Page 1 Service and Repair Manual Serial Number Range -135/70 ® from Z13505-101 to This manual includes: Z13513-2000 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...
Page 2: Find A Manual For This Model
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.
Page 3 October 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Initial Release Wire Color Legend 11/2015 Schematics Performance Specifications 6/2016 Specifications Procedures 4-9, 6-1 Repair Display Module 3/2018 Repair Perfromance Specifications 10/2018 Specifications Reference Examples: Electronic Version...
Page 4: Serial Number Legend
Service and Repair Manual October 2018 Introduction Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) Z®-135/70 Part No. 1268557GT...
Page 5: Safety Rules
October 2018 Service and Repair Manual Safety Rules Section 1 Safety R ules 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.
Page 6 Service and Repair Manual October 2018 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
Page 7: Table Of Contents
October 2018 Table of Contents 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 ...................
Page 8 October 2018 Table of Contents 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 ............
Page 9 October 2018 Table of Contents 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....................
Page 10 October 2018 Table of Contents 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 ....................
Page 11 October 2018 Table of Contents Axle Components ..................... 158 10-1 Steer Sensors .................... 158 How to Calibrate a Replacement Steer Sensor ..........160 How to Calibrate All Steer Sensors ............... 161 10-2 Steer Cylinders ................... 163 10-3 Axle Extension Cylinders ................164 10-4 Axle Angle Sensors ..................
Page 12 October 2018 Table of Contents Section 5 Schematics ....................... 191 Introduction ......................191 Wire Circuit Legend ................... 192 Wire Color Legend ..................... 196 Limit Switches and Angle Sensors..............201 Circuit Connector Legend .................. 205 Drive Chassis and Platform Controller Pin Legend ........... 208 Safety Controller Pin Legend ................
Page 13 October 2018 Service and Repair Manual This page intentionally left blank. Part No. 1268557GT Z®-135/70...
Page 15: Specifications
October 2018 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Performance Specifications Tires and wheels Drive speed, maximum Tire size 445/65D22.5, FF Stowed position, high speed 2.8 mph 4.5 km/h Tire ply rating 40 ft / 9.7 sec Tire weight, new foam-filled 815 lbs 12.2 m / 9.7 sec...
Page 16: Hydraulic Specification
Service and Repair Manual October 2018 Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
Page 17 October 2018 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
Page 18 Service and Repair Manual October 2018 Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade Viscosity index ISO Grade Kinematic Viscosity Viscosity index cSt @ 200°F / 100°C Kinematic Viscosity cSt @ 104°F / 40°C 44.4 cSt @ 149°F / 65°C Flash point...
Page 19: Hydraulic Component Specifications
October 2018 Service and Repair Manual Specifications Hydraulic Component Auxiliary Pump Specifications Type: fixed displacement gear pump Displacement per revolution 0.15 cu in Drive Pump 2.47 cc Type: bi-directional variable displacement piston pump Function manifold Displacement per revolution 2.8 cu in System relief valve pressure, maximum 3100 psi 46 cc...
Page 20 Service and Repair Manual October 2018 Specifications Brakes Manifold Component Specifications Brake relief pressure 190 psi Plug torque 13 bar SAE No. 2 36 in-lbs / 4 Nm Drive Motors SAE No. 4 10 ft-lbs / 13 Nm (before serial number 180) SAE No.
Page 21: Deutz Bf4L 2011 Engine Specifications
October 2018 Service and Repair Manual Specifications Deutz BF4L 2011 Engine Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Displacement 189.6 cu. in 2.8 to 4.1 bar 3.1 liters Oil capacity (including filter) 11 quarts Number of cylinders 10.4 liters Bore and Stroke 3.7 x 4.409 inches...
Page 22 Service and Repair Manual October 2018 Specifications Deutz BF4L 2011 cont. Fuel injection system Motorpal Injection pump pressure, 15,000 psi maximum 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine.
Page 23: Deutz Td2011L04I Engine Specifications
October 2018 Service and Repair Manual Specifications Deutz TD2011L04i Engine Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Displacement 220.9 cu. in 2.8 to 4.1 bar 3.62 liters Oil capacity (including filter) 12.8 quarts Number of cylinders 12.1 liters Bore and Stroke 3.78 x 4.92 inches...
Page 24 Service and Repair Manual October 2018 Specifications Deutz TD2011L04i cont. Fuel injection system Motorpal Injection pump pressure, 15,000 psi maximum 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Starter motor Current draw, normal load 140 - 200A...
Page 25: Cummins B4.5L Engine Specifications
October 2018 Service and Repair Manual Specifications Cummins B4.5L Engine Lubrication system Oil pressure, hot (@ 2000 rpm) 50 psi Displacement 275 cu. in 3.45 bar 4.5 liters Oil capacity (including filter) 9.5 quarts Number of cylinders 9 liters Bore and Stroke 4.02 x 5.42 inches Oil viscosity requirements 102 x 138 mm...
Page 26 Service and Repair Manual October 2018 Specifications Cummins B4.5L cont. Fuel injection system Delphi Injection pump pressure, 3480 to 3680 psi maximum 240 to 254 bar Injector opening pressure 3480 psi 240 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine.
Page 27: Cummins B3.3T Engine Specifications
October 2018 Service and Repair Manual Specifications Cummins B3.3T Engine Lubrication system Oil pressure, hot (@ 2000 rpm) 31 psi Displacement 199 cu. in 72 bar 3.26 liters Oil capacity (including filter) 9 quarts Number of cylinders 8.5 liters Bore and Stroke 3.74 x 4.53 inches Oil viscosity requirements 95 x 115 mm...
Page 28 Service and Repair Manual October 2018 Specifications Cummins B3.3T cont. Fuel injection system Zexel Injection pump pressure, 12,000 psi maximum 827 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Engine coolant Capacity 9.1 quarts 8.6 liters Starter motor Current draw, maximum load...
Page 29: Perkins 1104C-44 Engine Specifications
October 2018 Service and Repair Manual Specifications Perkins 1104C-44 Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Displacement 268.5 cu. in 2.8 to 4.1 bar 4.4 liters Oil capacity (including filter) 7.3 quarts Number of cylinders 6.9 liters Bore and Stroke 4.13 x 5 inches...
Page 30 Service and Repair Manual October 2018 Specifications Perkins 1104C-44 cont. Starter motor Current draw, normal load 140 - 200A Cranking speed 200 - 250 rpm Battery – Auxiliary power units Type 6V DC Quantity Battery capacity, maximum 285 AH Reserve capacity @ 25A rate 745 minutes Battery –...
Page 31: Perkins 804D-33T Engine Specifications
October 2018 Service and Repair Manual Specifications Perkins 804D-33T Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Displacement 203 cu. in 2.8 to 4.1 bar 3.33 liters Oil capacity (including filter) 10.6 quarts Number of cylinders 10 liters Bore and Stroke 3.7 x 4.72 inches...
Page 32 Service and Repair Manual October 2018 Specifications Perkins 804D-33T cont. Starter motor Current draw, normal load 200A Cranking speed 250 rpm Battery – Auxiliary power units Type 6V DC Quantity Battery capacity, maximum 285 AH Reserve capacity @ 25A rate 745 minutes Battery –...
Page 33: Machine Torque Specifications
October 2018 Service and Repair Manual Specifications Machine Torque Specifications Drive motors and hubs Drive hub mounting bolts, lubricated 180 ft-lbs Platform Rotator 217 Nm 1-8 center bolt, GR 5 480 ft-lbs Drive motor mounting bolts, dry 75 ft-lbs 651 Nm 102 Nm 3/8 -16 bolts, GR 8 44 ft-lbs...
Page 34: Hydraulic Hose And Fitting Torque Specifications
Service and Repair Manual October 2018 Specifications Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...
Page 35: Torque Procedure
October 2018 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Seal-Lok™ fittings Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten Replace the O-ring. The O-ring must be the hex nut to the body hex fitting to hand tight, replaced anytime the seal has been broken.
Page 36 Service and Repair Manual October 2018 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
Page 37: Sae And Metric Fasteners Torque Charts
October 2018 Service and Repair Manual Specifications Part No. 1268557GT Z®-135/70...
Page 38: Repair Procedures
Service and Repair Manual October 2018 Repair Procedures Section 3 Repair Pr oc edures Machine Configuration: Unless otherwise specified, perform each repair procedure with the machine in the following configuration: · Machine parked on a firm, level surface · Key switch in the off position with the key Observe and Obey: removed ·...
Page 39 October 2018 Service and Repair Manual Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.
Page 40: Platform Controls
Service and Repair Manual October 2018 Platform Controls Platform Controls The platform controls contains two printed circuit boards: The LED circuit board is mounted to the underside of the control box lid which contains the LEDs. The LED circuit board sends the input from the operator to the platform controls circuit board (PCON).
Page 41: Platform Circuit Board
October 2018 Service and Repair Manual Platform Controls Attach a grounded wrist strap to the ground screw inside the control box. Platform Circuit Board Electrocution/burn hazard. Electrocution/burn hazard. Contact with electrically charged Contact with electrically charged circuits could result in death or circuits could result in death or serious injury.
Page 42: How To Remove The Led Circuit Board
Service and Repair Manual October 2018 Platform Controls How to R emove the LED Circui t Board How to Remove the LED Circuit Board Push in the red Emergency Stop button to the off position at both the ground and platform controls.
Page 43: Membrane Decal
October 2018 Service and Repair Manual Platform Controls Install the new membrane decal while guiding the ribbon cables through the control box lid. Membrane Decal Note: Be sure that all LED locations on the membrane decal align with the LEDs on the How to Replace the Membrane membrane circuit board.
Page 44: Joysticks - How To Calibrate A Joystick
Service and Repair Manual October 2018 Platform Controls Press the plus button to select YES, then press the enter button. Joysticks Do not start the engine. Locate the drive/steer joystick. How to Calibrate a Joystick Move the drive/steer joystick full stroke in the The joystick controllers on this machine utilize forward direction and hold for 5 seconds, then digital Hall Effect technology for proportional control.
Page 45 October 2018 Service and Repair Manual Platform Controls Steer functions: Secondary boom up/down and extend/retract functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground control panel while turning the key switch to Press and hold the enter button on the ground platform controls.
Page 46 Service and Repair Manual October 2018 Platform Controls Primary boom extend/retract functions: Primary boom up/down functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to...
Page 47 October 2018 Service and Repair Manual Platform Controls Jib boom up/down functions: Turntable rotate functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to...
Page 48: How To Reset A Proportional Valve Coil Default
Service and Repair Manual October 2018 Platform Controls How to R es et a Proportional Val ve Coil D efault How to Set the F unc tion T hresholds and D efault Func tions Speeds How to Reset a Proportional Valve How to Set the Function Coil Default Thresholds and Default Functions...
Page 49 October 2018 Service and Repair Manual Platform Controls Function speeds: Slowly move the joystick off center in the opposite direction just until the machine Note: Be sure the machine is in the stowed position function starts to move, then move the joystick and the boom is rotated between the circle end very slowly towards the neutral or center tires.
Page 50: How To Adjust The Function Speeds
Service and Repair Manual October 2018 Platform Controls How to Adj ust the Functi on Speeds Turntable rotate function, primary boom extended: Extend the primary boom How to Adjust the Function approximately 4 ft / 1.2 m. Move the rotate Speeds joystick full stroke in either the left or right direction until the alarm sounds.
Page 51: How To Adjust The Function Ramp Rate Setting
October 2018 Service and Repair Manual Platform Controls How to Adj ust the Functi on R amp R ate Setti ng Press the enter button to save the setting in memory. How to Adjust the Function Ramp Press the enter or previous button on the Rate Setting LCD screen until EXIT is displayed.
Page 52 Service and Repair Manual October 2018 Platform Controls Press the previous button until the function to be adjusted is displayed. Press the plus button to increase the ramp rate or press the minus button to decrease the ramp rate. Press the enter button to save the setting in memory.
Page 53: Platform Components
October 2018 Service and Repair Manual Platform Components Place a block under the platform leveling cylinder for support. Platform Leveling Cylinder Remove the external snap rings from the The platform leveling cylinder keeps the platform barrel-end pivot pin. Use a soft metal drift to level through the entire range of boom motion.
Page 54: Platform Rotator
Service and Repair Manual October 2018 Platform Components Remove the platform angle sensor retaining fasteners. Remove the platform angle sensor Platform Rotator from the platform rotator. The platform rotator is a hydraulically activated Component damage hazard. The helical gear assembly used to rotate the platform platform angle sensor is a very 160 degrees.
Page 55: How To Bleed The Platform Rotator
October 2018 Service and Repair Manual Platform Components How to Bleed the Pl atfor m R otator Remove the hose and cable guide retaining fasteners and remove the guide from the How to Bleed the Platform Rotator platform support. Note: Do not start the engine. Use auxiliary power Remove the weld cable from the platform (if for all machine functions in this procedure.
Page 56: Platform Level Sensor - How To Calibrate The Platform Level Sensor
Service and Repair Manual October 2018 Platform Components Before serial number 321: Platform Level Sensor Locate the 2 pin connector in the lower left hand area of the ground control box. The platform level sensor is mounted to the side of Remove the connector plug and insert a the platform rotator.
Page 57: Platform Overload System (If Equipped)
October 2018 Service and Repair Manual Platform Components 11 Press the enter or previous button on the LCD screen until SET PLATFORM LEVEL Platform Overload System (if SENSOR TO GRAVITY is displayed. equipped) 12 Press the plus button to select YES, then press the enter button to accept.
Page 58 Service and Repair Manual October 2018 Platform Components Determine the limit switch trigger point: Confirm the setting: Gently move the platform up and down by Start the engine from the platform controls. hand, so it bounces approximately 1 to Lift the test weight off the platform floor using a 2 inches / 2.5 to 5 cm.
Page 59 October 2018 Service and Repair Manual Platform Components Test all machine functions from the platform controls. Result: All platform control functions should not operate. 10 Turn the key switch to ground controls. 11 Test all machine functions from the ground controls.
Page 60: Jib Boom Components
Service and Repair Manual October 2018 Jib Boom Components 1 primary extension boom 7 jib boom 2 jib boom manifold 8 jib extension boom 3 bellcrank 9 hose and cable junction box 4 cable track tube 10 jib boom lift cylinder 5 platform rotator 11 jib boom cable track 6 platform leveling cylinder...
Page 61: Jib Boom Cable Track
October 2018 Service and Repair Manual Jib Boom Components Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to Jib Boom Cable Track the platform manifold. Cap the fittings on the manifold. The jib boom cable track guides the cables and hoses running up the jib boom.
Page 62 Service and Repair Manual October 2018 Jib Boom Components Remove the hose and cable clamp retaining 17 Remove the fasteners from the cable track fasteners at the platform end of the jib boom tube guide at the platform end of the jib boom. cable track tube.
Page 63: How To Repair The Cable Track
October 2018 Service and Repair Manual Jib Boom Components How to R epair the C abl e Tr ac k Lift up the hoses and cables and carefully insert the new 4-link section of cable track. How to Repair the Cable Track Component damage hazard.
Page 64: Jib Boom
Service and Repair Manual October 2018 Jib Boom Components Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to Jib Boom the platform manifold. Cap the fittings on the manifold. How to Remove the Jib Boom Bodily injury hazard.
Page 65 October 2018 Service and Repair Manual Jib Boom Components Place blocks between the upper and lower 12 Remove the jib boom angle sensor mounting cable tracks and secure the upper and lower bracket fasteners from the side of the primary tracks together.
Page 66: Jib Boom Lift Cylinder
Service and Repair Manual October 2018 Jib Boom Components 23 Use a soft metal drift to tap the pin halfway out in one direction and lower one side of the jib Jib Boom Lift Cylinder boom bellcrank. Tap the pin in the other direction and lower the other side of the jib boom bellcrank.
Page 67: Jib Boom Level Cylinder
October 2018 Service and Repair Manual Jib Boom Components Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Use a soft Jib Boom Level Cylinder metal drift to remove the pin and let the cylinder hang down. How to Remove the Jib Boom Attach a lifting strap from an overhead crane to Level Cylinder...
Page 68: Jib Boom Extension Cylinder
Service and Repair Manual October 2018 Jib Boom Components Remove the external snap rings from the jib boom level cylinder barrel-end pivot pin. Use a Jib Boom Extension Cylinder soft metal drift to remove the pin. Tag, disconnect and plug the jib boom level How to Remove the Jib Boom cylinder hydraulic hoses from the jib boom Extension Cylinder...
Page 69 October 2018 Service and Repair Manual Jib Boom Components Extend the jib boom until the jib boom Pull the electrical cables out of the lower cable extension cylinder rod-end pivot pin is track that lead to the primary boom. accessible. 10 Attach a lifting strap from a second overhead Tag, disconnect and plug the two hydraulic crane to the pivot end of the jib boom for...
Page 70: Jib Boom Bellcrank Angle Sensor
Service and Repair Manual October 2018 Jib Boom Components 16 Attach a lifting strap from an overhead crane to the barrel end of the jib boom extension Jib Boom Bellcrank Angle Sensor cylinder. The jib boom bellcrank angle sensor is monitored 17 Remove the pin retaining fasteners from the jib by the control system to keep the jib boom bellcrank boom extension cylinder barrel-end pivot pin.
Page 71 October 2018 Service and Repair Manual Jib Boom Components Remove the angle sensor cover retaining 11 Align the side of the sensor with flat area of the fastener. Remove the cover. boom pivot pin as shown below. Remove the angle sensor mounting bracket retaining fasteners.
Page 72: How To Calibrate The Jib Boom Bellcrank Angle Sensor
Service and Repair Manual October 2018 Jib Boom Components How to C alibr ate the Jib Boom Bellcrank Angle Sens or 13 Rotate the angle sensor mounting bracket, while holding the key in the sensor, clockwise How to Calibrate the Jib Boom until the mounting bracket fits into the Bellcrank Angle Sensor machined pocket.
Page 73 October 2018 Service and Repair Manual Jib Boom Components Note: Use the following chart to identify the Before serial number 321: description of each LCD screen control button used Locate the 2 pin connector in the lower left in this procedure. hand area of the ground control box.
Page 74 Service and Repair Manual October 2018 Jib Boom Components 11 Enter sensor calibration mode by pressing the 16 Attach the digital level to the surface of the jib buttons at the ground controls in the following boom bellcrank as shown. sequence: (plus)(enter)(enter)(plus).
Page 75 October 2018 Service and Repair Manual Jib Boom Components 18 Press and hold a function enable/speed select 22 Press and hold a function enable/speed select button and the platform level down button until button and raise the jib boom above horizontal the digital level displays approximately 34 ±...
Page 76 Service and Repair Manual October 2018 Jib Boom Components 25 Press and hold a function enable/speed select 28 At the ground controls, press the plus button button and the platform level down button until or minus button to adjust the display to the the digital level displays approximately 44 ±...
Page 77 October 2018 Service and Repair Manual Jib Boom Components Before serial number 321: After serial number 320: 33 Remove the wire jumper from the 2 pin 35 Remove the fastener that was temporarily connector in the lower left hand area of the installed.
Page 78: Boom Components
Service and Repair Manual October 2018 Boom Components 1 upper primary boom lift cylinder linkage arm 8 primary boom lift cylinder 2 primary boom 9 number 1 secondary boom tube 3 cable track 10 number 2 secondary boom tube 4 primary extension boom 11 number 3 secondary boom tube 5 jib boom manifold 12 lower primary boom lift cylinder linkage arm...
Page 79: Primary Boom Cable Track
October 2018 Service and Repair Manual Boom Components Pull the electrical cables out of the lower cable track that lead to the primary boom. Primary Boom Cable Track Component damage hazard. The primary boom cable track guides the cables Cables can be damaged if they and hoses running up the boom.
Page 80 Service and Repair Manual October 2018 Boom Components 10 Remove the retaining fasteners from the cable 15 Locate the two hydraulic hoses inside the end track guide at the platform end of the boom. of the secondary boom that lead to the primary Remove the cable track guide from the boom cable track.
Page 81: How To Repair The Primary Boom Cable Track
October 2018 Service and Repair Manual Boom Components How to R epair the Primar y Boom C abl e Tr ac k 20 Remove the mounting fasteners that attach the lower cable track to the primary boom lift How to Repair the Primary Boom cylinder.
Page 82: Secondary Boom Cable Track
Service and Repair Manual October 2018 Boom Components Remove the upper rollers from the replacement section of cable track. Secondary Boom Cable Track Lift up the hoses and cables and carefully The secondary boom cable track guides the cables insert the new 4-link section of cable track. and hoses running up through the inside of the Component damage hazard.
Page 83 October 2018 Service and Repair Manual Boom Components Remove the cover retaining fasteners and 10 Pull the hydraulic hoses just removed through remove the cover from the secondary boom. the turntable bulkhead. Crushing hazard. The secondary Component damage hazard. boom end cover could become Hoses can be damaged if they unbalanced and fall when are kinked or pinched.
Page 84: How To Repair The Secondary Boom Cable Track
Service and Repair Manual October 2018 Boom Components How to R epair the Sec ondar y Boom C able Tr ac k 17 Working at the counterweight end of the secondary boom, attach a lifting strap from an How to Repair the Secondary overhead crane to the secondary boom cable Boom Cable Track track.
Page 85: Primary Boom
October 2018 Service and Repair Manual Boom Components Remove the upper rollers from the replacement section of cable track. Primary Boom Lift up the hoses and cables and carefully insert the new 4-link section of cable track. How to Remove the Primary Component damage hazard.
Page 86 Service and Repair Manual October 2018 Boom Components Remove the primary boom cable track. Refer 10 Tag, disconnect and plug the primary boom to repair procedure, How to Remove the Cable extension cylinder hydraulic hoses. Cap the Track. fittings on the cylinder. Remove the end cover from the pivot end of Bodily injury hazard.
Page 87: Primary Boom Lift Cylinder
October 2018 Service and Repair Manual Boom Components 17 Use a soft metal drift to tap the pin halfway out and lower one of the linkage arms down. Tap Primary Boom Lift Cylinder the pin in the other direction and lower the other linkage arm down.
Page 88: Secondary Boom Lift Cylinder
Service and Repair Manual October 2018 Boom Components Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on Secondary Boom Lift Cylinder the cylinder. Bodily injury hazard. Spraying How to Remove the Secondary hydraulic oil can penetrate and Boom Lift Cylinder burn skin.
Page 89 October 2018 Service and Repair Manual Boom Components Remove the engine pivot plate retaining Tag, disconnect and plug the fuel hoses from fastener. Swing the engine pivot plate out the fuel tank. Clean up any fuel that may have away from the machine. spilled.
Page 90 Service and Repair Manual October 2018 Boom Components 13 Remove the turntable cover using a suitable 19 Attach an overhead crane or similar lifting lifting device. device to the battery box for the auxiliary power unit batteries. Crushing hazard. The turntable 20 Remove the battery box retaining fasteners cover may become unbalanced and carefully remove the battery box from the...
Page 91 October 2018 Service and Repair Manual Boom Components 24 Remove the secondary boom lift cylinder 29 Use a slide hammer to remove the barrel-end rod-end pivot pin retaining fasteners. Use a pivot pin. soft metal drift to remove the pin through the Component damage hazard.
Page 92: Primary Boom Extension Cylinder
Service and Repair Manual October 2018 Boom Components Remove the access cover from the pivot end of the primary boom. Primary Boom Extension Cylinder Tag, disconnect and plug the primary boom The primary boom extension cylinder extends and extension cylinder hydraulic hoses. Cap the retracts the primary boom extension tube.The fittings on the cylinder.
Page 93: Secondary Boom Extension Cylinders
October 2018 Service and Repair Manual Boom Components Raise the primary boom approximately 10 feet / 3 m. Turn the machine off. Secondary Boom Extension Working at the platform end of the secondary Cylinders boom, support and secure the secondary boom end cover to a suitable lifting device.
Page 94 Service and Repair Manual October 2018 Boom Components Note: When installing the middle and upper Attach a lifting strap from an overhead crane to secondary boom extension cylinders, be sure the the rod end of the upper extension cylinder. grooved wear pads are correctly aligned with the Using the overhead crane, lift the extension channels on the top of the cylinders.
Page 95: Primary Boom Angle Sensor
October 2018 Service and Repair Manual Boom Components Install the new angle sensor onto the mounting bracket. Primary Boom Angle Sensor Install one spring, removed in step 5, into the The primary boom angle sensor is used to limit the hex-shaped hole in the angle sensor.
Page 96: How To Calibrate The Primary Boom Angle Sensor
Service and Repair Manual October 2018 Boom Components How to C alibr ate the Pri mary Boom Angle Sens or 11 While holding the hex-shaped key in position, rotate the angle sensor mounting bracket How to Calibrate the Primary clockwise until it aligns with the machined Boom Angle Sensor pocket.
Page 97 October 2018 Service and Repair Manual Boom Components 6 Point Calibration procedure Note: If the axle sensor or secondary boom angle sensor have been removed or replaced, or the Note: Use this procedure for software versions turntable level sensor has been replaced, they must before 4.01.
Page 98 Service and Repair Manual October 2018 Boom Components Press and hold the enter button on the ground 17 Press and hold a function enable/speed select control panel while pulling out the ground button and the primary boom down button and controls red Emergency Stop button to the on lower the primary boom down until the digital position.
Page 99 October 2018 Service and Repair Manual Boom Components 22 At the ground controls, press the plus button 27 Press and hold the engine start button for or minus button to adjust the display to the approximately 5 seconds to shut off the engine exact value shown on the digital level and and to save the calibration settings.
Page 100 Service and Repair Manual October 2018 Boom Components After serial number 320: 2 Point Calibration procedure 34 Remove the fastener that was temporarily Note: Use this procedure for software versions installed. Close the control box door and install 4.01 and higher. the door retaining fasteners.
Page 101 October 2018 Service and Repair Manual Boom Components 47 Press the plus button to select YES, then 58 Turn the key back to the run position and press the enter button to accept. remove the key from the bypass/recovery key switch.
Page 102: Secondary Boom Angle Sensor
Service and Repair Manual October 2018 Boom Components Install the new angle sensor onto the mounting bracket. Secondary Boom Angle Sensor Install one spring, removed in step 5, into the The secondary boom angle sensor is used to limit hex-shaped hole in the angle sensor. Install the angle of the primary boom relative to the angle the other spring into the hex-shaped hole in the of the secondary boom and gravity.
Page 103: How To Calibrate The Secondary Boom Angle Sensor
October 2018 Service and Repair Manual Boom Components How to C alibr ate the Sec ondar y Boom Angle Sensor 11 While holding the hex-shaped key in position, rotate the angle sensor mounting bracket How to Calibrate the Secondary clockwise until it aligns with the machined Boom Angle Sensor pocket.
Page 104 Service and Repair Manual October 2018 Boom Components 6 Point Calibration procedure Press and hold the enter button on the ground control panel while pulling out the ground Note: Use this procedure for software versions controls red Emergency Stop button to the on before 4.01.
Page 105 October 2018 Service and Repair Manual Boom Components 11 Press the enter or previous button on the 17 At the ground controls, press the plus button LCD screen until DELETE SECONDARY or minus button to adjust the display to the BOOM ANGLE SENSOR CALIBRATION is exact value shown on the digital level and displayed.
Page 106 Service and Repair Manual October 2018 Boom Components 22 Press and hold a function enable/speed select 27 Press the enter or previous button on the button and the secondary boom up button until LCD screen until EXIT is displayed. the digital level displays 65 degrees. 28 Press the plus button to select YES, then 23 At the ground controls, press the plus button press the enter button to accept.
Page 107 October 2018 Service and Repair Manual Boom Components After serial number 320: 2 Point Calibration procedure 33 Remove the fastener that was temporarily Note: Use this procedure for software versions installed. Close the control box door and install 4.01 and higher. the door retaining fasteners.
Page 108 Service and Repair Manual October 2018 Boom Components 43 Press the enter or previous button on the 53 Press the plus button to select YES, then LCD screen until DELETE SECONDARY press the enter button to accept. BOOM ANGLE SENSOR CALIBRATION is 54 Turn the key back to the run position and displayed.
Page 109: Engines
October 2018 Service and Repair Manual Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the engine Refer to Maintenance Procedure in the appropriate and the pump. It is bolted to the engine flywheel and Service or Maintenance Manual for your machine, has a splined center to drive the pump.
Page 110: How To Install A Type "A" Flex Plate
Service and Repair Manual October 2018 Engines How to i nstall a T ype "A" Flex Pl ate How to Remove the Flex Plate How to Install a Type "A" Flex Plate Disconnect the wiring plug at the electronic displacement controller (EDC), located on the Install the flex plate onto the engine flywheel drive pump.
Page 111 October 2018 Service and Repair Manual Engines Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between the coupler and pump end plate for your engine. 1 pump 2 pump shaft 3 pump coupler 4 flex plate with raised spline 5 engine flywheel...
Page 112: How To Install A Type "B" Flex Plate
Service and Repair Manual October 2018 Engines How to i nstall a T ype "B" Flex Pl ate Deutz and Perkins models How to Install a Type "B" Flex Plate Deutz and Perkins models: Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the pump.
Page 113: Ground Controls
October 2018 Service and Repair Manual Ground Controls Bypass/Recovery Key Switch The turntable control box (TCON) is the communication and operations center for the machine. The turntable control box contains two key switches. The main key switch towards the top of the control box is for selection of ground or platform controls.
Page 114 Service and Repair Manual October 2018 Ground Controls Turn the bypass/recovery key switch to the bypass position. How to Use the Bypass Mode Using auxiliary power, operate the ground Tip-over hazard. Operating the control buttons to level the platform. machine outside of the operating Note: Only the auxiliary power unit can be used to envelope while in Bypass mode correct an out of level platform fault.
Page 115: How To Use The Recovery Mode
October 2018 Service and Repair Manual Ground Controls How to Us e the R ec overy Mode Note: This procedure is for machines using software version 1.11 and later. For machines How to Use the Recovery Mode using software version 1.01, contact Genie Product Support.
Page 116: Circuit Boards
Service and Repair Manual October 2018 Ground Controls How to Remove the LCD Display Circuit Boards Screen Circuit Board The ground control box contains a replaceable membrane decal with touch sensitive buttons for Push in the red Emergency Stop button to the various machine functions.
Page 117 October 2018 Service and Repair Manual Ground Controls Tag and carefully disconnect the wire connectors from the circuit board. How to Remove the ALC-1000 Carefully disconnect the LCD circuit board Circuit Board ribbon cable from the ECM circuit board. Note: If the ALC-1000 circuit board (TCON) has Carefully disconnect the two ribbon cables been replaced, the entire machine must be from the membrane decal at the ECM circuit...
Page 118: Membrane Decal
Service and Repair Manual October 2018 Ground Controls Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit Membrane Decal board. The membrane decal is a special decal that Electrocution/burn hazard. consists of a decal with an electronic membrane on Contact with electrically charged the backside.
Page 119: Full Machine Calibration
October 2018 Service and Repair Manual Ground Controls Note: Start this procedure with the booms in the fully stowed position and the axle retracted. Full Machine Calibration Full machine calibration must be completed in the Full machine calibration must be completed in the following sequence: proper sequence when the ALC-1000 circuit board ·...
Page 120: Display Module
Service and Repair Manual October 2018 Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters. Tip-over hazard.
Page 121 October 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Machine Status With key switch on, press the Hydraulic pressure PSI 0-4500 PSI (plus)(minus) buttons at the same (English) time. Hydraulic pressure kPa (metric) 0-31000 kPa Primary boom to secondary +22°...
Page 122 Service and Repair Manual October 2018 Display Module Screen or Menu Procedure Description Range or Selection Default Reset With key switch , press and hold Delete drive functions the enter button and turn key switch to Software version Delete boom function speed on position.
Page 123 October 2018 Service and Repair Manual Display Module Screen or Procedure Description Range or Menu Selection Boom With key switch , press and hold Primary boom up speed stowed Function the enter button and turn key switch Speeds to on position. Release the enter button and press Primary boom up speed not stowed (plus)(plus)(minus)(minus)
Page 124 Service and Repair Manual October 2018 Display Module Screen or Menu Procedure Description Range or Selection Lift Functions With key switch , press and Primary boom up/down ramp Ramps hold the enter button and turn key acceleration % switch to on position. Primary boom up/down ramp Release the enter button and deceleration %...
Page 125 October 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Valve With key switch , press and hold the Delete drive valve calibration Calibration enter button and turn key switch to on position. Delete primary boom up/down Release the enter button and press valve calibration (minus)(minus)(enter)(enter).
Page 126 Service and Repair Manual October 2018 Display Module Screen or Menu Procedure Description Range or Selection Sensor Calibration With key switch , press and hold the Set unit X-axis to gravity enter button and turn key switch to on (before software version 4.01) Set unit Y-axis to gravity position.
Page 127 October 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Sensor Calibration With key switch , press and hold the Set unit X-axis to gravity enter button and turn key switch to on Set unit Y-axis to gravity (software version position.
Page 128 Service and Repair Manual October 2018 Display Module Screen or Procedure Description Range or Menu Selection Options With key switch , press and hold Boom Function Limit No LT= No limit; the enter button and turn key switch (NO LT/EXT LT) EXT LT= to on position.
Page 129: Hydraulic Pumps
October 2018 Service and Repair Manual Hydraulic Pumps Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying The function pump is a pressure compensated, hydraulic oil can penetrate and variable displacement piston pump.
Page 130: How To Prime The Function Pump
Service and Repair Manual October 2018 Hydraulic Pumps How to Prime the F uncti on Pump How to Adj ust the Functi on Pump Standby Pr ess ure How to Prime the Function Pump How to Adjust the Function Pump Standby Pressure Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose...
Page 131: How To Adjust The Function Pump Pressure Compensator
October 2018 Service and Repair Manual Hydraulic Pumps Loosen the set screw for the pressure Adjust the function pump standby pressure. compensator adjustment screw. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. Turn the engine off and remove the pressure gauge.
Page 132: Drive Pump
Service and Repair Manual October 2018 Hydraulic Pumps Locate the two hydraulic tank valves at the hydraulic tank. Close the valves. Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump.
Page 133: How To Prime The Drive Pump
October 2018 Service and Repair Manual Hydraulic Pumps How to Prime the Dri ve Pump Carefully pull the drive pump out until the pump coupler separates from the flex plate. How to Prime the Drive Pump Remove the drive pump from the machine. Component damage hazard.
Page 134: Manifolds
Service and Repair Manual October 2018 Manifolds Function Manifold - View 1 (before serial number 440) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Check valve Prevents the draining of 30-35 ft-lbs / 41-47 Nm hydraulic oil from the jib manifold and platform...
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Page 136 Service and Repair Manual October 2018 Manifolds Function Manifold - View 2 (before serial number 440) Index Schematic Description Function Torque Item Check valve Prevents hydraulic pressure from flowing back into auxiliary pump #1 Check valve Prevents hydraulic pressure from flowing back into auxiliary pump #2 Differential sensing valve, Turntable rotate circuit,...
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Page 138: Function Manifold - (After Serial Number 439)
Service and Repair Manual October 2018 Manifolds Function Manifold - View 1 (after serial number 439) The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Solenoid Valve, 2 position 3 way Primary boom up/down 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way...
Page 139 October 2018 Service and Repair Manual Manifolds Part No. 1268557GT Z®-135/70...
Page 140 Service and Repair Manual October 2018 Manifolds Function Manifold - View 2 (after serial number 439) Index Description Schematic Item Function Torque Check valve Prevents hydraulic pressure from flowing back into auxiliary pump Check valve Prevents the draining of 30-35 ft-lbs / 41-47 Nm hydraulic oil from the jib manifold and platform manifold Differential sensing valve,...
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Page 142: Valve Adjustments - Function Manifold
Service and Repair Manual October 2018 Manifolds Simultaneously push and hold the auxiliary power button and the primary boom retract Valve Adjustments - button with the primary boom fully retracted. Function Manifold Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specification.
Page 143: How To Adjust The Primary Boom Extend Relief Valve
October 2018 Service and Repair Manual Manifolds How to Adj ust the Pri mar y Boom Extend R elief Val ve Simultaneously push and hold the auxiliary power button and the primary boom retract How to Adjust the Primary Boom button with the primary boom fully retracted.
Page 144 Service and Repair Manual October 2018 Manifolds Simultaneously push and hold the function enable/high speed button and the primary boom extend button with the primary boom fully extended. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specifications.
Page 145: Platform Manifold
October 2018 Service and Repair Manual Manifolds Platform Manifold The platform manifold is mounted to the platform mounting weldment. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform rotate left/right 20-25 ft-lbs / 27-34 Nm Proportional solenoid valve, 3 position 4 way Platform level up/down 20-25 ft-lbs / 27-34 Nm...
Page 146: Jib Boom Manifold
Service and Repair Manual October 2018 Manifolds Jib Boom Manifold The jib boom manifold is mounted inside the primary extension boom at the platform end. Index Schematic Description Function Torque Item Pressure compensator valve, Jib boom up/down circuit, 30-35 ft-lbs / 41-47 Nm 150 psi / 10.3 bar regulates pressure drop across jib boom up/down proportional...
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Page 148: Flow Control Mainfold
Service and Repair Manual October 2018 Manifolds Flow Control Manifold The flow control manifold is located at the platform next to the jib manifold. Index Schematic Description Function Torque Item Flow regulator valve, 0.5 gpm / 1.9 L/min Controls flow in the jib and platform 20 ft-lbs / 27 Nm manifold recirculation circuit Z®-135/70...
Page 149: Function Enable Valve
October 2018 Service and Repair Manual Manifolds Function Enable Valve The function enable valve is mounted behind the medium pressure filter. Index Schematic Description Function Torque Item Solenoid valve, 2 position 2 way Enables lift pump to provide 20-25 ft-lbs / hydraulic pressure for all boom and 27-34 Nm steer/axle functions...
Page 150: Turntable Rotation Manifold
Service and Repair Manual October 2018 Manifolds Turntable Rotation Manifold The turntable rotation manifolds are mounted to the turntable rotation drive hub motors. Index Schematic Description Function Torque Item Counterbalance valve Turntable rotate right 25-30 ft-lbs / 34-41 Nm Counterbalance valve Turntable rotate left 25-30 ft-lbs / 34-41 Nm...
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Page 152: Steer And Axle Manifold
Service and Repair Manual October 2018 Manifolds Steer and Axle Manifold The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Flow control valve, 1.5 gpm / 5.7 L/min Right front steer cylinder retract 20-25 ft-lbs / circuit...
Page 153 October 2018 Service and Repair Manual Manifolds Part No. 1268557GT Z®-135/70...
Page 154 Service and Repair Manual October 2018 Manifolds Steer and Axle Manifold, continued The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Flow regulator valve, 1.5 gpm / 5.7 L/min Left rear steer cylinder retract 20-25 ft-lbs / circuit...
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Page 156: Valve Adjustments - Steer And Axle Manifold
Service and Repair Manual October 2018 Manifolds 8-10 Turn the engine off. Valve Adjustments - Steer and Adjust the internal hex socket. Turn it clockwise to increase the pressure or Axle Manifold counterclockwise to decrease the pressure. Install the relief valve cap. How to Adjust the Axle Relief Component damage hazard.
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Page 158: Traction Manifold
Service and Repair Manual October 2018 Manifolds 8-11 Traction Manifold - View 1 The traction manifold is mounted inside the manifold box at the blue triangle side of the machine. Index Schematic Description Function Torque Item 20-25 ft-lbs / Check valve, 5 psi / 0.3 bar Drive motor anti-cavitation 27.1-33.9 Nm 20-25 ft-lbs /...
Page 159 October 2018 Service and Repair Manual Manifolds Part No. 1268557GT Z®-135/70...
Page 160 Service and Repair Manual October 2018 Manifolds Traction Manifold - View 2 Index Schematic Description Function Torque Item Orifice, 0.063 in / 1.6 mm (before serial number Equalizes pressure on both sides of 180 except for serial number divider/combiner valve AM 102) Orifice, 0.039 in / 1 mm (serial Equalizes pressure on both sides of...
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Page 162: Valve Adjustments - Traction Manifold
Service and Repair Manual October 2018 Manifolds 8-12 Hold the hot oil relief valve and remove the cap. Valve Adjustments - Traction Start the engine from the ground controls. Manifold 10 Press and hold the function enable/high rpm select button (rabbit symbol) position. How to Adjust the Hot Oil 11 Adjust the internal hex socket until the Relief Valve...
Page 163: Drive Oil Diverter Manifold (Welder Option)
October 2018 Service and Repair Manual Manifolds 8-13 Drive Oil Diverter Manifold (welder option) The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item Directional valve Diverter valve 80-90 ft-lbs / 108-122 Nm Orifice, 0.030 inch / 0.080 cm Delays shift to drive Solenoid Valve...
Page 164: Valve Coils
Service and Repair Manual October 2018 Manifolds Valve Coil Resistance 8-14 Specification Valve Coils Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As How to Test a Coil valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...
Page 165 October 2018 Service and Repair Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.
Page 166: Turntable Rotation Components
Service and Repair Manual October 2018 Turntable Rotation Components Remove the drive hub mounting bolts and remove the turntable rotation assembly from Turntable Rotation Assembly the machine. Repeat steps 3 through 5 for the other How to Remove a Turntable turntable rotation assembly.
Page 167: How To Adjust The Turntable Rotation Gear Backlash
October 2018 Service and Repair Manual Turntable Rotation Components How to Adj ust the Tur ntabl e R otati on Gear Bac klas h Turn the adjustment bolt 1/2 to 3/4 turn counterclockwise. Tighten the lock nut on the How to Adjust the Turntable adjustment bolt.
Page 168: Turntable Level Sensor - How To Calibrate The Turntable Level Sensor
Service and Repair Manual October 2018 Turntable Rotation Components After serial number 320: Turntable Level Sensor Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left How to Calibrate the Turntable direction.
Page 169 October 2018 Service and Repair Manual Turntable Rotation Components All models: 10 Enter sensor calibration mode by pressing the buttons at the ground controls in the following Turn the key switch to ground controls. sequence: (plus)(enter)(enter)(plus). Remove the key from the main key switch. Insert the key into the bypass/recovery key switch and turn it to the bypass position.
Page 170 Service and Repair Manual October 2018 Turntable Rotation Components 12 Place a digital level that has ben calibrated to 13 Press the plus button or minus button to gravity on the X axis of the turntable. adjust the display to the exact value shown on the digital level and press the enter button.
Page 171 October 2018 Service and Repair Manual Turntable Rotation Components 23 Remove the fastener that was temporarily 16 Press the plus button or minus button to installed. Close the control box door and install adjust the display to the exact value shown on the door retaining fasteners.
Page 172: Axle Components
Service and Repair Manual October 2018 Axle Components 10-1 Remove the steer sensor cover retaining fasteners. Remove the steer sensor assembly. Steer Sensors Note: If the sensor activator pin needs to be The steer sensors measure steer angle and replaced, install the new activator pin per Illustration communicates that information to the ground controls ECM.
Page 173 October 2018 Service and Repair Manual Axle Components Left front (square-end, blue side) and right rear Install the steer sensor cover retaining (circle-end, yellow side) angle sensors: fasteners. Do not tighten the cover retaining fasteners. Connect the steer sensor assembly cable to the main harness.
Page 174: How To Calibrate A Replacement Steer Sensor
Service and Repair Manual October 2018 Axle Components How to C alibr ate a Repl acement Steer Sens or 10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable How to Calibrate a Replacement angled away from the tire.
Page 175: How To Calibrate All Steer Sensors
October 2018 Service and Repair Manual Axle Components How to C alibr ate All Steer Sensors All models: How to Calibrate All Steer Turn the key switch to ground controls and pull Sensors out the ground controls red Emergency Stop button to the on position.
Page 176 Service and Repair Manual October 2018 Axle Components Delete all Steer Sensor Calibrations 11 Press and hold the enter button on the ground control panel while pulling out the ground 13 Press the enter or previous button on the controls red Emergency Stop button to the on LCD screen until DELETE ALL STEER position.
Page 177: Steer Cylinders
October 2018 Service and Repair Manual Axle Components 10-2 22 Push in the red Emergency Stop button to the off position. Steer Cylinders Before serial number 321: How to Remove a Steer Cylinder 23 Remove the wire jumper from the 2 pin connector in the lower left hand area of the Note: When removing a hose assembly or fitting, ground control box that was installed in step 2.
Page 178: Axle Extension Cylinders
Service and Repair Manual October 2018 Axle Components 10-3 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension Axle Extension Cylinders cylinder. Note: Connect the pressure hose from the power How to Remove an Axle unit to the "R"...
Page 179: Axle Angle Sensors
October 2018 Service and Repair Manual Axle Components 10-4 Axle Angle Sensors The axle angle sensors measure the axle angle and communicates that information to the ground controls ECM. There are two axle angle sensors. They are located on opposite axle pivot pins at each end of the chassis.
Page 180 Service and Repair Manual October 2018 Axle Components Position the new angle sensor assembly over Rotate the sensor housing in a clockwise the sensor activator pin as shown. Refer to direction until the sensor cable is parallel with illustration 2. the drive chassis side plate.
Page 181: How To Calibrate The Axle Angle Sensors
October 2018 Service and Repair Manual Axle Components How to C alibr ate the Axl e Angle Sens ors Rotate the sensor cover clockwise or counterclockwise until the voltage reading is How to Calibrate the Axle Angle between 4.2 to 4.4V DC. Tighten the sensor Sensors cover retaining fasteners.
Page 182 Service and Repair Manual October 2018 Axle Components All models: 13 Press and hold the enter button on the ground control panel while pulling out the ground 12 Remove the key from the main key switch. controls red Emergency Stop button to the on Insert the key into the bypass/recovery key position.
Page 183 October 2018 Service and Repair Manual Axle Components 26 Turn the key back to the run position and 18 Press the plus button to select YES, then remove the key from the bypass/recovery key press the enter button to accept. switch.
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Page 185: Fault Codes
October 2018 Service and Repair Manual Fault Codes Section 4 Faul t Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test Observe and Obey: equipment are available and ready for use.
Page 186: Control System Fault Codes
Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Primary Ext/Ret Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick. Check the connections to Value Too High ensure the connector terminals have not backed out.
Page 187 October 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up/Down Fault Check (both Primary Boom Up/Down disabled, Check ribbon and connector from buttons on TCON buttons pressed) display message on LCD membrane switch. If necessary replace membrane switch.
Page 188 Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Switch P3 Fault Check Internal fault not on Z135 Display message on LCD P3 SAFETY SWITCH FAULT Safety Switch P6R1 Fault Check Display message on LCD P6R1 Check wiring for circuit P53LS SAFETY SWITCH FAULT (white/black wire) for damage resulting...
Page 189 October 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Safety Switch P10 Fault Check Recycle power Display message on LCD P10 SAFETY SWITCH FAULT Safety Switch P11 Fault Check Display message on LCD P11 SAFETY Recycle power and check wiring on SWITCH FAULT circuit S140ENL (orange/black)
Page 190 Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Platform Overload Fault Check Display message on LCD. Disable all Check for an overload in the platform. (if active) functions from PCON. Limit functions at Check the overload switch mounted on TCON to AUX Power.
Page 191 October 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Not calibrated Calibrate Thresholds Primary Boom Up/Down Normal function except threshold for Flow Valve one or the other direction is zero. Display message on LCD Just calibrated Initiate one second beep of audible Self-clearing (transient)
Page 192 Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Primary Boom Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
Page 193 October 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Fault Check Secondary Boom Limited Speed and Direction frozen at Check for defective or damaged wiring. Extend Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil. Repair or replace as necessary.
Page 194 Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Value at 5.0 V Safety Secondary Boom Primary up, Secondary up/down and Check for an open ground circuit going Angle Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
Page 195 October 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick. Check the connections to ensure the connector terminals have Value Too High not backed out.
Page 196 Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Value at 5.0 V Check that SCON is grounded Safety Turntable Level Primary up and extend disabled, Alarm Sensor Y Direction sounds Value Too High Replace SCON Value Too Low Value at 0 V...
Page 197 October 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Not calibrated Perform calibration procedure Jib Level (Bellcrank) Normal function except threshold for Up/Down Flow Valve(s) one or the other direction is zero. Display message on LCD Just calibrated Initiate one second beep of audible Self-clearing (transient)
Page 198 Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Jib Extend/Retract Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick. Check the connections to ensure the connector terminals have not backed out.
Page 199 October 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Rear Axle Angle Sensor Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and Sensor is out of range.
Page 200 Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Left Front Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
Page 201 October 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Value at 5.0 V Right Rear Steer Angle Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
Page 202 Service and Repair Manual October 2018 Fault Codes Error Source Error Type Effects Recovery Actions Inhibit Secondary Boom Extend if the If the fault occurs on extend, retract Secondary Boom Switch Too much time Timeout has elapsed from fault occurs. boom until LSS1RO is engaged and try when LSS1RO is again.
Page 203: Fault Matrix
October 2018 Service and Repair Manual Fault Codes P_38 - Propel P_39 - Turntable P_10 - Primary P_11 - Primary / P_9B - P_30 - Secondary Rotate Boom Extend Secondary Up Ignition/Fuel Extend/Down P_38 P_39 P_10 P_11 P_30 P_9B Turntable tilt Y axis (+5°, secondary boom not stowed) Primary Boom angle (crosscheck) Secondary Boom angle (crosscheck) Secondary Boom safety (not retracted and not raised)
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Page 205: Schematics
October 2018 Service and Repair Manual Schematics Section 5 Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.
Page 206: Wire Circuit Legend
Service and Repair Manual October 2018 Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the circuit prefix, circuit number and circuit suffix. Control The circuit prefix indicates the type of circuit. Data The circuit number describes the function of the circuit.
Page 207 October 2018 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Auxiliary Boom Valve Engine Speed Select Alternator Field Axle Front Position Auxiliary Forward Valve Flashing Beacon Auxiliary Hydraulic Pump Function Enable Angle Fuel Select (gas/LP) Auxiliary Platform Valve Filter Restricted Auxiliary Reverse Valve Filter Switch...
Page 208 Service and Repair Manual October 2018 Wire Circuit Legend Suffix Definition Suffix Definition Jib Select Valve Platform Level Flow Control Jib Up Propel Lockout Jib Up/Down Control Primary Boom Extend/Retract Signal Load Sensor Platform Level Up Left Front Platform Rotate Control Left Front Steer Sensor Platform Rotate Flow Control Lockout...
Page 209 October 2018 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Right Rear Steer Sensor Starter Rotary Sensor Sec Boom Up/Down Flow Control Start Aid (Glow Plug or choke) Tilt Alarm X axis Secondary Boom Tilt Alarm Y axis Sec Boom Down Ground Control Sec Boom Extend...
Page 210: Wire Color Legend
Service and Repair Manual October 2018 Wire Color Legend Power Circuits Wire Coloring All cylinder extension colors are solid and all Primary boom down valve retract functions are striped black. When using Engine ignition / Fuel black wire, the stripe shall be white. Primary boom extend valve All rotations that are LEFT or CW are solid, Primary boom up valve...
Page 211 October 2018 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Primary boom up driver WH/RD Power to temp sender RD/BK Primary boom down driver Auxiliary Power RD/WH Primary boom up/down flow RD/BK Platform level alarm control proportional valve driver...
Page 212 Service and Repair Manual October 2018 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function GR/BK Axle oscillation Hydraulic Filter restricted Foot switch/TCON estop power Platform Level Safety Power RD/WH Boom down safety interlock RD/BK Platform Level Safety Output RD/BK Safety interlock to engine Platform Level Safety Ground...
Page 213 October 2018 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Flashing Beacon Primary Boom Angle Signal Safety Lift Speed Reduction Secondary Boom Angle Signal Hydraulic Pressure Sensor Output Safety Oil Cooler Fan BL/RD Drive Enable Left Axle Oscillate Left...
Page 214 Service and Repair Manual October 2018 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Boom Length Signal Safety Safety cross check OR/BK Boom Length Signal Operational Data Receive BL/RD Primary Boom Hydraulic Valve BK/WH Data Transmit Lockout WH/RD Multi-Function Pressure Relief...
Page 215: Limit Switches And Angle Sensors
October 2018 Service and Repair Manual Limit Switches and Angle Sensors Limit Switch Legend 1 RSP1AO 14 Plat Angle Sensor 2 RSP1AS 15 PCON 3 LSP1RO 16 SCON 4 LST2O 17 RSRA1SO 5 LST1O 18 LSRA1ES 6 LST1S 19 RSLR1SO 7 LSS1RS 20 RSRR1SO 8 LSS1RO...
Page 216 Service and Repair Manual October 2018 Limit Switches and Angle Sensors Numbering Legend Types of Limit Switches Limit Front Circuit Load Operational Switch Axle Number moment There are two types of limit switches, found in Rear Stringpot Angle Safety various locations throughout the machine: Axle mechanical-type operational/safety switches and Rotary...
Page 217 October 2018 Service and Repair Manual Limit Switches and Angle Sensors LSFA1ES: Limit switch, Front Axle #1 Extended Safety. Prevents boom functions with the axles Rotary Sensor Numbering retracted. Switch closes when axles are fully extended. RSP1AO Primary boom angle sensor RSP1AS Primary boom angle sensor, safety LSRA1ES: Limit switch, Rear Axle #1 Extended...
Page 218 Service and Repair Manual October 2018 Limit Switches and Angle Sensors RSRA1O: Rotary Sensor, Rear Axle #1 Operational. Provides front axle positioning Rotary Sensor Functions information for adjusting steering neutral setting during axle extension. RSP1AO: Rotary Sensor, Primary #1 Angle Operational.
Page 219: Circuit Connector Legend
October 2018 Service and Repair Manual Circuit Connector Legend Number Description Number Description Ribbon connector from TCON to membrane 2 pin Deutsch connector for primary boom up valve Ribbon connector from TCON to membrane 2 pin Deutsch connector for primary boom down valve Black 23 pin AMP connector on TCON 2 pin Deutsch connector for primary boom...
Page 220 Service and Repair Manual October 2018 Circuit Connector Legend Number Description Number Description 2 pin Deutsch connector for two-speed motor J121 12 pin Deutsch gray SCON connector stroke valve J122 12 pin Deutsch black SCON connector 2 pin Deutsch connector for right rear steer J124 2 pin Deutsch connector for drive enable right valve...
Page 221 October 2018 Service and Repair Manual Circuit Connector Legend Number Description Number Description J148 1 way Deutsch connector for platform J223 CAN Gateway 8 pin Molex connector ground jib/primary J224 Telematics connector J149 2 pin Deutsch connector, boom composite J228 Gateway to TCON interface connector J150 4 pin Deutsch connector, boom composite...
Page 222: Drive Chassis And Platform Controller Pin Legend
Service and Repair Manual October 2018 Drive Chassis and Platform Controller Pin Legend Pin Numbering - 23 pin connector Pin Numbering - 35 pin connector Plat Controller Plat Controller Drive Chassis Drive Chassis GNDPCON - BR VLVRET1 - BR VLVRET1 - BR GND-DCON - BR P52PCON - WH V153JBE - BK...
Page 223: Safety Controller Pin Legend
October 2018 Service and Repair Manual Safety Controller Pin Legend J121 Safety Controller Pin Numbering for 12 pin connectors J122 Safety Controller S132LDS - BL/WH P21DCON - WH S73SLE - BL/RD C142SBS - OR (UNUSED) C141PBS - RD C145CAL - RD/WH C60AXE - GR/WH (UNUSED) S12SB - BL/WH...
Page 224: Turntable Controller Pin Legend
Service and Repair Manual October 2018 Turntable Controller Pin Legend Pin Numbering - 35 pin connector Pin Numbering - 23 pin connector Pin Numbering - 4 pin connector Turntable Turntable Turntable Turntable Controller Controller Controller Controller VLVRET4 - BR GNDPCON - BR GNDSCON - BR (UNUSED) V03PUD - RD/WH...
Page 225: Engine Relay And Fuse Panel Legend - Deutz Bf4L 2011, Td2011L04I, Perkins 1104C-44 And 804D-33T
October 2018 Service and Repair Manual Engine Relay and Fuse Panel Legend - Deutz BF4L 2011, TD2011L04i, Perkins 1104C-44 and 804D-33T Number Component Description CR28 Engine / Fuel Relay CR17 Hydraulic Oil Cooler Fan Relay CR41 Flashing Beacon Relay Horn Relay CB10 Circuit Breaker, 20A, RPM Solenoid Fuse, 30A, Engine / Start / Alternator...
Page 226: Engine Relay And Fuse Panel Legend - Cummins B4.5L And B3.3T
Service and Repair Manual October 2018 Engine Relay and Fuse Panel Legend - Cummins B4.5L and B3.3T Number Component Description CR28 Engine Run / Alternator Relay CR17 Hydraulic Oil Cooler Fan Relay CR41 Flashing Beacon Relay Horn Relay CB10 Circuit Breaker, 20A, RPM Solenoid Fuse, 30A, Engine / Start / Alternator Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler Fan / Horn...
Page 227: Electrical Symbols Legend
October 2018 Service and Repair Manual Electrical Symbols Legend Battery Motor Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid Connection - no Circuits crossing no Quick disconnect Circuit breaker with...
Page 228: Hydraulic Symbols Legend
Service and Repair Manual October 2018 Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve or motor) 3 way...
Page 229 October 2018 Service and Repair Manual Perkins 1104C-44 and 804D-33T Engine Electrical Schematic...
Page 230: Perkins 1104C-44 And 804D-33T Engine Electrical Schematic
Service and Repair Manual October 2018 Perkins 1104C-44 and 804D-33T Engine Electrical Schematic Z®-135/70 Part No. 1268557GT...
Page 231: Cummins B4.5L And B3-3.3T Engine Electrical Schematic
October 2018 Service and Repair Manual Cummins B4.5L and B3.3T Engine Electrical Schematic Part No. 1268557GT Z®-135/70...
Page 232 Service and Repair Manual October 2018 Cummins B4.5L and B3.3T Engine Electrical Schematic...
Page 233 October 2018 Service and Repair Manual Generator Wiring Schematic...
Page 234: Generator Wiring Schematic
Service and Repair Manual October 2018 Generator Wiring Schematic Z®-135/70 Part No. 1268557GT...
Page 235: Hydraulic Generator (Welder Option)
October 2018 Service and Repair Manual Hydraulic Generator (Welder Option) Part No. 1268557GT Z®-135/70...
Page 236 Service and Repair Manual October 2018 Hydraulic Generator (Welder Option)
Page 237 October 2018 Service and Repair Manual Hydraulic Schematic (before serial number 180, except for serial number 102)
Page 238 Service and Repair Manual October 2018 Hydraulic Schematic (before serial number 180, except for serial number 102) Z®-135/70 Part No. 1268557GT...
Page 239 October 2018 Service and Repair Manual Hydraulic Schematic (serial number 102 and from serial number 180 to 534) Part No. 1268557GT Z®-135/70...
Page 240 Service and Repair Manual October 2018 Hydraulic Schematic (serial number 102 and from serial number 180 to 534)
Page 241: Hydraulic Schematic (Serial Number 102 And From Serial Number 180 To 534)
October 2018 Service and Repair Manual Hydraulic Schematic (from serial number 535) Part No. 1268557GT Z®-135/70...
Page 242 Service and Repair Manual October 2018 Hydraulic Schematic (from serial number 535)
Page 243: Electrical Schematic
SERVICE HORN (BN5) GENERATOR AUXILIARY START ENGINE DRIVE AXLE ENGINE DRIVE STEER MODE STEER MODE SPARE ON/OFF PUMP ASSIST START ENABLE EXT/RET SPEED SPEED SELECT SELECT (TS17) (TS1) (TS6) (TS2) (TS15) (TS23) (TS4) (TS5) (TS22) (TS22) (TSx) BL/WH ESTOP SERV BYPASS GROUND NC 1 RECOVERY...

Terex Genie Z-135/70 Service And Repair Manual

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