Terex Genie Z-135/70 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

Z®-135/70

from Z13505-101 to

Z13513-

2000

This manual includes:

Repair

procedures

Fault Codes

Electrical and

Hydraulic Schematics

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1268557GT

Rev A4

October 2018

Service and Repair Manual October 2018

Introduction

ii Z®-135/70 Part No. 1268557GT

Intr oduct io n Intr oduct io n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1268557 Rev A, September 2015

First Edition, First Printing

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries.

“Z” is a trademark of Terex South Dakota, Inc.

October 2018 Service and Repair Manual

Introduction

Part No. 1268557GT Z®-135/70 iii

Revision History

Revision

Date

Section

Procedure / Page / Description

A 9/2015

Initial Release

11/2015

Schematics Wire Color Legend

6/2016

Specifications Performance Specifications

Repair Procedures 4-9, 6-1

3/2018

Repair Display Module

10/2018

Specifications

Perfromance Specifications

Reference Examples:

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual October 2018

Introduction

iv Z®-135/70 Part No. 1268557GT

Serial Number Legend

1 Model

2 Model year

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

October 2018 Service and Repair Manual

Safety Rules

Part No. 1268557GT Z®-135/70 v

Section 1 Safet y Rul es

Danger

Failure to obey the instructions and safety rules in

this manual and the appropriate Operator's Manual

on your machine will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

RYou are trained and qualified to perform

maintenance on this machine.

RYou read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

RYou have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual October 2018

Safety Rules

vi Z®-135/70 Part No. 1268557GT

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

ead each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol

—

used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

avoid possible injury or death.

Indicates a imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to wear protective eye wear and

other

protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved

steel

-toed shoes.

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and lighted

tobacco away from flammable and

combustible

materials like battery gases

and engine fuels. Always have an

approved fire extinguisher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get in

to machine

components and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are in good condition and of

ample

capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self

-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved

container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

October 2018

Table of Contents

Part No. 1268557GT Z®-135/70 vii

Introduction Introduction...........................................................................................................ii

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

Find a Manual for this Model..................................................................................ii

Serial Number Legend ..........................................................................................iv

Section 1 Safety Rules..........................................................................................................v

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

Section 2 Specifications.......................................................................................................1

Machine Specifications...........................................................................................1

Performance Specifications....................................................................................1

Hydraulic Specification...........................................................................................2

Hydraulic Component Specifications......................................................................5

Deutz BF4L 2011 Engine Specifications................................................................7

Deutz TD2011L04i Engine Specifications..............................................................9

Cummins B4.5L Engine Specifications ................................................................11

Cummins B3.3T Engine Specifications................................................................13

Perkins 1104C-44 Engine Specifications.............................................................15

Perkins 804D-33T Engine Specifications.............................................................17

Machine Torque Specifications............................................................................19

Hydraulic Hose and Fitting Torque Specifications ...............................................20

Torque Procedure ................................................................................................21

SAE and Metric Fasteners Torque Charts ...........................................................23

October 2018

Table of Contents

viii Z®-135/70 Part No. 1268557GT

Section 3 Repair Procedures.............................................................................................24

Introduction ..........................................................................................................24

Platform Controls...............................................................................................26

Platform Controls .................................................................................................26

1-1 Platform Circuit Board....................................................................................27

How to Remove the LED Circuit Board ..........................................................28

1-2 Membrane Decal ...........................................................................................29

1-3 Joysticks - How to Calibrate a Joystick .........................................................30

How to Reset a Proportional Valve Coil Default.............................................34

How to Set the Function Thresholds and Default Functions Speeds.............34

How to Adjust the Function Speeds ...............................................................36

How to Adjust the Function Ramp Rate Setting .............................................37

Platform Components .......................................................................................39

2-1 Platform Leveling Cylinder.............................................................................39

2-2 Platform Rotator.............................................................................................40

How to Bleed the Platform Rotator.................................................................41

2-3 Platform Level Sensor - How to Calibrate the Platform Level Sensor...........42

2-4 Platform Overload System (if equipped)........................................................43

Jib Boom Components......................................................................................46

3-1 Jib Boom Cable Track ...................................................................................47

How to Repair the Cable Track.......................................................................49

3-2 Jib Boom........................................................................................................50

3-3 Jib Boom Lift Cylinder....................................................................................52

3-4 Jib Boom Level Cylinder................................................................................53

3-5 Jib Boom Extension Cylinder.........................................................................54

3-6 Jib Boom Bellcrank Angle Sensor .................................................................56

How to Calibrate the Jib Boom Bellcrank Angle Sensor ................................58

October 2018

Table of Contents

Part No. 1268557GT Z®-135/70 ix

Boom Components ............................................................................................64

4-1 Primary Boom Cable Track............................................................................65

How to Repair the Primary Boom Cable Track...............................................67

4-2 Secondary Boom Cable Track.......................................................................68

How to Repair the Secondary Boom Cable Track..........................................70

4-3 Primary Boom.................................................................................................71

4-4 Primary Boom Lift Cylinder ............................................................................73

4-5 Secondary Boom Lift Cylinder........................................................................74

4-6 Primary Boom Extension Cylinder .................................................................78

4-7 Secondary Boom Extension Cylinders...........................................................79

4-8 Primary Boom Angle Sensor..........................................................................81

How to Calibrate the Primary Boom Angle Sensor.........................................82

4-9 Secondary Boom Angle Sensor.....................................................................88

How to Calibrate the Secondary Boom Angle Sensor....................................89

Engines................................................................................................................95

5-1 RPM Adjustment ............................................................................................95

5-2 Flex Plate .......................................................................................................95

How to install a Type "A" Flex Plate................................................................96

How to install a Type "B" Flex Plate................................................................98

Ground Controls.................................................................................................99

6-1 Bypass/Recovery Key Switch ........................................................................99

How to Use the Recovery Mode ...................................................................101

6-2 Circuit Boards...............................................................................................102

6-3 Membrane Decal..........................................................................................104

6-4 Full Machine Calibration...............................................................................105

Display Module.................................................................................................106

October 2018

Table of Contents

x Z®-135/70 Part No. 1268557GT

Hydraulic Pumps..............................................................................................115

7-1 Function Pump.............................................................................................115

How to Prime the Function Pump.................................................................116

How to Adjust the Function Pump Standby Pressure...................................116

How to Adjust the Function Pump Pressure Compensator..........................117

7-2 Drive Pump..................................................................................................118

How to Prime the Drive Pump ......................................................................119

Manifolds ..........................................................................................................120

8-1 Function Manifold - (before serial number 440)...........................................120

8-2 Function Manifold - (after serial number 439)..............................................124

8-3 Valve Adjustments - Function Manifold .......................................................128

How to Adjust the System Relief Valve ........................................................128

How to Adjust the Primary Boom Extend Relief Valve.................................129

8-4 Platform Manifold.........................................................................................131

8-5 Jib Boom Manifold .......................................................................................132

8-6 Flow Control Mainfold..................................................................................134

8-7 Function Enable Valve.................................................................................135

8-8 Turntable Rotation Manifold.........................................................................136

8-9 Steer and Axle Manifold...............................................................................138

8-10 Valve Adjustments - Steer and Axle Manifold ...........................................142

8-11 Traction Manifold .......................................................................................144

8-12 Valve Adjustments - Traction Manifold......................................................148

8-13 Drive Oil Diverter Manifold (welder option)................................................149

8-14 Valve Coils.................................................................................................150

Turntable Rotation Components....................................................................152

9-1 Turntable Rotation Assembly.......................................................................152

How to Adjust the Turntable Rotation Gear Backlash..................................153

9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor.....154

Andere Handbücher für Genie Z-135/70

Inhaltsverzeichnis

Andere Terex Hubarbeitsbühne Handbücher

Terex

Terex Genie Z-51/30J Bedienungsanleitung

Terex

Terex Genie Z-45/25 Bi-Energy Bedienungsanleitung

Terex

Terex Genie Z-34/22 Installations- und Betriebsanleitung

Terex

Terex Genie S-80 Installations- und Betriebsanleitung

Terex

Terex Z-33 Bedienungsanleitung

Terex

Terex Genie S65XCD-1251 Bedienungsanleitung

Terex

Terex Genie S-40 Trax Bedienungsanleitung

Terex

Terex Genie Z-33/18 Installations- und Betriebsanleitung

Terex

Terex Genie S-40XC Bedienungsanleitung

Terex

Terex Genie Z-34/22 IC Installations- und Betriebsanleitung

Terex

Terex Genie ZX-135/70 Bedienungsanleitung

Terex

Terex Genie Z-34/22N Bedienungsanleitung

Terex

Terex Genie Z-80 Installations- und Betriebsanleitung

Terex

Terex ZX13515-2558 Bedienungsanleitung

Terex

Terex TM Series Bedienungsanleitung

Terex

Terex Genie Z6215A-101 Bedienungsanleitung

Terex

Terex Genie GS-4655 Bedienungsanleitung

Terex

Terex Genie ZX-135/70 Bedienungsanleitung

Terex

Terex Genie Z4525XCM-2501 Bedienungsanleitung

Terex

Terex Genie Z-45/25J Bi-Energy Bedienungsanleitung

Terex

Terex Genie Z-25J Bedienungsanleitung

Terex

Terex Z60H-3506 Bedienungsanleitung

Terex

Terex Genie Z331815M-101 Bedienungsanleitung

Terex

Terex Z40NF-6200 Bedienungsanleitung

Beliebte Hubarbeitsbühne Handbücher anderer Marken

Genie

Genie Z-80 Bedienungsanleitung

Genie

Genie Z-45/25 Bedienungsanleitung

JLG

JLG Skytrak 6036 Gebrauchs- und Pflegehandbuch

LGMG

LGMG T65JE Bedienungsanleitung

Genie

Genie Z-135/70 Bedienungsanleitung

Oshkosh Corporation

Oshkosh Corporation JLG H800AJ Gebrauchs- und Pflegehandbuch

Oshkosh

Oshkosh JLG 1500SJ Installations- und Benutzerhandbuch

Skyjack

Skyjack SJ30AJE Bedienungsanleitung

Oshkosh

Oshkosh JLG 800A Installations- und Benutzerhandbuch

Skyjack

Skyjack SJ 46AJ Bedienungsanleitung

Molift

Molift Quick Raiser 205 Bedienungsanleitung

Snorkel

Snorkel SL26RTE Kurzanleitung

Oshkosh Corporation

Oshkosh Corporation JLG E300A Bedienungsanleitung

Skyjack

Skyjack SJ45 T+ Bedienungsanleitung

Genie

Genie S-105 Bedienungsanleitung

nifty

nifty 170SD series Montageanleitung

JLG

JLG 15MVL Series Bedienungsanleitung

Genie

Genie Z-45 XC Bedienungsanleitung