Genie Maintenance Manuals From SN 05-101 to 13-2000 Service Manual

Service and Repair Manual

Serial Number Range

Z®-135/70

from Z13505-101 to

2000

This manual includes: Repair 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

Z13513-

procedures

Service and Repair Manual October 2018

Introduction

Introducti on Introducti on

Important

Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any procedure.

This manual provides troubleshooting and repair procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center.

Technical Publications

Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice.

Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.

Contact Us:

Internet: www.genielift.com E-mail: awp.techpub@terex.com

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operatio n, inspec t ion and scheduled maintenance.

Find a Manual for this Model

Go to http://www.genielift.com Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair Manuals, Parts Manuals and Operator's Manuals.

the U.S.A. and many other countries. “Z” is a trademark of Terex South Dakota, Inc.

ii Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Revision

Date

Section

Procedure / Page / Description

A4 10/2018

Specifications

Reference Examples:

Introduction

Revision Histor y

A 9/2015 A1

A2

A3

11/2015 6/2016

3/2018

Initial Release

Schematics Specifications Repair Repair

Wire Color Legend Performance Specifications Procedures 4-9, 6-1 Display Module Perfromance Specifications

Section – Repair Procedure, 4-2 Section – Fault Codes, All charts Section – Schematics, Legends and schematics

Part No. 1268557GT Z®-135/70 iii

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

Electronic Version

the update.

Service and Repair Manual October 2018

Introduction

Serial Number Legend

1 Model 2 Model year 3 Sequence number 4 Serial label (located under cover)

iv Z®-135/70 Part No. 1268557GT

5 Serial number (stamped on chassis)

October 2018 Service and Repair Manual

Safety Rules

Section 1 Safety Rules

Danger

Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury.

Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.

Do Not Perform Maintenance Unless:

R You are trained and qualified to perform

maintenance on this machine.

R You read, understand and obey:

• manufacturer's instructions and safety rules

• employer's safety rules and worksite

regulations

• applicable governmental regulations

R You ha ve the appr o priate tools, lifting

equipment and a suitable workshop.

Part No. 1268557GT Z®-135/70 v

Service and Repair Manual October 2018

R manual and the decals on the machine, use signal words to identify the following:

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to

Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Be sure to wear protective eye wear and other warrants it.

Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel

Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible and engine fuels. Always have an approved fire extinguisher within easy reach.

Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get in components and cause damage.

Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample

Be sure that fasteners intended for one time use (i.e., cotter pins and self nuts) are not reused. These components may fail if they are used a second time.

Be sure to properly dispose of old oil or other fluids. Use an approved Please be environmentally safe.

Be sure that your workshop or work area is properly ventilated and well lit.

Safety Rules

Personal Safety

Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

ead each procedure thoroughly. This

avoid possible injury or death.

Workplace Safety

Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

materials like battery gases

to machine

capacity.

protective clothing if the situation

-toed shoes.

-locking

container.

vi Z®-135/70 Part No. 1268557GT

October 2018

Section 2 Specificati ons

Machine Specificati ons

-filled

46.5 i

22.5 i

13 i

10 @ 3/4 -

420 ft-

320 ft-

40 g

65 g

123 g

47 f

40 f

0 multipurpose hypoid gear oil

815 l

370 k

118.1 c

57.2 c

151.4 l

246 l

466 l

1390 c

1183 c

33 c

Performance Specifications

2.8 m

4.5 k

40 ft / 9.7 s

12.2 m / 9.7 s

0.7 m

1.1 k

40 ft / 40 s

12.2 m / 40 s

0.4 m

Primary and Jib

12.2 m / 68.5 s

3 to 6 f

up/down 38 to 43 s

27 to 38 s

60° to +70°

35 to 48 s

80 to 95 s

110 to 125 s

88 to 98 s

88 to 92 s

160 to 180 s

280 to 350 s

For operational specifications, refer to the Operator's Manual.

0.6 k

40 ft / 68.5 s

1 to 2

Part No. 1268557GT Z®-135/70 1

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Service and Repair Manual October 2018

Hydraulic Fluid Specifications

Genie specifications require designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation prevention, corrosio n conditioning, and foam and aeration suppression properties.

Cleanliness level, minimum

ISO 15/13

Water content, maximum

pm

Recommended Hydraulic Fluid

Hydraulic oil type

Chevron Rando HD Premium

Viscosity grade

32

Viscosity

200

Optional Hydraulic Fluids

Mineral based Shell Tellus S2 V 32

Shell Tellus S2 V 46

Shell Tellus S4 VX 32 Shell

Shell Donax TG (Dexron III)

Chevron 5606A

Biodegradable

46

Fire resistant

5046

Optional fluids may not have the same hydraulic lifespan and may result in component dama

Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the differences in base additive chemistry. When incompatible fluids are mixed, insoluble materials may form and deposit in the hydraulic system, plugging hydraulic lines, filt control valves and may result in component damage.

Specifications

Hydraulic Oil Specifica t ions

hydraulic oils which are

inhibition, seal

index

250 p

ers,

Note: Do not operate the machine when the ambient air temperature is consistently above 120°F / 49°C.

Hydraulic Fluid Tempera t ure Range

Petro Canada Environ MV

UCON Hydrolube HP-

Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult Genie Product Support before use.

ge.

Note: Extended machine operation can cause the hydraulic fluid temperature to increase beyond it's maximum allowable range. If the hydraulic fluid temperature consistently exceeds 200°F / 90°C an optional oil cooler may be required.

2 Z®-135/70 Part No. 1268557GT

Ambient air temperature

1 Chevron hydraulic oil 5606A 2 Petro-Canada Environ MV 46 3 UCON Hydrolube HP-5046D 4 Chevron Rando HD premium oil MV

October 2018 Service and Repair Manual

ISO Grade

32

Viscosity index 200

Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C

7.5

33.5

Brookfield Viscosity cP @ cP @

1040 3310

Flash point 375°F / 190°C

Pour point

50°C

Maximum continuous operating temperature

171°F / 77°C

ISO Grade

15

Viscosity index 300

Kinematic Viscosity cSt @ 200°F / 100°C cSt @ cSt @

5.5

15.0 510

Flash point 180°F / 82°C

Pour point

63°C

Maximum continuous operating temperature

124°F / 51°C

Specifications

Chevron Rando HD Premium Oil MV Fluid Properties

Chevron 5606A Hydraulic Oil Fluid Properties

-4°F / -20°C

-22°F / -30°C

-58°F / -

Note: A hydraulic oil heating system is recommended when the ambient temperature is consistently below 0°F / -18°C.

Note: Do not operate the machine when the ambient temperature is below -20°F / -29 °C w ith Rando HD Premium MV.

104°F / 40°C

-40°F / -40°C

-81°F / -

Note: Use of Chevron 5606A hydraulic fluid, or equivalent, is required when ambient temperatures are consistently below 0°F / -17°C unless an oil heating system is used.

Continued use of Chevron 5606A hydraulic fluid, or equivalent, when ambient temperatures are consistently above 32°F / 0°C may result in component damage

Part No. 1268557GT Z®-135/70 3

Service and Repair Manual October 2018

ISO Grade

46

Viscosity index 154

Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C

8.0

44.4

Flash point 482°F / 250°C

Pour point

45°C

Maximum continuous operating temperature

180°F / 82°C

ISO Grade

32

Viscosity index 300

Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C

9

33.8

Brookfield Viscosity cSt @ cSt @ cSt @

481

702.4 2624

Flash point >100

Pour point

60°C

Maximum continuous operating temperature

103°F / 75°C

ISO Grade

46

Viscosity index 192

Kinematic Viscosity cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 0°F /

22 46

1300

Flash point None

Pour

63°C

Maximum continuous operating temperature

189°F / 87°C

Specifications

Petro-Canada Environ MV 46 Fluid Properties

-49°F / -

UCON Hydrolube HP-5046 Fluid Properties

-18°C

Shell Tellus S4 VX Fluid Properties

-4°F / -20°C

-13°F / -25°C

-40°F / -40°C

-76°F / -

point -81°F / -

4 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Drive Pump

Type: bi

Displacement per revolution

u in

c

Flow rate @ 235

pm

108 L/min

Drive pressure, maximum

si

ar

Charge Pump

Type

gerotor

Displacement per revolution

u in

c

Flow rate @ 235

pm

34 L/min

Charge pressure @ 235 Neutral position

s

ar

Function pump

Type: variable displacement piston pu mp

Displacement per revolution

u in

c

Flow rate @ 235

pm

Pressure, maximum

si

ar

Pressure compensator

si

ar

Standby

si

ar

Auxiliary Pump

Type: fixed displacement gear pump

Displacement per revolution

u in

c

Function manifold

System relief valve pressure, maximum (measured at test port)

si

ar

Primary boom extend (measured at ptest port)

si

ar

Jib and platform manifolds

Platform rotate and platform level flow regulator

pm

0.76 L/min

Jib manifold flow regulator

pm

7.6 L/min

Steer/Axle Manifold

Axle extend relief pressure

si

ar

Traction Manifold

Hot oil relief pressure

si

ar

Hydraulic Filters

High pressure filter:

Beta 3 ≥ 200

High pressure filter bypass pressure

si

ar

Medium pressure filter

Beta 3 ≥ 200

Medium pressure filter bypass

si

ar

Hydraulic tank return filter

icron

si /

ar

bypass

Drive motor case drain return filter

Beta 10 ≥ 2

Specifications

Hydraulic Component Specifications

-directional varia ble displacement piston pump

2.8 c

0 rpm 28.5 g

3625 p

0.85 c

0 rpm 9 g

0 rpm

0 to 2.75 c

0 rpm 0 to 28 g

2900 p

pressure 250 p

46 c

250 b

13.9 c

315 p

i21.7 b

0 to 45 c

0 to 106 L/min

200 b

17 b

0.15 c

2.47 c

relief pressure

2 g

2400 p

250 p

102 p

pressure 51 p

10 m

3100 p

213.7 b 2600 p

179 b

0.2 g

165 b

17.2 b

7 b

3.5 b

with 25 p

1.7 b

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1268557GT Z®-135/70 5

Service and Repair Manual October 2018

Brakes

Brake relief pressure

si

ar

Drive Motors (before serial number 180) (see note below)

Displacement per revolution, high speed

u in

c

Displacement per revolution, low speed (square end)

u in

c

Displacement per revolution, low speed (circle end)

u in

c

Drive Motors (after serial number 179)

Manifold Component Specifications

Plug torque

SAE No. 2

SAE No. 4

lbs / 13 Nm

SAE No. 6

lbs / 19 Nm

SAE No. 8

lbs / 51 Nm

SAE No. 10

lbs / 55 Nm

SAE No. 12

lbs / 76 Nm

Valve coil resistance specifications

Proportional solenoid valve (schematic items N, P, R, T, V)

o

5.5Ω

Solenoid valve, (schematic item B)

Solenoid valve, (schematic items BN, BO, BP, BQ)

Solenoid valve, (schematic item AH)

o 10Ω

Proportional solenoid valve, (schematic

o 10Ω

Solenoid Valve, (schematic items F and AD)

o

7.5Ω

Solenoid Valve, (schematic items AE, AF)

o 10Ω

Solenoid valve, (schematic items H, J)

o

5.5Ω

Solenoid Valve, (schematic items C, D, G, I, K, AX , AY, BU, BT)

o

9.5Ω

Solenoid valve, (schematic item A)

o

5.5Ω

Specifications

190 p

13 b

0.8 c

13.3 c

2.7 c 45 c

1.5 c 25 c

Displacement per revolution, high speed

Displacement per revolution, low speed (square end)

Displacement per revolution, low speed (circle end)

0.8 cu in

13.3 cc

2.7 cu in 45 cc

1.5 cu in 25 cc

Note: Serial number 102 is equipped with drive motors equal to those used on machines after serial number 179.

36 in-lbs / 4 Nm 10 ft 14 ft 38 ft-

41 ft 56 ft-

3.5 t

3 position 4 way

4 to 6Ω

3 position 4 way

7 to 9Ω

3 position 4 way

8 t

3 position 4 way

8 t

items Y, AI)

2 position 3 way

5.5 t

2 position 3 way

8 t

2 position 2 way

3.5 t

2 position 3 way

7.5 t

2 position 2 way

3.5 t

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

6 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Displacement

u. in

Number of cylinders

4

Bore and Stroke

nches

m

Horsepower net intermittent Continuous @ 250 Net

W W

Firing order

2

Low idle

pm

383 Hz

High idle

pm

599 Hz

Compression ratio

17.5:1

Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the cylinder

Governor

centrifugal

mechanical

Valve Clearance, cold

Intake

n

m

Exhaust

n

m

Lubrication system

Oil pressure, hot (@ 200

si

ar

Oil capacity (including filter)

uarts

iters

Oil viscosity requirements

-

30

(synthetic)

-

40

Above 23°F /

50

Unit ships with 15W temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil temperature switch

Installation torque

lbs

24 Nm

Temperature switch point

275°F

135°C

Oil Pressure switch

Installation torque

lbs

24 Nm

Pressure switch point

si

ar

Specifications

Deutz BF4L 2011 Engine

0 rpm

intermittent @ 2500 rpm

0.012 i

0.020 i

3.7 x 4.409 i

189.6 c

3.1 liters

94 x 112 m

69 hp / 51 k 73 hp / 54 k

1 - 3 - 4 -

1500 r

2350 r

highest

0.3 m

0.5 m

0 rpm) 40 to 60 p

2.8 to 4.1 b

11 q

10.4 l

22°F to 86°F / -30°C to 30°C 5W-

4°F to 90°F / -20°C to 32°C 10W-

-5°C 20W-

-40. Extreme operating

8 - 18 ft-

11 -

8 - 18 ft-

11 -

7 p

0.48 b

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1268557GT Z®-135/70 7

Service and Repair Manual October 2018

Fuel injection system

Motorpal

Injection pump pressure, maximum

si

ar

Injector opening pressure

si

ar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Starter motor

Current draw, normal load

200A

Cranking speed

pm

Battery

Type

6V DC

Quantity

2

Battery capacity, maximum

285 AH

Reserve capacity @ 25A rate

inutes

Battery

Type 12V DC, Group 31

Quantity

1

Battery capacity, maximum

1000A

Reserve

200 Minutes

Alternator output

80A @ 14V DC

Fan belt deflection

nch

m

Specifications

Deutz BF4L 2011 cont.

15,000 p

3046 p

140 -

200 - 250 r

– Auxiliary power units

745 m

– Engine starting and control system

1034 b

210 b

capacity @ 25A rate

3/8 to 1/2 i

9.5 to 12.5 m

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

8 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Displacement

u. in iters

Number of cylinders

4

Bore and Stroke

nches

m

Horsepower net intermittent @ 240

W

Induction system

turbocharged

Firing order

2

Low idle

pm

383 Hz

High idle

pm

599 Hz

Compression ratio

17.5:1

Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder

Governor

centrifugal

Valve Clearance, cold

Intake

n

m

Exhaust

n

m

Lubrication system

Oil pressure, hot (@ 200

si

ar

Oil capacity (including filter)

uarts

iters

Oil viscosity requirements

-

30

(synthetic)

-

40

Above 5°F /

40

Unit ships with 15W temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil temperature switch

Installation torque

lbs

24 Nm

Temperature switch point

275°F

135°C

Oil Pressure switch

Installation torque

lbs

24 Nm

Pressure switch point

si

ar

Specifications

Deutz TD2011L04i Engine

0 rpm

0.012 i

0.020 i

3.78 x 4.92 i

220.9 c

3.62 l

96 x 125 m

74 hp / 55 k

1 - 3 - 4 -

1500 r

2350 r

mechanical

0.3 m

0.5 m

0 rpm) 40 to 60 p

2.8 to 4.1 b

12.8 q

12.1 l

22°F to 86°F / -30°C to 30°C 5W-

4°F to 104°F / -20°C to 40°C 10W-

-15°C 15W-

-40. Extreme operating

8 - 18 ft-

11 -

8 - 18 ft-

11 -

22 p

1.5 b

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1268557GT Z®-135/70 9

Service and Repair Manual October 2018

Fuel injection system

Motorpal

Injection pump pressure, maximum

si

ar

Injector

si

ar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Starter motor

Current draw, normal load

200A

Cranking speed

pm

Battery

Type

DC

Quantity

2

Battery capacity, maximum

285 AH

Reserve capacity @ 25A rate

inutes

Battery

Type 12V DC, Group 31

Quantity

1

Battery capacity, maximum

1000A

Reserve capacity @ 25A rate

200 Minutes

Alternator

80A @ 14V DC

Fan belt deflection

nch

m

Specifications

Deutz TD2011L04i cont.

15,000 p

opening pressure 3046 p

140 -

250 - 350 r

– Auxiliary power units

6V

745 m

– Engine starting and control system

1034 b

210 b

output

3/8 to 1/2 i

9.5 to 12.5 m

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

10 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Displacement

u. in iters

Number of cylinders

4

Bore and Stroke

nches

m

Horsepower net intermittent @ 220

W

Firing order

2

Low idle

pm

368 Hz

High idle

pm

599 Hz

Compression ratio

18:1

Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder

Governor

centrifugal mechanical

Valve Clearance, cold

Intake

n

m

Exhaust

n

m

Lubrication system

Oil pressure, hot (@ 200

si

ar

Oil capacity (including filter)

uarts

iters

Oil viscosity requirements

Below 68°F / 20°C

30

-

40

Above 15°F /

40

Unit ships with temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Specifications

Cummins B4.5L Engine

0 rpm

0.010 i

0.020 i

4.02 x 5.42 i

275 c

4.5 l

102 x 138 m

80 hp / 60 k

1 - 3 - 4 -

1300 r

2350 r

0.254 m

0.508 m

0 rpm) 50 p

3.45 b

9.5 q 9 l

5W-

10°F to 68°F / -23°C to 20°C 10W-

-9°C 15W-

15W-40. Extreme operating

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1268557GT Z®-135/70 11

Service and Repair Manual October 2018

Fuel injection system

Delphi

Injection pump pressure, maximum

si

ar

Injector opening pressure

si

ar

Fuel requirement

For fuel requirements, refer to the Manual for your engine.

Engine coolant

Capacity

uarts

iters

Coolant temperature switch

Installation torque

lbs

24 Nm

Temperature switch point

230°F

110°C

Starter motor

Current draw, no load 125A

Brush

n

m

Battery

Type

6V DC

Quantity

2

Battery capacity, maximum

285 AH

Reserve capacity @ 25A rate

inutes

Battery

Type 12V DC, Group 31

Quantity

1

Battery

1000A

Reserve capacity @ 25A rate

200 Minutes

Alternator output

95A @ 12V DC

Fan belt deflection

nch

m

Specifications

Cummins B4.5L cont.

3480 to 3680 p

3480 p

engine Operator

17 q

8 - 18 ft-

240 to 254 b

240 b

16 l

11 -

length, minimum 0.72 i

18.3 m

– Auxiliary power units

745 m

– Engine starting and control system

capacity, maximum

3/8 to 1/2 i

9.5 to 12.5 m

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

12 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Displacement

u. in iters

Number of cylinders

4

Bore and Stroke

nches

m

Horsepower net intermittent @ 220

W

Firing order

3

Low idle

pm

368 Hz

High idle

pm

599 Hz

Compression ratio

17:1

Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder

Valve Clearance, cold

Intake

n

m

Exhaust

n

m

Lubrication system

Oil pressure, hot (@ 200

si

ar

Oil capacity (including filter)

uarts

iters

Oil viscosity requirements

Below 68°F / 20°C

30

-

40

Above 14°F /

40

Unit ships with 15W temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Specifications

Cummins B3.3T Engine

0 rpm

0.014 i

0.020 i

3.74 x 4.53 i

199 c

3.26 l

95 x 115 m

80 hp / 60 k

1 - 2 - 4 -

1300 r

2350 r

0.35 m

0.508 m

0 rpm) 31 p

72 b

9 q

8.5 l

5W-

10°F to 68°F / -23°C to 20°C 10W-

-10°C 15W-

-40. Extreme operating

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1268557GT Z®-135/70 13

Service and Repair Manual October 2018

Fuel injection system

Zexel

Injection pump pressure, maximum

si

ar

Fuel requirement

For fuel requirements, refer to the engine Manual for your engine.

Engine coolant

Capacity

uarts

iters

Starter motor

Current draw, maximum load

550A

Cranking speed

pm

Battery

Type

6V DC

Quantity

2

Battery capacity, maximum

285 AH

Reserve

inutes

Battery

Type 12V DC, Group 31

Quantity

1

Battery capacity, maximum

1000A

Reserve capacity @ 25A rate

200 Minutes

Alternator output

120A @ 12V DC

Fan belt deflection

nch

m

Specifications

Cummins B3.3T cont.

12,000 p

9.1 q

130 r

– Auxiliary power units

capacity @ 25A rate 745 m

– Engine starting and control system

827 b

Operator

8.6 l

3/8 to 1/2 i

9.5 to 12.5 m

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

14 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Displacement

u. in iters

Number of

4

Bore and Stroke

nches

m

Horsepower net intermittent Gross intermittent @ 240 Net intermittent @ 240

W W

Firing order

2

Low idle

pm

312 Hz

High idle

pm

572 Hz

Compression ratio

18.2:1

Compression pressure pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder

Governor

centrifugal

mechanical

Valve Clearance, cold

Intake

n

m

Exhaust

n

m

Lubrication system

Oil pressure, hot (@ 200

si

ar

Oil capacity (including filter)

uarts

iters

Oil viscosity requirements

Below 68°F / 20°C

20

10°F to 104°F /

40

Above 14°F /

40

Unit ships with 15W temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil Pressure switch

Installation torque

lbs

24 Nm

Pressure

si

ar

Fuel injection system

Injection pump make

Bosch

Injector opening pressure

si

ar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Specifications

Perkins 1104C-44

cylinders

0 rpm

0.008 i

0.018 i

268.5 c

4.4 l

4.13 x 5 i 105 x 127 m

86 hp / 64 k 83 hp / 62 k

1 - 3 - 4 -

1300 r

2350 r

0.2 m

0.45 m

0 rpm) 40 to 60 p

2.8 to 4.1 b

7.3 q

6.9 l

5W-

-12°C to 40°C 10W-

-10°C 15W-

-40. Extreme operating

8 - 18 ft-

11 -

switch point 8 p

0.55 b

2200 p

152 b

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1268557GT Z®-135/70 15

Service and Repair Manual October 2018

Starter motor

Current draw, normal load

200A

Cranking speed

pm

Battery

Type

6V DC

Quantity

2

Battery capacity, maximum

285 AH

Reserve capacity @ 25A rate

inutes

Battery – Engine starting and control system

Type 12V DC, Group 31

Quantity

1

Battery capacity, maximum

1000A

Reserve capacity @ 25A rate

200 Minutes

Engine

Capacity

uarts

iters

Coolant temperature switch

Installation torque

lbs

24 Nm

Temperature switch point

230°F

110°C

Alternator output

85A @ 13.8V DC

Fan belt deflection

nch

m

Specifications

Perkins 1104C-44 cont.

140 -

200 - 250 r

– Auxiliary power units

745 m

coolant

14 q

13.2 l

8 - 18 ft-

11 -

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

16 Z®-135/70 Part No. 1268557GT

3/8 i

9.5 m

October 2018 Service and Repair Manual

Displacement

u. in iters

Number of cylinders

4

Bore and Stroke

nches

m

Horsepower net intermittent Gross intermittent @ 220

W

Induction system

turbocharged

Firing order

2

Low idle

pm

316 Hz

High idle

pm

572 Hz

Compression ratio

19.5:1

Compression pressure pressure lowest cylinder must be at least 75% of the highest cylinder

Governor

centrifugal

mechanical

Valve Clearance, cold

Intake

n

m

Exhaust

n

m

Lubrication system

Oil pressure, hot (@ 200

si

ar

Oil capacity (including filter)

uarts

iters

Oil viscosity requirements

Below 86°F / 30°C

20

-

30

Above 14°F /

40

Unit ships with 15W temperatures may oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil Pressure switch

Installation torque

lbs

24 Nm

Pressure switch point

si

ar

Fuel injection system

Injection pump make

Bosch

Injector opening pressure

si

ar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Specifications

Perkins 804D-33T

0 rpm

0.0098 i

3.7 x 4.72 i

(psi or bar) of the

203 c

3.33 l

94 x 120 m

83 hp / 62 k

1 - 3 - 4 -

1300 r

2350 r

0.25 m

0 rpm) 40 to 60 p

2.8 to 4.1 b

10.6 q 10 l

5W-

4°F to 104°F / -20°C to 40°C 10W-

-10°C 15W-

-40. Extreme operating

require the use of alternative engine

8 - 18 ft-

11 -

8 p

0.55 b

2200 p

152 b

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

Part No. 1268557GT Z®-135/70 17

Service and Repair Manual October 2018

Starter motor

Current draw, normal load

200A

Cranking speed

pm

Battery

Type

6V DC

Quantity

2

Battery capacity, maximum

285 AH

Reserve capacity @

inutes

Battery – Engine starting and control system

Type 12V DC, Group 31

Quantity

1

Battery capacity, maximum

1000A

Reserve capacity @ 25A rate

200 Minutes

Engine coolant

Capacity

uarts

iters

Coolant temperature switch

Installation torque

lbs

24 Nm

Temperature switch point

230°F

110°C

Alternator output

90A @ 12V DC

Fan belt deflection

nch

m

Specifications

Perkins 804D-33T cont.

250 r

– Auxiliary power units

25A rate 745 m

12.5 q

11.8 l

8 - 18 ft-

11 -

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or obligation.

18 Z®-135/70 Part No. 1268557GT

3/8 to 1/2 i

9.5 to 12.5 m

October 2018 Service and Repair Manual

Platform Rotator

1

lbs

651 Nm

3/8

lbs

60 Nm

Turntable rotate assembly

Rotate bearing (3/4

lbs

434 Nm

Rotate bearing mounting bolts, lubricated (5/8

lbs

244 Nm

Rotate drive hub mounting bolts, lubricated

lbs

108 Nm

Drive motor mounting bolts, dry

lbs

102 Nm

Drive

lbs

76 Nm

Backlash plate mounting bolts, lubricated

lbs

434 Nm

Drive motors and hubs

Drive hub mounting bolts, lubricated

lbs

217 Nm

Drive motor mounting bolts, dry

lbs

102 Nm

Drive motor

lbs

76 Nm

Engine vibration isolators

Mounting bolts, dry

lbs

81 Nm

Mounting bolts, lubricated

lbs

61 Nm

Specifications

Machine Torque Specifications

-8 center bolt, GR 5 480 ft-

-16 bolts, GR 8 44 ft-

mounting bolts, lubricated

-10 SHC)

-11 SHC)

75 ft-

motor mounting bolts, lubricated 56 ft-

320 ft-

180 ft-

80 ft-

320 ft-

180 ft-

75 ft-

mounting bolts, lubricated 56 ft-

60 ft-

45 ft-

Continuous improvement of our produ cts is a Genie policy. Product specifications are subject to change without notice or ob ligation.

Part No. 1268557GT Z®-135/70 19

Service and Repair Manual October 2018

Specifications

Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok™ ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.

Seal-Lok™ Fittings

(hose end - ORFS)

SAE Dash Size Torque

-4 10 ft-lbs / 13.6 Nm

-6 30 ft-lbs / 40.7 Nm

-8 40 ft-lbs / 54.2 Nm

-10 60 ft-lbs / 81.3 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

SAE O-ring Boss Port

(tube fitting - installed into Aluminum)

(all types)

SAE Dash Size Torque

-4 14 ft-lbs / 19 Nm

-6 23 ft-lbs / 31.2 Nm

-8 36 ft-lbs / 54.2 Nm

-10 62 ft-lbs / 84 Nm

-12 84 ft-lbs / 114 Nm

-16 125 ft-lbs / 169.5 Nm

-20 151 ft-lbs / 204.7 Nm

-24 184 ft-lbs / 249.5 Nm

JIC 37° Fittings

(swivel nut or hose connection)

SAE Dash Size Thread Size Flats

-4 7/16-20 2

-6 9/16-18 1 ¼

-8 3/4-16 1

-10 7/8-14 1

-12 1 1/16-12 1

-16 1 5/16-12 1

-20 1 5/8-12 1

-24 1 7/8-12 1

Adjustable Fitting Non-adjustable fitting

1 jam nut

SAE O-ring Boss Port

(tube fitting - installed into Steel)

SAE Dash Size Torque

-4 ORFS / 37° (Adj) ORFS (Non-adj) 37° (Non-adj)

-6 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)

-8 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)

-10 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)

-12 (All types) 135 ft-lbs / 183 Nm

-16 (All types) 200 ft-lbs / 271.2 Nm

-20 (All types) 250 ft-lbs / 339 Nm

-24 (All types) 305 ft-lbs / 413.5 Nm

15 ft-lbs / 20.3 Nm 26 ft-lbs / 35.3 Nm

22 ft-lbs / 30 Nm

35 ft-lbs / 47.5 Nm 29 ft-lbs / 39.3 Nm

60 ft-lbs / 81.3 Nm 52 ft-lbs / 70.5 Nm

100 ft-lbs / 135.6 Nm

85 ft-lbs / 115.3 Nm

20 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Specifications

Torque Procedure

Seal-Lok™ fittings

1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.

Note: The O-ring in Parker Seal Lok™ fittings and hose end are custom-size O-rings. They are not standard size O-rings. T he y are avai lable in the O-ring field service kit (Genie part number 49612).

2 Lubricate the O-ring before installation. 3 Be sure the O-ring face seal is seated and

retained properly.

4 Position the tube and nut squarely on the face

seal end of the fitting, and tighten the nut finger tight.

5 Tighten the nut or fitting to the appropriate

torque. Refer to the appropriate torque chart in this section.

6 Operate all machine functions and inspect the

hose, fittings and related components to confirm there are no leaks.

JIC 37° fittings

1 Align the tube flare (hex nut) against the nose

of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, approximately 30 in-lbs / 3.4 Nm.

2 Using a permanent ink marker, make a

reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting. Refer to Illustration 1.

Illustration 1

1 hex nut 2 reference mark 3 body hex fitting

Part No. 1268557GT Z®-135/70 21

Service and Repair Manual October 2018

Specifications

3 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.

Note: The marks indicate the correct tightening positions have been determined. Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened.

Illustration 2

1 body hex fitting 2 reference mark 3 second mark

4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the body hex fitting.

5 Operate all machine functions and inspect the

hose, fittings and related components to confirm there are no leaks.

22 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Specifications

T

Part No. 1268557GT Z®-135/70 23

Service and Repair Manual October 2018

Repair Procedures

Section 3 Repair Proc edures

Observe and Obey:

R Repair procedures shall be completed by a

person trained and qualified on the repair of this machine.

R I m m ediate ly tag and remove from service a

damaged or malfunctioning machine.

R Repair any machine damage or malfunction

before operating the machine.

Before Repairs Start:

R Read, understand and obey the safety rules

and operating instructions in the appropriate operator's manual on your machine.

Machine Configuration:

R 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

removed

• The red Emergency Stop button in the off position at both the ground and platform controls

• Wheels chocked

• All external AC power suppl y discon nect ed

from the machine

• Boom in the stowed position

• Turntable secured with the turntable rotation

lock

R Be sure that all necessary tools and parts are

available and ready for use.

R Use only Genie approved replacement parts. R R ead each pr oc edure com plet ely and adhere

to the instructions. Attempting shortcuts may produce hazardous conditions.

24 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or

Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially ha situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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. Then to re-assemble, perform the disassembly steps in reverse order.

Symbols Legend

death.

zardous

Indicates that a specific result is expected after

performing a series of steps.

Indicates that an incorrect result has occurred

after performing a series of steps.

Part No. 1268557GT Z®-135/70 25

Service and Repair Manual October 2018

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). The circuit board (PCON) sends the data to the turntable control box (TCON) for processing.

The platform controls ECM circuit board communicates with the turntable controls. The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment. The operating parameters of the joysticks are stored in memory at the turntable controls. If a joystick controller error occurs or if a joystick is replaced, it will need to be calibrated before that particular machine function will operate. Refer to Repair Procedure, How to Calibrate a Joystick Controller.

Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion.

For further information or assistance, consult Genie Product Support.

1 platform controls ALC-1000 circuit board 2 jib boom up/down, jib boom extend/retract

and platform rotate left right joystick

3 secondary boom up/extend and

down/retract joystick 4 drive/steer joystick control ler 5 LED circuit board 6 primary boom up/down, primary boom

extend/retract and turntable rotate left/right

joystick

26 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Electrocution/burn hazard. Contact with electrically charged circuits could result in serious injury. Remove all rings, watches and other jewelry.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.

Platform Controls

1-1 Platform Circuit Board

death or

Note: When the platform circuit board is replaced, jib bellcrank and platform level will need to be calibrated. Refer to Repair Procedures, How to

Calibrate the Jib Boom Bellcrank Angle Sensor or How to Calibrate the Platform Level Sensor.

How to Remove the Circuit Board

1 Push in the red Emergency Stop button to the

off position at both the ground and platform controls.

2 Locate the cables that connect to the bottom of

the control box. Number each cable and its location at the control box.

3 Disconnect the cables from the bottom of the

platform control box.

4 Remove the control cable receptacle retaining

fasteners from the bottom of the platform control box.

7 Attach a grounded wrist strap to the ground

screw inside the control box.

8 Tag and carefully disconnect the wire

connectors from the circuit board.

9 Tag and disconnect the ribbon cable from the

LED circuit board. 10 Remove the circuit board mounting fasteners. 11 Carefully remove the circuit board from the

control box.

5 Remove the platform control box lid retaining

fasteners. Open the control box lid.

6 Locate the circuit board mounted to the inside

of the platform control box.

Part No. 1268557GT Z®-135/70 27

Service and Repair Manual October 2018

Electrocution/burn hazard. Contact with electrically charged circuits could result in serious injury. Remove all rings, watches and other jewelry.

Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all t circuit boards OR use a grounded wrist strap.

Platform Controls

How to Remove the LED Circuit Board

1 Push in the red Emergency Stop button to the

off position at both the ground and platform controls.

2 Remove the platform control box lid retaining

fasteners. Open the control box lid.

3 Locate the circuit board mounted to the inside

of the platform control box.

death or

imes when handling printed

4 Tag and carefully disconnect the ribbon cables

from the membrane circuit board. 5 Remove the circuit board mounting fasteners. 6 Carefully remove the LED circuit board from

the platform control box lid. Do not lose the

plastic spacers. Note: When installing the LED circuit board, be sure

the plastic spacers are installed between the circuit board and the control box lid.

28 Z®-135/70 Part No. 1268557GT

October 2018 Service and Repair Manual

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Component damage hazard. Electrostatic can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.

Platform Controls

1-2 Membrane Decal

How to Replace the Membrane Decal

The membrane decal is a special decal that consists of a decal with an electronic membrane on the backside. The membrane contains touch sensitive areas that, when pushed, activate the machine functions. The membrane contains touch sensitive areas that activate the machine functions.

1 Push in the red Emergency Stop button to the

off position at both the ground and platform controls.

2 Remove the platform control box lid retaining

fasteners. Open the control box lid.

8 Install the new membrane decal while guiding

the ribbon cables through the control box lid.

Note: Be sure that all LED locations on the membrane decal align with the LEDs on the membrane circuit board.

9 Install a new platform controls decal over the

membrane decal.

10 Open the control box lid and carefully connect

the ribbon cables from the membrane decal to the membrane circuit board.

3 Tag and carefully disconnect the two ribbon

cables from the membrane circuit board.

4 Close the control box lid. 5 Remove the platform controls decal from the

platform control box.

6 Carefully remove the membrane decal from

the control box lid while guiding the ribbon cables out of the control box lid.

discharge (ESD)

7 Remove any decal adhesive from the control

box lid with a mild solvent.

Note: Do not allow any solvent to come in contact with the membrane circuit board.

Part No. 1268557GT Z®-135/70 29

Service and Repair Manual October 2018

Platform Controls

1-3 Joysticks

5 Press the plus button to select YES, then

press the enter button.

6 Do not start the engine.

How to Calibrate a Joystick

The joystick controllers on this machine utilize digital Hall Effect technology for proportional control. If a joystick controller is disconnected or replaced, it must be calibrated before that particular machine function will operate.

Note: The joystick must be calibrated before the threshold, max-out or ramping can be set.

Note: After each joystick is calibrated, check the display at the ground control box. There should be no calibration faults shown on the display. If calibration faults exist, repeat procedure for that joystick controlled function.

Note: Perform this procedure with the engine off. Note: Use the following chart to identify the

description of each LCD screen control button used in this procedure.

7 Locate the drive/steer joystick . 8 Move the drive/steer joystick full stroke in the

forward direction and hold for 5 seconds, the n return to the center or neutral position.

9 Move the drive/steer joystick full stroke in the

reverse direction and hold for 5 seconds, then return to the center or neutral position.

Result: The alarm at the ground controls

should sound for a successful calibration.

Plus Minus Previous Enter

Drive functions: 1 Turn the key switch to the off position.

2 Press and hold the enter button on the ground

control panel while turning the key switch to

platform controls. Hold the enter button for

approximately 5 seconds. 3 Press the minus button twice, then press the

enter button twice. 4 Use the scroll button to scroll through the

menu until

DEFAULTS is displayed.

30 Z®-135/70 Part No. 1268557GT

DELETE DRIVE JOYSTICK

October 2018 Service and Repair Manual

Platform Controls

Steer functions:

1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground

control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds.

3 Press the minus button twice, then press the

enter button twice.

4 Use the scroll button to scroll through the

menu until DELETE

STEER JOYSTICK

DEFAULTS is displayed.

5 Press the plus button to select YES, then

press the enter button. 6 Do not start the engine. 7 Locate the drive/steer joystick . 8 Move the drive/steer joystick or thumb rocker

switch (if equipped) full stroke in the left

direction and hold for 5 seconds, then return to

the center or neutral position. 9 Move the drive/steer joystick or thumb rocker

switch (if equipped) full stroke in the right

direction and hold for 5 seconds, then return to

the center or neutral position.

Result: The alarm at the ground controls

should sound for a successful calibration.

Secondary boom up/down and extend/retract functions:

1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground

control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds.

3 Press the minus button twice, then press the

enter button twice.

4 Use the scroll button to scroll through the

menu until DELETE SECONDARY BOOM JOYSTICK DEFAULTS is displayed.

5 Press the plus button to select YES, then

press the enter button. 6 Do not start the engine. 7 Locate the secondary boom up/down and

extend/retract joystick. 8 Move the secondary boom up/down and

extend/retract joystick full stroke in the

up/extend direction and hold for 5 seconds,

then return to the center or neutral position. 9 Move the secondary boom up/down and

extend/retract joystick full stroke in the

down/retract direction and hold for 5 seconds,

then return to the center or neutral position.

Result: The alarm at the ground controls

should sound for a successful calibration.

Part No. 1268557GT Z®-135/70 31

Service and Repair Manual October 2018

Platform Controls

Primary boom extend/retract functio n s:

Primary boom up/down functions:

1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground

control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds.

3 Press the minus button twice, then press the

enter button twice.

4 Use the scroll button to scroll through the

menu until DELETE PRI M A RY BOOM EXTEND/RETRACT JOYSTICK DEFAULTS is displayed.

5 Press the plus button to select YES, then

press the enter button. 6 Do not start the engine. 7 Locate the thumb rocker switch on top of the

primary boom/turntable rotate joystick. 8 Move the primary boom extend/retract thumb

rocker switch full stroke in the extend direction

and hold for 5 seconds, the n return t o

thecenter or neutral position. 9 Move the primary boom extend/retract thumb

rocker switch full stroke in the retract direction

and hold for 5 seconds, then return to the

center or neutral position.

1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground

control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds.

3 Press the minus button twice, then press the

enter button twice.

4 Use the scroll button to scroll through the

menu until DELETE PRI M A RY BOOM UP/DOWN JOYSTICK DEFAULTS is displayed.

5 Press the plus button to select YES, then

press the enter button. 6 Do not start the engine. 7 Locate the primary boom/turntable rot ate

joystick. 8 Move the boom/turntable rotate joystick full

stroke in the up direction and hold for

5 seconds, then return to the center or neutral

position. 9 Move the boom/turntable rotate joystick full

stroke in the down direction and hold for

5 seconds, then return to the center or neutral

position.

Result: The alarm at the ground controls

should sound for a successful calibration.

32 Z®-135/70 Part No. 1268557GT

Result: The alarm at the ground controls

should sound for a successful calibration.

October 2018 Service and Repair Manual

Platform Controls

Jib boom up/down functions:

Turntable rotate functions:

1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground

control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds.

3 Press the minus button twice, then press the

enter button twice.

4 Use the scroll button to scroll through the

menu until RESET JIB BOOM UP/DOWN JOYSTICK DEFAULTS is displayed.

5 Press the plus button to select YES, then

press the enter button. 6 Do not start the engine. 7 Locate the jib boom joystick. 8 Move the jib boom joystick full stroke in the up

direction and hold for 5 seconds, then return to

the center or neutral position. 9 Move the jib boom joystick full stroke in the

down direction and hold for 5 seconds, then

return to the center or neutral position.

Result: The alarm at the ground controls

should sound for a successful calibration.

1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground

control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds.

3 Press the minus button twice, then press the

enter button twice.

4 Use the scroll button to scroll through the

menu until DELETE TURNTABLE ROTATE JOYSTICK DEFAULTS is displayed.

5 Press the plus button to select YES, then

press the enter button. 6 Do not start the engine. 7 Locate the primary boom/turntable rot ate

joystick. 8 Move the boom/turntable joystick full stroke in

the left direction and hold for 5 seconds, then

return to the center or neutral position. 9 Move the boom/turntable joystick full stroke in

the right direction and hold for 5 seconds, then

return to the center or neutral position.

Result: The alarm at the ground controls

should sound for a successful calibration.

Part No. 1268557GT Z®-135/70 33

Service and Repair Manual October 2018

Platform Controls

How to Res et a Propor tional Val ve Coil Def ault

How to Set t he Functio n Threshol ds and Def ault Functi ons Speeds

How to Reset a Proportional Valve Coil Default

Note: Use the following chart to identify the description of each LCD screen control button used in this procedure.

Plus Minus Previous Enter

Note: This procedure only needs to be performed if a proportional valve has been replaced.

Note: After the valve coil defaults have been set, each machine function threshold and default function speed must be set. Refer to Repair Procedure, How to Set the Function Thresholds and Default Function Speeds.

1 Turn the key switch to the off position. 2 Press and hold the enter button on the ground

control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds.

3 Press the minus button twice, then press the

enter button twice.

4 Use the previous button to scroll through the

menu until the function valve that needs to be reset is displayed. Press the plus button to select yes, then press the enter button to save the setting.

How to Set the Function Thresholds and Default Functions Speeds

Note: Before the threshold and default function speeds can be set, the boom function proportional valve coil defaults must be set first. Refer to Repair Procedure, How to Reset a Proportional Valve Coil Default.

Note: If a boom function proportional valve coil has not been replaced and just want to reset the function speed to original factory settings, proceed to Function speeds procedure.

1 Start the engine from the platform controls. 2 Press down the foot switch. Note: Be sure the engine rpm is set to foot switch

activated high idle. Function threshold: 3 Select a joystick controlled function that needs

to have the threshold set.

4 Slowly move the joystick off center in either

direction just until the machine function starts to move, then move the joystick very slowly towards the neutral or center position just before the machine function stops. Do not let go of the joystick.

5 While holding the joystick in position, press the

engine start button at the platform controls to set the joystick controller threshold.

5 Press the enter or previous button on the

LCD screen until EXIT is displayed.

6 Press the plus button or minus button to

select YES and then press the enter button.

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Platform Controls

6 Slowly move the joystick off center in the

opposite direction just until the machine function starts to move, then move the joystick very slowly towards the neutral or center position just before the machine function stops. Do not let go of the joystick.

7 While holding the joystick in position, press the

engine start button at the platform controls to set the joystick controller threshold.

8 Repeat steps for each joystick controlled

machine function:

• Primary boom up/down

• Turntable rotate left/right

Function speeds: Note: Be sure the machine is in the stowed position

and the boom is rotated between the circle end tires.

Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions.

Note: Unless the LCD screen displays NOT CALIBRATED, it will be necessary to enter the valve calibration menu.

12 Start the engine from the platform controls. 13 Select a function that needs the function speed

set.

• Primary boom extend/retract

• Secondary up/down and extend/retract

• Drive forward/reverse

9 Once the threshold has been set, press and

hold the engine start button until the engine shuts off. Do not press the red Emergency Stop button.

Note: Approximately 3 seconds after the engine shuts off, the alarm at the ground controls will sound to indicate the settings are being saved in memory.

10 At the ground controls, turn the key switch to

the off position, wait a moment and then turn the key switch to platform controls.

11 Check the display at the ground controls to be

sure there are no calibration faults.

Note: There should be no calibration faults shown on the display. If calibration faults exist, repeat this procedure.

14 Primary boom up/down and extend/retract

functions: Move the joystick full stroke in the

up or extend direction. When the alarm

sounds, move the joystick in the opposite

direction full stroke until the alarm sounds

again. Return the joystick to center.

Secondary boom up and down functions:

Starting from the stowed position, move the

joystick full stroke in the up direction. When the

alarm sounds, move the joystick in the down

direction full stroke until the alarm sounds

again. Return the joystick to center.

Turntable rotate function, fully retracted:

Move the rotate joystick full stroke in either the

left or right direction until the alarm sounds.

Return the joystick to center.

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Service and Repair Manual October 2018

Platform Controls

Turntable rotate function, primary boom extended: Extend the primary boom

approximately 4 ft / 1.2 m. Move the rotate joystick full stroke in either the left or right direction until the alarm sounds. Return the joystick to center.

Turntable rotate function, primary and jib booms extended: With the primary boom

extended approximately 4 ft / 1.2 m, extend the jib boom approximately 1 ft / 0.3 m. Move the rotate joystick full stroke in either the left or right direction until the alarm sounds. Return the joystick to center.

15 Once the function speeds have been set,

press and hold the engine start button until the engine shuts off. Do not press the red Emergency Stop button.

Note: Approximately 3 seconds after the engine shuts off, the alarm at the ground controls will sound to indicate the settings are being saved in memory.

16 At the ground controls, turn the key switch to

the off position, wait a moment and then turn the key switch to platform controls.

17 Check the display at the ground controls to be

sure there are no calibration faults.

Note: There should be no calibration faults shown on the display. If calibration faults exist, repeat this procedure.

How to Adjus t the Funct ion Speeds

How to Adjust the Function Speeds

Note: Perform this procedure with the boom in the stowed position.

Note: Use the following chart to identify the description of each LCD screen control button used in this procedure.

Plus Minus Previous Enter

1 Pull out the red Emergency Stop button to the

on position at both the ground and platform controls.

2 Press and hold the enter button on the ground

control panel while turning the key switch to platform controls. Hold the enter button for approximately 5 seconds.

3 Press the plus button twice, then press the

minus button twice.

4 Press the previous button until the function to

be adjusted is displayed.

5 Press the plus button to increase the speed or

press the minus button to decrease the speed.

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Platform Controls

6 Press the enter button to save the setting in

memory.

7 Press the enter or previous button on the

LCD screen until EXIT is displayed.

8 Press the plus button or minus button to

select YES and then press the enter button.

9 Continue to perform this procedure until the

machine function speed meets specification. Refer to Specifications, Performance Specifications.

How to Adjus t the Funct ion Ramp R ate Setti ng

How to Adjust the Function Ramp Rate Setting

The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output, when moved out of the neutral position. The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine.

Note: Perform this procedure with the boom in the stowed position.

Note: Use the following chart to identify the description of each LCD screen control button used in this procedure.

Plus Minus Previous Enter

1 Pull out the red Emergency Stop button to the

on position at both the ground and platform

controls. 2 Press and hold the enter button on the ground

control panel while turning the key switch to

platform controls. Hold the enter button for

approximately 5 seconds. 3 Press the plus button twice, then press the

previous button twice.

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Service and Repair Manual October 2018

Platform Controls

4 Press the previous button until the function to

be adjusted is displayed.

5 Press the plus button to increase the ramp

rate or press the minus button to decrease the ramp rate.

6 Press the enter button to save the setting in

memory.

7 Press the enter or previous button on the

LCD screen until EXIT is displayed.

8 Press the plus button or minus button to

select YES and then press the enter button.

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Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hyd connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Crushing hazard. The platform leveling cylinder may fall if not properly suppor removed from the machine.

Platform Comp onents

2-1 Platform Leveling Cylinder

The platform leveling cylinder keeps the platform level through the entire range of boom motion. The platform is maintained level to the turntable. To accomplish this, the ECM at the ground controls compares the difference in readings between the platform angle sensor and the turntable level sensor, which then sends a signal to the platform controls to open or close the appropriate platform level proportional valve on the platform manifold to maintain a level platform. The platform leveling cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Platform Leveling Cylinder

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Extend the jib boom until the platform leveling

cylinder barrel-end pivot pin is accessible.

4 Place a block under the platform leveling

cylinder for support. 5 Remove the external snap rings from the

barrel-end pivot pin. Use a soft metal drift to

remove the barrel-end pivot pin. 6 Support the rod end of the platform level

cylinder. 7 Remove the pin retaining fasteners from the

platform leveling cylinder rod-end pivot pin.

Use a soft metal drift to remove the barrel-end

pivot pin. 8 Carefully pull the platform leveling cylinder out

of the boom to access the hydraulic hoses. 9 Tag, disconnect and plug the hydraulic hoses

from the platform leveling cylinder. Cap the

fittings on the cylinder.

raulic

10 Remove the platform leveling cylinder from the

machine.

2 Raise the jib boom slightly and place blocks

under the platform.

3 Lower the jib boom until the platform is resting

on the blocks just enough to support the platform.

Note: Do not rest the entire weight of the boom on the blocks.

Part No. 1268557GT Z®-135/70 39

ted when

Service and Repair Manual October 2018

Component damage hazard. Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment. The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal. If a new rotator is installed or the rotator is disassembled, proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position.

Component damage hazard. The platform angle sensor is a very sensitive instrument. It can be damaged internally if is dropped or sustains any physical shock, even if the damage is not visible.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not squirt or spray.

Platform Comp onents

2-2 Platform Rotator

The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees.

How to Remove the Platform Rotator

3 Remove the platform angle sensor retaining

fasteners. Remove the platform angle sensor from the platform rotator.

4 Tag, disconnect and plug the hydraulic hoses

from the platform rotator manifold. Cap the fittings on the manifold.

5 Tag, disconnect and plug the hydraulic hoses

from the platform manifold. Cap the fittings on the manifold.

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Remove the platform. Refer to Repair

Procedure, How to Remove the Platform.

2 Tag and disconnect the electrical connector

from the platform angle sensor.

40 Z®-135/70 Part No. 1268557GT

6 Remove the power to platform electrical outlet

box bracket mounting fasteners. Do not disconnect the wiring.

allow oil to

October 2018 Service and Repair Manual

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Crushing hazard. The platform mounting weldment may become unbalanced is not properly supported.

Crushing hazard. The platform rotator could fall when removed from the machine if not properly supported.

Platform Comp onents

7 Remove the hose and cable guide retaining

fasteners and remove the guide from the platform support.

8 Remove the weld cable from the platform (if

equipped).

9 Support the platform mounting weldment, but

do not apply any lifting pressure.

10 Remove the eight mounting bolts from the

platform mounting weldment.

11 Remove the center bolt and slide the platform

mounting weldment off of the platform rotator.

How to Blee d the Platf orm Rotat or

How to Bleed the Platform Rotator

Note: Do not start the engine. Use auxiliary power for all machine functions in this procedure.

1 Rotate the platform full right, then full left until

air is completely out of the rotator. Bleeding the

valve is not necessary.

and fall if it

12 Support the platform rotator with a suitable

lifting device. Do not apply any lifting pressure.

13 Place a block under the platform leveling

cylinder for support.

14 Remove the pin retaining fasteners from the

platform leveling cylinder rod-end pivot pin. Do not remove the pin.

15 Remove the pin retaining fasteners from the jib

boom to platform rotator pivot pin. Do not remove the pin.

16 Use a soft metal drift to remove both pins and

remove the platform rotator from the machine.

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Service and Repair Manual October 2018

Platform Comp onents

2-3 Platform Level Sensor

The platform level sensor is mounted to the side of the platform rotator. The platform level sensor is monitored by the control system to maintain a level platform through boom range of motion. If a platform level sensor is replaced, it must be calibrated prior to machine operation.

How to Calibrate the Platfor m Level Sensor

Note: Perform this procedure with the machine on a firm, level surface.

Note: Perform this procedure with the boom in the stowed position.

Note: Use the following chart to identify the description of each LCD screen control button used in this procedure.

Plus Minus Previous Enter

1 Secure a digital level to one of the side railings

of the platform.

2 Start the machine and level the platform to

gravity. Turn the machine off.

3 Open the ground control box.

Before serial number 321: 4 Locate the 2 pin connector in the lower left

hand area of the ground control box.

5 Remove the connector plug and insert a

jumper wire between the two pins of the connector.

After serial number 320: 6 Locate the calibration toggle switch at the top

of the ground control box. Activate calibration mode by moving the toggle switch in the left direction.

7 Temporarily install a control box door retaining

fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine.

All models: 8 Insert the key into the bypass/recovery key

switch and turn it to the bypass position.

Note: The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated.

9 Press and hold the enter button on the ground

control panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds.

10 Enter sensor calibration mode by pressing the

buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus).

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Tip remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over, resulting in death or serious injury. The jumper wire must be removed before operating the machine.

Platform Comp onents

11 Press the enter or previous button on the

LCD screen until SET SENSOR TO GRAVITY is displayed.

12 Press the plus button to select YES, then

press the enter button to accept.

13 Press the enter or previous button on the

LCD screen until EXIT is displayed.

14 Press the plus button to select YES, then

press the enter button to accept.

Before serial number 321: 15 Remove the wire jumper from the 2 pin

connector in the lower left hand area of the ground control box that was installed in step 5. Install the connector plug.

PLATFORM LEVEL

-over hazard. Failure to

2-4 Platform Overload System (if equipped)

Proper calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over.

How to Calibrate the Platfor m Overload System (if equippe d)

Note: Perform this procedure with the machine on a firm, level surface.

1 Level the platform. 2 Determine the maximum platform capacity.

Refer to the machine serial plate.

16 Close the ground control box and install the

door retaining fasteners.

After serial number 320: 17 Remove the fastener that was temporarily

installed. Close the control box door and install the door retaining fasteners.

Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode.

Part No. 1268557GT Z®-135/70 43

3 Using a suitable lifting device, place an

appropriate test weight equal to that of the

maximum platform capacity at the center of the

platform floor.

Service and Repair Manual October 2018

Platform Comp onents

Determine the limit switch trigger p o int:

Confirm the setting:

4 Gently move the platform up and down by

hand, so it bounces approximately 1 to 2 inches / 2.5 to 5 cm. Allow the platform to settle.

Result: The overload indicator light and the

alarm is on. Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off.

Note: The platform will need to be moved up and down and allowed to settle in between adjustments.

Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds.

Result: The overload indicator light and

alarm is off. Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on.

Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds.

Note: The platform will need to be moved up and down and allowed to settle in between adjustments.

5 Start the engine from the platform controls. 6 Lift the test weight off the platform floor using a

suitable lifting device.

7 Place the test weight back onto the center of

the platform floor using a suitable lifting device.

Result: The alarm should be off. The platform

overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls.

Note: There may be an 2 second delay before the overload indicator lights and alarm turn off.

8 Add an additional 15 lbs / 6.8 kg test weight to

the original test weight to overload the platform.

Result: The alarm should be sounding. The

platform overload indicator light should be flashing at the platform controls and platform overload should be displayed on the LCD screen at the ground controls.

Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds.

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Platform Comp onents

9 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.

Result: All ground control functions should not

operate.

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Service and Repair Manual October 2018

Jib Boom Component s

1 primary extension boom 2 jib boom manifold 3 bellcrank 4 cable track tube 5 platform rotator 6 platform leveling cylinder

7 jib boom 8 jib extension boom 9 hose and cable junction box 10 jib boom lift cylinder 11 jib boom cable track 12 jib boom leveling cylinder

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Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Jib Boom Component s

3-1 Jib Boom Cable Track

The jib boom cable track guides the cables and hoses running up the jib boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire jib boom cable track is only necessary when performing major repairs that involve removing the jib boom.

How to Remove the Jib Boom Cable Track

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Raise the jib boom to a horizontal position.

Turn the machine off. 2 Remove the cover from the hose and cable

junction box under the jib boom cable track.

4 Tag, disconnect and plug the two hydraulic

hoses from the jib boom manifold that lead to the platform manifold. Cap the fittings on the manifold.

Note: The jib boom manifold is located at the platform end of the primary extension boom.

5 Pull the hoses out of the plastic hose guide

located on the primary extension boom near the jib boom manifold.

6 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on the cylinder.

3 Tag and disconnect the electrical connectors

inside the cable track junction box.

Part No. 1268557GT Z®-135/70 47

7 Remove the hose and cable clamp retaining

fasteners from the jib boom cable track junction box. Remove the clamps.

8 Pull the jib boom lift cylinder hydraulic hoses

out of the jib boom cable track junction box.

Service and Repair Manual October 2018

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.

Crushing hazard. The cable track could become unbalanced and fall i properly attached to the overhead crane.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Jib Boom Component s

9 Remove the hose and cable clamp retaining

fasteners at the platform end of the jib boom cable track tube. Remove the clamps.

10 Tag and disconnect the electrical connectors

from the platform manifold.

11 Tag and disconnect the electrical connectors

from the platform box.

17 Remove the fasteners from the cable track

tube guide at the platform end of the jib boom. Remove the cable track tube guide from the jib boom.

18 Place blocks between the upper and lower

cable tracks and secure the upper and lower tracks together.

12 Tag and disconnect the electrical connector

from the foot switch.

13 Tag and disconnect the ele c tric al connec tor

from the platform angle sensor.

14 Tag, disconnect and plug the hydraulic hoses

from the "P" and "T" ports on the platform manifold.

15 Pull the two hydraulic hoses just removed and

all of the cables through the hose and cable guide at the platform support.

16 Remove the cotter pin from the upper cable

track tube at the platform end of the jib boom. Do not discard the washer.

Note: Always replace the cotter pin with a new one.

19 Attach a lifting strap from an overhead crane to

the cable track.

20 Remove the mounting fasteners that attach the

lower cable track to the jib boom.

21 Carefully remove the cable track from the

machine and lay it on a structure capable of supporting it.

f not

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Component damage hazard. The boom cable track can damaged if it is twisted.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Jib Boom Component s

How to Repai r the Cabl e Track

How to Repair the Cable Track

6 Lift up the hoses and cables and carefully

insert the new 4-link section of cable track.

be

Note: A cable track repair kit is available through the Genie Service Parts Department.

1 Visually inspect the cable track and determine

which 4-link section needs to be replaced. 2 Carefully remove the snap rings and pins from

each end of the damaged section of cable

track. 3 Remove the retaining fasteners from the upper

black rollers from the 4-link section of cable

track to be replaced. Remove the rollers. 4 Lift up the hoses and cables and carefully

remove the damaged 4-link section of cable

track.

5 Remove the upper rollers from the

replacement section of cable track.

7 Connect the ends of the replacement cable

track section to the existing cable track using the pins and snap rings.

8 Install the rollers onto the new section of cable

track.

9 Operate the jib boom extend/retract function

through a full cycle to ensure smooth operation of the new section of cable track.

Part No. 1268557GT Z®-135/70 49

Service and Repair Manual October 2018

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not al squirt or spray.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Jib Boom Component s

3-2 Jib Boom

How to Remove the Jib Boom

Note: Perform this procedure with the boom in the stowed position.

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Remove the platform mounting weldment and

the platform rotator. Refer to Repair Procedure, How to Remove the Platform Rotator.

2 Tag, disconnect and plug the two hydraulic

hoses from the jib boom manifold that lead to the platform manifold. Cap the fittings on the manifold.

low oil to

3 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses from the jib boom manifold. Cap the fittings on the manifold.

4 Remove the cotter pin from the upper cable

track tube at the platform end of the jib boom.

Note: Always replace the cotter pin with a new one. 5 Remove the cable track guide fasteners from

the cable track guide at the platform end of the jib boom and remove the cable track guide from the jib boom.

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Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.

Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane.

Component Cables and hoses can be damaged if they are kinked or pinched.

Crushing hazard. The jib boom could fall when the barrel pivot pin is removed if not properly supported by the overhead crane.

Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane.

Jib Boom Component s

6 Place blocks between the upper and lower

cable tracks and secure the upper and lower

tracks together.

12 Remove the jib boom angle sensor mounting

bracket fasteners from the side of the primary extension boom.

7 Attach a lifting strap from an overhead crane to

the cable track. 8 Remove the mounting fasteners that attach the

lower cable track to the jib boom. 9 Remove the cable track from the machine and

lay to the side.

damage hazard.

10 Disconnect the electrical connector from the jib

boom angle sensor located at the jib boom

pivot pin on the engine side of the machine.

13 Carefully remove the bracket and sensor

assembly. Note the location of the springs. Do not lose the springs.

Note: There is one spring inside the jib boom pivot pin and one inside the angle sensor.

Note: When the jib boom is installed, the jib boom angle sensor will need to be calibrated. Refer to repair procedure, Jib Boom Bellcrank Angle Sensor for the calibration procedure.

14 Attach a lifting strap from an overhead crane to

the platform end of the jib boom.

15 Support the barrel end of the jib boom lift

cylinder with another suitable lifting device.

16 Remove the pin retaining fasteners from the jib

boom lift cylinder barrel-end pivot pin.

17 Use a soft metal drift to remove the jib boom lift

cylinder barrel-end pivot pin.

-end

11 Remove the cover retaining fasteners from the

jib boom angle sensor. Remove the cover.

Part No. 1268557GT Z®-135/70 51

18 Secure the jib boom lift cylinder to the jib boom

with a strap or other suitable device.

19 Raise the jib boom to a horizontal position

using the overhead crane.

20 Attach a second lifting strap from the overhead

crane to the pivot end of the jib boom.

21 Remove the pin retaining fastener from the jib

boom pivot pin. Do not remove the pin.

22 Place a block under the jib boom level cylinder

for support. Protect the cylinder rod from damage.

Service and Repair Manual October 2018

Crushing hazard. The jib boom may become unbalanced and fall when it is re machine if it is not properly supported by the overhead crane.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Jib Boom Component s

23 Use a soft metal drift to tap the pin halfway out

in one direction and lower one side of the jib boom bellcrank. Tap the pin in the other direction and lower the other side of the jib boom bellcrank.

24 Use a soft metal drift to remove the jib boom

pivot pin. Remove the jib boom from the machine and place it on a structure capable of supporting it.

3-3 Jib Boom Lift Cylinder

How to Remove the Jib Boom Lift Cylinder

Note: Perform this procedure with the boom in the stowed position.

moved from the

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Raise the jib boom slightly and place blocks

under the platform mounting weldment. Lower the jib boom until the platform is resting on the blocks just enough to support the platform.

Note: Do not rest the entire weight of the boom on the blocks.

2 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on the cylinder.

52 Z®-135/70 Part No. 1268557GT

3 Support the rod end of the jib boom lift cylinder

with a suitable lifting device.

October 2018 Service and Repair Manual

Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane.

Crushing hazard. The jib boom could fall if not properly supported when th level cylinder rod-end pivot pin is removed.

Jib Boom Component s

4 Remove the pin retaining fasteners from the jib

boom lift cylinder rod-end pivot pin. Use a soft

metal drift to remove the pin and let the

cylinder hang down. 5 Attach a lifting strap from an overhead crane to

the barrel end of jib boom lift cylinder. 6 Remove the pin retaining fasteners from the jib

boom lift cylinder barrel-end pivot pin. Use a

soft metal drift to remove the pin. 7 Remove the jib boom lift cylinder from the

machine.

3-4 Jib Boom Level Cylinder

How to Remove the Jib Boom Level Cylinder

Note: Perform this procedure with the boom in the stowed position.

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Extend the primary boom until the jib boom

level cylinder barrel-end pivot pin is

accessible. 2 Raise the jib boom above horizontal. 3 Attach an overhead crane to the jib boom

assembly for support. 4 Place a block under the jib boom level cylinder

for support. Protect the cylinder rod from

damage. 5 Remove the pin retaining fasteners from the jib

boom level cylinder rod-end pivot pin. Use a

soft metal drift to remove the pin.

e jib boom

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Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt

Crushing hazard. The jib boom level cylinder could become unbalanced and fall when removed from the machine if not properly supported.

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended.

Jib Boom Component s

6 Remove the external snap rings from the jib

boom level cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin.

3-5 Jib Boom Extension Cylinder

7 Tag, disconnect and plug the jib boom level

cylinder hydraulic hoses from the jib boom manifold. Cap the fittings on the manifold.

or spray.

8 Attach an overhead crane or other suitable

device to the jib boom level cylinder for support.

9 Carefully remove the jib boom level cylinder

from the machine.

How to Remove the Jib Boom Extension Cylinder

nd a

Note: Perform this procedure with the boom in the stowed position.

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Remove the jib boom lift cylinder. Refer to

Repair Procedure, How to Remove the Jib Boom Lift Cylinder.

54 Z®-135/70 Part No. 1268557GT

2 Attach a lifting strap from an overhead crane to

the platform end of the jib boom for support. Raise the jib boom to a horizontal position using the overhead crane.

October 2018 Service and Repair Manual

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow t gradually. Do not allow oil to squirt or spray.

Crushing hazard. The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane.

Jib Boom Component s

3 Extend the jib boom until the jib boom

extension cylinder rod-end pivot pin is accessible.

4 Tag, disconnect and plug the two hydraulic

hoses from the jib boom manifold that lead to the platform manifold. Cap the fittings on the manifold.

5 Tag, disconnect and plug the jib boom lift

cylinder and jib boom extension cylinder hydraulic hoses from the jib boom manifold. Cap the fittings on the manifold.

9 Pull the electrical cables out of the lower cable

track that lead to the primary boom. 10 Attach a lifting strap from a second overhead

crane to the pivot end of the jib boom for

support. Do not apply any lifting pressure. 11 Place a block under the jib boom level cylinder

for support. Protect the cylinder rod from

damage. 12 Remove the pin retaining fastener from the jib

boom pivot pin. Do not remove the pin. 13 Use a soft metal drift to tap the pin halfway out

in one direction and lower one side of the jib

boom bellcrank. Tap the pin in the other

direction and lower the other side of the jib

boom bellcrank. 14 Use a soft metal drift to remove the jib boom

pivot pin. Remove the jib boom from the

machine and place it on a structure capable of

supporting it.

he oil pressure to dissipate

6 Remove the cover from the lower jib boom

cable track.

7 Tag and disconnect the electrical connectors

inside the lower cable track.

8 Remove the hose and cable clamp retaining

fasteners from lower cable track at the pivot end of the jib boom. Remove the clamps.

15 Remove the pin retaining fasteners from the jib

boom extension cylinder rod-end pivot pin.

Use a soft metal drift to remove the pin.

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Crushing hazard. The jib boom extension cylinder could become unbalanced and fall when removed from the jib boom if not properly supported.

Jib Boom Component s

16 Attach a lifting strap from an overhead crane to

the barrel end of the jib boom extension cylinder.

17 Remove the pin retaining fasteners from the jib

boom extension cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin.

18 Carefully slide the jib boom extension cylinder

out of the jib boom and place it on a structure capable of supporting it.

Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.

3-6 Jib Boom Bellcrank Angle Sensor

The jib boom bellcrank angle sensor is monitored by the control system to keep the jib boom bellcrank vertical and to help maintain a level platform through boom range of motion. If a jib boom bellcrank angle sensor is replaced, it must be calibrated prior to machine operation. The jib boom bellcrank angle sensor is mounted to the bellcrank pivot pin on the engine side of the machine.

How to Replace the Jib Boom Bellcrank Angle Sensor

Note: Perform this procedure with the machine on a firm, level surface with the boom in the stowed position.

1 Locate the jib boom bellcrank angle sensor

where the jib boom bellcrank connects to the primary boom.

2 Disconnect the electrical connector from the

sensor. Remove any tie wraps securing the wiring.

3 Remove the retaining fasteners from the angle

sensor guard. Remove the guard from the machine.

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Jib Boom Component s

4 Remove the angle sensor cover retaining

fastener. Remove the cover.

5 Remove the angle sensor mounting bracket

retaining fasteners.

6 Remove the angle sensor and bracket

assembly. Do not lose the two springs or the hex-shaped key.

7 Remove the sensor retaining fasteners from

the mounting bracket. Remove the angle sensor.

Note: Note the sensor orientation on the bracket during removal so the new sensor will be installed in the same position.

8 Install the new angle sensor onto the mounting

bracket.

9 Install one spring, removed in step 6, into the

hex-shaped hole in the angle sensor. Install the other spring into the hex-shaped hole in the center of the boom pivot pin.

10 Insert the hex-shaped key into the angle

sensor.

11 Align the side of the sensor with flat area of the

boom pivot pin as shown below.

1 flat area 2 angle sensor 3 hex-shaped hole

12 Insert the hex-shaped key into the bellcrank

pivot pin allowing free clockwise rotation of the

angle sensor mounting br a cket. Note: Be sure the hex-shaped key remains

engaged in the sensor.

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Jib Boom Component s

13 Rotate the angle sensor mounting bracket,

while holding the key in the sensor, clockwise until the mounting bracket fits into the machined pocket.

14 Install the angle sensor bracket retaining

fasteners.

15 Install the angle sensor cover and install the

cover retaining fasteners.

16 Connect the electrical connector to the new

sensor.

17 Install the angle sensor guard over the angle

sensor.

18 Calibrate the jib boom bellcrank angle sensor.

Refer to Repair Procedure, How to Calibrate the Jib Boom Bellcrank Angle Sensor.

How to Cali brate the Ji b Boom Bel lcrank Ang le Sensor

How to Calibrate the Jib Boom Bellcrank Angle Sensor

Note: If the primary boom or secondary boom angle sensors have been removed or replaced, or the turntable level sensor has been replaced, they must be calibrated before the jib boom bellcrank angle sensor. Refer to Repair Procedures, How to

Calibrate the Primary Boom Angle Sensor or How to Calibrate the Secondary Boom Angle Sensor or How to Calibrate the Turntable Level Sensor.

Note: Perform this procedure with the machine on a firm, level surface and in the stowed position with the axles extended.

Note: A digital lev el w i ll be required to perform this procedure.

Note: A kit is available through Genie Product Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.

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Jib Boom Component s

Note: Use the following chart to identify the description of each LCD screen control button used in this procedure.

Plus Minus Previous Enter

Digital levels with alternate zero fu n ction: 1 Prepare the digital level by placing it vertically

on a known surface that is perpendicular to gravity. Zero out the level with the alternate zero function.

Note: When the level is calibrated correctly, it should read 0° on a vertical surface.

Digital levels without alternate zero function:

Before serial number 321:

5 Locate the 2 pin connector in the lower left

hand area of the ground control box. 6 Remove the connector pl ug and insert a

jumper wire between the two pins of the

connector. After serial number 320:

7 Locate the calibration toggle switch at the top

of the ground control box. Activate calibration

mode by moving the toggle switch in the left

direction. 8 Temporarily install a control box door retaining

fastener between the door and the box to

prevent the control box door from moving the

toggle switch while calibrating the machine. All models:

Note: If your digital level does not have an alternate zero function, it will read 90° on a vertical surface. During calibration, the measured value will need to be subtracted from 90 degrees to get the correct number to enter into the system.

2 Raise the jib boom to a slightly less than

horizontal position.

3 Push in the ground controls red Emergency

Stop button to the off position. Do not turn the key switch to the off position.

4 Open the ground control box.

9 Remove the key from the main key switch.

Insert the key into the bypass/recovery key

switch and turn it to the bypass position. Note: The angle sensor calibration values will not

be saved correctly unless the key switch is in the bypass position.

10 Press and hold the enter button on the ground

control panel while pulling out the ground

controls red Emergency Stop button to the on

position. Hold the enter button for

approximately 5 seconds and then release it.

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Jib Boom Component s

11 Enter sensor calibration mode by pressing the

buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus).

12 Press the enter or previous button on the

LCD screen until DELETE JIB LEVEL ANGLE SENSOR CALIBRATION is displayed.

13 Press the plus button to select YES, then

press the enter button to accept.

14 At the jib level calibration deg 60.0deg screen,

start the engine.

Note: If the system exits out of calibration mode when the engine is started, repeat step 7 and continue to step 12.

15 Press and hold a function enable/speed select

button and the platform level up button. Fully extend the jib boom level cylinder.

Note: When in service/bypass mode, the platform level buttons are used to adjust the jib boom level cylinder.

Note: With the jib boom level cylinder is fully extended, the jib boom bellcrank angle should be at approximately 60 ± 2 degrees.

16 Attach the digital level to the surface of the jib

boom bellcrank as shown.

1 jib boom angle sensor 2 jib boom bellcrank 3 place level on this surface

17 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

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Jib Boom Component s

18 Press and hold a function enable/speed select

button and the platform level down button until the digital level displays approximately 34 ± 2 degrees.

22 Press and hold a function enable/speed select

button and raise the jib boom above horizontal

to provide additional ground clearance for the

remaining calibration points.

19 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

20 Press and hold a function enable/speed select

button and the platform level down button until the digital level displays approximately 8 ± 2 degrees.

21 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

23 Press and hold a function enable/speed select

button and the platform level down button until

the digital level displays approximately 18 ±

2 degrees.

Calibration angles

24 At the ground controls, press the plus button

or minus button to adjust the display to the

exact value shown on the digital level and

press the enter button. Note: Be sure the number entered at the ground

controls is a negative number. Note: If the measured angle already matches the

angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

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Jib Boom Component s

25 Press and hold a function enable/speed select

button and the platform level down button until the digital level displays approximately 44 ± 2 degrees.

28 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

26 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

Note: Be sure the number entered at the ground controls is a negative number.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

27 Press and hold a function enable/speed select

button and the platform level down button until the digital level displays approximately 70 ± 2 degrees. The jib boom level cylinder should be fully retracted at this point.

Note: Be sure the number entered at the ground controls is a negative number.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

Note: With the jib boom level cylinder fully retracted, the jib boom bellcrank angle should be at approximately 70 degrees.

29 Press and hold the engine start button for

approximately 5 seconds to shut off the engine and to save the calibration settings.

Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved.

30 Press the enter or previous button on the

LCD screen until EXIT is displayed.Press the

plus button to select YES, then press the enter button to accept.

31 Turn the key back to the run position and

remove the key from the bypass/recovery key switch. Insert the key into the main key switch and turn it to ground controls.

Note: Be sure that the bypass/recovery key switch is in the run position before attempting to operate the machine.

32 Wait approximately 20 seconds and turn the

machine off by pressing the red Emergency Stop button in.

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Tip remove the jumper wire will result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in the machine tipping over, resulting in death or serious injury. The jumper wire must be removed before operating the machine.

Jib Boom Component s

Before serial number 321:

33 Remove the wire jumper from the 2 pin

connector in the lower left hand area of the ground control box that was installed in step 6. Install the connector plug.

-over hazard. Failure to

34 Close the ground control box and install the

door retaining fasteners.

After serial number 320: 35 Remove the fastener that was temporarily

installed. Close the control box door and install

the door retaining fasteners. Note: When the control box door is closed, the

calibration toggle switch is automatically activated to exit out of calibration mode.

All models: 36 Pull out the red Emergency Stop button. Start

the engine and lower the boom to the stowed

position. Be sure there are no calibration faults

shown on the display.

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Boom Component s

1 upper primary boom lif t cylinder lin kage arm 2 primary boom 3 cable track 4 primary extension boom 5 jib boom manifold 6 secondary boom lift cylinder 7 secondary boom cable track (inside of

secondary boom)

8 primary boom lift cylinder 9 number 1 secondary boom tube 10 number 2 secondary boom tube 11 number 3 secondary boom tube 12 lower primary boom lift cylinde r lin kage ar m 13 number 4 secondary boom tube

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Component damage hazard. Cables can be damaged if they are kinked or pinched.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and b connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Boom Component s

4-1 Primary Boom Cable Track

The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom.

How to Remove the Primary Boom Cable Track

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

Note: Perform this procedure with the machine on a firm, level surface.

Note: Perform this procedure with the boom in the stowed position.

1 Remove the cover from the lower jib boom

cable track.

2 Tag and disconnect the electrical connectors

inside the lower cable track.

3 Remove the hose and cable clamp retaining

fasteners from lower cable track at the pivot end of the jib boom. Remove the clamps.

4 Pull the electrical cables out of the lower cable

track that lead to the primary boom.

5 Tag and disconnect the electrical connectors

from the jib boom manifold located at the

platform end of the primary extension boom. 6 Tag, disconnect and plug the two hydraulic

hoses from the jib boom manifold that lead to

the platform manifold. Cap the fittings on the

manifold.

urn skin. Loosen hydraulic

7 Remove the retaining fasteners from the hose

and cable guide at the platform end of the

primary boom. Remove the hose and cable

guide. 8 Tag and disconnect the electrical connector

from the limit switch on the side of the primary

boom. Do not remove the limit switch. 9 Remove the cotter pin from the upper cable

track tube at the platform end of the primary

extension boom. Note: Always replace the cotter pin with a new one.

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Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.

Crushing hazard. The secondary boom lower end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Boom Component s

10 Remove the retaining fasteners from the cable

track guide at the platform end of the boom. Remove the cable track guide from the machine.

11 Place blocks between the upper and lower

cable tracks and secure the upper and lower tracks together.

15 Locate the two hydraulic hoses inside the end

of the secondary boom that lead to the primary boom cable track.

16 Tag, disconnect and plug the hydraulic hoses

from the unions. Cap the fittings on the unions.

12 Remove the hose and cable clamps from the

primary boom lift cylinder.

13 At the counterweight end of the secondary

boom, support and secure the secondary boom lower end cover to a suitable lifting device.

14 Remove the cover retaining fasteners and

remove the cover from the end of the secondary boom.

allow

17 Disconnect the electrical connectors for the

electrical cables that lead to the cable track at the end of the secondary boom.

18 Pull all hydraulic hoses and electrical cables

that lead to the cable track out of the secondary boom riser.

19 Attach a lifting strap to each end of the cable

track from an overhead crane for support. Do not apply any lifting pressure.

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Crushing hazard. The primary boom cable track could become unbalanced and fall when removed from the primary boom if not properly supported by the overhead crane.

Component damage hazard. The damaged if it is twisted.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Boom Component s

20 Remove the mounting fasteners that attach the

lower cable track to the primary boom lift cylinder.

21 Remove the mounting fasteners that attach the

cable track to the primary boom.

22 Carefully remove the cable track from the

machine and lay it on a structure capable of supporting it.

boom cable track can be

How to Repai r the Pri mary Boom C able Trac k

How to Repair the Primary Boom Cable Track

Component damage hazard. The boom cable track can be damaged if it is twisted.

Note: A cable track repair kit is available through the Genie Service Parts Department.

1 Visually inspect the cable track and determine

which 4-link section needs to be replaced. 2 Support the cable track assembly above the

section to be replaced. 3 Carefully remove the snap rings and pins from

each end of the damaged section of cable

track. 4 Remove the retaining fasteners from the upper

black rollers from the 4-link section of cable

track to be replaced. Remove the rollers.

remove the damaged 4-link section of cable

track.

5 Lift up the hoses and cables and carefully

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Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Crushing hazard. The secondary boom end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to

Boom Component s

6 Remove the upper rollers from the

replacement section of cable track.

7 Lift up the hoses and cables and carefully

insert the new 4-link section of cable track.

8 Connect the ends of the replacement cable

track section to the existing cable track using the pins and snap rings.

9 Install the rollers onto the new section of cable

track.

10 Operate the primary boom extend/retract

function through a full cycle to ensure smooth operation of the new section of cable track.

4-2 Secondary Boom Cable Track

The secondary boom cable track guides the cables and hoses running up through the inside of the secondary boom. It can be repaired link by link without removing the cables and hoses that run through it. Removal of the secondary boom cable track is required to repair it.

How to Remove the Secondary Boom Cable Track

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Working at the counterweight end of the

secondary boom, support and secure the secondary boom end cover to a suitable lifting device.

2 Remove the cover retaining fasteners and

remove the cover from the secondary boom.

the lifting device.

3 Working at the platform end of the secondary

boom, support and secure the secondary boom end cover to a suitable lifting device.

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Crushing hazard. The secondary boom end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Component damage hazard. Hoses can be damaged if they are kinked or pinched.

Boom Component s

4 Remove the cover retaining fasteners and

remove the cover from the secondary boom.

10 Pull the hydraulic hoses just removed through

the turntable bulkhead.

5 Working at the platform end of the secondary

boom, remove the hose and cable U-bolt fasteners near the upper cable track tube.

6 Working at the platform end of the secondary

boom, remove the upper cable track tube retaining fasteners. Remove the curved hose guide.

7 Working at the platform end of the secondary

boom, remove the lower cable track retaining fasteners.

8 Working at the counterweight end of the

secondary boom, remove the lower cable track retaining fasteners.

9 Tag, disconnect and plug the hydraulic hoses

from the following ports of the function manifold: PE, PR, P2, T1, PU and PD. Cap the fittings on the manifold.

11 Working at the counterweight end of the

secondary boom, tag, disconnect and plug the

hydraulic hoses from the unions that lead to

the cable track. 12 Working at the counterweight end of the

secondary boom, tag and disconnect the

electrical connectors to all of the cables that

lead to the secondary boom cable track. 13 Tag, disconnect and plug the primary boom lift

cylinder hydraulic hoses. Cap the fittings on

the cylinder. 14 Tag, disconnect and plug the primary boom

extension cylinder hydraulic hoses at the

unions located above the primary boom lift

cylinder. Cap the fittings on the unions. 15 Pull the hydraulic hoses for the primary boom

lift cylinder and extension cylinder out through

the hole in the number 4 secondary boom

tube.

Part No. 1268557GT Z®-135/70 69

16 Working at the platform end of the secondary

boom, place blocks between the upper and

lower cable tracks for support.

Service and Repair Manual October 2018

Crushing hazard. The secondary boom cable track could become unbalanced and fall if not pro removed from the machine.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Component damage hazard. The secondary boom cable track can be damaged if it is twisted.

Component damage hazard. The boom cable track can be damaged if it is twisted.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Boom Component s

17 Working at the counterweight end of the

secondary boom, attach a lifting strap from an overhead crane to the secondary boom cable track.

18 Carefully pull the secondary boom cable track

out of the counterweight end of the boom.

19 Remove the secondary boom cable track from

the machine and place it on a structure capable of supporting it.

How to Repai r the Sec ondary Boo m Cable Tr ack

How to Repair the Secondar y Boom Cable Track

Note: A cable track repair kit is available through the Genie Service Parts Department.

perly supported when

Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.

1 Remove the secondary boom cable track.

Refer to Repair Procedure, How to Remove the Secondary Boom Cable Track.

2 Visually inspect the cable track and determine

which 4-link section needs to be replaced.

3 Carefully remove the snap rings and pins from

each end of the damaged section of cable track.

4 Remove the retaining fasteners from the upper

black rollers from the 4-link section of cable track to be replaced. Remove the rollers.

5 Lift up the hoses and cables and carefully

remove the damaged 4-link section of cable track.

Note: If the section of cable track being replaced has clamps or wear pads, those items will need to be transferred to the replacement section of cable track.

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Comp Cables and hoses can be damaged if they are kinked or pinched.

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended.

Boom Components

6 Remove the upper rollers from the

replacement section of cable track.

7 Lift up the hoses and cables and carefully

insert the new 4-link section of cable track.

onent damage hazard.

4-3 Primary Boom

How t o R emove the Primary Boom

8 Connect the ends of the replacement cable

track section to the existing cable track using the pins and snap rings.

9 Install the rollers onto the new section of cable

track.

10 Install the secondary boom cable track into the

secondary boom.

11 Operate the secondary boom up/extend and

down/retract functions through a full cycle to ensure smooth operation of the new section of cable track.

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

Note: Perform this procedure with the boom in the stowed position.

1 Remove the platform. 2 Remove the platform mounting weldment and

the platform rotator. Refer to Repair

Procedure, How to Remove the Platform

Rotator. 3 Remove the jib boom. Refer to Repair

Procedure, How to Remove the Jib Boom.

Part No. 1268557GT Z®-135/70 71

Note: When the jib boom is installed, the jib boom angle sensor will need to be calibrated. Refer to Repair Procedure, How to Calibrate the Jib Boom Bellcrank Angle Sensor.

Service and Repair Manual October 2018

Bodily injury hazard. Sprayi ng hydraulic burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Boom Component s

4 Remove the primary boom cable track. Refer

to repair procedure, How to Remove the Cable Track.

10 Tag, disconnect and plug the primary boom

extension cylinder hydraulic hoses. Cap the fittings on the cylinder.

5 Remove the end cover from the pivot end of

the primary boom.

6 Remove the limit switch mounting fasteners

from the limit switch on the ground controls side of the primary boom. Do not disconnect the wiring. Remove the limit switch.

7 Disconnect the electrical connector from the

primary boom angle sensor.

Note: The primary boom angle sensor is located inside the primary boom at the pivot end.

8 Remove the primary boom angle sensor

bracket mounting fasteners and remove the primary boom angle sensor from the primary boom. Do not remove the angle sensor from the bracket. Note the location of the springs. Do not lose the springs.

Note: There is one spring inside the primary boom pivot pin and one inside the angle sensor.

Note: When the primary boom is installed, the primary boom angle sensor will need to be calibrated. Refer to Repair Procedure, How to Calibrate the Primary Boom Angle Sensor.

9 Remove the hose and cable guide fasteners at

the primary boom pivot pin. Remove the hose and cable guide.

oil can penetrate and

11 Place blocks under both ends of the primary

boom lift cylinder for support.

12 Attach a lifting strap from an overhead crane to

the rod end of the primary boom lift cylinder.

13 Remove the pin retaining fasteners from the

primary boom lift cylinder rod-end pivot pin.

14 Use a soft metal drift to remove the rod-end

pivot pin. Rest the rod end of the primary boom lift cylinder on the blocks.

15 Support both upper primary boom lift cylinder

linkage arms with a suitable lifting device. Do not apply any lifting pressure.

16 Remove the pin retaining fasteners from the

upper primary boom lift cylinder linkage arm pivot pin where it connects to the primary boom.

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Crushing hazard. The upper primary boom lift cy arms could fall if not properly supported when the pivot pins are removed.

Crushing hazard. The primary boom could become unbalanced and fall when re machine if not properly attached to the overhead crane.

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended.

Boom Component s

17 Use a soft metal drift to tap the pin halfway out

and lower one of the linkage arms down. Tap the pin in the other direction and lower the other linkage arm down.

linder linkage

4-4 Primary Boom Lift Cylinder

The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with a counterbalanc e valve to prevent movement in the event of a hydraulic line failure.

18 Attach a 5 ton / 5000 kg overhead crane to

both ends of the primary boom. Do not apply any lifting pressure.

19 Remove the pin retaining fasteners from the

primary boom pivot pins.

20 Use a soft metal drift to remove the primary

boom pivot pins.

21 Carefully remove the primary boom from the

machine and place it on a structure capable of supporting it.

moved from the

How to Remove the Primary Boom Lift Cylinder

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

Note: Perform this procedure with the boom in the stowed position.

1 Remove the hose and cable clamps from the

primary boom lift cylinder.

Part No. 1268557GT Z®-135/70 73

2 Remove the cable track retaining fasteners at

the primary boom lift cylinder. 3 Place blocks under both ends of the primary

boom lift cylinder. Place another block under

the cylinder linkage arms under the primary

boom lift cylinder barrel-end pivot pin.

Service and Repair Manual October 2018

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic conne the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Crushing haz cylinder may become unbalanced and fall if it is not properly supported when it is removed from the machine.

Crushing hazard. The primary boom lift cylinder linkage arms may fall if not properly supported when the barrel pivot

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attemptin this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Boom Component s

4 Tag, disconnect and plug the primary boom lift

cylinder hydraulic hoses. Cap the fittings on the cylinder.

4-5 Secondary Boom Lift Cylinder

ctions very slowly to allow

5 Attach a lifting strap from an overhead crane to

the rod end of the primary boom lift cylinder. Do not apply any lifting pressure.

6 Remove the pin retaining fasteners from the

primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin and rest the cylinder on the block.

7 Attach a lifting strap from a second overhead

crane to the barrel end of the primary boom lift cylinder. Do not apply any lifting pressure.

8 Remove the primary boom lift cylinder

barrel-end pivot pin retaining fasteners.

9 Use a soft metal drift to remove the barrel-end

pivot pin. Carefully remove the primary boom lift cylinder from the machine.

ard. The boom lift

How to Remove the Secondary Boom Lift Cylinder

g

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

Note: Perform this procedure with the machine on a firm, level surface and in the stowed position with the axles extended.

1 Tag, disconnect and plug the hydraulic hoses

from the secondary boom lift cylinder. The hoses can be accessed from under the turntable.

74 Z®-135/70 Part No. 1268557GT

pin is removed.

-end

October 2018 Service and Repair Manual

Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.

Component damage hazard. The engine must not be started with the hydraulic tank shut valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch inform personnel of the condition.

Boom Component s

2 Remove the engine pivot plate retaining

fastener. Swing the engine pivot plate out away from the machine.

1 engine pivot plate anchor hole 2 engine pivot plate retaining fastener

3 Locate the engine pivot plate anchor hole at

the pivot end of the engine pivot plate.

4 Install the bolt that was just removed into the

anchor hole to secure the engine pivot plate from moving.

5 Remove the retaining fasteners from the fixed

turntable cover at the ground controls side of the machine. Remove the fixed turntable cover from the machine.

6 Tag, disconnect and plug the fuel hoses from

the fuel tank. Clean up any fuel that may have

spilled. 7 Close the two hydraulic tank shut-off valves at

the hydraulic tank.

-off

and tag the machine to

8 Remove the drain plug from the hydraulic tank

and completely drain the tank into a container

of suitable capacity. Refer to Specifications,

Fluid Capacity Specifications. 9 Tag, disconnect and plug the two suction

hoses from the hydraulic tank. 10 Tag, disconnect and plug the two supply hoses

for the auxiliary power units. Cap the fittings on

the hydraulic tank. 11 Tag, disconnect and plug the hydraulic hose

from the drive motor case drain filter at the

hydraulic tank. Cap the fitting on the hydraulic

tank.

Part No. 1268557GT Z®-135/70 75

12 Tag, disconnect and plug the hydraulic hose at

the return filter. Cap the fitting on the return

filter housing.

Service and Repair Manual October 2018

Crushing hazard. The turnta cover may become unbalanced and fall if not properly supported and secured to a suitable lifting device.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rin watches and other jewelry.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious inju watches and other jewelry.

Crushing hazard. The battery box could become unbalanced and fall when removed from the machine if not properly supported.

Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spill s with baking soda and water.

Crushing hazard. Th tank could become unbalanced and fall if not properly supported when removed from the machine.

Boom Component s

13 Remove the turntable cover using a suitable

lifting device.

ble

14 Remove the ground control box mounting

fasteners. Move the ground control box out of the way.

15 Remove the hydraulic tank retaining fasteners.

19 Attach an overhead crane or similar lifting

device to the battery box for the auxiliary power unit batteries.

20 Remove the battery box retaining fasteners

and carefully remove the battery box from the machine.

16 Remove the cover from the auxiliary power

unit batteries.

17 Tag and disconnect the cables from the

auxiliary power unit batteries.

gs,

18 Tag and disconnect the cables from the engine

starting/controls battery located on the engine side of the machine.

ry. Remove all rings,

21 Support the hydraulic tank with 2 lifting straps.

Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate lifting device.

22 Remove the hydraulic tank from the machine.

e hydraulic

23 Place a block under the secondary boom lift

cylinder for support.

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October 2018 Service and Repair Manual

Crushing hazard. The boom assembly can fall if not properly supported by the overhead crane.

Component damage hazard. Hoses and cables ca damaged if the barrel end of the secondary boom lift cylinder is allowed to fall when the barrel

Crushing hazard. The secondary boom lift cylinder unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

Component damage hazard. Hoses and cables can be damaged if the secondary boom lift cylinder is pulled across them.

Boom Component s

24 Remove the secondary boom lift cylinder

rod-end pivot pin retaining fasteners. Use a soft metal drift to remove the pin through the access holes in the turntable bulkheads.

25 Attach an overhead crane with a minim um

capacity of 7 tons / 7000 kg to the counterweight end of the secondary boom.

26 Raise the boom assembly with the overhea d

crane approximately 20 feet / 6 m.

29 Use a slide hammer to remove the barrel-end

pivot pin.

n become

-end pivot pin is removed.

30 Carefully remove the secondary boom lift

cylinder from the machine.

27 Remove the secondary boom lift cylinder

barrel-end pivot pin retaining fasteners. Do not remove the pin.

28 Attach a lifting strap from a second overhead

crane to each end of the secondary boom lift cylinder.

Note: Protect the hoses and cables underneath the cylinder from damage.

could become

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Service and Repair Manual October 2018

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could resu serious injury and significant component damage. Dealer service is strongly recommended.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Crushing hazard. The extension cylinder could become unbalanced and fall when removed from primary boom extension tube if not properly supported.

Boom Component s

4-6 Primary Boom Extension Cylinder

The primary boom extension cylinder extends and retracts the primary boom extension tube.The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Primary Boom Extension Cylinder

lt in death or

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

2 Remove the access cover from the pivot end of

the primary boom.

3 Tag, disconnect and plug the primary boom

extension cylinder hydraulic hoses. Cap the fittings on the cylinder.

4 At the platform end, remove the external snap

rings from the extension cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

5 Remove the extension cylinder retainers from

the saddle blocks.

6 Attach a lifting strap from an overhead crane to

the barrel end of the primary boom extension cylinder.

7 Using the overhead crane, lift the extension

cylinder to clear the saddle blocks.

8 Support and slide the primary boom extension

cylinder out of the primary boom and place it on a structure capable of supporting it.

Note: Perform this procedure with the machine on a firm, level surface and in the stowed position with the axles extended.

1 Extend the primary boom until the primary

boom extension cylinder rod-end pivot pin is accessible in the primary boom extension tube.

78 Z®-135/70 Part No. 1268557GT

Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.

Note: Note the length of the cylinder after removal. The cylinder must be at the same length for installation.

October 2018 Service and Repair Manual

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or ser component damage. Dealer service is strongly recommended.

Crushing hazard. The secondary boom end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device.

Bodily injury hazard. Sprayi ng hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

Boom Component s

4-7 Secondary Boom Extension Cylinders

The secondary boom extension cylinders extend and retract the secondary boom. The secondary boom extension system consists of 3 hydraulic cylinders and each are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Secondary Boom Extension Cylinders

ious injury and significant

1 Raise the primary boom approximately 10 feet

/ 3 m. Turn the machine off. 2 Working at the platform end of the secondary

boom, support and secure the secondary

boom end cover to a suitable lifting device. 3 Remove the cover retaining fasteners and

remove the cover from the secondary boom.

4 Remove the retaining fasteners from both

secondary boom extend limit switches and

remove the limit switches. Do not disconnect

the wiring. Note: Label the location of each limit switch as they

are not the same and their mounting locations cannot be exchanged.

Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

Note: Perform this procedure with the machine on a firm, level surface and in the stowed position with the axles extended.

Part No. 1268557GT Z®-135/70 79

5 Tag, disconnect and plug all hydraulic hoses

for the 3 secondary boom extension cylinders.

Cap the fittings on the cylinder.

6 Remove the upper extension cylinder retainers

from the saddle blocks.

Service and Repair Manual October 2018

Crushing hazard. The extension cylinder could fall when removed from the secondary boom if not properly supported.

Boom Component s

7 Attach a lifting strap from an overhead crane to

the rod end of the upper extension cylinder.

8 Using the overhead crane, lift the extension

cylinder to clear the saddle blocks.

9 Support and slide the upper extension cylinder

out of the secondary boom and place it on a structure capable of supporting it.

Note: During removal, the overhead crane strap will need to be adjusted for proper balancing.

Note: When installing the middle and upper secondary boom extension cylinders, be sure the grooved wear pads are correctly aligned with the channels on the top of the cylinders.

10 Repeat steps 6 through 9 for the remaining

secondary boom extension c ylinders .

Note: The secondary boom extension cylinders must be installed in the same order they were removed.

1 upper extension cylinder (#1) 2 middle extension cylinder (#2) 3 bottom extension cylinder (#3) 4 cylinder grooved wear pads 5 channels

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October 2018 Service and Repair Manual

Boom Component s

4-8 Primary Boom Angle Sensor

The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity.

How to Replace the Primary Boom Angle Sensor

Note: Perform this procedure with the machine on a firm, level surface with the boom in the stowed position.

1 Remove the retaining fasteners from the boom

end cover at the pivot end of the primary boom. Remove the cover from the machine.

2 Locate the primary boom angle sensor inside

the primary boom at the boom pivot pin.

3 Disconnect the electrical connector from the

sensor.

4 Remove the angle sensor mounting bracket

retaining fasteners.

7 Install the new angle sensor onto the mounting

bracket. 8 Install one spring, removed in step 5, into the

hex-shaped hole in the angle sensor. Install

the other spring into the hex-shaped hole in the

center of the boom pivot pin. 9 Insert the hex-shaped key into the angle

sensor. 10 Align the side of the sensor with flat area of the

boom pivot pin as shown below while holding

the bracket away from key insertion.

5 Remove the angle sensor and bracket

assembly. Do not lose the two springs or the hex-shaped key.

6 Remove the sensor retaining fasteners from

the mounting bracket. Remove the angle sensor.

Note: Note the sensor orientation on the bracket during removal so the new sensor will be installed in the same position.

1 flat area 2 angle sensor 3 hex-shaped hole

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Service and Repair Manual October 2018

Boom Component s

11 While holding the hex-shaped key in position,

rotate the angle sensor mounting bracket clockwise until it aligns with the machined pocket. Do not allow the key to rotate while holding it.

12 Insert the hex-shaped key into the boom pivot

pin and the bracket into the machined pocket.

How to Cali brate the Pr imary Bo om Angle Sens or

How to Calibrate the Primary Boom Angle Sensor

The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity.

Note: Be sure the hex-shaped key remains engaged in the sensor.

13 Install the angle sensor bracket retaining

fasteners.

14 Connect the electrical connector to the new

sensor. 15 Install the primary boom end cover. 16 Calibrate the primary boom angle sensor.

Refer to Repair Procedure, How to Calibrate

the Primary Boom Angle Sensor.

The primary boom maximum angle is gradually reduced as the downhill slope (positi ve degre e Y axis) is increased. A flat level surface of 0° allows the primary boom maximum operational angle to reach 68°. On a 5° downhill slope the primary boom maximum operational angle is reduced to 43°.

0° slope, 68° boom angle 5° slope, 43° boom angle

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October 2018 Service and Repair Manual

Tip properly calibrate the machine could cause the machine to tip over resulting in death or serious injury.

Boom Component s

Note: If the axle sensor or secondary boom angle sensor have been removed or replaced, or the turntable level sensor has been replaced, they must be calibrated first. Refer to Repair Procedures, How

to Calibrate the Axle Angle Sensors or How to Calibrate the Secondary Boom Angle Sensor or How to Calibrate the Turntable Level Sensor.

-over hazard. Failure to

6 Point Calibration procedure Note: Use this procedure for software versions

before 4.01. Note: For the 2 Point Calibration procedure,

proceed to step 37. 1 Push in the ground controls red Emergency

Stop button to the off position. Do not turn the key switch to the off position.

2 Turn the key switch to ground controls.

Note: For software versions 4.01 and higher, use the 2 Point Calibration procedure. For software versions before 4.01, use the 6 Point Calibration procedure. The software version is displayed on the LCD screen when the red Emergenc y Stop button is pulled out to the on position.

Note: A digital level will only be required to perf orm the 6 Point Calibration procedure.

Note: A kit is available through Genie Product Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.

Note: Use the following chart to identify the description of each LCD screen control button used in this procedure.

Plus Minus Previous Enter

Note: Perform this procedure with the machine on a firm, level surface with the booms in the fully stowed position, in the drive enable zone and the axles fully extended.

3 Open the ground control box. Before serial number 321:

4 Locate the 2 pin connector in the lower left

hand area of the ground control box.

5 Remove the connector plug and insert a

jumper wire between the two pins of the connector.

After serial number 320: 6 Locate the calibration toggle switch at the top

of the ground control box. Activate calibration mode by moving the toggle switch in the left direction.

7 Temporarily install a control box door retaining

fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine.

All models: 8 Remove the key from the main key switch.

Insert the key into the bypass/recovery key switch and turn it to the bypass position.

Note: The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated.

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Service and Repair Manual October 2018

Boom Component s

9 Press and hold the enter button on the ground

control panel while pulling out the ground

controls red Emergency Stop button to the on

position. Hold the enter button for

approximately 5 seconds and then release it. 10 Enter sensor calibration mode by pressing the

buttons at the ground controls in the following

sequence: (plus)(enter)(enter)(plus).

17 Press and hold a function enable/speed select

button and the primary boom down button and lower the primary boom down until the digital level displays -50 degrees.

18 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

11 Press the enter or previous button on the

LCD screen until DELETE PRIMARY BOOM

ANGLE SENSOR CALIBRATION is displayed. 12 Press the plus button to select YES, then

press the enter button to accept. 13 Place a digi tal lev el t hat has be en cal i brat ed t o

gravity on top of the primary boom and note

the angle displayed on the digital level. 14 At the PRIMARY BOOM ANGLE TO GRAVITY

0.0 DEG screen, press the plus button or

minus button to adjust the display to the exact

value show n on the digi tal lev el, then pr ess the

enter button. Note: If the measured angle already matches the

angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

15 Start the engine from the ground controls. Note: If the system exits out of calibration mode

when the engine is started, repeat step 8 and then continue with step 14.

Note: Be sure the number entered at the ground controls is a negative number.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

19 Press and hold a function enable/speed select

button and the primary boom up button until the digital level displays -20 degrees.

20 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

Note: Be sure the number entered at the ground controls is a negative number.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

16 Fully raise the secondary boom. The boom is

fully raised when the cylinder is fully extended

and the boom stops moving.

84 Z®-135/70 Part No. 1268557GT

21 Press and hold a function enable/speed select

button and the primary boom up button until the digital level displays 10 degrees.

October 2018 Service and Repair Manual

result in an unsafe configuration which will compromise machine stability. Operating the machine in this configuration will result in

injury. The jumper wire must be

Boom Component s

22 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

23 Press and hold a function enable/speed select

button and the primary boom up button until the digital level displays 40 degrees.

24 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

25 Press and hold a function enable/speed select

button and the primary boom up button until the primary boom is fully raised. The boom is fully raised when the cylinder is fully extended and the boom stops moving. The angle will be 70 degrees.

26 At the ground controls, press the plus button

or minus button to adjust the display to the exact value shown on the digital level and press the enter button.

Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured value. The system must detect a change in displayed value to record the calibrated value.

27 Press and hold the engine start button for

approximately 5 seconds to shut off the engine and to save the calibration settings.

Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved.

28 Press the enter or previous button on the

LCD screen until EXIT is displayed.

29 Press the plus button to select YES, then

press the enter button to accept.

30 Turn the key back to the run position and

remove the key from the bypass/recovery key switch. Insert the key into the main key switch and turn it to ground controls.

Note: Be sure that the bypass/recovery key switch is in the run position before attempting to operate the machine.

31 Wait approximately 20 seconds and turn the

machine off by pressing the red Emergency Stop button in.

Before serial number 321 32 Remove the wire jumper from the 2 pin

connector in the lower left hand area of the ground control box that was installed in step 5. Install the connector plug.

Tip-over hazard. Failure to remove the jumper wire will

the machine tipping over, resulting in death or serious

removed before operating the machine.

33 Close the ground control box and install the

door retaining fasteners.

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Service and Repair Manual October 2018

Boom Component s

After serial number 320:

34 Remove the fastener that was temporarily

installed. Close the control box door and install

the door retaining fasteners. Note: When the control box door is closed, the

calibration toggle switch is automatically activated to exit out of calibration mode.

All models: 35 Pull out the red Emergency Stop button. Start

the engine and lower the boom to the stowed

position. Be sure there are no calibration faults

shown on the display. 36 Perform a primary boom angle test. Refer to

Maintenance Procedure in the appropriate

Service or Maintenance Manual, Test the

Primary Boom Angle Sensor.

2 Point Calibration procedure Note: Use this procedure for software versions

4.01 and higher. 37 Push in the ground controls red Emergency

Stop button to the off position. Do not turn the

key switch to the off position. 38 Turn the key switch to ground controls. 39 Open the ground control box. 40 Locate the calibration toggle switch at the top

of the ground control box. Activate calibration

mode by moving the toggle switch in the left

direction. 41 Temporarily install a control box door retaining

fastener between the door and t he box to

prevent the control box door from moving the

toggle switch while calibrating the machine. 42 Remove the key from the main key switch.

Insert the key into the bypass/recovery key

switch and turn it to the bypass position. 43 Note: The angle sensor calibration values will

not be saved correctly unless the key switch is

in the bypass position and the calibration

toggle switch is activated. 44 Press and hold the enter button on the ground

control panel while pulling out the ground

controls red Emer genc y Stop butto n to the on

position. Hold the enter button for

approximately 5 seconds and then release it. 45 Enter sensor calibration mode by pressing the

buttons at the ground controls in the following

sequence: (plus)(enter)(enter)(plus). 46 Press the enter or previous button on the

LCD screen until DELETE PRIMARY BOOM

ANGLE SENSOR CALIBRATION is displayed.

86 Z®-135/70 Part No. 1268557GT

Genie Maintenance Manuals From SN 05-101 to 13-2000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Find a Manual for this Model

Serial Number Legend

Safety Rules

Table of Contents

Section 2 Specificati ons

Machine Specificati ons

Performance Specifications

Hydraulic Component Specifications

Machine Torque Specifications

Hydraulic Hose and Fitting Torque Specifications

Torque Procedure

Section 3 Repair Proc edures

Platform Controls

Platform Controls

1-1 Platform Circuit Board

How to Remove the LED Circuit Board

1-2 Membrane Decal

How to Res et a Propor tional Val ve Coil Def ault

How to Set t he Functio n Threshol ds and Def ault Functi ons Speeds

How to Adjus t the Funct ion Speeds

How to Adjus t the Funct ion Ramp R ate Setti ng

Platform Comp onents

2-1 Platform Leveling Cylinder

2-2 Platform Rotator

How to Blee d the Platf orm Rotat or

2-4 Platform Overload System (if equipped)

Jib Boom Component s

3-1 Jib Boom Cable Track

How to Repai r the Cabl e 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 Cali brate the Ji b Boom Bel lcrank Ang le Sensor

Boom Component s

4-1 Primary Boom Cable Track

How to Repai r the Pri mary Boom C able Trac k

4-2 Secondary Boom Cable Track

How to Repai r the Sec ondary Boo m Cable Tr ack

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 Cali brate the Pr imary Bo om Angle Sens or