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Genie Z-135/70 Serivce Manual and Parts List Manual

Serial Number Range:
From ZX13513-2001 to ZX13514-2532
(does not include ZX13514-2463, ZX13514-2469 and ZX13514-2531)

Content for Service Manual:
Introduction
Important Information
Find a Manual for this Model
Revision History
Serial Number Legend

Section 1. Safety Rules
General Safety Rules

Section 2. Specifications
Machine Specifications
Performance Specifications
Hydraulic Specification
Hydraulic Component Specifications
Deutz TD2011L04i Engine Specifications
Deutz TD 2.9 Engine Specifications
Perkins 1104D-44T Engine Specifications
Perkins 854F-34T Engine Specifications
Machine Torque Specifications
Hydraulic Hose and Fitting Torque Specifications
Torque Procedure
SAE and Metric Fasteners Torque Charts

Section 3. Scheduled Maintenance Procedures
Introduction
Pre-Delivery Preparation Report
Maintenance Inspection Report

Checklist A Procedures
A-1 Inspect the Manuals and Decals
A-2 Perform Pre-operation Inspection
A-3 Perform Function Tests
A-4 Perform Engine Maintenance - Perkins Models
A-5 Perform Engine Maintenance - Deutz Models
A-6 Check the Hydraulic Return Filter Condition Indicator
A-7 Perform 30-Day Service
A-8 Grease the Turntable Rotation Bearing and Rotate Gear
A-9 Replace the Drive Hub Oil

Checklist B Procedures
B-1 Inspect the Batteries
B-2 Inspect the Electrical Wiring
B-3 Test the Key Switches
B-4 Inspect the Engine Air Filter
B-5 Check the Oil Cooler and Cooling Fins - Deutz Models
B-6 Check the Exhaust System
B-7 Confirm the Proper Brake Configuration
B-8 Inspect the Tires, Wheels and Lug Nut Torque
B-9 Check the Drive Hub Oil Level and Fastener Torque
B-10 Test the Platform Self-leveling
B-11 Test the Engine Idle Select Operation
B-12 Test the Ground Control Override
B-13 Test the Drive Brakes
B-14 Test the Drive Speed - Stowed Position
B-15 Test the Drive Speed - Raised or Extended
B-16 Test the Drive Speed - Raised and Extended
B-17 Test the Alarm and Optional Flashing Beacon
B-18 Perform Hydraulic Oil Analysis
B-19 Test the Turntable Level Sensor
B-20 Test the Secondary Boom Angle Sensor
B-21 Test the Primary Boom Angle Sensor
B-22 Test the Safety Envelope Limit Switches
B-23 Test the Recovery Mode System
B-24 Inspect the Calibration Decal
B-25 Inspect for Turntable Bearing Wear

Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models
C-2 Perform Engine Maintenance - Deutz Models
C-3 Perform Engine Maintenance - Perkins Models
C-4 Replace the Engine Air Filter Element
C-5 Grease the Platform Overload Mechanism (if equipped)
C-6 Test the Platform Overload System (if equipped)
C-7 Check and Adjust the Engine RPM
C-8 Inspect for Turntable Bearing Wear

Checklist D Procedures
D-1 Check the Boom Wear Pads
D-2 Check the Free-wheel Configuration
D-3 Replace the Drive Hub Oil
D-4 Adjust the Turntable Rotatation Gear Backlash
D-5 Replace the Hydraulic Filter Elements
D-6 Perform Engine Maintenance - Deutz Models
D-7 Perform Engine Maintenance - Perkins Models
D-8 Check the Turntable Rotation Bearing Bolts

Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil
E-2 Perform Engine Maintenance - Perkins Models
E-3 Perform Engine Maintenance - Deutz Models
E-4 Perform Engine Maintenance - Perkins Models
E-5 Perform Engine Maintenance - Perkins Models
E-6 Perform Engine Maintenance - Deutz Models
E-7 Perform Engine Maintenance - Perkins Models
E-8 Perform Engine Maintenance - Deutz Models

Section 4. Repair Procedures
Introduction
Platform Controls
Platform Controls
1-1 Platform Circuit Board
How to Remove the LED Circuit Board
1-2 Joysticks - How to Calibrate a Joystick
How to Reset a Proportional Valve Coil Default
How to Set the Function Thresholds and Default Functions Speeds
How to Adjust the Function Speeds
How to Adjust the Function Ramp Rate Setting
Platform Components
2-1 Platform
2-2 Platform Leveling Cylinder
2-3 Platform Rotator
How to Bleed the Platform Rotator
2-4 Platform Level Sensor - How to Calibrate the Platform Level Sensor
2-5 Platform Overload System (if equipped)
2-6 Platform Overload Recovery Message
Jib Boom Components
3-1 Jib Boom Cable Track
How to Repair the Cable Track
3-2 Jib Boom
3-3 Jib Boom Lift Cylinder
3-4 Jib Boom Level Cylinder
3-5 Jib Boom Extension Cylinder
3-6 Jib Boom Bellcrank Angle Sensor - How to Calibrate the Jib Boom Bellcrank Angle Sensor
Boom Components
4-1 Primary Boom Cable Track
How to Repair the Primary Boom Cable Track
4-2 Secondary Boom Cable Track
How to Repair the Secondary Boom Cable Track
4-3 Primary Boom
4-4 Primary Boom Lift Cylinder
4-5 Secondary Boom Lift Cylinder
4-6 Primary Boom Extension Cylinder
4-7 Secondary Boom Extension Cylinders
4-8 Primary Boom Angle Sensor - How to Calibrate the Primary Boom Angle Sensor
4-9 Secondary Boom Angle Sensor - How to Calibrate the Secondary Boom Angle Sensor
(i) 6 Point Calibration procedure
Engines
5-1 RPM Adjustment
5-2 Flex Plate
How to Install the Flex Plate
Ground Controls
6-1 Bypass/Recovery Key Switch
How to Use the Recovery Mode
6-2 Circuit Boards
6-3 Membrane Decal
6-4 Full Machine Calibration
Display Module
Hydraulic Pumps
7-1 Function Pump
How to Prime the Function Pump
How to Adjust the Function Pump Standby Pressure
How to Adjust the Function Pump Pressure Compensator
7-2 Drive Pump
How to Prime the Drive Pump
Manifolds
8-1 Function Manifold Components
8-2 Valve Adjustments - Function Manifold
8-3 Platform Manifold
8-4 Jib Boom Manifold
8-5 Flow Control Mainfold
8-6 Function Enable Valve
8-7 Turntable Rotation Manifold
8-8 Steer and Axle Manifold
8-9 Valve Adjustments - Steer and Axle Manifold
8-10 Traction Manifold Components
8-11 Valve Adjustments - Traction Manifold
8-12 Drive Oil Diverter Manifold Components (welder option)
8-13 Valve Coils
How to Test a Coil Diode
Turntable Rotation Components
9-1 Turntable Rotation Assembly
How to Adjust the Turntable Rotation Gear Backlash
9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor Axle Components
10-1 Steer Sensors
How to Calibrate a Replacement Steer Sensor
How to Calibrate All Steer Sensors
10-2 Steer Cylinders
10-3 Axle Extension Cylinders
10-4 Axle Angle Sensors - How to Calibrate the Axle Angle Sensors

Section 5. Fault Codes
Introduction
Control System Fault Codes
Fault Matrix
Deutz TD 2.9 L4 Engine Fault Codes
Perkins 854F-34T Engine Fault Code

Section 6. Schematics
Introduction
Wire Circuit Legend
Wire Color Legend
Limit Switches and Angle Sensors
Circuit Connector Legend
Drive Chassis and Platform Controller Pin Legend
Safety Controller Pin Legend
Turntable Controller Pin Legend
Telematics Connector Pin Legend
Engine Relay and Fuse Panel Legend - Deutz TD2011L04i
Engine Relay and Fuse Panel Legend- Deutz TD2.9 Models
Engine Relay and Fuse Panel Legend - Perkins 1104D-44T
Engine Relay and Fuse Panel Legend- Perkins 854F Models
Electrical Symbols Legend
Hydraulic Symbols Legend
Perkins 1104D Engine Electrical Schematic
Perkins 854F-34T Engine Electrical Schematic
Perkins 854F-34T Engine Harness
Deutz TD2.9 Engine Electrical Schematic
Deutz TD2.9 Engine Harness
Generator Wiring Schematic
Hydraulic Generator (Welder Option)
Hydraulic Schematic
Electrical Schematic (Includes Deutz Engine)

--------------

Content for Parts List Manual:
How to Read Your Serial Number
Parts Stocking List
How to Order Parts
Service Parts Fax Order Form

001 Parts Stocking List
001.1 Parts Stocking List

100 Decals
101.1 Decals with Words, Hydraulic Tank Side
102.1 Decals with Words, Hydraulic Tank Side (chassis)
103.1 Decals with Words, Engine Side
104.1 Decals with Words, Engine Side (chassis)
105.1 Decals with Words, Boom
106.1 Decals with Words, Platform, ANSI & CSA
107.1 Decals with Words, Platform, AUS
108.1 Decals with Symbols, Hydraulic Tank Side, Asia and South America
109.1 Decals with Symbols, Hydraulic Tank Side, CE
110.1 Decals with Symbols, Hydraulic Tank Side (chassis)
111.1 Decals with Symbols, Engine Side
112.1 Decals with Symbols, Engine Side (chassis)
113.1 Decals with Symbols, Boom
114.1 Decals with Symbols, Platform, Asia and South America
115.1 Decals with Symbols, Platform, CE

200 Chassis Components
201.1 Chassis Components, Top View
202.1 Chassis Components, Bottom View
203.1 Chassis Components, Tank Side
204.1 Chassis Components, Engine Side
205.1 Steer Yoke, Wheel Drive and Motor

300 Turntable Components
301.1 Tank Side Covers
302.1 Engine Side Covers
303.1 Engine Compartment Components
304.1 Hydraulic Tank Side Components
305.1 Ground Control Box Deutz TD2011-L04i and Perkins 1104D-44T
305.2 Ground Control Box Deutz TD 2.9L4 and Perkins 854F-E34T
306.1 Turntable Center Components
307.1 Secondary Boom Lift Cylinder
308.1 Wire Harness Diagram

400 Engine Components
401.1 Deutz TD2011L04i Engine, View 1
402.1 Deutz TD2011L04i Engine, View 2
403.1 Deutz TD 2.9L4 Engine - View 1
404.1 Deutz TD 2.9L4 Engine - View 2
405.1 Deutz TD 2.9L4 Engine - View 3
406.1 Deutz TD 2.9L4 Engine - View 4
407.1 Perkins 1104D-44T Engine - View 1
408.1 Perkins 1104D-44T Engine - View 2
409.1 Perkins 1104D-44T Engine - View 3
410.1 Perkins 854F-E34T Engine - View 1
411.1 Perkins 854F-E34T Engine - View 2
412.1 Perkins 854F-E34T Engine - View 3
413.1 Perkins 854F-E34T Engine - View 4

500 Boom Components
501.1 Secondary Boom Tube Reference
502.1 Secondary Boom Tube 1
503.1 Secondary Boom Tube 2
504.1 Secondary Boom Tube 3
505.1 Secondary Boom Tube 4
506.1 Secondary Boom Extension Cylinders
507.1 Secondary Boom Cable Track and Pull Tube
508.1 Secondary Boom Cable and Hose Clamps, Front View
509.1 Secondary Boom Cable and Hose Clamps, Rear View
510.1 Primary Boom Link, Lever and Lift Cylinder
511.1 Primary Boom Angle Sensor and Retract Limit Switch
512.1 Primary Boom Cable Track
513.1 Primary Boom Bearings and Wear Pads
514.1 Primary Extension Boom
515.1 Bellcrank, Bellcrank Level Cylinder and Jib Boom Lift Cylinder
516.1 Jib Boom Cable Track
517.1 Jib Boom Extension and Platform Level Cylinders
518.1 Jib Boom Tubes and Wear Pads
519.1 Platform Rotator

600 Platform Components
601.1 Platform Mount
602.1 Platform Configurations (to SN 2888)
602.2 Platform Configurations (from SN 2889)
603.1 Platform Controls
604.1 Joysticks

700 Hydraulic Components
701.1 Traction Manifold
702.1 Steer/Axle Manifold (to SN 3228)
702.2 Steer/Axle Manifold (from SN 3229)
703.1 Jib Manifold (to SN 2804)
703.2 Jib Manifold (from SN 2805)
704.1 Function Manifold
705.1 Function Enable Valve and Platform Rotator Manifold
706.1 Platform Manifold (to SN 2804)
706.2 Platform Manifold (from SN 2805)
707.1 Hydraulic Hoses and Fittings, Drive System
708.1 Hydraulic Hoses and Fittings, Steering System
709.1 Hydraulic Hoses and Fittings, Turntable Components
710.1 Hydraulic Hoses and Fittings, Boom Components
711.1 Hydraulic Hoses and Fittings, Platform Components
712.1 Pumps

800 Accessories
801.1 Platform Accessories (to SN 2888)
801.2 Platform Accessories (from SN 2889)
801.3 Platform Accessories, Half-Mesh and Pipe Cradle Options (from SN 2889)
802.1 Hostile Enviroment Option - Secondary Boom Wipers
802.2 Hostile Enviroment Option - Primary and Jib Boom Wipers, Cable Track Covers
803.1 Hostile Enviroment Option - Bellows Installation
804.1 Hostile Environment Option - Engine Air Cleaners
804.2 Engine Air Cleaners - Deutz TD 2.9L4 and Perkins 854F-E34T
805.1 Hostile Environment DLX Option - Slew Ring Guard
806.1 Belt Driven Generator, Cummins Models
807.1 Belt Driven Generator,Perkins Models
807.2 Belt Driven Generator, Perkins 854TF Models
808.1 Belt Driven Generator, Deutz Models
808.2 Belt Driven Generator, Deutz D2.9L4 Models
809.1 Circuit Board Heater Option
810.1 Load Sense
811.1 Cold Start Package (to SN 2125)
811.2 Cold Start Package (from SN 2126)
812.1 Welder Option - Chassis Components
813.1 Welder Option - Platform Components
813.2 Welder Option - Platform Components (from SN ZX13516H-2790)
814.1 Welder Option - Hydraulic Hoses and Fittings
815.1 Welder Option - Generator Components
816.1 Hydraulic Generator Option
817.1 Hydraulic Hoses and Fittings, Hydraulic Generator Option
818.1 Boom Latch Kit
819.1 Aircraft Protection Package (to SN 2315)
819.2 Aircraft Protection Package (from SN 2316)
820.1 Operator Protection Structure
821.1 Air Line to Platform
822.1 Drive Light and Flashing Beacon
823.1 Fall Arrest Bar
824.1 Operators Protection Alarm (to January 2017)
824.2 Lift Guard Contact Alarm Option (from January 2017)
825.1 Platform Recirculating Hydraulic Oil Option

Indices
Part Number Index
Part Description Index

Cross References
Fittings Cross Reference
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