Terex Genie Z-135/70 Installation and operating manual

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.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
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.
Copyright © 2015 by Terex Corporation
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
A1 11/2015 Schematics Wire Color Legend
A2 6/2016 Specifications Performance Specifications
Repair Procedures 4-9, 6-1
A3 3/2018 Repair Display Module
A4
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.
R
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
to
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