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Genie Z-135/70 Service & Repair Manual 1268557 – PDF DOWNLOAD
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Genie Z-135/70 Service & Repair Manual 1268557 – PDF DOWNLOAD
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Description
Genie Z-135/70 Service & Repair Manual 1268557 – PDF DOWNLOAD
Language : English
Pages : 244
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie Z-135/70 Service & Repair Manual 1268557 – PDF DOWNLOAD
Front Cover ........................................................................................... 1 Introduction .......................................................................................... 2 Important Information.............................................................................. 2 Find a Manual for this Model....................................................................... 2 Serial Number Legend............................................................................... 4 Safety Rules....................................................................................... 5 Table of Contents ..................................................................................... 7 Section 2 Specifications............................................................................... 15 Machine Specifications............................................................................. 15 Performance Specifications......................................................................... 15 Hydraulic Specification............................................................................ 16 Hydraulic Component Specifications................................................................. 19 Deutz BF4L 2011 Engine Specifications.............................................................. 21 Deutz TD2011L04i Engine Specifications............................................................. 23 Cummins B4.5L Engine Specifications................................................................ 25 Cummins B3.3T Engine Specifications................................................................ 27 Perkins 1104C-44 Engine Specifications............................................................. 29 Perkins 804D-33T Engine Specifications............................................................. 31 Machine Torque Specifications...................................................................... 33 Hydraulic Hose and Fitting Torque Specifications................................................... 34 Torque Procedure................................................................................... 35 SAE and Metric Fasteners Torque Charts............................................................. 37 Section 3 Repair Procedures............................................................................ 38 Introduction....................................................................................... 38 Platform Controls.................................................................................. 40 Platform Controls.............................................................................. 40 1-1 Platform Circuit Board..................................................................... 41 How to Remove the LED Circuit Board........................................................ 42 1-2 Membrane Decal............................................................................. 43 1-3 Joysticks - How to Calibrate a Joystick.................................................... 44 How to Reset a Proportional Valve Coil Default............................................. 48 How to Set the Function Thresholds and Default Functions Speeds............................ 48 How to Adjust the Function Speeds.......................................................... 50 How to Adjust the Function Ramp Rate Setting............................................... 51 Platform Components................................................................................ 53 2-1 Platform Leveling Cylinder................................................................. 53 2-2 Platform Rotator........................................................................... 54 How to Bleed the Platform Rotator.......................................................... 55 2-3 Platform Level Sensor - How to Calibrate the Platform Level Sensor......................... 56 2-4 Platform Overload System (if equipped)..................................................... 57 Jib Boom Components................................................................................ 60 3-1 Jib Boom Cable Track....................................................................... 61 How to Repair the Cable Track.............................................................. 63 3-2 Jib Boom................................................................................... 64 3-3 Jib Boom Lift Cylinder..................................................................... 66 3-4 Jib Boom Level Cylinder.................................................................... 67 3-5 Jib Boom Extension Cylinder................................................................ 68 3-6 Jib Boom Bellcrank Angle Sensor............................................................ 70 How to Calibrate the Jib Boom Bellcrank Angle Sensor....................................... 72 Boom Components.................................................................................... 78 4-1 Primary Boom Cable Track................................................................... 79 How to Repair the Primary Boom Cable Track................................................. 81 4-2 Secondary Boom Cable Track................................................................. 82 How to Repair the Secondary Boom Cable Track............................................... 84 4-3 Primary Boom............................................................................... 85 4-4 Primary Boom Lift Cylinder................................................................. 87 4-5 Secondary Boom Lift Cylinder............................................................... 88 4-6 Primary Boom Extension Cylinder............................................................ 92 4-7 Secondary Boom Extension Cylinders......................................................... 93 4-8 Primary Boom Angle Sensor.................................................................. 95 How to Calibrate the Primary Boom Angle Sensor............................................. 96 4-9 Secondary Boom Angle Sensor................................................................102 How to Calibrate the Secondary Boom Angle Sensor...........................................103 Engines............................................................................................109 5-1 RPM Adjustment.............................................................................109 5-2 Flex Plate.................................................................................109 How to install a Type "A" Flex Plate.......................................................110 How to install a Type "B" Flex Plate.......................................................112 Ground Controls....................................................................................113 6-1 Bypass/Recovery Key Switch.................................................................113 How to Use the Recovery Mode...............................................................115 6-2 Circuit Boards.............................................................................116 6-3 Membrane Decal.............................................................................118 6-4 Full Machine Calibration...................................................................119 Display Module.....................................................................................120 Hydraulic Pumps....................................................................................129 7-1 Function Pump..............................................................................129 How to Prime the Function Pump.............................................................130 How to Adjust the Function Pump Standby Pressure...........................................130 How to Adjust the Function Pump Pressure Compensator.......................................131 7-2 Drive Pump.................................................................................132 How to Prime the Drive Pump................................................................133 Manifolds..........................................................................................134 8-1 Function Manifold - (before serial number 440).............................................134 8-2 Function Manifold - (after serial number 439)..............................................138 8-3 Valve Adjustments - Function Manifold......................................................142 How to Adjust the System Relief Valve......................................................142 How to Adjust the Primary Boom Extend Relief Valve.........................................143 8-4 Platform Manifold..........................................................................145 8-5 Jib Boom Manifold..........................................................................146 8-6 Flow Control Mainfold......................................................................148 8-7 Function Enable Valve......................................................................149 8-8 Turntable Rotation Manifold................................................................150 8-9 Steer and Axle Manifold....................................................................152 8-10 Valve Adjustments - Steer and Axle Manifold...............................................156 8-11 Traction Manifold.........................................................................158 8-12 Valve Adjustments - Traction Manifold.....................................................162 8-13 Drive Oil Diverter Manifold (welder option)...............................................163 8-14 Valve Coils...............................................................................164 Turntable Rotation Components......................................................................166 9-1 Turntable Rotation Assembly................................................................166 How to Adjust the Turntable Rotation Gear Backlash.........................................167 9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor.......................168 Axle Components....................................................................................172 10-1 Steer Sensors.............................................................................172 How to Calibrate a Replacement Steer Sensor................................................174 How to Calibrate All Steer Sensors.........................................................175 10-2 Steer Cylinders...........................................................................177 10-3 Axle Extension Cylinders..................................................................178 10-4 Axle Angle Sensors........................................................................179 How to Calibrate the Axle Angle Sensors....................................................181 Section 4 Fault Codes..................................................................................185 Introduction.......................................................................................185 Control System Fault Codes.........................................................................186 Fault Matrix.......................................................................................203 Section 5 Schematics...................................................................................205 Introduction.......................................................................................205 Wire Circuit Legend................................................................................206 Wire Color Legend..................................................................................210 Limit Switches and Angle Sensors...................................................................215 Circuit Connector Legend...........................................................................219 Drive Chassis and Platform Controller Pin Legend...................................................222 Safety Controller Pin Legend.......................................................................223 Turntable Controller Pin Legend....................................................................224 Engine Relay and Fuse Panel Legend - Deutz BF4L 2011, TD2011L04i, Perkins 1104C-44 and 804D-33T....225 Engine Relay and Fuse Panel Legend - Cummins B4.5L and B3.3T.......................................226 Electrical Symbols Legend..........................................................................227 Hydraulic Symbols Legend...........................................................................228 Perkins 1104C-44 and 804D-33T Engine Electrical Schematic..........................................230 Cummins B4.5L and B3-3.3T Engine Electrical Schematic..............................................231 Generator Wiring Schematic.........................................................................234 Hydraulic Generator (Welder Option)................................................................235 Hydraulic Schematic (before serial number 180, except for serial number 102).......................238 Hydraulic Schematic (serial number 102 and from serial number 180 to 534)..........................239 Hydraulic Schematic (from serial number 535).......................................................241 Electrical Schematic...............................................................................243
S.S 05/24
