Genie ZX-135/70 Service And Repair Manual
  1. Manuals
  2. Brands
  3. Genie Manuals
  4. Boom Lifts
  5. ZX-135/70 with Jib-Extend
  6. Service and repair manual

Genie ZX-135/70 Service And Repair Manual

Hide thumbs Also See for ZX-135/70:
Table of Contents

Advertisement

Quick Links

See also: Service Manual , Maintenance Manual
Service and Repair Manual
ZX-135/70
Serial Number Range
From ZX13514-2533 to
ZX13516H-3199
Includes:
ZX13514-2463
ZX13514-2469
ZX13514-2631
From ZX135H-3200
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268558
Rev A4
October 2016

Advertisement

Table of Contents
loading

Related Manuals for Genie ZX-135/70

Summary of Contents for Genie ZX-135/70

  • Page 1 Service and Repair Manual Serial Number Range ZX-135/70 This manual includes: Repair procedures From ZX13514-2533 to ZX13516H-3199 Fault Codes Includes: Electrical and ZX13514-2463 ZX13514-2469 Hydraulic Schematics ZX13514-2631 From ZX135H-3200 For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    Copyright © 2015 by Terex Corporation 1268558 Rev A4, October 2016 First Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “ZX” is a trademark of Terex South Dakota, Inc..
  • Page 3 Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section – Fault Codes, All charts the update. Section – Schematics, Legends and schematics Part No. 1268558 ZX-135/70...

  • Page 4: Serial Number Legend

    2 Serial label (located under cover) 3 Facility code 3 Serial number (stamped on chassis) From September 1, 2016 1 Model 1 Serial label (located under cover) 2 Facility code 2 Serial number (stamped on chassis) 3 Sequence number ZX-135/70 Part No. 1268558...

  • Page 5: Safety Rules

     You read, understand and obey: • manufacturer's instructions and safety rules • employer's safety rules and worksite regulations • applicable governmental regulations  You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 1268558 ZX-135/70...
  • Page 6 Be sure that your workshop or work area warrants it. is properly ventilated and well lit. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. ZX-135/70 Part No. 1268558...

  • Page 7: Table Of Contents

    How to Set the Function Thresholds and Default Functions Speeds ..... 28 How to Adjust the Function Speeds ..............30 How to Adjust the Function Ramp Rate Setting ..........31 Platform Components ..................32 2-1 Platform ......................32 Part No. 1268558 ZX-135/70...
  • Page 8 4-9 Secondary Boom Angle Sensor - How to Calibrate the Secondary Boom Angle Sensor ......................78 Engines ........................ 84 5-1 RPM Adjustment .................... 84 5-2 Flex Plate......................84 How to Install the Flex Plate ................85 Ground Controls ....................86 6-1 Bypass/Recovery Key Switch................. 86 viii ZX-135/70 Part No. 1268558...
  • Page 9 How to Adjust the Turntable Rotation Gear Backlash ........137 9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor ..138 Axle Components ..................... 141 10-1 Steer Sensors .................... 141 How to Calibrate a Replacement Steer Sensor ..........143 Part No. 1268558 ZX-135/70...
  • Page 10 Perkins 1104D Engine Electrical Schematic ............222 Perkins 854F-34T Engine Electrical Schematic ..........224 Perkins 854F-34T Engine Harness ..............225 Deutz TD2.9 Engine Electrical Schematic ............228 Deutz TD2.9 Engine Harness ................229 Hydraulic Generator (Welder Option) ..............232 ZX-135/70 Part No. 1268558...
  • Page 11 October 2016 Table of Contents Generator Wiring Schematic ................233 Hydraulic Schematic (to SN ZX13516H-2804) ........... 236 Hydraulic Schematic (from SN ZX13516H-2805) ..........237 Electrical Schematic ................... 239 Electrical Schematic ................... 240 Part No. 1268558 ZX-135/70...

  • Page 13: Specifications

    Drive hub oil type: SAE 90 multipurpose hypoid gear oil primary booms extended API service classification GL5 Turntable rotate, 360°jib and 280 to 350 seconds primary booms extended For operational specifications, refer to the Operator's Manual. Part No. 1268558 ZX-135/70...

  • Page 14: Hydraulic Oil Specifications

    Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 15 Note: Do not operate the machine when the 5606A hydraulic fluid, or equivalent, when ambient ambient temperature is below -20°F / -29°C with Rando HD Premium MV. temperatures are consistently above 32°F / 0°C may result in component damage Part No. 1268558 ZX-135/70...
  • Page 16 @ 104°F / 40°C 33.8 Brookfield Viscosity cSt @ -4°F / -20°C cSt @ -13°F / -25°C 702.4 cSt @ -40°F / -40°C 2624 Flash point >100 Pour point -76°F / -60°C Maximum continuous operating 103°F / 75°C temperature ZX-135/70 Part No. 1268558...

  • Page 17: Hydraulic Component Specifications

    3.5 bar Pressure compensator 2900 psi Hydraulic tank return filter 10 micron 200 bar with 25 psi / Standby pressure 250 psi 1.7 bar 17 bar bypass Beta 10 ≥ 2 Drive motor case drain return filter Part No. 1268558 ZX-135/70...
  • Page 18 (schematic items AE ) 8.8Ω Proportional solenoid valve, 3 position 4 way (schematic items Y and AF) 7.1Ω Solenoid Valve, 2 position 3 way (schematic items AD) Solenoid valve, 2 position 2 way 3.5 to 5.5Ω (schematic item A) ZX-135/70 Part No. 1268558...

  • Page 19: Deutz Td 2.9 Engine Specifications

    Fan belt deflection 3/8 to 1/2 inch Unit ships with 15W-40. 9 to 12 mm Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine. Part No. 1268558 ZX-135/70...

  • Page 20: Deutz Td2011L04I Engine Specifications

    Governor centrifugal Oil Pressure switch mechanical Installation torque 8 - 18 ft-lbs Valve Clearance, cold 11 - 24 Nm Intake 0.012 in Pressure switch point 22 psi 0.3 mm 1.5 bar Exhaust 0.020 in 0.5 mm ZX-135/70 Part No. 1268558...
  • Page 21 Battery – Engine starting and control system Type 12V DC, Group 31 Quantity Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes Alternator output 80A @ 14V DC Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm Part No. 1268558 ZX-135/70...

  • Page 22: Perkins 854F-34T Engine Specifications

    Unit ships with 15W-40. Extreme operating Battery capacity, maximum 1000A temperatures may require the use of alternative engine Reserve capacity @ 25A rate 200 Minutes oils. For oil requirements, refer to the Engine Operator Manual for your engine. ZX-135/70 Part No. 1268558...
  • Page 23 18.4 ft-lbs 25 Nm Maximum continuous temperature 226°F 108°C Temperature Sensor Settings 215°F 37 ohms 102°C 170°F 78 ohms 82°C Alternator output 120A @ 12V DC Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm Part No. 1268558 ZX-135/70...

  • Page 24: Perkins 1104D-44T Engine Specifications

    Fuel injection system Valve Clearance, cold Injector opening pressure 43 psi Intake 0.008 in 3 bar 0.2 mm Fuel requirement Exhaust 0.018 in 0.45 mm For fuel requirements, refer to the engine Operator Manual for your engine. ZX-135/70 Part No. 1268558...
  • Page 25 11 - 24 Nm Temperature switch point 230°F 110°C Temperature Sensor Settings 215°F 37 ohms 102°C 170°F 78 ohms 82°C Alternator output 85A @ 12V DC Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm Part No. 1268558 ZX-135/70...

  • Page 26: Machine Torque Specifications

    Drive hub mounting bolts, lubricated 180 ft-lbs 217 Nm Drive motor mounting bolts, dry 75 ft-lbs 102 Nm Drive motor mounting bolts, lubricated 56 ft-lbs 76 Nm Engine vibration isolators Compressed height >0.375 in Compressed height <0.625 in ZX-135/70 Part No. 1268558...

  • Page 27: Hydraulic Hose And Fitting Torque Specifications

    SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...

  • Page 28: Torque Procedure

    Refer to Illustration 1. hose end are custom-size O-rings. They are not standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly.
  • Page 29 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting. Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. Part No. 1268558 ZX-135/70...
  • Page 30 Service and Repair Manual October 2016 This page intentionally left blank. ZX-135/70 Part No. 1268558...

  • Page 31: Repair Procedures

     Be sure that all necessary tools and parts are available and ready for use.  Use only Genie approved replacement parts.  Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.

  • Page 32: About This Section

    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. ZX-135/70 Part No. 1268558...

  • Page 33: Platform Controls

    Each joystick controller should operate smoothly 6 primary boom up/down, primary boom extend/retract and turntable rotate left/right and provide proportional speed control over its joystick entire range of motion. For further information or assistance, consult Genie Product Support. Part No. 1268558 ZX-135/70...

  • Page 34: Platform Circuit Board

    Remove the platform control box lid retaining fasteners. Open the control box lid. Locate the circuit board mounted to the inside of the platform control box. ZX-135/70 Part No. 1268558...

  • Page 35: How To Remove The Led Circuit Board

    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. Part No. 1268558 ZX-135/70...
  • Page 36 5 seconds, then return to Result: The alarm at the ground controls should the center or neutral position. sound for a successful calibration. Result: The alarm at the ground controls should sound for a successful calibration. ZX-135/70 Part No. 1268558...
  • Page 37 Result: The alarm at the ground controls Result: The alarm at the ground controls should sound for a successful calibration. should sound for a successful calibration. Part No. 1268558 ZX-135/70...
  • Page 38 5 seconds, then return to the center or neutral position. Result: The alarm at the ground controls should sound for a successful calibration. ZX-135/70 Part No. 1268558...

  • Page 39: How To Reset A Proportional Valve Coil Default

    Press the enter or previous button on the LCD screen until EXIT is displayed. Press the plus button or minus button to select YES and then press the enter button. Part No. 1268558 ZX-135/70...

  • Page 40: How To Set The Function Thresholds And Default Functions Speeds

    11 Check the display at the ground controls to be set the joystick controller threshold. sure there are no calibration faults. Note: There should be no calibration faults shown on the display. If calibration faults exist, repeat this procedure. ZX-135/70 Part No. 1268558...
  • Page 41 Note: There should be no calibration faults shown Move the rotate joystick full stroke in either the on the display. If calibration faults exist, repeat this left or right direction until the alarm sounds. procedure. Return the joystick to center. Part No. 1268558 ZX-135/70...

  • Page 42: How To Adjust The Function Speeds

    Press the plus button twice, then press the minus button twice. Press the previous button until the function to be adjusted is displayed. Press the plus button to increase the speed or press the minus button to decrease the speed. ZX-135/70 Part No. 1268558...

  • Page 43: How To Adjust The Function Ramp Rate Setting

    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. Press the plus button twice, then press the previous button twice. Part No. 1268558 ZX-135/70...

  • Page 44: Platform Components

    Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Remove the power to platform electrical outlet box from the platform and lay it to the side. ZX-135/70 Part No. 1268558...

  • Page 45: Platform Leveling Cylinder

    Lower the jib boom until the platform is resting removed from the machine. on the blocks just enough to support the platform. Note: Do not rest the entire weight of the boom on the blocks. Part No. 1268558 ZX-135/70...

  • Page 46: Platform Rotator

    Remove the power to platform electrical outlet Remove the platform. Refer to Repair box bracket mounting fasteners. Do not Procedure, How to Remove the Platform. disconnect the wiring. Tag and disconnect the electrical connector from the platform angle sensor. ZX-135/70 Part No. 1268558...

  • Page 47: How To Bleed The Platform Rotator

    16 Use a soft metal drift to remove both pins and remove the platform rotator from the machine. Crushing hazard. The platform rotator could fall when removed from the machine if not properly supported. Part No. 1268558 ZX-135/70...

  • Page 48: Platform Level Sensor - How To Calibrate The Platform Level Sensor

    13 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. ZX-135/70 Part No. 1268558...

  • Page 49: Platform Overload System (If Equipped)

    Note: The platform will need to be moved up and down and allowed to settle in between adjustments. Part No. 1268558 ZX-135/70...
  • Page 50 LCD screen at the ground controls. Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds. ZX-135/70 Part No. 1268558...

  • Page 51: Platform Overload Recovery Message

    Enter Turn the key switch to the off position. Press and hold the enter button on the ground control panel while turning the key switch to ground controls. Hold the enter button for approximately 5 seconds. Part No. 1268558 ZX-135/70...

  • Page 52: Jib Boom Components

    8 jib extension boom 3 bellcrank 9 hose and cable junction box 4 cable track tube 10 jib boom lift cylinder 5 platform rotator 11 jib boom cable track 6 platform leveling cylinder 12 jib boom leveling cylinder ZX-135/70 Part No. 1268558...

  • Page 53: Jib Boom Cable Track

    Remove the hose and cable clamp retaining fasteners from the jib boom cable track junction box. Remove the clamps. Pull the jib boom lift cylinder hydraulic hoses out of the jib boom cable track junction box. Part No. 1268558 ZX-135/70...
  • Page 54 Do not discard the washer. overhead crane. Note: Always replace the cotter pin with a new one. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. ZX-135/70 Part No. 1268558...

  • Page 55: How To Repair The Cable Track

    Note: A cable track repair kit is available through pinched. the Genie Service Parts Department. Connect the ends of the replacement cable Visually inspect the cable track and determine track section to the existing cable track using which 4-link section needs to be replaced.

  • Page 56: Jib Boom

    Remove the cable track guide fasteners from the platform rotator. Refer to Repair the cable track guide at the platform end of the Procedure, How to Remove the Platform jib boom and remove the cable track guide Rotator. from the jib boom. ZX-135/70 Part No. 1268558...
  • Page 57 12 Remove the cover retaining fasteners from the removed from the machine if it is jib boom angle sensor. Remove the cover. not properly supported by the overhead crane. Part No. 1268558 ZX-135/70...

  • Page 58: Jib Boom Lift Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Support the rod end of the jib boom lift cylinder with a suitable lifting device. ZX-135/70 Part No. 1268558...

  • Page 59: Jib Boom Level Cylinder

    Use a soft metal drift to remove the pin. Crushing hazard. The jib boom could fall if not properly supported when the jib boom level cylinder rod-end pivot pin is removed. Part No. 1268558 ZX-135/70...

  • Page 60: Jib Boom Extension Cylinder

    Repair Procedure, How to Remove the Jib Boom Lift Cylinder. 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. ZX-135/70 Part No. 1268558...
  • Page 61 Use a soft metal drift to remove the pin. Tag and disconnect the electrical connectors inside the lower cable track. Remove the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom. Remove the clamps. Part No. 1268558 ZX-135/70...

  • Page 62: Angle Sensor

    Note: A digital level will only be required to perform 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.

  • Page 63: Note: Use The Following Chart To Identify The Description Of Each Lcd Screen Control Button Used In This Procedure

    8 and continue to step 12. Push in the ground controls red Emergency Stop button to the off position. Do not turn the key switch to the off position. Open the ground control box. Part No. 1268558 ZX-135/70...
  • Page 64 The system must detect a change in displayed value to record the calibrated value. ZX-135/70 Part No. 1268558...
  • Page 65 44 ± displayed value to record the calibrated value. 2 degrees. Note: With the jib boom level cylinder fully retracted, the jib boom bellcrank angle should be at approximately 70 degrees. Part No. 1268558 ZX-135/70...
  • Page 66 Be sure there are no calibration faults control panel while pulling out the ground controls red Emergency Stop button to the on shown on the display. position. Hold the enter button for approximately 5 seconds and then release it. ZX-135/70 Part No. 1268558...
  • Page 67 56 Pull out the red Emergency Stop button. Start press the enter button to accept. the engine and lower the boom to the stowed position. Be sure there are no calibration faults shown on the display. Part No. 1268558 ZX-135/70...

  • Page 68: Boom Components

    11 number 3 secondary boom tube 5 jib boom manifold 12 lower primary boom lift cylinder linkage arm 6 secondary boom lift cylinder 13 number 4 secondary boom tube 7 secondary boom cable track (inside of secondary boom) ZX-135/70 Part No. 1268558...

  • Page 69: Primary Boom Cable Track

    Remove the hose and cable clamp retaining extension boom. fasteners from lower cable track at the pivot end of the jib boom. Remove the clamps. Note: Always replace the cotter pin with a new one. Part No. 1268558 ZX-135/70...
  • Page 70 Do become unbalanced and fall not apply any lifting pressure. when removed from the secondary boom if not properly supported and secured to the lifting device. ZX-135/70 Part No. 1268558...

  • Page 71: How To Repair The Primary Boom Cable Track

    Note: A cable track repair kit is available through supporting it. the Genie Service Parts Department. Crushing hazard. The primary Visually inspect the cable track and determine boom cable track could become which 4-link section needs to be replaced.

  • Page 72: Secondary Boom Cable Track

    Working at the platform end of the secondary boom, support and secure the secondary boom end cover to a suitable lifting device. ZX-135/70 Part No. 1268558...
  • Page 73 16 Working at the platform end of the secondary connections very slowly to allow boom, place blocks between the upper and the oil pressure to dissipate lower cable tracks for support. gradually. Do not allow oil to squirt or spray. Part No. 1268558 ZX-135/70...

  • Page 74: How To Repair The Secondary Boom Cable Track

    19 Remove the secondary boom cable track from Note: A cable track repair kit is available through the machine and place it on a structure the Genie Service Parts Department. capable of supporting it. Remove the secondary boom cable track.

  • Page 75: Primary Boom

    Procedure, How to Remove the Jib Boom. 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. Part No. 1268558 ZX-135/70...
  • Page 76 Calibrate the Primary Boom Angle Sensor. pivot pin where it connects to the primary boom. Remove the hose and cable guide fasteners at the primary boom pivot pin. Remove the hose and cable guide. ZX-135/70 Part No. 1268558...

  • Page 77: Primary Boom Lift Cylinder

    Remove the cable track retaining fasteners at the primary boom lift cylinder. 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. Part No. 1268558 ZX-135/70...

  • Page 78: Secondary Boom Lift Cylinder

    Crushing hazard. The primary the oil pressure to dissipate boom lift cylinder linkage arms gradually. Do not allow oil to may fall if not properly squirt or spray. supported when the barrel-end pivot pin is removed. ZX-135/70 Part No. 1268558...
  • Page 79 Remove the fixed turntable cover hydraulic tank. Cap the fitting on the hydraulic from the machine. tank. 12 Tag, disconnect and plug the hydraulic hose at the return filter. Cap the fitting on the return filter housing. Part No. 1268558 ZX-135/70...
  • Page 80 Electrocution/burn hazard. machine. Contact with electrically charged circuits could result in death or 23 Place a block under the secondary boom lift serious injury. Remove all rings, cylinder for support. watches and other jewelry. ZX-135/70 Part No. 1268558...
  • Page 81 Hoses and cables can be cylinder. damaged if the secondary boom lift cylinder is pulled across them. Note: Protect the hoses and cables underneath the cylinder from damage. Part No. 1268558 ZX-135/70...

  • Page 82: Primary Boom Extension Cylinder

    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. ZX-135/70 Part No. 1268558...

  • Page 83: Secondary Boom Extension Cylinders

    Note: Perform this procedure with the machine on a gradually. Do not allow oil to firm, level surface and in the stowed position with squirt or spray. the axles extended. Remove the upper extension cylinder retainers from the saddle blocks. Part No. 1268558 ZX-135/70...
  • Page 84 1 upper extension cylinder (#1) Note: The secondary boom extension cylinders 2 middle extension cylinder (#2) must be installed in the same order they were 3 bottom extension cylinder (#3) removed. 4 cylinder grooved wear pads 5 channels ZX-135/70 Part No. 1268558...

  • Page 85: Sensor

    Note: A digital level will only be required to perform the 6 Point Calibration procedure. Note: A kit is available through Genie Product 0° slope, 68° boom angle 5° slope, 43° boom angle Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.
  • Page 86 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. ZX-135/70 Part No. 1268558...
  • Page 87 14 Fully raise the secondary boom. The boom is button and the primary boom up button until fully raised when the cylinder is fully extended the digital level displays 10 degrees. and the boom stops moving. Part No. 1268558 ZX-135/70...
  • Page 88 Primary Boom Angle Sensor. 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. ZX-135/70 Part No. 1268558...
  • Page 89 41 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus). 42 Press the enter or previous button on the LCD screen until DELETE PRIMARY BOOM ANGLE SENSOR CALIBRATION is displayed. Part No. 1268558 ZX-135/70...

  • Page 90: Secondary Boom Angle Sensor - How To Calibrate The Secondary Boom Angle Sensor

    Be sure there are no calibration faults over resulting in death or serious shown on the display. injury. Perform a primary boom angle test. Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual, Test the Primary Boom Angle Sensor. ZX-135/70 Part No. 1268558...
  • Page 91 Note: A digital level will only be required to perform the 6 Point Calibration procedure. Turn the key switch to ground controls. Note: A kit is available through Genie Product Open the ground control box. Support (Genie part number 58351). This kit...
  • Page 92 The system must detect a change in displayed value to record the calibrated value. ZX-135/70 Part No. 1268558...
  • Page 93 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. Part No. 1268558 ZX-135/70...
  • Page 94 48 Press the enter or previous button on the approximately 5 seconds and then release LCD screen until EXIT is displayed. it.Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus). ZX-135/70 Part No. 1268558...
  • Page 95 Be sure there are no calibration faults shown on the display. Perform secondary boom angle test. Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual, Test the Secondary Boom Angle Sensor. Part No. 1268558 ZX-135/70...

  • Page 96: Engines

    Then remove all of the pump mounting plate to engine bell housing bolts. Carefully pull the pump away from the engine and secure it from moving. Remove the flex plate mounting fasteners, then remove the flex plate from the engine flywheel. ZX-135/70 Part No. 1268558...

  • Page 97: How To Install The Flex Plate

    28 ft-lbs / 38 Nm. Then torque the flex plate mounting bolts in sequence to 40 ft-lbs / 54 Apply a high viscosity coupling grease (Genie part number 128025) to the splines of the pump shaft and flex plate.

  • Page 98: Ground Controls

    Recovery is only to be used as a last attempt to lower the platform when the operator in the platform is unable to do so, system failure or in emergency 1 Run situations. 2 Bypass 3 Recovery ZX-135/70 Part No. 1268558...
  • Page 99 Turn the main key switch to ground controls. Remove the key from the main key switch and insert the key into the bypass/recovery key switch. Note: The main key switch must remain in the ground control position. Part No. 1268558 ZX-135/70...

  • Page 100: How To Use The Recovery Mode

    Note: If the Recovery function has been used, this may indicate there may be faults with the machine. Tag and remove the machine from service until the fault has been corrected by trained personnel. ZX-135/70 Part No. 1268558...

  • Page 101: Circuit Boards

    Carefully disconnect the LCD circuit board ribbon cable from the ECM circuit board. Remove the LCD display circuit board retaining fasteners. Carefully remove the LCD display circuit board from the ground control box lid. Part No. 1268558 ZX-135/70...
  • Page 102 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. ZX-135/70 Part No. 1268558...

  • Page 103: Membrane Decal

    LCD display screen. Install the new membrane decal while guiding the ribbon cables through the control box lid. Connect the ribbon cables to the ECM circuit board. Close the control box lid and install the retaining fasteners. Part No. 1268558 ZX-135/70...

  • Page 104: Full Machine Calibration

    Note: A digital level will be required to perform this How to Calibrate All Steer Sensors. procedure. • Secondary boom angle sensor. Refer to Note: A kit is available through Genie Product Repair Procedure, How to Calibrate the Support (Genie part number 58351). This kit Secondary Boom Angle Sensor.

  • Page 105: Display Module

    >100°F Engine temperature °C (metric) engine temp will not display until temp is >38°C Primary boom angle to gravity Turntable level sensor X° direction Turntable level sensor Y° direction Platform level sensor degree Battery volts Part No. 1268558 ZX-135/70...
  • Page 106 Delete boom function speed on position. Release the enter button and press Delete lift function ramps (minus)(minus)(previous)(previous) Delete all (Contact Genie Product Support before using this option) Delete Faults Delete faults will reset active latching faults.
  • Page 107 Reverse high drive speed % 120% (max) 100% (default) 50% (min) Drive acceleration % 125% (max) 100% (default) 25% (min) Drive deceleration % 125% (max) 100% (default) 25% (min) Speed limit on steer angle 100% (max) 50% (default) 0% Part No. 1268558 ZX-135/70...
  • Page 108 Secondary boom extend speed Secondary boom retract speed Turntable rotate speed retracted Turntable rotate speed not retracted Turntable rotate speed extended Jib up speed retracted Jib up speed not retracted Jib down speed retracted Jib down speed not retracted ZX-135/70 Part No. 1268558...
  • Page 109 Secondary boom extend/retract ramp deceleration % Turntable rotate ramp acceleration % Turntable rotate ramp deceleration % Jib boom up/down ramp acceleration % 120% max and 50% min, 100% (default), 5% incr Jib boom up/down ramp deceleration % Part No. 1268558 ZX-135/70...
  • Page 110 Delete drive joystick calibration Delete primary boom up/down joystick calibration Delete primary boom extend/retract joystick calibration Delete secondary boom joystick calibration Delete turntable rotate joystick calibration Delete steer joystick calibration Delete jib up/down joystick calibration ZX-135/70 Part No. 1268558...
  • Page 111 60° jib level calibration deg to gravity 34° jib level calibration deg to gravity 8° jib level calibration deg to gravity -18° jib level calibration deg to gravity -44° jib level calibration deg to gravity -70° Part No. 1268558 ZX-135/70...
  • Page 112 Delete primary boom angle sensor calibration? (YES/NO) Primary boom fully lowered? (YES/NO)° Primary boom fully raised? (YES/NO)° Delete jib level angle sensor calibration? (YES/NO) Jib level cylinder fully extended? (YES/NO) Jib level cylinder fully retracted? (YES/NO) ZX-135/70 Part No. 1268558...
  • Page 113 30.0 max and 0.0 min, 10.0 (default) Platform Always Level to Gravity (NO/YES) Axle Motion Only While Driving (NO/YES) Holding +/- button will cause display to scroll through options or increment number settings automatically at 0.2 min increase/decrease Part No. 1268558 ZX-135/70...

  • Page 114: Hydraulic Pumps

    Sauer-Danfoss service center. Contact the oil pressure to dissipate Genie Product Support to locate your local gradually. Do not allow oil to authorized service center. squirt or spray.

  • Page 115: How To Prime The Function Pump

    Clean up any oil that may have spilled. Properly discard the used oil. Start the engine from the ground controls. Check for hydraulic leaks. 1 standby pressure set screw 2 standby pressure adjustment screw Part No. 1268558 ZX-135/70...

  • Page 116: How To Adjust The Function Pump Pressure Compensator

    Turn the engine off and remove the pressure gauge. gauge. Result: The gauge should show 2900 psi / 200 bar. Result: If the gauge does not show 2900 psi / 200 bar, proceed to step 6 to adjust the function pump pressure compensator. ZX-135/70 Part No. 1268558...

  • Page 117: Drive Pump

    (EDC), located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should be performed at an authorized Sauer-Danfoss service center. Contact Genie open closed Product Support to locate your local authorized service center.

  • Page 118: How To Prime The Drive Pump

    250 psi / 17 bar. Perkins models: Connect the engine wiring harness to the fuel solenoid. Deutz models: Release the manual fuel shutoff valve. Start the engine from the ground controls. Check for hydraulic leaks. ZX-135/70 Part No. 1268558...
  • Page 119 October 2016 Service and Repair Manual This page intentionally left blank. Part No. 1268558 ZX-135/70...

  • Page 120: Manifolds

    Relief valve, 3100 psi / 214 bar System relief 30-35 ft-lbs / 41-47 Nm Differential sensing valve, 150 psi / Secondary boom up/down 50-55 ft-lbs / 68-75 Nm 10.3 bar circuit, regulates pressure drop across secondary boom up/down proportional valve ZX-135/70 Part No. 1268558...
  • Page 121 October 2016 Service and Repair Manual Manifolds Part No. 1268558 ZX-135/70...
  • Page 122 Primary boom up/down circuit 50-55 ft-lbs / 68-75 Nm valve Differential sensing valve, Primary boom up/down circuit, 30-35 ft-lbs / 41-47 Nm 150 psi / 10.3 bar regulates pressure drop across primary boom up/down proportional valve ZX-135/70 Part No. 1268558...
  • Page 123 October 2016 Service and Repair Manual Manifolds Part No. 1268558 ZX-135/70...

  • Page 124: Valve Adjustments - Function Manifold

    Turn the valve stem counterclockwise several turns. Do not allow the relief valve to come apart. Tighten the lock nut. Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test port on the function manifold ZX-135/70 Part No. 1268558...
  • Page 125 Start the engine from the ground controls and press and release the rpm select button until 13 Remove the pressure gauge. the engine changes to high idle. 14 Start the engine and fully retract the primary boom. Turn the engine off. Part No. 1268558 ZX-135/70...

  • Page 126: Platform Manifold

    20-25 ft-lbs / 27-34 Nm Proportional solenoid valve, 3 position 4 way Platform level up/down 20-25 ft-lbs / 27-34 Nm Flow control valve,0.2 gpm / 0.76 L/min Platform rotate left/right circuit 20-25 ft-lbs / 27-34 Nm ZX-135/70 Part No. 1268558...
  • Page 127 October 2016 Service and Repair Manual This page intentionally left blank. Part No. 1268558 ZX-135/70...

  • Page 128: Jib Boom Manifold

    10-12 ft-lbs / 14-16 Nm Proportional solenoid valve, Jib boom up/down 20-25 ft-lbs / 27-34 Nm 3 position 4 way Proportional solenoid valve, Jib boom bellcrank level up/down 20-25 ft-lbs / 27-34 Nm 3 position 4 way ZX-135/70 Part No. 1268558...
  • Page 129 October 2016 Service and Repair Manual Part No. 1268558 ZX-135/70...

  • Page 130: Flow Control Mainfold

    The flow control manifold is located at the platform next to the jib manifold. Index Schematic Description Function Torque Item Flow regulator valve, 0.5 gpm / 1.9 L/min Controls flow in the jib and platform 20 ft-lbs / 27 Nm manifold recirculation circuit ZX-135/70 Part No. 1268558...

  • Page 131: Function Enable Valve

    The function enable valve is mounted behind the medium pressure filter. Index Schematic Description Function Torque Item Solenoid valve, 2 position 2 way Enables lift pump to provide 20-25 ft-lbs / hydraulic pressure for all boom and 27-34 Nm steer/axle functions Part No. 1268558 ZX-135/70...

  • Page 132: Turntable Rotation Manifold

    Counterbalance valve Turntable rotate left 25-30 ft-lbs / 34-41 Nm Shuttle valve. 2 position, 3 way Turntable rotation brake release 8-10 ft-lbs / 11-14 Nm Orifice Plug, 0.030 inch / 0.76 mm Turntable rotation brake release ZX-135/70 Part No. 1268558...
  • Page 133 October 2016 Service and Repair Manual This page intentionally left blank. Part No. 1268558 ZX-135/70...

  • Page 134: Steer And Axle Manifold

    Flow control valve, 7 gpm / 26.5 L/min Axle extend/retract circuit 50-55 ft-lbs / 68-75 Nm Solenoid Valve, 2 position 3 way Axle retract 50-55 ft-lbs / 68-75 Nm Solenoid Valve, 2 position 3 way Axle extend 50-55 ft-lbs / 68-75 Nm ZX-135/70 Part No. 1268558...
  • Page 135 October 2016 Service and Repair Manual Manifolds Part No. 1268558 ZX-135/70...
  • Page 136 27-34 Nm Solenoid valve, 3 position 4 way Steer left/right, left front steer 20-25 ft-lbs / cylinder 27-34 Nm Solenoid valve, 3 position 4 way Steer left/right, right front steer 20-25 ft-lbs / cylinder 27-34 Nm ZX-135/70 Part No. 1268558...
  • Page 137 October 2016 Service and Repair Manual Manifolds Part No. 1268558 ZX-135/70...

  • Page 138: Valve Adjustments - Steer And Axle Manifold

    Start the engine from the platform controls and press down the foot switch. Press and hold the axle extend button at the platform controls. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specifications. ZX-135/70 Part No. 1268558...
  • Page 139 October 2016 Service and Repair Manual This page intentionally left blank. Part No. 1268558 ZX-135/70...

  • Page 140: Traction Manifold Components

    20-25 ft-lbs / Check valve, 5 psi / 0.3 bar Drive motor anti-cavitation 27.1-33.9 Nm Flow control valve, 2 gpm / 7.6 Equalizes pressure on both sides of 30-35 ft-lbs / L/min divider/combiner valve 40.7-47.5 Nm ZX-135/70 Part No. 1268558...
  • Page 141 October 2016 Service and Repair Manual Manifolds Part No. 1268558 ZX-135/70...
  • Page 142 Flow divider/combiner valve forward and reverse 122-135.6 Nm 90-100 ft-lbs / Flow divider/combiner valve Controls flow to divider/combiner valves 122-135.6 Nm 20-25 ft-lbs / Check valve, 5 psi / 0.3 bar Drive motor anti-cavitation 27.1-33.9 Nm ZX-135/70 Part No. 1268558...
  • Page 143 October 2016 Service and Repair Manual Manifolds Part No. 1268558 ZX-135/70...

  • Page 144: Valve Adjustments - Traction Manifold

    (rabbit symbol) position. Note the reading on the pressure gauge. Turn the engine off. Remove the pressure gauge from the drive pump. Connect the gauge to the test port located on the traction manifold. ZX-135/70 Part No. 1268558...

  • Page 145: Drive Oil Diverter Manifold Components (Welder Option)

    Solenoid Valve Pilot valve to diverter 35-40 ft-lbs / 47-54 Nm Relief valve, 270 psi / 18.6 bar Charge pressure circuit 35-40 ft-lbs / 47-54 Nm Check valve Prevents oil to generator 35-40 ft-lbs / 47-54 Nm Part No. 1268558 ZX-135/70...

  • Page 146: Valve Coils

    Tag and disconnect the wiring from the coil to be tested. Test the coil resistance. Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. ZX-135/70 Part No. 1268558...
  • Page 147 6. Resistor 10Ω Set a multimeter to read DC current. Genie part number 27287 Note: The multimeter, when set to read DC current, Note: The battery should read 9V DC or more when should be capable of reading up to 800 mA.

  • Page 148: Turntable Rotation Components

    Do not allow oil to squirt or spray. Attach a lifting strap from an overhead crane or other suitable lifting device to the lifting eye on the turntable rotation assembly. ZX-135/70 Part No. 1268558...

  • Page 149: How To Adjust The Turntable Rotation Gear Backlash

    Loosen the lock nut on the adjustment bolt. Turn the adjustment bolt clockwise until it contacts the backlash pivot plate. 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts Part No. 1268558 ZX-135/70...

  • Page 150: Turntable Level Sensor - How To Calibrate The Turntable Level Sensor

    Turn the key switch to ground controls. Note: A digital level will 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.
  • Page 151 Emergency Stop button to the on position. Hold the enter button for approximately 5 seconds and then release it. Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus). negative degree side slope Part No. 1268558 ZX-135/70...
  • Page 152 20 Start the engine. Be sure there are no calibration faults shown on the display. Perform level sensor test. Refer to Maintenance negative degree uphill slope Procedure, Test the Level Sensor. ZX-135/70 Part No. 1268558...

  • Page 153: Axle Components

    Align the remaining wheels on the machine so they are visually parallel to the chassis as close as possible. Disconnect the steer sensor assembly cable from the main harness to be replaced. Part No. 1268558 ZX-135/70...
  • Page 154 Illustration 3 1 installed position Rotate the sensor housing in a clockwise 2 starting position direction until the sensor cable is pointing 3 sensor cover away from the machine. Refer to Illustration 2. 4 rotation arrow ZX-135/70 Part No. 1268558...

  • Page 155: How To Calibrate A Replacement Steer Sensor

    Tighten the sensor cover fasteners. Note: If available, WebGPI can also be used for this procedure. Push in the red Emergency Stop button to the off position. Part No. 1268558 ZX-135/70...

  • Page 156: How To Calibrate All Steer Sensors

    Loosen the steer angle sensor cover retaining fasteners. Do not remove the fasteners or the sensor cover. Using a voltmeter set to DC voltage, probe the back of the electrical connector at pins B and ZX-135/70 Part No. 1268558...
  • Page 157 19 Press the plus button to select YES, then 2 Bypass press the enter button to accept. 3 Recovery 10 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus). Part No. 1268558 ZX-135/70...

  • Page 158: Steer Cylinders

    Use a soft metal drift to remove the pins. Remove the steering cylinder from the machine. Crushing hazard. The steer cylinder may become unbalanced and fall if not properly supported by the lifting device when removed from the machine. ZX-135/70 Part No. 1268558...

  • Page 159: Axle Extension Cylinders

    Do not allow oil to squirt or spray. Remove the axle extension limit switch cover fasteners. Remove the cover. Remove the limit switch mounting fasteners and remove the limit switch. Do not disconnect the wiring. Part No. 1268558 ZX-135/70...

  • Page 160: Axle Angle Sensors - How To Calibrate The Axle Angle Sensors

    Emergency Stop button to the on direction. position. Hold the enter button for approximately 5 seconds and then release it. ZX-135/70 Part No. 1268558...
  • Page 161 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. Part No. 1268558 ZX-135/70...
  • Page 162 Service and Repair Manual October 2016 This page intentionally left blank. ZX-135/70 Part No. 1268558...

  • Page 163: Fault Codes

    • All external AC power supply disconnected from the machine • Boom in the stowed position • Turntable secured with the turntable rotation lock • Welder disconnected from the machine (if equipped with the weld cable to platform option) Part No. 1268558 ZX-135/70...

  • Page 164: Control System Fault Codes

    If necessary replace and Value at 0 V recalibrate joystick. Not calibrated Joystick Speed and Direction frozen at Calibrate Joystick zero and neutral Just calibrated Initiate one second beep of audible Self-clearing (transient) warning device ZX-135/70 Part No. 1268558...
  • Page 165 Alarm sounds ground. Replace coil if necessary Value Too Low Limited Speed and Direction frozen at Check for opens in the wiring or a bad zero and neutral, Alarm sounds ground. Replace coil if necessary Part No. 1268558 ZX-135/70...
  • Page 166 Use aux to get the boom back into operational limits. Check P54ENG and P58LS between SCON and TCON for damage. Check SCON chart for possible fault conditions. ZX-135/70 Part No. 1268558...
  • Page 167 SCON and TCON. Check SCON chart for possible faults. Safety Switch P39 Fault Check Display message on LCD P39 SAFETY Recycle power and check wiring on SWITCH FAULT circuit S139TRF (white/red) between SCON and TCON. Check SCON chart for possible faults. Part No. 1268558 ZX-135/70...
  • Page 168 Check CAN bus wiring from TCON to propel DCON through rotator. Repair or replace wiring or DCON. CAN Bus Fault Check Display message on LCD Check CAN bus wiring from TCON to SCON/PCON. Repair or replace wiring or SCON/PCON. ZX-135/70 Part No. 1268558...
  • Page 169 Primary up, Secondary up/down and Recalibrate sensor Extend disabled, Alarm sounds Not calibrated Primary up only active from TCON, Perform calibration procedure per activate alarm service manual Just calibrated Initiate one second beep of audible Self-clearing (transient) warning device Part No. 1268558 ZX-135/70...
  • Page 170 Display message on LCD membrane switch. If necessary replace Switches on TCON membrane switch. Secondary Boom Up/Down Not calibrated Display message on LCD and allow See service manual on how to perform Speed operation at default speed this procedure. ZX-135/70 Part No. 1268558...
  • Page 171 Primary up, Secondary up/down and Extend disabled, Alarm sounds Not calibrated Secondary up only active from TCON, Perform calibration procedure per activate alarm service manual Just calibrated Initiate one second beep of audible Self-clearing (transient) warning device Part No. 1268558 ZX-135/70...
  • Page 172 Check that SCON is grounded Sensor X Direction activate alarm Value Too High Replace SCON Value Too Low Value at 0 V Out of Tolerance Just calibrated Initiate one second beep of audible Self-clearing (transient) warning device ZX-135/70 Part No. 1268558...
  • Page 173 Check that SCON is grounded Sensor Y Direction sounds Value Too High Replace SCON Value Too Low Value at 0 V Out of Tolerance Just calibrated Self-clearing (transient) Initiate one second beep of audible warning device Part No. 1268558 ZX-135/70...
  • Page 174 Initiate one second beep of audible Self-clearing (transient) warning device Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad zero and neutral, Alarm sounds ground. Replace coil if necessary Value Too Low ZX-135/70 Part No. 1268558...
  • Page 175 If necessary replace Value Too Low and recalibrate joystick. Value at 0 V Not calibrated Joystick Speed and Direction frozen at zero and neutral Just calibrated Initiate one second beep of audible Self-clearing (transient) warning device Part No. 1268558 ZX-135/70...
  • Page 176 Primary up, Secondary up/down and Recalibrate sensor Extend disabled, Alarm sounds Not calibrated Primary up only active from TCON, Perform calibration procedure per activate alarm service manual Just calibrated Initiate one second beep of audible Self-clearing (transient) warning device ZX-135/70 Part No. 1268558...
  • Page 177 Motor Valve Speed Fault Check Limited Speed and Direction frozen at Check for defective or damaged zero and neutral, Alarm sounds wiring. Check for an open or shorted valve coil. Repair or replace as Brake Valve necessary. Part No. 1268558 ZX-135/70...
  • Page 178 Check for 5.0 VDC at the sensor. Extend disabled, Alarm sounds Check for damaged wiring going to the sensor. Check that the % .0 VDC LED is lit on the TCON board. Repair or replace as necessary ZX-135/70 Part No. 1268558...
  • Page 179 Steer Valves - LF, RF, LR, Fault Check Limited Speed and Direction frozen at Check for defective or damaged zero and neutral, Alarm sounds wiring. Check for an open or shorted valve coil. Repair or replace as necessary. Part No. 1268558 ZX-135/70...
  • Page 180 Inhibit secondary boom extend and Check switch for proper operation or switch within a sound an audible warning damage. Use TCON display menu or specified time laptop with WebGPI to clear faults. after the secondary boom was raised ZX-135/70 Part No. 1268558...

  • Page 181: Fault Matrix

    Turntable tilt angle (crosscheck SCON internal sensors 3 in a delta configuration) Primary Boom safety (max angle) Loss of CAN LSS1RS disconnected (SCON pin #2) Platform Overload (SCON pin #1) Secondary Boom length (crosscheck LSS1RS and LSS1RO) Part No. 1268558 ZX-135/70...

  • Page 182: Deutz Td 2.9 L4 Engine Fault Codes

    Actuator error EGR-Valve; signal Sensor error water in fuel; signal range check low range check low 1223 Actuator EGR-Valve; open load 1157 Water in fuel level prefilter; maximum value exceeded 1014 Actuator error EGR-Valve; signal range check high ZX-135/70 Part No. 1268558...
  • Page 183 Sesnor error rail pressure; signal temperature; shut off threshold range check high exceeded Sensor error rail pressure; signal Sensor error charged air range check low temperature; signal range check high Sensor error charged air temperature; signal range check Part No. 1268558 ZX-135/70...
  • Page 184 Sensor ambient air temperature; Sensor camshaft speed; plausibility error disturbed signal Intake air sensor; plausibility error Sensor error intake air; signal range check high Sensor error intake air sensor; signal range check low ZX-135/70 Part No. 1268558...
  • Page 185 Injector 1 (in firing order); short Physical range check low for circuit EGR differential pressure High side to low side short circuit Sensor error differential pressure in the injector 1 (in firing order) Venturiunit (EGR); signal range check low Part No. 1268558 ZX-135/70...
  • Page 186 CAN-Receive-Frame TSC1TE; Cold start aid relay error. Setpoint Cold start aid relay open load 1079 13 Sensor supply voltage monitor 1 error (ECU) 1080 13 Sensor supply voltage monitor 2 error (ECU) ZX-135/70 Part No. 1268558...
  • Page 187 1231 14 CAN-Bus 1 "BusOff-Status" 1180 1 1194 Physical range check low for 1235 14 CAN-Bus 2 "BusOff-Status" exhaust gas temperature upstream turbine 1180 1 1461 Turbocharger Wastegate CAN feedback; shut off threshold exceeded Part No. 1268558 ZX-135/70...
  • Page 188 Injector diagnostics; timeout error of short circuit to ground 4765 0 1039 Physical range check high for measurement cyl. Bank 0 exhaust gas temperature upstream (DOC) 4765 1 1042 Physical range check low for exhaust gas temperature upstream (DOC) ZX-135/70 Part No. 1268558...
  • Page 189 523470 Pressure Relief Valve (PRV) 523006 Controller mode switch; short forced to open; performed by circuit to battery pressure shock 523006 Controller mode switch; short circuit to ground 523008 Manipulation control was triggered Part No. 1268558 ZX-135/70...
  • Page 190 Internal ECU monitoring Traction Control detection reported error 523606 Timeout Error of 523612 Internal ECU monitoring CAN-Receive-Frame TSC1AR; detection reported error Retarder 523612 Internal software error ECU; injection cut off 523612 Internal ECU monitoring detection reported error ZX-135/70 Part No. 1268558...
  • Page 191 Minimum rail pressure exceeded (RailMeUn3) 523766 Timeout Error of CAN-Receive-Frame Active 523613 Setpoint of metering unit in TSC1AE overrun mode not plausible 523767 Timeout Error of 523615 Metering unit (Fuel-System); CAN-Receive-Frame Passive short circuit to battery highside TSC1AE Part No. 1268558 ZX-135/70...
  • Page 192 Timeout Error of CAN-Receive-Frame UAA11; AGS sensor data 523895 Check of missing injector adjustment value programming (IMA) injector 1 (in firing order) 523896 check of missing injector adjustment value programming (IMA) injector 2 (in firing order) ZX-135/70 Part No. 1268558...
  • Page 193 523960 1011 Physical range check high for 523932 Fuel Balance Control integrator EGR cooler downstream temp. injector 4 (in firing order); minimum value exceeded 523935 Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages Part No. 1268558 ZX-135/70...
  • Page 194 1327 Injector cylinder bank 2 slave; ground short circuit 524034 1436 Disc Separator; open load 523999 1328 Injector powerstage output Slave 524034 1437 Disc Separator; powerstage over defect temperature 524014 1254 Air pressure glow plug flush line; below limit ZX-135/70 Part No. 1268558...
  • Page 195 1673 Timeout error of 524104 9 1676 Timeout error of CAN-Receive-Frame CAN-Receive-Frame ComRxCustSCR3 ComRxDPFCtl 524105 9 1668 Timeout error of CAN-Transmit-Frame ComEGRMsFlw 524106 9 1677 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1 524107 9 1678 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2 Part No. 1268558 ZX-135/70...
  • Page 196 1683 Timeout error of CAN-Receive-Frame ComRxTrbChActr 524122 9 1684 Timeout error of CAN-Receive-Frame ComRxUQSens 524123 9 1685 Timeout error of CAN-Receive-Frame ComSCRHtCtl 524124 9 1686 Timeout error of CAN-Receive-Frame ComTxAT1IMG 524125 9 1687 Timeout error of CAN-Receive-Frame ComTxTrbChActr ZX-135/70 Part No. 1268558...

  • Page 197: Perkins 854F-34T Engine Fault Code

    Engine Air Filter 1Differential Pressure : Switch Circuits - Test Erratic,Intermittent,or Incorrect Engine Air Filter 1Differential Pressure :High - Inlet Air Is Restricted least severe (1) Engine Air Filter 1Differential Pressure :High - Inlet Air Is Restricted moderate severity(2) Part No. 1268558 ZX-135/70...
  • Page 198 Engine Rated Power :Erratic, Intermittent or ECM Memory- Test Incorrect Engine Rated Power :Special Instruction ECM Memory - Test Battery Potential/ Power Input 1 :Voltage Below Ignition Keyswitch Circuit and Battery Supply Circuit Normal - Test ZX-135/70 Part No. 1268558...
  • Page 199 Injector Solenoid Circuit - Test Normal Engine Injector Cylinder #01 : Current Above Injector Solenoid Circuit- Test Normal Engine Injector Cylinder#01 :Data Drifted High Injector Data Incorrect- Test Engine Injector Cylinder#01 :Data Drifted Low Injector Data Incorrect - Test Part No. 1268558 ZX-135/70...
  • Page 200 Engine Speed Sensor #2 :Abnormal Engine Speed/liming Sensor Circuit - Test Frequency,Pulse Width, or Period PTO Governor State : Erratic,Intermittent, or PTO Switch Circuit - Test Incorrect 1041 Start Signal Indicator :Erratic,Intermittent,or Start Relay Circuit- Test Incorrect ZX-135/70 Part No. 1268558...
  • Page 201 1239 Engine Fuel Leakage 1 :High- most severe (3) Fuel Rail Pressure Problem 1485 ECM Main Relay :Not Responding Properly Electrical Power Supply- Test 1485 ECM Main Relay :Special Instruction Electrical Power Supply- Test Part No. 1268558 ZX-135/70...
  • Page 202 After treatment #1 Intake 02 :Failure Oxygen Level- Test 3217 After treatment #1 Intake 02 : Out of Calibration Oxygen Level- Test 3217 After treatment #1 Intake 02 : High - least Oxygen Level- Test severe (1) ZX-135/70 Part No. 1268558...
  • Page 203 Sensor Supply Voltage 3 : Erratic,Intermittent,or 5 Volt Sensor Supply Circuit - Test Incorrect 3697 Particulate Trap Lamp Command :Current Indicator Lamp Circuit- Test Above Normal 3698 Exhaust System High Temperature Lamp Indicator Lamp Circuit- Test Command :Current Below Normal Part No. 1268558 ZX-135/70...
  • Page 204 Relief Valve : Special Instruction 5571 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem Relief Valve :High - moderate severity (2) 5826 Emission Control System Operator Inducement Refer to "Operator Inducement Codes". Severity :High - moderate severity (2) ZX-135/70 Part No. 1268558...

  • Page 205: Schematics

     Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use. Part No. 1268558 ZX-135/70...

  • Page 206: Wire Circuit Legend

    V61AXR – V stands for valve power. Number 61 stands for axle retracted circuit; AXR stands for Axle retracted. R46HRN – R stands for Relay output, supplying power to the horn (HRN). Number 46 is the circuit number for the horn. ZX-135/70 Part No. 1268558...
  • Page 207 Data High Jib Extend/Retract Control Data Low Jib Up/Down Flow Control Electrical Displacement Control Propel Signal Envelope Lockout Joystick 5V DC Power Envelope Light Jib Rotate Left (CCW) Extend/Retract Lockout Jib Rotate Right (CW) Engine Status Lamp Part No. 1268558 ZX-135/70...
  • Page 208 Primary Boom Up Reverse Pressure Comp Enable Right Front Platform Control Right Front Steer Sensor Primary Ext/Ret Lockout Retract Lockout Primary Boom Extend/Retract Flow Control Primary Boom Up/Down Signal Right Rear Primary Lockout Platform Level Down ZX-135/70 Part No. 1268558...
  • Page 209 Steering Valve (CW) Test Switch Sensor Turntable Tilt Alarm Sec Boom Extend/Retract Flow Control Turntable Tilt Sensor CAN Shield Secondary Boom Lockout Valve (riser down) Secondary Boom Lockout Valve (extend) Spare Speed Sensor Steer Control Signal Part No. 1268558 ZX-135/70...

  • Page 210: Wire Color Legend

    Wire Color Legend Blue BL/BK Blue/Black BL/RD Blue/Red BL/WH Blue/White Black BK/RD Black/Red BK/WH Black/White BK/YL Black/Yellow Brown Green GR/BK Green/Black GR/WH Green/White RD/BK Red/Black RD/WH Red/White Orange OR/BK Orange/Black OR/RD Orange/Red White WH/BK White/Black WH/RD White/Red Yellow ZX-135/70 Part No. 1268558...
  • Page 211 Auxiliary Steer Key switch power to platform BL/RD Auxiliary Platform Power to platform WH/BK Boom envelope safety valve cutoff Power to warning senders BK/WH Power to safety interlock switches WH/BK Power to oil pressure sender (engine) Part No. 1268558 ZX-135/70...
  • Page 212 Can 2.0/J1939 Low Steer Signal to Solenoid Valve Can 2.0/J1939 High OR/RD Multi-function Valve GR/WH Tilt signal X axis BK/RD Load Moment Overweight GR/BK Tilt signal Y axis RD/BK Load Moment Underweight Tilt sensor power Hydraulic Oil Cooler ZX-135/70 Part No. 1268558...
  • Page 213 Joystick 5V DC power RD/WH Drive Power (P_38) BL/WH Primary Extend/Retract Signal RD/BK Primary Boom Up/Secondary RD/WH Primary Up/Down Signal Boom Down-Extend (P_11/30) WH/RD TT Rotate Signal WH/RD Turntable Rotate Flow Control Safety (P_39) OR/RD Boom Envelope Safety Part No. 1268558 ZX-135/70...
  • Page 214 Lift Power Relay CAN 2.0 / J1939 High 48 Volt Alternator field (or Battery) Ground or Return 24 Volt Battery Envelope or Load Sense Recovery Program setup Enable Encode A Encode B Bootstrap or Program Enable ZX-135/70 Part No. 1268558...

  • Page 215: Limit Switches And Angle Sensors

    17 RSRA1SO 5 LST1O 18 LSRA1ES 6 LST1S 19 RSLR1SO 7 LSS1RS 20 RSRR1SO 8 LSS1RO 21 DCON 9 RSS1AO 22 RSRF1SO 10 RSS1AS 23 RSLF1SO 11 LSP1EO 24 LSFA1ES 12 RSJ1AO 25 RSFA1SO 13 LSJ1RO Part No. 1268558 ZX-135/70...
  • Page 216 'circle' end of the drive chassis.In some cases, the engine LSFA1ES Front axle fully retracted will be stopped if safety parameters are exceeded. LSRA1ES Rear axle fully retracted ZX-135/70 Part No. 1268558...
  • Page 217 LSP1EO: Limit Switch, Primary Boom #1 Extend Operational. Switch closes when the primary boom is fully extended. NOHC when fully extended. LSP1RO: Limit Switch, Primary Boom #1 Retract Operational. Switch closes when the primary boom is retracted. NOHC when fully retracted Part No. 1268558 ZX-135/70...
  • Page 218 Cuts power to circuits P9B, P_11 and P_30 if the secondary boom drifts down while still extended. RSFA1O: Rotary Sensor, Front Axle #1 Operational. Provides front axle positioning information for adjusting steering neutral setting during axle extension. ZX-135/70 Part No. 1268558...

  • Page 219: Circuit Connector Legend

    4 pin Deutsch connector on sec boom retract 2 pin Deutsch connector for platform (LSS1RO) footswitch 6 pin Deutsch connector on platform tilt sensor 3 pin Deutsch connector on RPM solenoid 2 pin Deutsch connector for pri boom up/down flow control Part No. 1268558 ZX-135/70...
  • Page 220 J110 3 pin Deutsch connector for left front steer sensor J114 6 pin Deutsch connector for primary boom angle sensor (PBAS) J119 2 pin Deutsch connector for jib not retracted J120 4 pin Weatherpack EDC connection ZX-135/70 Part No. 1268558...
  • Page 221 6 pin Deutsch connector for jib bellcrank sensor J168 1 way 0.25 inch slide terminal for belt generator excite J169 20 pin Molex connector for circuit board to joystick and switches #2 J175 2 pin Deutsch connector Part No. 1268558 ZX-135/70...

  • Page 222: Drive Chassis And Platform Controller Pin Legend

    P61LSA - GR V37LFS - BL/BK P23PCON - BK P87PTS - RD (UNUSED) (UNUSED) (UNUSED) (UNUSED) V146JBU - BL V147JBD - BL/BK P109JBS - GR/WH P110JBS - BK C148JBS - BL/WH (UNUSED) VLVRET2 - BR (UNUSED) ZX-135/70 Part No. 1268558...

  • Page 223: Safety Controller Pin Legend

    D81CAN (-) - GR P53LS - WH/BK S59CNK - GR/WH S140ENL - OR/RD S56PRV - RD P54ENG - BK/WH S137PLL - RD/WH P58LS - RD/BK S139TRF - WH/RD S56PRV - RD GNDSCON - BR C61AXR - GR Part No. 1268558 ZX-135/70...

  • Page 224: Turntable Controller Pin Legend

    C143DEL - BL/RD (UNUSED) GND - BR (UNUSED) VLVRET6 - BR (UNUSED) (UNUSED) (UNUSED) (UNUSED) C27AUX - RD C123PBS - RD/BK (UNUSED) C124SBS - OR/BK V155PCE - OR/RD S140ENL - OR/RD V150HG - GR/BK GND16 - BR ZX-135/70 Part No. 1268558...

  • Page 225: Telematics Connector Pin Legend

    October 2016 Service and Repair Manual Telematics Connector Pin Legend Genie installed Telematics connector is wired with an Active High digital input. Connector Pin Numbering Note: A Deutsch plug p/n DT06-08SA mates with the Genie Telematics connector Circuit Type Circuit Properties Genie Machine Function(s)

  • Page 226: Engine Relay And Fuse Panel Legend - Deutz Td2011L04I

    Fuse, 30A, Eng / Start / Alt Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler / Horn B1PBAT Power from Battery B3PBAT Fused Power from B1 R21PIGN Ignition Fuse, 20A, RPM Solenoid 02PGND Ground Start Relay CR15 Glow Plug Relay ZX-135/70 Part No. 1268558...

  • Page 227: Engine Relay And Fuse Panel Legend - Deutz Td2.9

    Fuse, 30A, Eng / Start/ Alt Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler / Horn B3BAT Fused Power from B1 B3BAT Fused Power from B1 R21IGN Ignition 02GND Ground CR39 Engine Shutdown CR15 Glow Plug Relay Part No. 1268558 ZX-135/70...

  • Page 228: Engine Relay And Fuse Panel Legend - Perkins 1104D-44T

    Fuse, 30A, Eng / Start / Alt Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler / Horn B3PBAT Fused Power from B1 B1PBAT Power from Battery R21PIGN Ignition Fuse, 20A, RPM Solenoid 02PGND Ground Start Relay CR15 Glow Plug Relay ZX-135/70 Part No. 1268558...

  • Page 229: Engine Relay And Fuse Panel Legend - Perkins 854F-34T

    Fuse, 30A, Eng / Start / Alt Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler / Horn B3BAT Fused Power from B1 B1BAT Power from Battery R21PIGN Ignition 02PGND Ground Engine Starter CR81 ECU Power Part No. 1268558 ZX-135/70...

  • Page 230: Electrical Symbols Legend

    Relay Power relay Gauge sending unit button Diode starting aid, Oil temperature Coolant temperature Oil pressure switch Control relay contact glow plug or flame switch normally open switch - normally open normally closed normally open ignitor ZX-135/70 Part No. 1268558...

  • Page 231: Hydraulic Symbols Legend

    2 position, 3 way directional 3 way shuttle valve valve Solenoid operated Counterbalance valve with Pilot operated 2 position, 2 position, 2 way solenoid 3 position 4 way directional pressure and pilot ratio 2 way directional valve valve valve Part No. 1268558 ZX-135/70...
  • Page 232 Service and Repair Manual October 2016 This page intentionally left blank. ZX-135/70 Part No. 1268558...
  • Page 233 October 2016 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic...

  • Page 234: Perkins 1104D Engine Electrical Schematic

    Service and Repair Manual October 2016 Perkins 1104D-44T Engine Electrical Schematic ZX-135/70 Part No. 1268558...
  • Page 235 October 2016 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic...

  • Page 236: Perkins 854F-34T Engine Electrical Schematic

    Service and Repair Manual October 2016 Perkins 854F-34T Engine Electrical Schematic ZX-135/70 Part No. 1268558...

  • Page 237: Perkins 854F-34T Engine Harness

    October 2016 Service and Repair Manual Perkins 854F-34T Engine Harness Part No. 1268558 ZX-135/70...
  • Page 238 Service and Repair Manual October 2016 Perkins 854F-34T Engine Harness...
  • Page 239 October 2016 Service and Repair Manual Deutz TD2.9 Engine Electrical Schematic...

  • Page 240: Deutz Td2.9 Engine Electrical Schematic

    Service and Repair Manual October 2016 Deutz TD2.9 Engine Electrical Schematic ZX-135/70 Part No. 1268558...

  • Page 241: Deutz Td2.9 Engine Harness

    October 2016 Service and Repair Manual Deutz TD2.9 Engine Harness Part No. 1268558 ZX-135/70...
  • Page 242 Service and Repair Manual October 2016 Deutz TD2.9 Engine Harness...
  • Page 243 October 2016 Service and Repair Manual Hydraulic Generator (Welder Option)

  • Page 244: Hydraulic Generator (Welder Option)

    Service and Repair Manual October 2016 Hydraulic Generator (Welder Option) ZX-135/70 Part No. 1268558...

  • Page 245: Generator Wiring Schematic

    October 2016 Service and Repair Manual Generator Wiring Schematic Part No. 1268558 ZX-135/70...
  • Page 246 Service and Repair Manual October 2016 Generator Wiring Schematic...
  • Page 247 October 2016 Service and Repair Manual Hydraulic Schematic (to SN ZX13516H-2804)

  • Page 248: Hydraulic Schematic (To Sn Zx13516H-2804)

    Service and Repair Manual October 2016 Hydraulic Schematic (to SN ZX13516H-2804) ZX-135/70 Part No. 1268558...

  • Page 249: Hydraulic Schematic (From Sn Zx13516H-2805)

    October 2016 Service and Repair Manual Hydraulic Schematic (from SN ZX13516H-2805) Part No. 1268558 ZX-135/70...
  • Page 250 Service and Repair Manual October 2016 Hydraulic Schematic (from SN ZX13516H-2805)

  • Page 251: Electrical Schematic

    OUT PWR ENABLE OPT GBOX OPER. REC. OR (~SM)+(AH) TO MICRO BOOM RET RECOVERY SIGNAL HARN SERV. OR Genie ZX-135/70 Vbb BTS621 BOOM DWN RECOVERY SIGNAL PWR IN SERV OR OUT 1 P22R RECOVERY PROVIDES ST OUT 2 BOOM EXT/RET FC RECOVERY SIGNAL...

  • Page 252: Electrical Schematic

    OUT PWR ENABLE OPT GBOX OPER. REC. OR (~SM)+(AH) TO MICRO BOOM RET RECOVERY SIGNAL HARN SERV. OR Genie ZX-135/70 Vbb BTS621 BOOM DWN RECOVERY SIGNAL PWR IN SERV OR OUT 1 P22R RECOVERY PROVIDES ST OUT 2 BOOM EXT/RET FC RECOVERY SIGNAL...

This manual is also suitable for:

Z-135/70Genie z13505-101Genie z13513-2000

Table of Contents