 4 way ...... BF ......... Steer left/right ............................................... 25 ft-lbs / 34 Nm
10 Relief valve, 2100 psi / 145 bar ........ BV ......... Secondary boom down ............................... 20 ft-lbs / 27 Nm
11 Orifice, 0.046 inch / 1.17 mm ............ CF ......... Secondary boom down circuit
12 Check valve, 5psi / 0.3 bar ................ BT ......... Differential sensing circuit,secondary boom down ..................... 12-14 ft-lbs / 16-19 Nm
13 Check valve, 5psi / 0.3 bar ................ BW ........ Secondary boom circuit ............................... 25 ft-lbs / 34 Nm
14 Check valve, 5psi / 0.3 bar ................ BS ......... Differential sensing circuit,secondary boom up .......................... 12-14 ft-lbs / 16-19 Nm
15 Priority flow regulator valve,1.5 gpm / 5.7 L/min ............................ BB ......... Steer circuit .................................................. 25 ft-lbs / 34 Nm
16 Relief valve, 3200 psi / 220.6 bar ..... BA ......... System relief ................................................ 20 ft-lbs / 27 Nm
17 Shuttle valve ...................................... BO ........ Turntable rotate circuit ...................... 12-14 ft-lbs / 16-19 Nm
18 Check valve, 5psi / 0.3 bar ................ BQ ........ Differential sensing circuit,turntable rotate ................................. 12-14 ft-lbs / 16-19 Nm
19 Check valve, 5psi / 0.3 bar ................ CB ........ Differential sensing circuit,primary boom retract ........................ 12-14 ft-lbs / 16-19 Nm
20 Check valve, 5psi / 0.3 bar ................ BC ........ Differential sensing circuit,platform rotate left andjib boom up .................................................. 25 ft-lbs / 34 Nm
This list continues. Please turn the page.
Manifolds
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REV A MANIFOLDS
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REV A
Function Manifold Components, continued
Index SchematicNo. Description Item Function Torque
21 Check valve, 5 psi / 0.3 bar ............... BD ........ Differential sensing circuit,platform rotate right andjib boom down ............................................. 25 ft-lbs / 34 Nm
22 Flow regulator valve,0.1 gpm / 0.38 L/min .......................... BX ......... Primary boom load sense circuit ................. 20 ft-lbs / 27 Nm
23 Counterbalance valve,3000 psi / 207 bar ............................. CD ........ Primary boom down circuit ............... 30-35 ft-lbs / 45-50 Nm
24 Pressure compensator valve,80 psi / 5.5 bar ................................... BR ........ Turntable rotate circuit ................................. 25 ft-lbs / 34 Nm
25 Shuttle valve ...................................... CE ........ Differential sensing circuit,primary boom up/down ..................... 12-14 ft-lbs / 16-19 Nm
26 Flow regulator valve,0.4 gpm / 1.5 L/min ............................ BE ......... Jib boom and platform
rotate circuit ................................................. 20 ft-lbs / 27 Nm
27 Needle valve ..................................... BN ........ Platform level flow control ........................... 20 ft-lbs / 27 Nm
28 Relief valve, 2500 psi / 172 bar ........ BH ........ Platform level circuit .................................... 20 ft-lbs / 27 Nm
29 Check valve, 5psi / 0.3 bar ................ BK ......... Differential sensing circuit,platform level up ............................... 12-14 ft-lbs / 16-19 Nm
30 Check valve, 5psi / 0.3 bar ................ BL ......... Differential sensing circuit,platform level down .......................... 12-14 ft-lbs / 16-19 Nm
31 Solenoid valve, 2 position 3 way ...... CC ........ Primary boom retract ................................... 20 ft-lbs / 27 Nm
32 Shuttle valve ...................................... BI .......... Platform level circuit ......................... 12-14 ft-lbs / 16-19 Nm
33 Check valve, dual pilot operated,135 psi / 9.3 bar ................................. BJ ......... Platform level circuit .................................... 20 ft-lbs / 27 Nm
MANIFOLDS
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REV A MANIFOLDS
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September 2005Section 4 • Repair Procedures
REV AMANIFOLDS
8-2Valve Adjustments -Function Manifold
How to Adjust the SystemRelief Valve
Perform this procedure with theboom in the stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST1 port on the function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable switch to the high rpmposition and activate and hold the primary boomretract switch with the boom fully retracted.
4 Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BA).
6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.
Tip-over hazard. Do not adjustthe relief valve higher thanspecified.
7 Repeat steps 2 through 5 and recheck reliefvalve pressure.
8 Remove the pressure gauge.
How to Adjust the SecondaryBoom Down Relief Valve
Perform this procedure with theboom in the stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST1 port on the function manifold.
2 Start the engine from the ground controls.
3 Hold the function enable switch to the high rpmposition and activate and hold the secondaryboom down switch with the secondary boomfully lowered.
4 Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item BV).
6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.
Tip-over hazard. Do not adjustthe relief valve higher thanspecified.
7 Repeat steps 2 through 5 and recheck reliefvalve pressure.
8 Remove the pressure gauge.
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REV A
8-3Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to the platform support.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ..... G ........... Platform rotate/jib boom select ........... 8-10 ft-lbs / 11-14 Nm
MANIFOLDS
1
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REV A
8-4Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storagecompartment.
Index SchematicNo. Description Item Function
1 Counterbalance valve ...................... L ............ Turntable rotate right
2 Counterbalance valve ...................... J ............ Turntable rotate left
MANIFOLDS
1 2
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REV A
8-5Directional Valve Manifold Components
The directional valve manifold is mounted inside the drive chassis at the non-steer end.
IndexNo. Description Function Torque
1 Cap ................................................................... Breather ............................................ 20-25 ft-lbs / 27-33 Nm
2 Spool valve ...................................................... Directional control
MANIFOLDS
1
2
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September 2005Section 4 • Repair Procedures
REV A
How to Set Up the DirectionalValve Linkage
Adjustment of the directional valvelinkage is only necessary when thelinkage or valve has beenreplaced.
1 Lower the boom to the stowed position.
2 Use a "bubble type" level to be sure the floor iscompletely level.
Tip-over hazard. Failure to performthis procedure on a level floorcould compromise the stability ofthe machine resulting in themachine tipping over.
3 Check the tire pressure in all four tires and addair if needed to meet specification.
4 Remove the drive chassis cover and the non-steer axle covers.
5 Place a "bubble type" level across the drivechassis non-steer end. Check to be sure thedrive chassis is completely level.
6 To level the drive chassis, start the engine andloosen the lock nuts on both sides of theurethane cushions.
7 Push up or pull down on the threaded rod untilthe machine is completely level.
MANIFOLDS
8 Verify that the ground and drive chassis arecompletely level.
9 Tighten the nuts on both sides of the urethanecushions until they are snug. Tighten thelocknuts.
10 Check to be sure the drive chassis iscompletely level.
11 Measure the distance between the drive chassisand the non-steer axle on both sides (from theinside of the drive chassis).
If the distance is not equal and theadjustment to the linkage wascompleted with the ground anddrive chassis level, repeat steps 6through 10 OR consult GenieIndustries Service Department.
Part No. 110284 Z-51/30J 4 - 43
September 2005 Section 4 • Repair Procedures
REV A
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4 - 44 Z-51/30J Part No. 110284
September 2005Section 4 • Repair Procedures
REV A
8-6Traction Manifold Components
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index SchematicNo. Description Item Function Torque
1 Flow divider/combiner valve ............. U ........... Controls flow to non-steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm
2 Bi-directional flow control valve,2 gpm / 7.6 L/min ............................... Z ........... Non-steer end drive motor circuit ..... 25-30 ft-lbs / 34-41 Nm
3 Bi-directional flow control valve,1 gpm / 3.8 L/min ............................... X ........... Steer end drive motor circuit ............ 25-30 ft-lbs / 34-41 Nm
4 Directional control valve ................... AV ......... 2 speed motor shift circuit/High speed bypass ........................... 10-12 ft-lbs / 14-16 Nm
5 Diagnostic fitting ............................................... Testing
6 Shuttle valve, 3 position 3 way ......... R ........... Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump and allowslow pressure flow path forbrake release and 2-speedmotor shift ......................................... 15-18 ft-lbs / 20-24 Nm
7 Relief valve, 250 psi / 17.2 bar ......... AD ........ Charge pressure circuit .................... 10-12 ft-lbs / 14-16 Nm
8 Solenoid valve, 2 position 3 way ...... AG ........ 2-speed motor shift ........................... 10-12 ft-lbs / 14-16 Nm
9 Orifice, 0.030 inch / 0.76 mm ............ AE ......... Brake and 2-speed motor shift circuit
10 Solenoid valve, 2 position 3 way ...... AF ......... Braking ............................................. 10-12 ft-lbs / 14-16 Nm
11 Check valve ....................................... AH ........ 2 speed motor shift circuit ................. 10-12 ft-lbs / 14-16 Nm
12 Orifice, 0.025 inch / 0.64 mm ............ AI .......... 2 speed motor shift circuit
13 Flow divider/combiner valve ............. V ........... Controls flow to flowdivider/combiner valves 1 and 17 .... 25-30 ft-lbs / 34-41 Nm
14 Check valve ....................................... AC ........ Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
15 Orifice, 0.052 in / 1.32 mm ................ Y ........... Drive circuit
16 Check valve ....................................... T ........... Steer end drive motor circuit ............ 10-12 ft-lbs / 14-16 Nm
17 Flow divider/combiner valve ............. W .......... Controls flow to steer enddrive motors in forwardand reverse ....................................... 25-30 ft-lbs / 34-41 Nm
18 Check valve ....................................... S ........... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
19 Check valve ....................................... AA ......... Non-steer end drive motor circuit ..... 10-12 ft-lbs / 14-16 Nm
MANIFOLDS
Part No. 110284 Z-51/30J 4 - 45
September 2005 Section 4 • Repair Procedures
REV A
1 32 4 5 6 7 8 9
17
18
19
10
11
12
13
14
15
16
4 - 46 Z-51/30J Part No. 110284
September 2005Section 4 • Repair Procedures
REV AMANIFOLDS
8-7Valve Adjustments,Traction Manifold
How to Adjust the ChargePressure Relief Valve1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to the test port on the drive pump.
2 Hold the charge pressure relief valve at thetraction manifold and remove the cap (item AD).
3 Turn the internal hex socket clockwise fully untilit stops. Install the cap.
4 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position. Note the reading on thepressure gauge.
5 Turn the engine off.
6 Remove the pressure gauge from the drivepump. Connect the gauge to the test portlocated on the traction manifold.
7 Hold the charge pressure relief valve andremove the cap (item AD).
8 Start the engine and move and hold the functionenable/rpm select toggle switch to the high rpm(rabbit symbol) position.
9 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading on the pump. Turn itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the valve cap.
10 Turn the engine off and remove the pressuregauge.
8-8Valve Coils
How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
1 Tag and disconnect the wiring from the coil to betested.
2 Test the coil resistance.
Result: The resistance should be withinspecification, plus or minus 30%.
Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.
Valve Coil Resistance Specification
Proportional directional solenoid valve, 10V DC 6 to 8Ω(schematic items BP, BU and BY)
3 position 4 way directional valve, 10V DC 6 to 8Ω(schematic items BF, BM and CG)
2 position 3 way solenoid valve, 10V DC 6 to 8Ω(schematic items CA, CC, G, AF and AG)
Part No. 110284 Z-51/30J 4 - 47
September 2005 Section 4 • Repair Procedures
REV A
How to Test a Coil DiodeProperly functioning coil diodes protect theelectrical circuit by suppressing voltage spikes.Voltage spikes naturally occur within a functioncircuit following the interruption of electrical currentto a coil. Faulty diodes can fail to protect theelectrical system, resulting in a tripped circuitbreaker or component damage.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
1 Test the coil for resistance. See, How to Test aCoil.
2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.
Resistor, 10Genie part number 27287
The battery should read 9V DC ormore when measured across theterminals.
a multimeterb 9V DC batteryc 10Ω resistord coil
Note: Dotted lines in illustration indicate areversed connection as specified instep 6
3 Set a multimeter to read DC current.
The multimeter, when set to readDC current, should be capable ofreading up to 800 mA.
4 Connect the negative lead to the other terminalon the coil.
5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.
6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.
Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.
Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.
9V
BATTERY
10
RESISTOR
MULTI
METER
COIL
+
-
+
-
d
b
b
a
c
c
4 - 48 Z-51/30J Part No. 110284
September 2005Section 4 • Repair Procedures
REV A
3 Remove the safety pin from the engine pivotplate latch.
The engine pivot plate latch islocated under the engine turntablepivot plate at the counterweightend of the machine.
4 Remove the center turntable cover retainingfasteners. Remove the center turntable coverfrom the machine.
5 Open the engine pivot plate latch and swing theengine pivot plate out and away from themachine.
6 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor manifold. Capthe fittings on the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
7 Attach a lifting strap from and overhead crane orother suitable lifting device to the turntablerotator assembly.
8 Remove the turntable rotation assemblymounting fasteners.
9 Carefully remove the turntable rotation assemblyfrom the machine.
Tip-over hazard. The machinecould tip over when the turntablerotation assembly is removed if theturntable rotation lock is not in thelocked position.
Crushing hazard. The turntablerotation assembly could becomeunbalanced and fall when removedfrom the machine if not properlysupported by the overhead crane.
Turntable Rotation Components
9-1Turntable Rotation Assembly
How to Remove the TurntableRotation Assembly
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Raise the secondary boom until the upper pivotis above the turntable covers. Turn the machineoff.
2 Secure the turntable from rotating with theturntable rotation lock.
Tip-over hazard. The machinecould tip over when the turntablerotation assembly is removed if theturntable rotation lock is not in thelocked position.
Unlocked position
Locked position
Part No. 110284 Z-51/30J 4 - 49
September 2005 Section 4 • Repair Procedures
REV AAxle Components
10-1Oscillating AxleLock-out Cylinders
The oscillating axle cylinders extend and retractbetween the drive chassis and the oscillating axle.The cylinders are equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure. The valves are not adjustable.
How to Remove an OscillatingAxle Cylinder
Perform this procedure on a firm,level surface with the boom inthe stowed position.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.
1 Tag, disconnect and plug the oscillating axlecylinder hydraulic hoses. Cap the fittings on theoscillate cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
2 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.
3 Attach a lifting strap from an overhead crane tothe barrel end of the oscillating cylinder.
4 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pin.
Crushing hazard. The oscillatecylinder may become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.
5 Remove the oscillate cylinder from the machine.
4 - 50 Z-51/30J Part No. 110284
September 2005Section 4 • Repair Procedures
AXLE COMPONENTS
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Part No. 110284 Z-51/30J 5 - 1
September 2005 Section 5 • Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-51/30J Operator’s Manual.
Be sure that all necessary tools and testequipment are available and ready for use.
Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.
Be aware of the following hazards and followgenerally accepted safe workshop practices.
Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
Perform all troubleshooting on afirm level surface.
Two persons will be required tosafely perform sometroubleshooting procedures.
Fault Codes
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Boom in stowed position
· Turntable rotated with the boom betweenthe non-steer wheels
· Turntable secured with the turntablerotation lock
· Key switch in the off position with thekey removed
· Wheels chocked
· All external AC power disconnectedfrom the machine
5 - 2 Z-51/30J Part No. 110284
September 2005Section 5 • Fault Codes
REV AFAULT CODES
Fault Codes - Control System
How to Retrieve Control SystemFault Codes
At least one fault code is presentwhen the alarm at the platformcontrols produces two short beepsevery 30 seconds for 10 minutes.
Perform this procedure with theengine off, the key switch turned toplatform controls and the redEmergency Stop button pulled outto the on position at both theground and platform controls.
1 Open the platform control box lid.
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
2 Locate the red and yellow fault LEDs on theALC-500 circuit board inside the platform controlbox. Do not touch the circuit board.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. If the circuit boarddoes need to be handled, maintainfirm contact with a metal part ofthe machine that is grounded at alltimes when handling the printedcircuit board OR use a groundedwrist strap.
3 Determine the error source: The red LEDindicates the error source and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.
When the red LED is flashing thecode, the yellow LED will be onsolid.
4 Determine the error type: The yellow LEDindidates the error type and will flash twoseparate codes. The first code will indicate thefirst digit of the two digit code, flashing once persecond. It will then pause for 1.5 seconds andflash the second digit once per 0.5 second.
When the yellow LED is flashingthe code, the red LED will be onsolid.
5 Use the fault code table on the following pagesto aid in troubleshooting the machine bypinpointing the area or component affected.
Part No. 110284 Z-51/30J 5 - 3
September 2005 Section 5 • Fault Codes
REV A
Error Source Error TypeID Name ID Name
Condition Solution11121516
Value at 5VValue too highValue too lowValue at 0V
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedJoystick speed anddirection frozen atzero and neutral.
Calibrate joystick.
21 Boom 1 Joystick(primary boom up/down)
18 Just calibratedInitiate 1-second beepof alarm.
Self-clearing.(transient)
22 Boom 1 directionalvalves
21 Fault
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
1215
Value too highValue too low
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedCalibrate valvethresholds.
23 Boom 1 flowcontrol valve
18 Just calibrated
Normal functionexcept threshold forone or both directionsis zero.
Self-clearing.(transient)
11121516
Value at 5VValue too highValue too lowValue at 0V
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedJoystick speed anddirection frozen atzero and neutral.
Calibrate joystick.
31 Boom 2 Joystick(secondary boomup/down orprimary boomextend/retract)
18 Just calibratedInitiate 1 second beepof alarm.
Self-clearing.(transient)
32 Boom 2 directionalvalves
21 Fault
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
Continued on next page
FAULT CODES
5 - 4 Z-51/30J Part No. 110284
September 2005Section 5 • Fault Codes
REV A
Error Source Error TypeID Name ID Name
Condition Solution
1215
Value too highValue too low
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedCalibrate valvethresholds.
33 Boom 2 flowcontrol valve
18 Just calibrated
Normal functionexcept threshold forone or both directionsis zero.
Self-clearing.(transient)
11121516
Value at 5VValue too highValue too lowValue at 0V
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedJoystick speed anddirection frozen atzero and neutral.
Calibrate joystick.
41 Turntable rotatejoystick
18 Just calibratedInitiate 1-second beepof alarm.
Self-clearing.(transient)
42 Turntable rotatedirectional valves
21 Fault
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
1215
Value too highValue too low
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedCalibrate valvethresholds.
43 Turntable rotateflow control valve
18 Just calibrated
Normal functionexcept threshold forone or both directionsis zero.
Self-clearing.(transient)
44 Drive enableoverride switches 21 Fault
Enable overridedirection is frozen atneutral.
Power upcontroller withproblem corrected.
FAULT CODES
Part No. 110284 Z-51/30J 5 - 5
September 2005 Section 5 • Fault Codes
REV A
Error Source Error TypeID Name ID Name
Condition Solution11121516
Value at 5VValue too highValue too lowValue at 0V
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedJoystick speed anddirection frozen atzero and neutral.
Calibrate joystick
51 Drive joystick
18 Just calibratedInitiate 1-second beepof alarm.
Self-clearing.(transient)
1215
Value too highValue too low
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedCalibrate valvethresholds
53 Drive flow valve(EDC)
18 Just calibrated
Normal functionexcept threshold forone or both directionsis zero.
Self-clearing.(transient)
54 Drive brake valve
21 Fault
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
55 High speed drivemotor Valve 21 Fault
Motor speed frozen inthe low state. Alarmsounds indicatingfault.
Power upcontroller withproblem corrected.
11121516
Value at 5VValue too highValue too lowValue at 0V
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
17 Not calibratedJoystick speed anddirection frozen atzero and neutral.
Calibrate Joystick
61 Steer joystick
18 Just calibratedInitiate 1-second beepof alarm.
Self-clearing.(transient)
62 Steer directionalvalves
21 Fault
Limited speed anddirection frozen atzero and neutral.Alarm soundsindicating fault.
Power upcontroller withproblem corrected.
FAULT CODES
5 - 6 Z-51/30J Part No. 110284
September 2005Section 5 • Fault Codes
This page intentionally left blank.
Schematics
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions printed in theGenie Z-51/30J Operator's Manual on yourmachine.
Be sure that all necessary tools and testequipment are available and ready for use.
About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.
Electrical Schematics
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Hydraulic Schematics
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
General Repair Process
Malfunctiondiscovered
Identifysymptoms
Troubleshoot
Performrepair
Return toservice problem
solved
problemstill exists
Inspectand test
Part No. 110284 Z-51/30J 6 - 1
Section 6 • SchematicsSeptember 2005
September 2005Section 6 • Schematics
6 - 2 Z-51/30J Part No. 110284
Electrical Symbols Legend
Connectionno terminal
P3
Horn buttonnormally open
T-circuitsconnect
FB
Flashing beacon
Diode
Circuits crossingno connection
Quick disconnectterminal
BLK
WHT
T-circuits connectat terminal
WHT #21 TB21
Battery
+
-
Circuit breakerwith amperage
15A
CB1
Horn or alarm
H1 Emergency Stopbutton normally
closed
P1
Coilsolenoid or relay
Key switch(before serial number 22051)
KS1
GROUND
PLATFORM
Power relay
PR1
Toggle switch SPDT
TS2
START
ENG
INE
Toggle switch DPDT
TS6
UP
DO
WN
PLATFOR
MLEVEL
Gauge sending unit
HM
Hour meter
N.O.OTS2
Oil temperatureswitch
normally open
N.O.CTS1
Coolant temperatureswitch
normally open
Oil pressure switchnormally closed
N.C.OPS1
BLK
FS1
Foot switch
PumpAux
Auxiliary pump
FAN
Hydraulic oilcooling fan
G1
Gauge
Tilt sensorLED
L3
Limit switch
N.C.H.ON.O.H.C
LS3
Fusewith amperage
25A
F1
510
Resistor withohm value
Starting aid:glow plug orflame ignitor
Control relay contactnormally open
CR4N.O.
Coil
Fuel or RPMsolenoid
PU
LL
IN
HO
LD
CA B
Key switch(after serial number 22050)
KS1
REV A
September 2005 Section 6 • Schematics
Hydraulic Symbols Legend
Part No. 110284 Z-51/30J 6 - 3
Pumpfixed displacement
Motorbi-directional
Check valve
2 position, 3 way, shuttle valve
Double actingcylinder
Priorityflow regulator valve
Differentialsensing valve
Solenoid operatedproportional valve
Brake
Pilot operated 3 position,3 way, shuttle valve
Filter withbypass valverelief setting
25 psi(1.7 bar)
Motor2-speed,
bi-directional
Pumpbi-directional,
variable displacement
E
Pump prime mover(engine or motor)
Directional valve(mechanically activated)
o
Relief valvewith pressure setting
200 psi(13.8 bar)
Orifice with size
.035"(0.89 mm)
Solenoid operated 3 position,4 way, directional valve
Directional valvepilot operated
2 position, 2 way
Flow divider/combiner valvewith pressure balancing orifice
and flow percentages
50% 50%
Counterbalance valvewith pressure and pilot ratio
(206.8 bar)3000 psi
3:1
Solenoid operated 2 position,3 way, directional valve
2 position, 2 waysolenoid valve
Solenoid operated3 position, 4 way,
proportional directional valve
REV A
Electrical Schematic
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
March 2006Section 6 • Schematics
6 - 5 Z-51/30J Part No. 110284
REV B
C1
33
PL
AB
L/R
DP
13
4T
TS
WH
HO
RN
RE
LA
Y
LE
VE
LS
EN
SO
R
HO
RN
15A
+
-
RD
P2
0B
AT
RD
TB20
C1
07
AF
WH
C4
1R
PM
OR
/BK
CR5
C4
6H
RN
BK
/RD
NO
CB1
RD
RD
CB2
15A
TB41
C4
6H
RN
BK
/RD
TB23
KS1
PLAT
GND
P1
RD
P3
HORN
TB134
P2
2B
AT
BK
BK-(FS)C9P-1 BK
P2
GE
NE
RA
TO
RO
PT
ION
FL
AS
HIN
GB
EA
CO
NS
OP
TIO
N
HO
UR
ME
TE
R
PO
WE
RR
EL
AY
IGN
ITIO
N/S
TA
RT
RE
LA
Y
STA
RT
ER
MO
TO
R
AU
XIL
IAR
YP
UM
P
AU
XIL
IAR
YP
OW
ER
RE
LA
Y
TS2
GROUND
AUX. ON
KEY PWR.
BATTERY
TACHOMETER
IGN./FUEL ON
ENG. FAULT
KEY BYPASS
START INPUT
START RELAY
4
PUMP
PR1
C2
7A
UX
RD
PR1
NO
C2
8T
TA
RD
/BK
CR1CR1NO
R3
3S
TR
BK
TB21
TB25
CR2NO
8
7
6
5
10
9
CR2
TS51
C2
8T
TA
RD
/BK
TB27
RD
TS1
RD
TS52
BK
1
2
TB33
3IGNITION/STARTMODULE
C2
1IG
NW
H
FB1
C3
3S
TR
BK
C4
5G
EN
GR
/WH
TS47
P24FS WH
C9P-3RD-(FS)
FS1
BR
N
TS54
TS4
BRN
RD
BK
P24FS WH
P26ESTP BK
OIL
TE
MP
ER
AT
UR
EL
ED
C9P-2
REGULATOR
IND.
ALTERNATOR
BAT.+
STA.
BAT.-
EXCT.
FU
EL
SO
LE
NO
ID
TB24
TB26
C2
6T
SR
WH
/RD
C2
5P
SR
WH
/BK
L42
L43
OIL
PRES.
OIL
TEMP.
SW2NC
SW3NO
OIL
PR
ES
SU
RE
SW
ITC
H
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
OIL
PR
ES
SU
RE
LE
D
TB34
TS56
C3
4S
AB
K/W
H
TS6
PR3
NO
CR4
CR4
NO
HIG
HR
PM
SO
LE
NO
ID
HIG
HID
LE
RE
LA
Y
TIL
TA
LA
RM
P2
2B
AT
BK
W
GL
OW
PL
UG
WH-(FS)
H1
RD
WH
BR
NB
K
BK
C3
P-9
H2+
_
C41RPM OR/BK
RD
P25FS RD
P26ESTP BK
C1
P-2
C1
P-1
C2
7A
UX
RD
C7
P-1
C1
P-7
C1
P-8
C2
P-7
C1
P-9
C3
5R
PM
BK
/RD
C4
1R
PM
OR
/BK
C28TTA RD/BKC28TTA RD/BK
C28TTA RD/BK
C41RPM OR/BK
EN
GIN
ES
PE
ED
C1
B-9
C5
-18
C1
B-8
C5
-12
C1
B-7
C4
5G
EN
GR
/WH
C5
-22
C5
-14
C5
-16
C5
-11C6
-9
C3
4S
AB
K/W
H
C5
-5
C21IGN WH
C2
1IG
N2
WH
C3
B-9
C5
-2
C5-3
C7
B-4
C5
-17
C2
B-7
B112V DC
D1
C33MF
+
M2
M3
PR2PR2
NO
Q3
S8
U1
U32
C3
5R
PM
BK
/RD
BK
/RD
C6
-34
P1
34
FB
RD
C2
B-3
L30 L30
L29L29
FUSE 10A (ONLY FOR WORKLIGHTS)
C3
P-4
C3
B-4
DL
ITE
WH
C2
P-1
1
C2
P-1
2C
2P
-10
C2
P-9
PBOX GND
RD
RD
NO
CR23CR23
DR
IVE
LIG
HT
OP
TIO
N
WO
RK
LIG
HT
OP
TIO
N
C6
-38
C6
-39
TS48
RD
RD
C7
B-1
FUSE 10A
P20BAT RD
A B
C
HIG
HR
PM
SU
PR
ES
SIO
ND
IOD
E
4
6
12 8
7
5
C1
B-1
D3
D4
C7
P-2
P2
3B
AT
WH
C7
B-2
D2
D40
1 3
C2
P-5
C1
32
PL
IB
L/W
H
C1
34
PW
RG
NC
2B
-5
C1
B-1
2
TB22
C4
B-1
C1
B-2
P134 RD
5
BR
N
U33
PR3
C5
-23 C
6-2
7
TB35
GR/BK
ALT
ER
NA
TO
R
AU
XIL
IAR
YP
OW
ER
AU
XIL
IAR
YP
OW
ER
EN
GIN
ES
TA
RT
EN
GIN
ES
TA
RT
GL
OW
PL
UG
GL
OW
PL
UG
LO
WR
PM
HIG
HR
PM
LO
WR
PM
FU
NC
TIO
NE
NA
BL
E
GE
NE
RA
TO
R
WO
RK
LIG
HT
S
DR
IVE
LIG
HT
S
C1B & C1P = GRAYC2B & C2P = BLACKC3B & C3P = GREENC4B & C4P = BROWN
NOTE:
1. All switches and contacts are shown with the boomin the stowed position and the keyswitch off.
5 Add D40 only if unit has L4 and L48.
4 CE and platform overload option
H6 L45
L4
D39
4
LS18
C1
P-1
2
LO
AD
SE
NS
EM
OD
UL
E
FUSE70A
Electrical Schematic
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 110284 Z-51/30J 6 - 6
March 2006 Section 6 • Schematics
REV B
NOTES:1. ALL LIMIT SWITCHES SHOWNWITH BOOM IN STOWED POSITIONEXCEPT AS NOTED.
SWITCH SHOWN WITH BOOMROTATED PAST EITHER NON-STEERWHEEL.
2
C1B & C1P - GRAYC2B & C2P - BLACKC3B & C3P - GREENC4B & C4P - BROWN
WH
P26ESTP BK
C41RPM OR/BK
C28TTA RD/BK
BRN
RD
RD
BK
P24FS WH
WH
-4
BO
OM
RE
TR
AC
T
CR33
PL
AT
FO
RM
RO
TA
TE
RIG
HT
/JIB
BO
OM
DO
WN
PL
AT
FO
RM
RO
TA
TE
LE
FT
/JIB
BO
OM
UP
C6
-19
DE
SC
EN
TA
LA
RM
OP
TIO
N
JIB
BO
OM
VA
LV
E
H3
C2
2-2C
5-2
5
C2
3-2
PL
AT
FO
RM
LE
VE
LD
OW
N
PL
AT
FO
RM
LE
VE
LU
P
BO
OM
EX
TE
ND
C2
1-2
C2
0-2
C1
6-2
C1
7-2
C1
29
DA
BK
C1
8JD
GR
/BK
C2
2-1
C2
3-1
C1
7JU
GR
C6
-18
C6
-17
C1
5P
LD
OR
/BK
C1
4P
LU
OR
C2
1-1
C2
0-1
C8
PB
RB
K/W
H
C1
6-1
C1
7-1
C7
PB
EB
K
C6
-15
C6
-14
C6
-8
C6
-7
C6
-20
BK
-5 C6
-13
LS
4-
SE
CO
ND
AR
YB
OO
MU
PD
RIV
EL
IMIT
SW
ITC
H
LS
1-
PR
IMA
RY
BO
OM
EX
TE
ND
DR
IVE
LIM
ITS
WIT
CH
LS
2-
PR
IMA
RY
BO
OM
UP
DR
IVE
LIM
ITS
WIT
CH
LS
3-
DR
IVE
EN
AB
LE
LIM
ITS
WIT
CH
SE
CO
ND
AR
YB
OO
MU
P
SE
CO
ND
AR
YB
OO
MS
EL
EC
TR
EL
AY
SE
CO
ND
AR
YB
OO
MD
OW
N
C1
8-2
C1
9-2
PR
IMA
RY
BO
OM
UP
PR
IMA
RY
BO
OM
SE
LE
CT
RE
LA
Y
PR
IMA
RY
BO
OM
DO
WN
TU
RN
TA
BL
ER
OTA
TE
SE
LE
CT
RE
LA
Y
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
LE
FT
C1
3-2
C1
4-2
C1
2-2
C1
5-2
BK LS3
C6
-10
C6
-11
C1
0-1
WH
-6
RD
C11
-3B
K-7
C1
0-2
14
R11
SB
DB
L/B
K
R1
0S
BU
BL
C1
8-1
C1
9-1
LS2
22
21
C1
0-4
WH
-5
BK
-6
13
2
8587a 87
8630
CR37
R4
TR
LW
H
R5
TR
RW
H/B
K
R2
PB
DR
D/B
K
C1
3-1
C1
4-1
C1
2-1
C1
5-1
R1
PB
UR
D
8587a 87
8630
C6
-2
C6
-5
C6
-4
C6
-1
CR32
8587a 87
8630
BR
AK
ER
EL
EA
SE
VA
LV
E
TR
AV
EL
AL
AR
MO
PT
ION
MO
TO
RS
TR
OK
E
ST
EE
RL
EF
T
ST
EE
RR
IGH
T
C2
4-2
C2
5-2
C2
8-2
C2
6-2
DR
IVE
ED
CR
EV
ER
SE
DR
IVE
ED
CF
OR
WA
RD
GR
OU
ND
BR
N
BR
N
BK
RD
C3
7S
CW
BL
/BK
C3
6S
CC
BL
C2
4-1
C2
5-1
C2
9M
SR
D/W
H
C3
2B
RK
WH
/RD
C3
2TA
WH
/RD
C2
8-1
C2
6-1
H4
C6
-37
C6
-36
C6
-29
C6
-32
C6
-33
C3
1R
EV
WH
/BK
C3
0F
WD
WH
RD
BK
U4
C5
-20
C5
-21
TB5
C5
TR
RW
H/B
K
JIB
BO
OM
VA
LV
E GR
/BK
-44
J3 J1 J1
C1
29
DA
GR
/BK
C1
9JS
VG
R/W
H
C1
5P
LD
OR
/BK
C1
4P
LU
OR
C8
PB
RB
K/W
H
C7
PB
EB
K
P2
2L
SB
K
TB18
TB17
C4
B-5
C4
B-7
TB14
C4
B-6
TB15
C4
B-2
C4
B-3
TB7
TB8
C3
B-8
C3
B-7
C2
B-6
TB44
C1
7JU
GR
TS57
TS58
C4
P-7
C19JSV GR/WH
C4
P-5
C1
8JD
GR
/BK
C4
P-2
C4
P-3
TS59 TS63
C4
P-6
C2
P-6
C3
P-8
C3
P-7
C1
6P
DR
EO
R/R
D
C1
2S
BF
BL
/WH
C11
SB
DB
L/B
K
C3
PB
FR
D/W
H
C1
0S
BU
BL
C2
PB
DR
D/B
K
C1
PB
UR
D
LS1
C1
0-3
WH
-6
21
WH
-7
22
LS4
C11
-2
C6
-16
22BK
-4
C4
B-4
TB10
TB12
TB11
C3
B-1
0
C3
B-1
1
C11
-4
21
OR BK
-6
C6
-40 C11
-1
TB3
C3
B-1
2
C3
B-3
C3
B-2
C3
B-1
TB2
TB6
TB1
C3
B-5
14
BK
C2
B-2
C40LSS OR
TS60
U13 JOYSTICK CONTROL CARD
C2
P-2
C4
P-4
CELIFT/DRIVEOPTION
4 3
C3
P-1
0
C3
P-1
1
12
13
TS61 TS62
6R14
J2
C3
P-1
2
C3
P-2
C3
P-3
C3
P-1
8 7 6
C3
P-5
10
WH
CR13
TS7TS8
BRN
TS9
CR13
NC
TS13
6
P2
4F
SW
H
P2
6E
ST
PB
K
CR30NO
3 4
CR27NC
P2
4F
SW
H
BR
N
BR
N OR
YE
L
12
10 9 3
1 2 3 4 5
PW
R
GN
D
OU
T
JC1
SECONDARY BOOM UP/DOWN
P26ESTP BK
BR
N1
2
7 21
GN
D
RD
OR
BK
2
11 1
543 6 7
PW
R
XO
UT
YO
UT
PRIMARY BOOM UP/DOWN &TURNTABLE ROTATE
JC2
J1
C4
1R
PM
OR
/BK
J1
C3
7S
CW
BL
/BK
C2
9M
SR
D/W
H
C6
TR
FW
H/R
D
C3
6S
CC
BL
C3
1R
EV
WH
/BK
C3
2B
RK
WH
/RD
C3
0F
WD
WH
BA
TG
ND
C3
B-6
C1
B-1
0
C1
B-1
1
TB32
C1
B-3
C1
B-6
C1
B-5
C1
B-4
C7
B-3
C3
P-6
C1
P-1
0
C1
P-1
1
18
119 17
C1
P-3
C1
P-6
20
19
C1
P-5
C2
P-3
C1
P-4
C7
P-3
15
16 5
C28TTA RD/BK
RK
OU
T
L1
7
WH
BR
N
OR
BL
BL
14
5
13 4
GN
D21 3 4 5 6
PW
R
YO
UT
DR
IVE
MO
DE
CD
E3
BL
/RD
CD
E2
BL
/BK
6 7
16 8
CD
E1
BL
P24FS WH
P26ESTP BK
DRIVE & STEERING
JC3
TS15
15
TS14
WH
BK
RD
/WH
DO
WN
UP
JIB
BO
OM
RIG
HT
LE
FT
DR
IVE
EN
AB
LE
LE
FT
RIG
HT
BO
OM
EX
TE
ND
RE
TR
AC
T
PL
AT
FO
RM
LE
VE
LU
P
DO
WN
PL
AT
FO
RM
RO
TA
TE
RIG
HT
LE
FT
PL
AT
FO
RM
RO
TA
TE
DO
WN
UP
JIB
BO
OM
PL
AT
FO
RM
LE
VE
LU
P
DO
WN
BO
OM
EX
TE
ND
RE
TR
AC
T SE
CO
ND
AR
YB
OO
MU
P
DO
WN
PR
IMA
RY
BO
OM
UP
DO
WN
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
LE
FT
D314
20R4
7.5
Ground Control Box Terminal Strip Wiring Diagram
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
September 2005Section 6 • Schematics
6 - 7 Z-51/30J Part No. 110284
REV A
NOTE: DASHED LINES INDICATE OPTION WIRES30
85
87
86
87A
30 = COMMON (12V DC IN)87A = NC87 = NO85 = COIL NEGATIVE86 = COIL POSITIVE
DC
PR
IMA
RY
BO
OM
UP
1 2 3 4 5 6 7 8 10
PR
IMA
RY
BO
OM
DO
WN
PR
IMA
RY
BO
OM
FU
NC
TIO
NC
ON
TR
OL
TU
RN
TA
BL
ER
OTA
TE
RIG
HT
TU
RN
TA
BL
ER
OTA
TE
FU
NC
TIO
NC
TR
L
PR
IMA
RY
BO
OM
EX
TE
ND
PR
IMA
RY
BO
OM
RE
TR
AC
T
SE
CO
ND
AR
YB
OO
MU
P
+1
2V
OLT
PO
WE
R
PL
AT
FO
RM
RO
TA
TE
RIG
HT
/JIB
DO
WN
PL
AT
FO
RM
RO
TA
TE
LE
FT
/JIB
UP
PL
AT
FO
RM
LE
VE
LD
OW
N
PL
AT
FO
RM
LE
VE
LU
P
SE
CO
ND
AR
YB
OO
MF
UN
CT
ION
CT
RL
SE
CO
ND
AR
YB
OO
MD
OW
N
2011 15
17
18
14
12
AU
XIL
IAR
YP
UM
P
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
OIL
PR
ES
SU
RE
SW
ITC
H
KE
YS
WIT
CH
PO
WE
R
IGN
ITIO
NP
OW
ER
21
25
27
26
23
24
HIG
HR
PM
STA
RT
EN
GIN
E
BR
AK
E
39
35
38
33
34
32
ALT
ER
NA
TO
RP
UL
SE
PIC
KU
P4
1
44
42
BA
CR
32
#8
6R
D
C3
B-1
RD
C3
B-2
RD
/BK
C3
B-3
RD
/WH
CR
33
#8
6W
H/B
K
C3
B-5
WH
/BK
C3
B-6
WH
/RD
C6
-7B
K
C3
B-7
BK
C6
-8B
K/W
H
C3
B-8
BK
/WH
CR
37
#8
6B
L
C3
B-1
0B
L
C3
B-1
1B
L/B
K
CR
37
#3
0B
L/W
H
C3
B-1
2B
L/W
H
C6
-14
OR
C6
-15
OR
/BK
C6
-17
GR
C4
B-5
GR
C6
-18
GR
/BK
C4
B-6
GR
/BK
C1
B-1
RD
C7
B-4
RD
C5
-3W
H
C3
2-4
BK
C7
B-2
WH
C1
B-6
WH
/RD
C6
-32
WH
/RD
C1
B-7
BK
C5
-22
BK
/WH
C2
B-3
OR
/BK
C5
-2O
R/B
K
C2
B-6
GR
/BK
RD
-TS
61
RD
/BK
-TS
61
WH
/BK
-TS
62
BK
-TS
63
BK
/WH
-TS
63
BL
-TS
60
BL
/BK
-TS
60
BL
/WH
-TS
60
OR
-TS
59
OR
/BK
-TS
59
GR
-TS
57
GR
/BK
-TS
57
RD
-CB
1
BK
/RD
-TS
54
RD
/WH
-TS
61
WH
/RD
-TS
62
CR
33
#3
0W
H/R
D
C1B
C4B
C5
BATGND BRN
ENGINE HARNESS
FUNCTION HARNESS
WH
-23
B
RD
-27
B
GROUND CONTROL HARNESS
E.H.
F.H.
OR
/BK
-IS
2
TE
RM
INA
LB
AS
E(T
B)
1 2 3 4 5 6 7 8 10
11 15
17
18
14
12
20
24
26
27
25
23
21
38
39
34
35
32
33
44
42
41
GROUNDCONTROLHARNESS(TO SWITCHPANEL)
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
STA
RT
RE
LA
Y
TA
CH
OM
ET
ER
STA
RT
INP
UT
AU
XP
WR
UN
IT
GR
OU
ND
BA
TT
ER
Y
TO
KE
YS
W(D
IES
EL
ON
LY)
JU
MP
TO
7(G
AS
ON
LY)
IGN
OR
FU
EL
ON
TE
MP
OR
PR
ES
SF
AU
LT
13
47
10
92
12
/24
Vo
ltIG
NIT
ON
/STA
RT
MO
DU
LE
P/N
56
05
7
Ge
nie
Ind
ustr
ies
TO
RE
MO
VE
:
Pu
sh
ge
ntly
an
dlif
t
(SP
AR
E)
BK
-R1
OR
/BK
-41
A
BK
-33
B
RD
-27
B
BR
N-I
S5
WH
-23
B
WH
-R2
RD
-CR
1
CR
32
#3
0R
D/W
H
C4
B-2
OR
C4
B-3
OR
/BK
C6
-27
RD
WH
-IS
7
WH
-KS
RD
-TS
51
BK
-33
TS
52
OR
/BK
-41
A
WH
-IS
7
RD
-IS
4
OR
/BK
-IS
2
BK
-IS
1
WH
-IS
9
C5
-5B
K
C7B3 BRN
I.S.M. I.S.M. I.S.M. I.S.M.
C6
C4B
C5
C7B
WH
/RD
-AL
AR
MC
6-3
3
BK-ALARMBK-ALARMBK
C6
-33
WH
/RD
-AL
AR
M
C5
-19
BK
-AL
AR
M
WH
/RD
-32
A
BK
-AL
AR
M
BK
BK
WH/RD-ALARM
JIB
DO
WN
DE
SC
EN
TA
LA
RM
BR
NB
RN
GROUND BOLT
RD
-IS
6
RD
-IS
4
FUNCTIONS ENGINE19/18 CABLES
C5C6 C2B C1BC3BC4B
12V DC TO PLAT
C7B
CB
1P
OW
ER
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
WH
/RD
-L4
3(-
)
C3BC3B C3B C3B C3B
C2B
C2
B-1
BL
/RD
(SP
AR
E)
(SP
AR
E)
(SP
AR
E)
BL
/RD
-TS
53
BL
/WH
-L2
(-)
OIL
PR
ES
SU
RE
SW
ITC
H
BK
/RD
-CR
4
CR2POWERRELAY
CR1IGNITIONSTARTRELAY
BR
N
WH-21C
RD
-24
B
BRN
C3B
+1
2V
OLT
TO
PL
AT
FO
RM
22
22
C7B-3
C5-18 BK/RD
WH
BK/RD-35C
C16DRE OR/RDC6-16 C4B-4
C1
9JS
VG
R/W
HT
S5
7C
4B
-7G
R/W
H
C3B-4
C4B C4BC4B
C36STCC BLC6-36 C1B-10
C37STC BL/BKC6-37 C1B-11
C30FWD WHC1B-4 C5-21
C31REV WH/BKC1B-5 C5-20
C28TTA RD/BK C5-24C1B-2C29MS RD/WHC6-29 C1B-3
C40LS1 ORC6-40 C2B-2
GL
OW
PL
UG
GL
OW
PL
UG
C5
-22
BK
/WH
C1
B-8
BK
/WH
WH
-25
D&
26
D
C1
B-9
BK
/RD
C6
-20
BK
BK
/WH
-TS
56
WH
/BK
-L4
2(-
)
C5-11 WH
BK
-KS
I
CR4HIGH RPMSOLENOIDRELAY
BRN
R4
3D
LIT
E1
RD
R4
3D
LIT
E2
RD
P20DLITE RD
C4
3D
LIT
EG
R
WH
-IS
10
C2
B-4
OR
/RD
C5
-14
WH
/RD
C5
-14
WH
/RD
C45 GEN GR/WH C5-12C2B-7
RD
-CR
2
RD
-CB
1
RD
-CB
2C
R2
3R
D
RD
-20
CD
RIV
EL
IGH
TS
WH
-HM
WH
-CR
2
WH
-IS
7
C5
-16
WH
/RD
C5
-16
WH
/RD
GR
/BK
-TS
58
BK
-AL
AR
M
RELAY HARNESS
I.S.M.
BRN
WH
-23
BW
H-I
S7
WH
-23
B
BK
-33
BB
K-I
S3
BK
-IS
3
CR23DRIVE LIGHTOPTION RELAY
F1910A FUSE
C6-13 BK
BK-22B
RD
CR32PRIMARYBOOMRELAY
CR33TURNTABLEROTATERELAY
CR37SECONDARYBOOMRELAY
BRN
BRN
BR
N
RD
/WH
-3B
RD
-1B
C6
-2R
D/B
K
C6
-1R
D
C6
-5W
H/B
K
C6
-10
BL
C6
-4W
H
C6
-11
BL
/BK
WH
/RD
-6B
WH
/BK
-5B
BL
/WH
-12
BBL-10BBR
N
13
4K
SP
OW
ER
13
4A
KS
PO
WE
R
RD
KS
1C
5-1
7W
H
C3
B-4
WH
C6
-34
RD
BRN GND
GR/BK H6
RD TS52
RD TS51
BK C7B-1
BK 22B
RD H6
U33
C3
2
13
45
67
81
2
RD
H6
H6
RD
C3
2-1
RD
13
4B
GR
/BK
C3
2-8
GR
/BK
L4
5
GR
/BK
C4
B-1
C6
-38
C6
-39
CR5HORNRELAY
C3
B-9
BK
/RD
13
4A
13
4
C6
-9B
K/R
D
C3
+
BR
NB
RN
C3
+
RD
H6
RD
C3
2-1
RD
13
4B
GR
/BK
C3
2-8
GR
/BK
L4
5
GR
/BK
C4
B-1
BRN GND
GR/BK H6
RD TS52
RD TS51
BK 22B
BK/WH C1B-12
RD H6
C3
2
13
45
67
81
2
U33W
H-2
5D
&2
6D
WH
-IS
10
WH
/RD
-L4
3-
WH
/BK
-L4
2-
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
STA
RT
RE
LA
Y
TA
CH
OM
ET
ER
STA
RT
INP
UT
AU
XP
WR
UN
IT
GR
OU
ND
BA
TT
ER
Y
TO
KE
YS
W(D
IES
EL
ON
LY)
JU
MP
TO
7(G
AS
ON
LY)
IGN
OR
FU
EL
ON
TE
MP
OR
PR
ES
SF
AU
LT
13
47
10
92
12
/24
Vo
ltIG
NIT
ON
/STA
RT
MO
DU
LE
P/N
56
05
7
Ge
nie
Ind
ustr
ies
TO
RE
MO
VE
:
Pu
sh
ge
ntly
an
dlif
t
BK
-R1
OR
/BK
-41
A
BK
-33
B
RD
-27
B
BR
N-I
S5
WH
-R2
RD
-CR
1
I.S.M. I.S.M. I.S.M. I.S.M.I.S.M.
BK
-IS
1
RD
-IS
6
RD
-27
B
OR
/BK
-41
A
RD
-IS
4
OR
/BK
-IS
2
BK
-33
BB
K-I
S3
BK
-IS
3
RD
-IS
4
BRN
BRN-GND
C6 C6
(SP
AR
E)
(SP
AR
E)
BK
-CR
5
Ground Control Box Switch Panel Wiring Diagram
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 110284 Z-51/30J 6 - 8
September 2005 Section 6 • Schematics
REV A
P1 RED EMERGENCY STOP BUTTON
KS1 KEY SWITCH
TS51 AUXILIARY POWER TOGGLE SWITCH
TS52 ENGINE START TOGGLE SWITCH
TS54 FUNCTION ENABLE TOGGLE SWITCH
TS56 GLOW PLUG TOGGLE SWITCH (OPTION)
TS57 PLATFORM ROTATE TOGGLE SWITCH
TS58 JIB BOOM UP/DOWN TOGGLE SWITCH
TS59 PLATFORM LEVEL TOGGLE SWITCH
TS63 PRIMARY BOOM EXTEND/RETRACT TOGGLE SWITCH
TS61 PRIMARY BOOM UP/DOWN TOGGLE SWITCH
TS62 TURNTABLE ROTATE TOGGLE SWITCH
LABEL DESCRIPTION
TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH
CB1 CIRCUIT BREAKER, ENGINE, 15A
CB2 CIRCUIT BREAKER, CONTROLS, 15A
HM HOUR METER
R4 SPEED LIMITING VARIABLE RESISTOR 20 OHMS
L42 OIL PRESSURE LED
CR1 IGNITION / START RELAY
CR2 IG ITION POWER RELAYN
CR4 HIGH IDLE RELAY
CR5 HORN RELAY
L43 OIL TEMPERATURE LED
HIGH IDLE RELAY
L45 PLATFORM OVERLOAD
HO
UR
ME
TE
R
BA
SE
BO
XH
AR
NE
SS
(TO
TE
RM
INA
LS
TR
IP)
BK
/RD
-35
A
RD
-20
B
RD
RD
C2
3-7
RD
RD
-20
A
BK
-33
A
RD R
DR
D
RD
RD
RD
RD
RD
RD
RD
RDRD
RDRDRD
RDRDRD
RD
RDRD
BRN
WH
-21
BR
N
RD
RD
RD
RD
GR
/BK
-18
GR
/BK
-18
A
RD
RD
GR
GR
GRGR
GR/BK
GR
-17
GR
-17
A
C1
9JS
VG
R/W
HC
4B
-7G
R/W
H
RD
GR/BK
RD
GR/BK
RD
GR
/BK
OR
-14
A
RD
OR
/BK
-15
A
RDRD
BL
/WH
-12
A
BL
/BK
-11
A
RD
BL
-10
A
RD
RD
RDRD
RD
WH
/RD
-6
WH
-4
WH
/BK
-5
WH
/RD
-6A
WH
-4A
WH
/BK
-5A
RDRD
RDRD
RDRD
RDRD RD
RD
RD
RD
RD
BK
/WH
-8A
BK
-7A
RD
-1A
RD
RD
/WH
-3A
RD
/BK
-2A
RD
BK/WH-8
BK-7
RD
RD
WH-23WH-23
WH
/RD
-26
A
WH
/BK
-25
A
WH-23
RD
13
4A
RD
-27
RD
-27
A
WH
TS
59
PL
AT
FO
RM
LE
VE
L
TS
57
PL
AT
FO
RM
RO
TA
TE
CB
2C
IRC
UIT
BR
EA
KE
RC
ON
TR
OL
S1
5A
CB
1C
IRC
UIT
BR
EA
KE
RE
NG
INE
15
A
TS
54
FU
NC
TIO
NE
NA
BL
E
TS
52
STA
RT
EN
GIN
E
TS
60
SE
CO
ND
AR
YB
OO
MU
P/D
OW
N
TS
58
JIB
BO
OM
UP
/DO
WN
TS
62
TU
RN
TA
BL
ER
OTA
TE
TS
63
PR
IMA
RY
BO
OM
EX
TE
ND
/R
ET
RA
CT
TS
61
PR
IMA
RY
BO
OM
UP
/DO
WN
L4
3O
ILT
EM
PL
ED
R4
FU
NC
TIO
NS
PE
ED
CO
NT
RO
LV
AR
IAB
LE
RE
SIS
TE
R,
20
TS
51
AU
XIL
IAR
YP
OW
ER
P1
EM
ER
GE
NC
YS
TO
PS
WIT
CH
L4
2O
ILP
RE
SS
UR
EL
ED
GR
/BK
-44
A
RD
RD
RD
1
2
NC
1
2
NC
-+
RD
-24
A
TS
56
GL
OW
PL
UG
(OP
TIO
N)
-+
BK
/WH
-34
A
RD
WH-CR4
BK-22A
WH
-23
A
GR
/BK
H6
RD
C3
2-6
RD
L4
5P
LA
TF
OR
MO
VE
RL
OA
DL
ED
(CE
mo
de
ls)
-+
KS
1
G-BOX
P-BOX
RD
14
6
DA
LE
RH
-25
25
W7
.5o
hm
1%
R1
4S
EC
ON
DA
RY
BO
OM
UP
/DO
WN
SP
EE
DR
ES
IST
OR
R14 SECONDARY BOOM SPEED RESISTOR 7.5 OHMS
Platform Control Box Wiring Diagram
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
September 2005Section 6 • Schematics
6 - 9 Z-51/30J Part No. 110284
REV A
TILTALARM
WH
C1
9JS
V
RE
D-T
ILT
RE
D-T
ILT
C2
P-5
BR
NB
RN
C3P
JIB
F.S.
C7P
JIB BK JIB BK JIB
C3P
C7PBATGRN C7P-3
C1P
PLATFORM CONTROLHARNESS
(TO SWITCH PANEL)
H1
12V DC BATTERYSUPPY
C1
P(G
Y)
19/18 CONTROL CABLE
C7P C9
FOOT SWITCH
JIB
9
1
J1
JC
3-3
OR
DR
EA
BL
/WH
JC
3-2
BR
N
DR
EB
BL
/BK
C1
3L
ED
BL
/RD
C2
9M
SR
D/W
H
JC
2-5
BK
JC
1-5
YE
L
JC
2-3
OR
JC
3-4
BL
*
JC
2-2
BR
N
JC
3-5
WH
JC
1-3
OR
JC
2-4
RD
JC
1-2
BR
N
J2
1
11
1
P2
4F
SW
H
P24FS WH
P2
6E
ST
PB
K
J3
3
C2
P(B
K)
C3
P(G
R)
C4
P(B
R)
C28TTA RD/BK C1P-2
BR
N
C2
9M
SR
D/W
HC
1P
-3
C3
2B
RK
WH
/RD
C1
P-6
C5
TR
RW
H/B
KC
3P
-5
C3
6S
TC
CB
KC
1P
-10
C3
PB
FR
D/W
HC
3P
-3
C3
7S
TC
BL
/BK
C1
P-11
C2
PB
DR
D/B
KC
3P
-2
C3
1R
EV
WH
/BK
C1
P-5
C1
PB
UR
DC
3P
-1
C3
0F
WD
WH
C1
P-4
C4
1R
PM
OR
/BK
C2
P-3
C1
2S
BF
BL
/WH
C3
P-1
2
C4
0L
SS
OR
C2
P-2
C11
SB
DB
L/B
KC
3P
-11
C1
6D
RE
OR
/RD
C4
P-4
C1
0S
BU
BL
C3
P-1
0
C6
TR
FW
H/R
DC
3P
-6
C2
8T
TA
RD
/BK
H1
C2P
C2
7A
UX
RD
C1
P-1
C3
3S
TR
BK
C1
P-7
C3
5H
SB
K/R
DC
1P
-9
C4P
C4
4JD
AL
AR
MG
R/B
KC
2P
-6
C4
5G
EN
GR
/WH
C2
P-7
P2
4F
SW
HC
9-2
P2
5F
SR
DC
9-3
P2
6B
AT
BK
C9
-1
C7
PB
EB
KC
3P
-7
C8
PB
RB
K/W
HC
3P
-8
C9
HR
NB
K/R
DC
3P
-9
C1
4P
LU
OR
C4
P-2
C1
5P
LD
OR
/BK
C4
P-3
C1
7JU
GR
C4
P-5
C1
8JD
GR
/BK
C4
P-6
C1
9JS
VG
R/W
HC
4P
-7
P2
2B
AT
BK
C7
P-1
P2
3S
WB
AT
WH
C7
P-2
U13ALC-500
CR30 CR27
P2
4F
SW
HC
9P
-2
C4
0L
SS
OR
C2
P-2
C3
2B
RK
WH
/RD
C1
P-6
C3
2B
RK
WH
/RD
J2
-19
C4
0L
SS
OR
J2
-4
CE LIFT/DRIVE OPTION
TS
7
CW
LIT
ER
DC
2P
-11
CW
LIT
ER
DC
2P
-12
CD
LIT
EG
R
WLITE BRN C2P-10
WLITE BRN C2P-9
BRN
BRNBRN
BR
N
Y
RD
-P2
RD
-H1
RE
D-
LS
18
LS18CE OPTION
ONLYOPT.
H1
J3
J2
J1
U13
C1P - C4P
C7P
ALC-500 CONTROL BOARD
CONTROL BOARD POWER CONNECTOR
CONTROL BOARD OUTPUT CONNECTOR
CONTROL BOARD INPUT CONNECTOR
TILT ALARM
12V DC PLATFORM POWER CONNECTOR
48 PIN CONNECTOR BLOCK
DESCRIPTIONITEM
FOOT SWITCH CONNECTORC9
CR27 CONTROL RELAY (CE OPTION)
CR30 CONTROL RELAY (CE OPTION)
LS18 LOAD SENSE LIMIT SWITCH
RD
/BK
-L4
8(-)
GR
/BK
C4
P-1
GR
/BK
-L4
TS
1W
H
Platform Control Box Switch Panel Wiring Diagram
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 110284 Z-51/30J 6 - 10
September 2005 Section 6 • Schematics
REV A
P2EMERGENCY
STOPTS4HIGH/LOW
RPM
TS2ENGINESTART
TS15DRIVE
ENABLE
L1DRIVE
ENABLELED
DRIVESPEED
TS14HIGH/LOW(2WD/4WD)
TS13PRIMARY BOOM
EXTEND/RETRACT
TS8JIB BOOM
TS7PLATFORMROTATE
TS9PLATFORM
LEVEL
P3HORN TS1
AUXILIARYPUMP
C9
HR
NB
K/R
DC
3P
-9
RD
C1
4P
LU
OR
C4
P-2
C1
5P
LD
OR
/BK
C4
P-3
C1
8P
RR
GR
/BK
C4
P-6
C1
9JS
VG
R/W
HC
4P
-7
C1
7P
RL
GR
C4
P-5
C2
7A
UX
RD
C1
P-1
P2
5F
SR
DC
9-3
C3
3S
TR
BK
C1
P-7
BK
C9
P-1
WH
C7
P-2
RD
WH
GR/BK
RD
GR
RD
WH-24
RD RD RD
TS47GENERATOR
(OPTION)
C8
PB
RB
K/W
HC
3P
-8
BL
/RD
-DE
3J1
-16
C4
5G
EN
GR
/WH
C2
P-7
RD
BL
-DE
1J1
-6
GR/WH
RD
C7
PB
EB
KC
3P
-7
GR
/WH
RD
C2
9M
SR
D/W
HJ1
-8
TS6GLOWPLUG
(OPTION)
C3
4S
AB
K/W
HC
1P
-8WHWH
White wire replacedby CR27 and CR30on CE models
GR
/BK
-44
C2
P-6
RD
NOTE:DASHED LINES INDICATE OPTION WIRES
C3
5R
PM
BK
/RD
C1
P-9
2
1
NC
2
1
NC
BL
/BK
-DE
2J1
-7
4
2
1
3
5
6
7
OR
J1
-13
BR
NJ1
-14
WH
J1
-4
BL
J1
-5
OR
J1
-9
BR
NJ1
-10
YE
LJ1
-3
OR
J1
-11
BR
NJ1
-12
BK
J1
-2
RD
J1
-1
JC3DRIVE
FORWARD/REVERSE& STEER
LEFT/RIGHT
JC1SECONDARY BOOM
UP/DOWN
CR13JIB BOOMRELAY
WH
-JIB
C1
9JS
VG
R/W
H
P2
4F
SW
H
BR
N
WH
-JIB
P2
4F
SW
HC
9-2
RD
BK
BK
BK
BK
BK
BK
34 NO
PLATFORM CONTROLHARNESS
(TO CONTROL BOX)
BL
J1
-5
+
TS48DRIVE LIGHTS/WORK LIGHTS
(OPTION)
RD
RD
PD
LIT
ER
D
CW
LIT
ER
DC
2P
-11
CW
LIT
ER
DC
2P
-12
F18FUSE 10A
C3
P-4
DL
ITE
WH
2
1
3
5
4
6
7
2
1
3
5
4
6
7JC2
PRIMARY BOOM UP/DOWN& TURNTABLE ROTATE
LEFT/RIGHT
GE
NE
RA
TO
RO
PT
ION
2
1
NC
BK
J3
-3
BK
C7
P-1
RD
LS
18
L48TILT ALARM LED
+
L4PLATFORMOVERLOAD
LED
+
GR
/BK
H1
(D3
9)
BK
RD
RD
RD
RD
RD
/BK
H1
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Hydraulic Schematic
September 2005 Section 6 • Schematics
Part No. 110284 Z-51/30J 6 - 11
REV A
OSC
2.0GPM
0.1GPM
PR2 PR1
PR1PR2
L R
RE
FUNCTION MANIFOLD
JIB SELECT
MANIFOLD
LEFTREAR
RIGHTREAR
LEFTFRONT
RIGHTFRONT
TRACTION MANIFOLDRB
RFB
RFA
LFB
LFA
TEST
T2
T
67% 33%
0.052 inch
250PSI
0.030 inch
50%
50%
RA
LB
LA
2SPD
BRK
50%
50%
2.0
GP
M
1.0
GP
M
0.025 inch
2100 PSISET @2.5 GPMAT TEST
0.046 inch
2500PSI SET.6 GPM@ TEST2
3200 PSISET @ 7 GPM@ TEST1
0.4GPM
1.5GPM
T1
PRESS
102PSI
TEST1
3200 PSI
25 PSI
TEST 2
T
AUX P2P1S2S1SW2SW1PL2PL1PR2PR1 RETEXT
V1V2
J1 J2
3500 PSI
51PSI
315 PSI
V1
0.030 inch
V2
PRIMARY BOOMLIFT CYLINDER
TURNTABLE ROTATE
SLAVE
PLATFORM ROTATE
0.4 GPM
MASTER
0.4 GPM
JIB BOOM
STEER CYLINDERS
OSCILLATE AXLE CYLINDERS
APU
TANK
7
PUMP
FUNCTION
DRIVE PUMP
M
E
PRIMARY BOOMEXTENSION CYLINDER
ST1 ST2
RATIO PRESSURE
1000 PSI
3300 PSI
3800 PSI
3:1
3626 PSI
3:1
3:1
4.25:1
4.5:1 3500 PSI
3:1 3500 PSI
3:1 1500 PSI
COUNTERBALANCE VALVES
AB
PLATFORM LEVEL
MEDIUMPRESSURE
FILTER
7
5.0:1 1000 PSI
1.5:1 3800 PSI
E R
E R
E R
E R E R
B
A
SECONDARY BOOMELEVATE CYLINDERS
3:1 3000 PSI
0.1 GPM
0.60 GPM
HIGHPRESSURE
FILTER
BZ
BX
CA
CB
CC
CD
CE
BY
BW
BU
BS BT
CFBV
BO
BP
BQ BRBN
BM
BLBK
BJ
BI
BH
BDBC
CG
BEBB
BF
BG
BA
AJ AK
Q
P
CD
E F
H I
J L
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AC
AD
ABAI
AH
AA
Z
U
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AF AG
AE
C D
G
E F
H I
J L
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P Q
AKAJ
3.2 / 2.4 GPM 4.1 (regen) / 2.1 GPM
LEFT RIGHT
A
B
P
T
E R E R
B
A
A
BA
B
A
B
Genie North America
Genie Australia Pty Ltd.
Genie China
Genie Malaysia
Genie Japan
Genie Korea
Genie Africa
Genie Latin America
Phone
Toll Free
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425.881.1800
USA and Canada
800.536.1800
425.883.3475
61 7 3375 1660
61 7 3375 1002
86 21 53852570
86 21 53852569
60 4 228 1235
60 4 226 6872
81 3 3453 6082
81 3 3453 6083
82 2 558 7267
82 2 558 3910
27 11 455 0373
27 11 455 0355
55 11 4055 2499
55 11 4043 1661 Dis
trib
ute
dB
y:
California Proposition 65
WARNINGThe exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.
Genie Holland
Genie Scandinavia
Genie France
Genie Iberica
Genie Germany
Genie U.K.
Genie Mexico City
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31 70 51 78836
31 70 51 13993
46 31 3409612
33 (0)2 37 26 09 99
33 (0)2 37 26 09 98
34 93 579 5042
34 93 579 5059
49 (0)4202 88520
49 (0)4202 8852-20
44 (0)1476 584333
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52 55 5666 5242
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46 31 3409613
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