Genie ZX-135/70 Service Manual
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Genie ZX-135/70, August 2014 Service Manual Checklist A Procedures Part No. 218700 ZX-135/70 23 A-1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe ma
Genie ZX-135/70, Service Manual August 2014 Platform Components 108 ZX-135/70 Part No. 218700 Confirm the setting: 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 con
Genie ZX-135/70, August 2014 Service Manual Engines Part No. 218700 ZX-135/70 147 5-1 RPM Adjustment Refer to maintenance procedure, Check and Adjust the Engine RPM. 5-2 Flex Plate The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump. How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 2 Support the drive pump
Genie ZX-135/70, Service Manual August 2014 Circuit Connector Legend 236 ZX-135/70 Part No. 218700 Number Description J87 2 pin Deutsch connector for two-speed motor stroke valve J91 2 pin Deutsch connector for right rear steer right valve J92 2 pin Deutsch connector for right rear steer left valve J93 2 pin Deutsch connector for left rear steer right valve J94 2 pin Deutsch connector for left rear steer left valve J95 2 pin Deutsch connector for right front steer right valve J96 2 pin
Genie ZX-135/70, August 2014 Service Manual Checklist E Procedures Part No. 218700 ZX-135/70 75 7 Remove the turntable cover using a suitable lifting device. Crushing hazard. The turntable cover may become unbalanced and fall if not properly supported and secured to a suitable lifting device. 8 Remove the ground control box mounting fasteners. Move the ground control box out of the way. 9 Remove the cover from the auxiliary power unit batteries. 10 Tag and disconnect the cables from the auxiliary power unit batteries. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove al l rings, watc
August 2014 Service Manual Manifolds Part No. 218700 ZX-135/70 171 8-6 Turntable Rotation Manifold The turntable rotation manifolds are mounted to the turntable rotation drive hub motors. Index No. Description Schematic Item Function Torque 1 Counterbalance valve CA Turntable rotate right 25-30 ft- lbs / 34- 41 Nm 2 Coun
Genie ZX-135/70, Service Manual August 2014 Manifolds 174 ZX-135/70 Part No. 218700 Steer and Axle Manifold, continued The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index No. Description Schematic Item Function Torque 16 Pressure reducing valve, 240 0 psi / 16 5 bar P Axle extend/retract circuit 30-35 ft- lbs / 41- 47 Nm 17 Check valve U Prevents left rear steer cylinder from moving when not steering 20-25 ft- lbs / 27- 34 Nm 18 Flow control valve, 1. 5 gpm / 5.7 L/min N Left rear steer cylinder retract circuit 20-25 ft-
August 2014 Service Manual Manifolds Part No. 218700 ZX-135/70 185 How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical sys
Genie ZX-135/70, August 2014 Service Manual Checklist B Procedures Part No. 218700 ZX-135/70 43 B-13 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper brake action is essential to safe machine operation. The drive brake function should operate smoothly, free of hesitation, jerking and unusual noise. Hydraulically-released individual wheel brakes can appear to operate normally when they are actually not fully operational. Collision hazard. Be sure that the
Genie ZX-135/70, Service Manual August 2014 Jib Boom Components 110 ZX-135/70 Part No. 218700 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 m
Service Manual August 2014 Platform Controls 100 ZX-135/70 Part No. 218700 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 mai
August 2014 Service Manual Circuit Connector Legend Part No. 218700 ZX-135/70 235 Number Description J9 Ribbon connector from TCON to membrane #1 J10 Ribbon connector from TCON to membrane #2 J11 Black 2 3 pin AMP connector on TCON J12 Black 3 5 pin AMP connector on TCON J13 White 2 3 pin AMP connector on TCON
Genie ZX-135/70, Service Manual August 2014 Ground Controls 152 ZX-135/70 Part No. 218700 6-2 Circuit Boards How to Remove the LCD Display Screen Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the ground control box lid fasteners. 3 Open the ground control box. 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 fi
Genie ZX-135/70, August 2014 Service Manual Jib Boom Components Part No. 218700 ZX-135/70 123 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.Press the plus button to select YES, then press the
Genie ZX-135/70, August 2014 Service Manual Display Module Part No. 218700 ZX-135/70 85 Screen or Menu Procedure Description Range or Selection Boom Function Speeds With key switch OFF , press and hold the enter button and turn key switch to on position. Release the enter button and press (plus)(plus)(minus)(minus) Primary boom up speed stowed Primary boom up speed not stowed Primary boom down speed stowed Primary boom down speed not stowed Primary boom extend speed Primary boom retract s
Genie ZX-135/70, August 2014 Service Manual Turntable Rotation Components Part No. 218700 ZX-135/70 187 How to Adjust the Turntable Rotation Gear Backlash 1 Secure the turntable from rotating with the turntable rotation lock pin. 2 Remove the fixed turntable cover at the ground controls side of the machine. 3 Loosen the backlash pivot plate mounting bolts. 4 Push the backlash pivot plate towards the turntable as far as possible (this will push the rotation pinion gears into the turntable bearing ring gear). 5 Loosen the lock nut on the adjustment bolt. 6 Turn the adjustme
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