Genie ZX-135/70 Service Manual
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Genie ZX-135/70 Service Manual

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See also: Service & Repair Manual , Maintenance Manual
Service Manual
ZX-135/70
Serial Number Range
from ZX13513-2001
Part No. 218700
Rev D2
August 2014

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Summary of Contents for Genie ZX-135/70

  • Page 1 Service Manual Serial Number Range ZX-135/70 from ZX13513-2001 Part No. 218700 Rev D2 August 2014...

  • Page 2: Introduction

    Copyright © 2014 by Terex Corporation 218700 Rev D2, August 2014 First Edition, Fourth 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: Revision History

    Section – Maintenance, B-3 Electronic Version Section – Repair Procedure, 4-2 Click on any procedure or page number highlighted in blue to view Section – Fault Codes, All charts the update. Section – Schematics, Legends and schematics Part No. 218700 ZX-135/70...

  • Page 4: Serial Number Legend

    Service Manual August 2014 Introduction Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) ZX-135/70 Part No. 218700...

  • 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. 218700 ZX-135/70...

  • Page 6: Personal Safety

    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. 218700...

  • Page 7: Table Of Contents

    Deutz TD2011L04i Engine Specifications .............. 6 Perkins 1104D-44T Engine Specifications ............. 8 Machine Torque Specifications ................9 Hydraulic Hose and Fitting Torque Specifications ..........11 Torque Procedure ....................12 SAE and Metric Fasteners Torque Charts ............14 Part No. 218700 ZX-135/70...
  • Page 8 A-6 Check the Hydraulic Return Filter Condition Indicator ........26 A-7 Perform 30-Day Service ................27 A-8 Grease the Turntable Rotation Bearing and Rotate Gear ......27 A-9 Replace the Drive Hub Oil ................28 viii ZX-135/70 Part No. 218700...
  • Page 9 B-16 Test the Alarm and Optional Flashing Beacon ..........46 B-17 Perform Hydraulic Oil Analysis ..............46 B-18 Test the Safety Envelope Limit Switches ............ 47 B-19 Test the Primary Boom Angle Sensor ............51 B-20 Inspect for Turntable Bearing Wear ............. 52 Part No. 218700 ZX-135/70...
  • Page 10 E-5 Perform Engine Maintenance - Perkins Models ..........78 E-6 Perform Engine Maintenance - Deutz Models ..........78 E-7 Perform Engine Maintenance - Perkins Models ..........79 E-8 Perform Engine Maintenance - Deutz Models ..........79 ZX-135/70 Part No. 218700...
  • Page 11 3-1 Jib Boom Cable Track .................. 110 3-2 Jib Boom ...................... 113 3-3 Jib Boom Lift Cylinder .................. 115 3-4 Jib Boom Level Cylinder ................116 3-5 Jib Boom Extension Cylinder ............... 117 3-6 Jib Boom Bellcrank Angle Sensor ..............119 Part No. 218700 ZX-135/70...
  • Page 12 5-2 Flex Plate ..................... 147 Ground Controls ....................149 6-1 Service Bypass/Recovery Key Switch ............149 6-2 Circuit Boards ....................152 6-3 Membrane Decal ..................152 Hydraulic Pumps ....................154 7-1 Function Pump ..................... 154 7-2 Drive Pump ....................157 ZX-135/70 Part No. 218700...
  • Page 13 9-1 Turntable Rotation Assembly ............... 186 9-2 Turntable Level Sensor ................188 Axle Components ..................... 191 10-1 Steer Sensors .................... 191 10-2 Steer Cylinders ................... 196 10-3 Axle Extension Cylinders ................197 10-4 Axle Angle Sensors ..................198 Part No. 218700 ZX-135/70 xiii...
  • Page 14 Electrical Symbols Legend ................. 244 Hydraulic Symbols Legend ................245 Perkins 1104D Engine Electrical Schematic ............248 Generator Wiring Schematic ................249 Hydraulic Generator (Welder Option) ..............252 Hydraulic Schematic ..................253 Electrical Schematic (Includes Deutz Engine) ........... 255 ZX-135/70 Part No. 218700...
  • Page 15 August 2014 Service Manual This page intentionally left blank. Part No. 218700 ZX-135/70...

  • Page 16: Specifications

    Turntable rotate, 360°jib and 280 to 350 seconds primary booms extended For operational specifications, refer to the Operator's Manual. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 218700 ZX-135/70...

  • Page 17: Hydraulic Specification

    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 18 Maximum continuous operating 124°F / 51°C Continuous improvement of our products is a temperature Genie policy. Product specifications are Note: Use of Chevron 5606A hydraulic fluid, or subject to change without notice or obligation. equivalent, is required when ambient temperatures are consistently below 0°F / -17°C unless an oil...

  • Page 19: Hydraulic Component Specifications

    25 psi / 1.7 bar bypass Drive motor case drain return filter Beta 10 ≥ 2 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. ZX-135/70 Part No. 218700...
  • Page 20 Solenoid Valve, 2 position 3 way 7.1Ω (schematic items AD) Solenoid valve, 2 position, 2 way 3.5 to (schematic item A) 5.5Ω Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 218700 ZX-135/70...

  • Page 21: Deutz Td2011L04I Engine Specifications

    Intake 0.012 in Pressure switch point 22 psi 0.3 mm 1.5 bar Exhaust 0.020 in Continuous improvement of our products is a 0.5 mm Genie policy. Product specifications are subject to change without notice or obligation. ZX-135/70 Part No. 218700...
  • Page 22 Alternator output 80A @ 14V DC Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 218700 ZX-135/70...

  • Page 23: Perkins 1104D-44T Engine Specifications

    Exhaust 0.018 in 0.45 mm For fuel requirements, refer to the engine Operator Manual for your engine. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. ZX-135/70 Part No. 218700...

  • Page 24: Machine Torque Specifications

    Alternator output 85A @ 12V DC Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 218700 ZX-135/70...
  • Page 25 61 Nm Rotate drive hub mounting bolts, lubricated 80 ft-lbs Continuous improvement of our products is a 108 Nm Genie policy. Product specifications are Drive motor mounting bolts, dry 75 ft-lbs subject to change without notice or obligation. 102 Nm...

  • Page 26: Hydraulic Hose And Fitting Torque Specifications

    (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends 23 ft-lbs / 31.2 Nm be torqued to specification when they are removed and installed or when new hoses or fittings are 36 ft-lbs / 54.2 Nm...

  • Page 27: Torque Procedure

    Note: The O-ring in Parker Seal Lok™ fittings and 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 28: August

    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. 218700 ZX-135/70...

  • Page 29: Sae And Metric Fasteners Torque Charts

    Service Manual August 2014 Specifications ZX-135/70 Part No. 218700...

  • Page 30: Scheduled Maintenance Procedures

     Repair any machine damage or malfunction before operating the machine.  Use only Genie approved replacement parts.  Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.

  • Page 31: 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. 218700...
  • Page 32 Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with your employer, jobsite and governmental regulations and requirements. Part No. 218700 ZX-135/70...
  • Page 33 Service Manual August 2014 This page intentionally left blank. ZX-135/70 Part No. 218700...

  • Page 34: Pre-Delivery Preparation Report

    August 2014 Service Manual Pre-Delivery Preparation Report Fundamentals Instructions It is the responsibility of the dealer to perform the Use the operator’s manual on your machine. Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery.
  • Page 35 Service Manual August 2014 This page intentionally left blank. ZX-135/70 Part No. 218700...

  • Page 36: Maintenance Inspection Report

    • If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 218700 ZX-135/70...
  • Page 37 • If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box. Legend Y = yes, acceptable N = no, remove from service R = repaired ZX-135/70 Part No. 218700...

  • Page 38: Checklist A Procedures

    Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed every 8 hours or daily, whichever Result: The machine is equipped with all comes first.

  • Page 39: Perform Pre-Operation Inspection

    August 2014 Checklist A Procedures Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever comes first.

  • Page 40: Perform Engine Maintenance - Perkins Models

    TD2011 Operation Manual (Deutz part number engine information is available in the Perkins 03123547). 1100D Operation and Maintenance Manual (Perkins part number SEBU8172-00). Deutz TD2011 Operation Manual Genie part number 139320 Perkins 1100D Operation and Maintenance Manual Genie part number 123702 Part No. 218700...

  • Page 41: Check The Hydraulic Return Filter Condition Indicator

    Check the Hydraulic Return Filter on the in-tank return filter. Condition Indicator Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Maintaining the hydraulic filters in good condition is essential to good system performance and safe machine operation.

  • Page 42: Perform 30-Day Service

    Perform 30-Day Service Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation. The 30-day maintenance procedure is a onetime procedure to be performed after the first 30 days or Perform this procedure more often if dusty 40 hours of usage.

  • Page 43: Replace The Drive Hub Oil

    Failure to replace the drive hub oil may cause the machine to perform poorly and continued use may result in component damage. Refer to Section D maintenance procedure, Replace the Drive Hub Oil. ZX-135/70 Part No. 218700...

  • Page 44: Checklist B Procedures

    Note: Perform the remaining steps on the auxiliary power unit batteries and the engine starting battery. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Be sure that the battery cable connections are comes first.

  • Page 45: Inspect The Electrical Wiring

    Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever 10 Check the ambient air temperature and adjust comes first.
  • Page 46 • All wire harness connectors to ground • Jib boom/platform rotate manifold control box • Platform control box • Wire harness connectors to SCON module • Inside of the platform control box Part No. 218700 ZX-135/70...

  • Page 47: Test The Key Switches

    15 Inspect for a liberal coating of dielectric grease in the following locations: Test the Key Switches • All wire harness connectors to platform Genie specifications require that this procedure be control box performed every 250 hours or quarterly, whichever comes first.
  • Page 48 Pull out the red Emergency Stop button to the key switch. on position at both the ground and platform Note: The main key switch should remain in the controls. ground control position. Part No. 218700 ZX-135/70...

  • Page 49: Inspect The Engine Air Filter

    13 Raise the boom. Result: The boom should raise. 14 Remove the key from the service Genie specifications require that this procedure be bypass/recovery key switch and insert the key performed every 250 hours or quarterly, whichever into the main key switch.

  • Page 50: Check The Oil Cooler And Cooling Fins - Deutz Models

    Use a damp cloth to wipe the filter sealing surface and the inside of the outlet tube. Make sure that all contaminant is removed before Genie requires that this procedure be performed the filter is inserted. every 250 hours or quarterly, whichever comes first.

  • Page 51: Check The Exhaust System

    Inspect the fan blower fins for physical damage. Clean the fan blower fins of debris and foreign material. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Using a flashlight, inspect the head cooling comes first.

  • Page 52: Confirm The Proper Brake Configuration

    Crushing hazard. Failure to install the bolt into the engine Genie specifications require that this procedure be pivot plate to secure it from performed every 250 hours or quarterly, whichever moving could result in death or comes first.

  • Page 53: Inspect The Tires, Wheels And Lug Nut Torque

    Inspect the Tires, Wheels and Note: The free-wheel valve should always remain Lug Nut Torque closed. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the tires and wheels, including proper wheel fastener torque, is essential to safe operation and good performance.

  • Page 54: Check The Drive Hub Oil Level And Fastener Torque

    Install the plugs in the drive hub. Check the torque of the drive hub mounting fasteners. Refer to Specifications, Machine Torque Specifications. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Repeat this procedure for each drive hub. comes first.

  • Page 55: Test The Platform Self-Leveling

    Remove the plug located on the side of the hub and check the oil level. Genie specifications require that this procedure be Result: The oil level should be even with the performed every 250 hours or quarterly, whichever comes first.

  • Page 56: Test The Engine Idle Select Operation

    Operation LCD display. Result: The platform should remain level at all Genie specifications require that this procedure be times to within ±2 degrees. performed every 250 hours or quarterly, whichever comes first. Note: If the platform becomes out of level, the tilt...

  • Page 57: Test The Ground Control Override

    (turtle symbol). Test the Ground Control Override Result: The engine should return to low idle. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. A properly functioning ground control override is essential to safe machine operation.

  • Page 58: Test The Drive Brakes

    Bring the machine to top drive speed before reaching the test line. Release the drive controller when your reference point on the Genie specifications require that this procedure be machine crosses the test line. performed every 250 hours or quarterly, whichever comes first.

  • Page 59: Test The Drive Speed - Stowed Position

    Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Specifications, Performance Genie specifications require that this procedure be Specifications. performed every 250 hours or quarterly, whichever comes first.

  • Page 60: Test The Drive Speed - Raised Or Extended

    Continue at full speed and note the time when the machine reference point crosses the finish line. Refer to Specifications, Performance Genie specifications require that this procedure be Specifications. performed every 250 hours or quarterly, whichever Lower the boom to the stowed position.

  • Page 61: Test The Alarm And Optional Flashing Beacon

    B-17 Test the Alarm and Flashing Perform Hydraulic Oil Analysis Beacon Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.

  • Page 62: Test The Safety Envelope Limit Switches

    Working at the platform end of the turntable, Switches support and secure the lower turntable riser end cover to a suitable lifting device. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Remove the lower cover retaining fasteners comes first.
  • Page 63 20 Select YES, then press the enter button. through the entire length of travel. 21 Install the secondary boom end covers. Note: The limit switch ramp bracket is attached to the number 4 boom tube. ZX-135/70 Part No. 218700...
  • Page 64 25 Remove the multimeter leads and connect the deutsch connector to the limit switch. 26 Start the engine and rotate the turntable more than 15°. Turn the engine off 27 Locate and disconnect the deutsch connector to LST1S. Part No. 218700 ZX-135/70...
  • Page 65 37 Repeat steps 34 through 36 for the other axle extend safety limit switch. 38 Start the engine from the platform controls and fully extend the axles. Turn the machine off. ZX-135/70 Part No. 218700...

  • Page 66: Test The Primary Boom Angle Sensor

    Press the enter or previous button on the Sensor LCD screen until PRIMARY BOOM ANGLE TO GRAVITY DEGREES is displayed. Genie specifications require that this procedure be Raise the primary boom while watching the performed every 250 hours or quarterly, whichever display screen.

  • Page 67: Inspect For Turntable Bearing Wear

    1 inch / 2.5 cm from the turntable rotation bearing. Genie requires that this one-time procedure be performed after the first 300 hours of usage. After this interval, refer to the maintenance checklist for continued scheduled maintenance.

  • Page 68: August

    10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90° apart. 11 Lower the boom to the stowed position and turn the machine off. 12 Remove the dial indicator from the machine. Part No. 218700 ZX-135/70...

  • Page 69: Checklist C Procedures

    Deutz TD2011 Operation Manual (Deutz part number TD2011 Operation Manual (Deutz part number 03123547). 03123547). Deutz TD2011 Operation Manual Deutz TD2011 Operation Manual Genie part number 139320 Genie part number 139320 ZX-135/70 Part No. 218700...

  • Page 70: Perform Engine Maintenance - Perkins Models

    Replace the Engine Air Filter Perkins Models Element Engine specifications require that this procedure Genie specifications require that this procedure be be performed every 500 hours or annually. performed every 500 hours or six months, whichever comes first. • Engine oil and filter – change Maintaining the engine air filter in good condition is •...

  • Page 71: Grease The Platform Overload Mechanism (If Equipped)

    Service Manual August 2014 Checklist C Procedures Grease the Platform Overload Mechanism (if equipped) Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first. Perform this procedure more often if dusty conditions exist.

  • Page 72: Test The Platform Overload System (If Equipped)

    Genie specifications require that this procedure be performed every 500 hours or six months, As weight is added to the platform, the spring will...
  • Page 73 Refer to repair procedure, How to Calibrate the Platform Overload System (if equipped). Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds. ZX-135/70 Part No. 218700...

  • Page 74: Check And Adjust The Engine Rpm

    Result: All platform control functions should operate normally. Turn the key switch to ground controls. 10 Test all machine functions from the ground Genie specifications require that this procedure be controls. performed every 500 hours or six months, Result: All ground control functions should whichever comes first.
  • Page 75 Check for excessive movement in the linkage bar pins. Result: If there is excessive wear in the linkage, the linkage bar should be replaced. 1 low idle adjustment screw 2 yoke 3 high idle adjustment nut ZX-135/70 Part No. 218700...
  • Page 76 2 solenoid boot serious injury. 3 yoke lock nut Start the engine from the ground controls. Component damage hazard. Be sure the hydraulic supply hoses to the function and drive pumps are not kinked before starting the engine. Part No. 218700 ZX-135/70...

  • Page 77: Inspect For Turntable Bearing Wear

    Result: High idle should be 2350 rpm. If the high idle is correct, disregard adjustment step 8. Genie requires that this procedure be performed Loosen the low idle lock nut. Turn the low idle every 500 hours or six months, whichever comes...
  • Page 78 6 drive chassis 7 turntable rotation bearing Adjust the dial indicator needle to the "zero" position. Raise the secondary riser, but do not extend it. Move the primary boom and jib to horizontal and fully extend. Part No. 218700 ZX-135/70...

  • Page 79: Checklist D Procedures

    Check the Boom Wear Pads Top, bottom and side wear pads 5/8 inch (platform end of boom) 15.9 mm Genie specifications require that this procedure be Top and bottom wear pads 1/2 inch performed every 1000 hours or annually, (pivot end of boom) 12.7 mm...

  • Page 80: Check The Free-Wheel Configuration

    Lower the machine. Collision hazard. Failure to re-engage the drive hubs could result in death or serious injury Genie specifications require that this procedure be and property damage. performed every 1000 hours or annually, whichever comes first.

  • Page 81: Replace The Drive Hub Oil

    Lift the machine and remove the blocks. Lower the machine. Collision hazard. Failure to re-engage the drive hubs could Genie specifications require that this procedure be result in death or serious injury performed every 1000 hours or annually, and property damage.

  • Page 82: Bodily Injury Hazard. Spraying

    Crushing hazard. The turntable mounting bolts to specification. Refer to rotate drive hub assembly could Specifications, Machine Torque become unbalanced and fall Specifications. when removed from the machine if not properly supported by the lifting device. Part No. 218700 ZX-135/70...

  • Page 83: Adjust The Turntable Rotatation Gear Backlash

    Apply pipe thread sealant to the plug. Gear Backlash Install the plug. Refer to Specifications, Fluid Capacity Specifications. Genie specifications require that this procedure be performed every 1000 hours or annually, Repeat steps 3 through 7 for the other whichever comes first.

  • Page 84: Replace The Hydraulic Filter Elements

    Turn the adjustment bolt clockwise until it contacts the backlash pivot plate. Replace the Hydraulic Filter Elements Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Perform this procedure more often if dusty conditions exist.
  • Page 85 10 Use a filter wrench to remove the drive motor 22 Inspect the housing seal and replace it if case drain filter element. necessary. 11 Install the new drive motor case drain filter element onto the filter head and tighten it securely. ZX-135/70 Part No. 218700...

  • Page 86: Perform Engine Maintenance - Deutz Models

    Required maintenance procedures and additional no leaks. engine information is available in the Deutz TD2011 Operation Manual (Deutz part number 03123547). Deutz TD2011 Operation Manual Genie part number 139320 Part No. 218700 ZX-135/70...

  • Page 87: Perform Engine Maintenance - Perkins Models

    Check the Turntable Rotation Perkins Models Bearing Bolts Engine specifications require that this procedure Genie specifications require that this procedure be be performed every 1000 hours. performed every 1000 hours or annually, whichever comes first. • Engine valve lash – inspect/adjust...
  • Page 88 Refer to Specifications, Machine Torque Specifications. Bolt torque sequence (from above turntable) Lower the secondary boom to the stowed position. Bolt torque sequence (from below turntable) Part No. 218700 ZX-135/70...

  • Page 89: Checklist E Procedures

    The engine must not be started with the hydraulic tank shut-off valves in the closed position or Genie specifications require that this procedure be component damage will occur. If performed every 2000 hours or every two years, the tank valves are closed, whichever comes first.
  • Page 90 Remove all rings, when removed from the watches and other jewelry. machine. 17 Remove the suction strainers from the tank and clean them using a mild solvent. Part No. 218700 ZX-135/70...

  • Page 91: Perform Engine Maintenance - Perkins Models

    (Perkins part number SEBU8172-00). the hydraulic tank. 27 Clean up any oil that may have spilled during Perkins 1100D Operation and Maintenance Manual the installation procedure. Genie part number 123702 28 Start the engine and check for leaks. ZX-135/70 Part No. 218700...

  • Page 92: Perform Engine Maintenance - Deutz Models

    Perkins TD2011 Operation Manual (Deutz part number 1100D Operation and Maintenance Manual 03123547).. (Perkins part number SEBU8172-00). Deutz TD2011 Operation Manual Perkins 1100D Operation and Maintenance Manual Genie part number 139320 Genie part number 123702 Part No. 218700 ZX-135/70...

  • Page 93: Perform Engine Maintenance - Perkins Models

    • Charge air cooler entry- drain lube (Perkins part number SEBU8172-00). oil/condensate • Turbocharger compressor outlet- clean Perkins 1100D Operation and Maintenance Manual Genie part number 123702 Required maintenance procedures and additional engine information is available in the Deutz TD2011 Operation Manual (Deutz part number 03123547).

  • Page 94: Perform Engine Maintenance - Perkins Models

    Deutz 1100D Operation and Maintenance Manual TD2011 Operation Manual (Deutz part number (Perkins part number SEBU8172-00). 03123547). Perkins 1100D Operation and Maintenance Manual Deutz TD2011 Operation Manual Genie part number 123702 Genie part number 139320 Part No. 218700 ZX-135/70...

  • Page 95: 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 96 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. 218700 ZX-135/70...

  • Page 97: Display Module

    >100°F Engine temperature °C (metric) eng 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 ZX-135/70 Part No. 218700...
  • Page 98 Delete drive functions the enter button and turn key switch to Delete boom function speeds 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) Part No. 218700 ZX-135/70...
  • Page 99 Reverse high drive speed % 120% (max) 100% (default) 50% (min) Drive acceleration % 125% (max) 100% (default) 25% (min) Drive decceleration % 125% (max) 100% (default) 25% (min) Speed limit on steer angle 100% (max) 50% (default) 0% ZX-135/70 Part No. 218700...
  • Page 100 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 Part No. 218700 ZX-135/70...
  • Page 101 Secondary boom extend/retract ramp deceleration % Turntable rotate ramp acceleration % Turntable rotate ramp deceleration % Jib boom up/down ramp 120% max and 50% min, acceleration % 100% (default), 5% incr Jib boom up/down ramp deceleration % ZX-135/70 Part No. 218700...
  • Page 102 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 Part No. 218700 ZX-135/70...
  • Page 103 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° ZX-135/70 Part No. 218700...
  • Page 104 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. 218700 ZX-135/70...

  • Page 105: Platform Controls

    5 LED circuit board entire range of motion. 6 primary boom up/down, primary boom extend/retract and turntable rotate left/right For further information or assistance, consult joystick Genie Product Support. ZX-135/70 Part No. 218700...

  • Page 106: Alc-1000 Circuit Board

    Remove the control cable receptacle retaining fasteners from the bottom of the platform control box. 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. Part No. 218700 ZX-135/70...

  • Page 107: Joysticks

    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. ZX-135/70 Part No. 218700...
  • Page 108 5 seconds, then return Result: The alarm at the ground controls to the center or neutral position. should sound for a successful calibration. Result: The alarm at the ground controls should sound for a successful calibration. Part No. 218700 ZX-135/70...
  • Page 109 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. ZX-135/70 Part No. 218700...
  • Page 110 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. 218700 ZX-135/70...
  • Page 111 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. ZX-135/70 Part No. 218700...
  • Page 112 11 Check the display at the ground controls to be to 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. Part No. 218700 ZX-135/70...
  • Page 113 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. ZX-135/70 Part No. 218700...
  • Page 114 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. Part No. 218700 ZX-135/70...
  • Page 115 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. ZX-135/70 Part No. 218700...

  • Page 116: 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. Part No. 218700 ZX-135/70...

  • Page 117: 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. ZX-135/70 Part No. 218700...

  • Page 118: 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. Part No. 218700 ZX-135/70...
  • Page 119 Crushing hazard. The platform mounting weldment may become unbalanced and fall if it is not properly supported. 12 Support the platform rotator with a suitable lifting device. Do not apply any lifting pressure. ZX-135/70 Part No. 218700...

  • Page 120: Platform Level Sensor

    Plus Minus Previous Enter Secure a digital level to one of the side railings of the platform. Start the machine and level the platform to gravity. Turn the machine off. Open the ground control box. Part No. 218700 ZX-135/70...
  • Page 121 10 Press the plus button to select YES, then press the enter button to accept. 11 Press the enter or previous buttons on the LCD screen until PLATFORM LEVEL SENSOR MV PER DEGREE is displayed. ZX-135/70 Part No. 218700...

  • Page 122: Platform Overload System (If Equipped)

    Note: There may be a 2 second delay before the the platform floor. 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. Part No. 218700 ZX-135/70...
  • Page 123 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. 218700...

  • Page 124: 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 Part No. 218700 ZX-135/70...

  • Page 125: 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. ZX-135/70 Part No. 218700...
  • Page 126 Do not discard the washer. overhead crane. Note: Always replace the cotter pin with a new Component damage hazard. one. Cables and hoses can be damaged if they are kinked or pinched. Part No. 218700 ZX-135/70...
  • Page 127 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 128: Jib Boom

    Remove the cable track guide fasteners from the platform rotator. Refer to repair procedure, the cable track guide at the platform end of How to Remove the Platform Rotator. the jib boom and remove the cable track guide from the jib boom. Part No. 218700 ZX-135/70...
  • Page 129 12 Remove the cover retaining fasteners from removed from the machine if it is the jib boom angle sensor. Remove the cover. not properly supported by the overhead crane. ZX-135/70 Part No. 218700...

  • Page 130: 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. Part No. 218700 ZX-135/70...

  • Page 131: 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. ZX-135/70 Part No. 218700...

  • Page 132: Jib Boom Extension Cylinder

    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. Part No. 218700 ZX-135/70...
  • Page 133 Use a soft metal drift to remove the pin. 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. ZX-135/70 Part No. 218700...

  • Page 134: Jib Boom Bellcrank Angle Sensor

    Note: A digital level will be required to perform this procedure. Note: A kit is available through the Genie Product Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.
  • Page 135 7 and Open the ground control box. continue to step 12. 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. ZX-135/70 Part No. 218700...
  • Page 136 The system must detect a change in displayed value to record the calibrated value. Part No. 218700 ZX-135/70...
  • Page 137 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. ZX-135/70 Part No. 218700...
  • Page 138 33 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. Part No. 218700 ZX-135/70...

  • Page 139: Boom Components

    11 number 3 secondary boom tube 4 primary extension boom 12 lower primary boom lift cylinder linkage 5 jib boom manifold 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. 218700...

  • Page 140: 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. 218700 ZX-135/70...
  • Page 141 19 Attach a lifting strap to each end of the cable become unbalanced and fall track from an overhead crane for support. Do when removed from the not apply any lifting pressure. secondary boom if not properly supported and secured to the lifting device. ZX-135/70 Part No. 218700...
  • Page 142 22 Carefully remove the cable track from the Note: A cable track repair kit is available through machine and lay it on a structure capable of the Genie Service Parts Department. supporting it. Visually inspect the cable track and determine Crushing hazard.

  • Page 143: 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. 218700...
  • Page 144 16 Working at the platform end of the secondary the oil pressure to dissipate boom, place blocks between the upper and gradually. Do not allow oil to lower cable tracks for support. squirt or spray. Part No. 218700 ZX-135/70...
  • Page 145 Note: A cable track repair kit is available through 19 Remove the secondary boom cable track from the Genie Service Parts Department. the machine and place it on a structure capable of supporting it.

  • Page 146: Primary Boom

    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, Jib Boom Bellcrank Angle Sensor for the calibration procedure. Part No. 218700 ZX-135/70...
  • Page 147 Boom Angle Sensor for the calibration procedure. upper primary boom lift cylinder linkage arm pivot pin where it connects to the primary Remove the hose and cable guide fasteners boom. at the primary boom pivot pin. Remove the hose and cable guide. ZX-135/70 Part No. 218700...

  • Page 148: 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. 218700 ZX-135/70...

  • Page 149: Secondary Boom Lift Cylinder

    Do not allow oil to supported when the barrel-end squirt or spray. pivot pin is removed. ZX-135/70 Part No. 218700...
  • Page 150 Cap the fitting on the hydraulic the machine. Remove the fixed turntable tank. cover from the machine. 12 Tag, disconnect and plug the hydraulic hose at the return filter. Cap the fitting on the return filter housing. Part No. 218700 ZX-135/70...
  • Page 151 Electrocution/burn hazard. Contact with electrically charged 23 Place a block under the secondary boom lift circuits could result in death or cylinder for support. serious injury. Remove all rings, watches and other jewelry. ZX-135/70 Part No. 218700...
  • Page 152 Hoses and cables can be cylinder. damaged if the secondary boom lift cylinder is pulled across Note: Protect the hoses and cables underneath the them. cylinder from damage. Part No. 218700 ZX-135/70...

  • Page 153: Primary Boom Extension Cylinder

    Note: During removal, the overhead crane strap will need to be adjusted for proper balancing. accessible in the primary boom extension tube. Note: Note the length of the cylinder after removal. The cylinder must be at the same length for installation. ZX-135/70 Part No. 218700...

  • Page 154: Secondary Boom Extension Cylinders

    Do not allow oil to Note: Perform this procedure with the machine on squirt or spray. a firm, level surface and in the stowed position with the axles extended. Remove the upper extension cylinder retainers from the saddle blocks. Part No. 218700 ZX-135/70...
  • Page 155 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. 218700...

  • Page 156: Primary Boom Angle Sensor

    Press and hold the enter button on the Note: A kit is available through the Genie Product ground control panel while pulling out the Support (Genie part number 58351). This kit ground controls red Emergency Stop button to includes a digital level with a magnetic base and the on position.
  • Page 157 Note: Be sure the number entered at the ground the angle and then change back to the measured controls is a negative number. value. The system must detect a change in displayed value to record the calibrated value. ZX-135/70 Part No. 218700...
  • Page 158 31 Pull out the red Emergency Stop button. Start displayed value to record the calibrated value. the engine and lower the boom to the stowed position. Be sure there are no calibration faults shown on the display. Part No. 218700 ZX-135/70...

  • Page 159: Secondary Boom Angle Sensor

    Note: A kit is available through the Genie Product Press and hold the enter button on the Support (Genie part number 58351). This kit ground control panel while pulling out the...
  • Page 160 18 Press and hold a function enable/speed select button and the secondary boom up button button and the secondary boom up button until the digital level displays approximately until the digital level displays approximately 20 degrees. 50 degrees. Part No. 218700 ZX-135/70...
  • Page 161 30 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. ZX-135/70 Part No. 218700...

  • Page 162: Engines

    40 ft-lbs / 54 The flex plate acts as a coupler between the Apply a high viscosity coupling grease (Genie engine and the pump. It is bolted to the engine part number 128025) to the splines of the flywheel and has a splined center to drive the pump shaft and flex plate.
  • Page 163 Perkins engines. Torque the pump plate mounting bolts in sequence to 23 ft-lbs / 31 Nm. Then torque the pump plate mounting bolts in sequence to 47 ft-lbs / 63 Nm. Deutz TD2011L04i pump plate Perkins 1104D pump plate ZX-135/70 Part No. 218700...

  • Page 164: Ground Controls

    Remove the key from the main key switch and insert the key into the service bypass/recovery key switch. Note: The main key switch must remain in the ground control position. 1 Run 2 Service / Bypass 3 Recovery Part No. 218700 ZX-135/70...
  • Page 165 Turn the main key switch to the off position. Remove the key from the main key switch and insert the key into the service bypass/recovery key switch. ZX-135/70 Part No. 218700...
  • Page 166 How to Calibrate a Joystick. Note: When the ECM circuit board is replaced, all the boom, platform and axle angle sensors will need to be calibrated and in a specific order. Contact Genie Product Support. Part No. 218700 ZX-135/70...

  • Page 167: 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. ZX-135/70 Part No. 218700...
  • Page 168 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. 218700 ZX-135/70...

  • Page 169: 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 170 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. 218700 ZX-135/70...
  • Page 171 Turn the engine off and remove the pressure 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. 218700...

  • Page 172: 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 173: August

    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. 218700...
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  • Page 175: Manifolds

    Relief valve, 3100 psi / 214 bar System relief 30-35 ft-lbs / 41-47 Nm Differential sensing valve, Secondary boom up/down 50-55 ft-lbs / 68-75 Nm 150 psi / 10.3 bar circuit, regulates pressure drop across secondary boom up/down proportional valve ZX-135/70 Part No. 218700...
  • Page 176 August 2014 Service Manual Manifolds Part No. 218700 ZX-135/70...
  • Page 177 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. 218700...
  • Page 178 August 2014 Service Manual Manifolds Part No. 218700 ZX-135/70...

  • Page 179: 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. 218700...
  • Page 180 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. 218700 ZX-135/70...

  • Page 181: 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. 218700...
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  • Page 183: 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 20-25 ft-lbs / 27-34 Nm 3 position 4 way up/down ZX-135/70 Part No. 218700...
  • Page 184 August 2014 Service Manual Part No. 218700 ZX-135/70...

  • Page 185: 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 ZX-135/70 Part No. 218700...

  • Page 186: 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 Part No. 218700 ZX-135/70...

  • Page 187: Steer And Axle Manifold

    Flow control valve, 7 gpm / 26.5 L/min Axle extend/retract circuit 50-55 ft-lbs / 68-75 Solenoid Valve, 2 position 3 way Axle retract 50-55 ft-lbs / 68-75 Solenoid Valve, 2 position 3 way Axle extend 50-55 ft-lbs / 68-75 ZX-135/70 Part No. 218700...
  • Page 188 August 2014 Service Manual Manifolds Part No. 218700 ZX-135/70...
  • Page 189 27-34 Nm Solenoid valve, 3 position 4 way Steer left/right, left front steer cylinder 20-25 ft-lbs / 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. 218700...
  • Page 190 August 2014 Service Manual Manifolds Part No. 218700 ZX-135/70...

  • Page 191: Valve Adjustments - Steer And Axle Manifold

    Start the engine from the platform controls and press down the footswitch. 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. 218700...
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  • Page 193: Traction Manifold Components

    Check valve, 5 psi / 0.3 bar Drive motor anti-cavitation 20-25 ft-lbs / 27.1-33.9 Nm Equalizes pressure on both Flow control valve, 2 gpm / 7.6 sides of divider/combiner 30-35 ft-lbs / 40.7-47.5 Nm L/min valve ZX-135/70 Part No. 218700...
  • Page 194 August 2014 Service Manual Manifolds Part No. 218700 ZX-135/70...
  • Page 195 90-100 ft-lbs / 122-135.6 Nm motors in forward and reverse Controls flow to divider/combiner Flow divider/combiner valve 90-100 ft-lbs / 122-135.6 Nm valves Check valve, 5 psi / 0.3 bar Drive motor anti-cavitation 20-25 ft-lbs / 27.1-33.9 Nm ZX-135/70 Part No. 218700...
  • Page 196 August 2014 Service Manual Manifolds Part No. 218700 ZX-135/70...

  • Page 197: 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. 218700...

  • Page 198: 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. 218700 ZX-135/70...

  • Page 199: 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. 218700...
  • Page 200 Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA. Resistor 10Ω Genie part number 27287 Connect the negative lead to the other Note: The battery should read 9V DC or more terminal on the coil.

  • Page 201: 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. 218700...
  • Page 202 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. 218700 ZX-135/70...

  • Page 203: Turntable Level Sensor

    Note: A kit is available through the Genie Product Note: The angle sensor calibration values will not Support (Genie part number 58351). This kit be saved correctly unless the key switch is in the includes a digital level with a magnetic base and service/bypass position.
  • Page 204 The system must detect a change in displayed value to record the calibrated value. 12 Press the enter or previous button on the LCD screen,until SET UNIT Y AXIS LEVEL TO GRAVITY is displayed. Part No. 218700 ZX-135/70...
  • Page 205 LCD screen until EXIT is displayed. 16 Press the plus button to select YES, then press the enter button to accept. 17 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in. ZX-135/70 Part No. 218700...

  • Page 206: Axle Components

    (square end, yellow side and circle end, blue side shown) 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. 218700 ZX-135/70...
  • Page 207 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. 218700...
  • Page 208 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. 218700 ZX-135/70...
  • Page 209 Stop button to the on position. 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. 218700...
  • Page 210 10 Enter sensor calibration mode by pressing the LCD screen until EXIT is displayed. buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus). 19 Press the plus button to select YES, then press the enter button to accept. Part No. 218700 ZX-135/70...

  • Page 211: 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. 218700...

  • Page 212: 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. 218700 ZX-135/70...

  • Page 213: Axle Angle Sensors

    Locate the calibration toggle switch at the top the on position. Hold the enter button for of the ground control box. Activate calibration approximately 5 seconds and then release it. mode by moving the toggle switch in the left direction. ZX-135/70 Part No. 218700...

  • Page 214: August

    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. 1 Run 2 Service / Bypass 3 Recovery Part No. 218700 ZX-135/70...
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  • Page 216: 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. 218700 ZX-135/70...

  • Page 217: 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. 218700...
  • Page 218 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. 218700 ZX-135/70...
  • Page 219 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. 218700...
  • Page 220 SCON and TCON. Check SCON chart for possible faults. Safety Switch P39 Fault Check Display message on LCD P39 Recycle power and check wiring on SAFETY SWITCH FAULT circuit S139TRF (white/red) between SCON and TCON. Check SCON chart for possible faults. Part No. 218700 ZX-135/70...
  • Page 221 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. 218700...
  • Page 222 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. 218700 ZX-135/70...
  • Page 223 Display message on LCD membrane switch. If necessary Switches on TCON replace 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. 218700...
  • Page 224 Primary up, Secondary up/down and Recalibrate sensor 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. 218700 ZX-135/70...
  • Page 225 Check that SCON is grounded Sensor X Direction and 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. 218700...
  • Page 226 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 Initiate one second beep of audible Self-clearing (transient) warning device Part No. 218700 ZX-135/70...
  • Page 227 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. 218700...
  • Page 228 If necessary replace and Value Too Low 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. 218700 ZX-135/70...
  • Page 229 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. 218700...
  • Page 230 Check for an open or shorted valve coil. Repair or replace as Brake Valve necessary. Auxiliary Propel Valve Fault Check Fault Check Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary. Part No. 218700 ZX-135/70...
  • Page 231 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. 218700...
  • Page 232 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. 218700 ZX-135/70...
  • Page 233 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. 218700...

  • Page 234: Fault Matrix

    Turntable tilt angle (crosscheck SCON internal sensors 3 in a delta configuration) Primary Boom safety (max angle) Boom not stowed (not faulted) Loss of CAN LSS1RS disconnected (SCON pin #2) Platform Overload (SCON pin #1) Secondary Boom length (crosscheck LSS1RS and LSS1RO) Part No. 218700 ZX-135/70...
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  • Page 236: 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. 218700 ZX-135/70...

  • Page 237: Wire Circuit Legend

    V61AXR – V stands for valve power. Number 61 stands for axle retracted circuit; AXR stands for Axle retracted. R46HN – R stands for Relay output, supplying power to the horn (HN). Number 46 is the circuit number for the horn. ZX-135/70 Part No. 218700...
  • Page 238 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. 218700 ZX-135/70...
  • Page 239 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. 218700...
  • Page 240 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. 218700 ZX-135/70...

  • Page 241: 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 ZX-135/70 Part No. 218700...
  • Page 242 12V DC ignition supply BL/RD Auxiliary Platform Key switch power to platform WH/BK Boom envelope safety valve Power to platform cutoff Power to warning senders BK/WH Power to safety interlock switches WH/BK Power to oil pressure sender (engine) Part No. 218700 ZX-135/70...
  • Page 243 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. 218700...
  • Page 244 Power to Safety Module BL/WH Primary Extend/Retract Signal RD/WH Drive Power (P_38) RD/WH Primary Up/Down Signal RD/BK Primary Boom Up/Secondary 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. 218700 ZX-135/70...
  • Page 245 Extend/Retract Lockout Control Module Status Light Drive Power Relay Lift Power Relay 48 Volt Alternator field (or Battery) 24 Volt Battery Envelope or Load Sense Recovery Program setup Enable Encode A Encode B Bootstrap or Program Enable ZX-135/70 Part No. 218700...

  • Page 246: Limit Switches And Angle Sensors

    17 RSRA1SO 5 LST10 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. 218700 ZX-135/70...
  • Page 247 LST1S Drive enable safety, retracted axles 'circle' end of the drive chassis.In some cases, the LSFA1ES Front axle fully retracted engine will be stopped if safety parameters are LSRA1ES Rear axle fully retracted exceeded. ZX-135/70 Part No. 218700...
  • Page 248 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 extended. NCHO when fully retracted Part No. 218700 ZX-135/70...
  • Page 249 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. 218700...

  • Page 250: Circuit Connector Legend

    2 pin Deutsch connector for prox kill (LSS1RO) 2 pin Deutsch connector for platform 6 pin Deutsch connector on platform tilt footswitch sensor 3 pin Deutsch connector on RPM solenoid 2 pin Deutsch connector for pri boom up/down flow control Part No. 218700 ZX-135/70...
  • Page 251 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. 218700...
  • Page 252 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. 218700 ZX-135/70...

  • Page 253: 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. 218700...

  • Page 254: 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. 218700 ZX-135/70...

  • Page 255: 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. 218700...

  • Page 256: Telematics Connector Pin Legend

    J1939 Engine Messages, Receive Proprietary Genie Telematics Message *Note: Genie Databus Proprietary message support will be available at a future date, consult Genie Product Support for more information. Remote Disable Relay Configuration: Telematic device software should monitor that Pin 3 is at 0V before activating Disable Relay.

  • Page 257: 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. 218700...

  • Page 258: 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 Part No. 218700 ZX-135/70...

  • Page 259: Electrical Symbols Legend

    Relay Power relay Gauge sending unit button Diode starting aid, Oil temperature switch Coolant temperature Oil pressure switch Control relay contact glow plug or flame normally open switch - normally open normally closed normally open ignitor ZX-135/70 Part No. 218700...

  • Page 260: 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. 218700 ZX-135/70...
  • Page 261 Service Manual August 2014 This page intentionally left blank. ZX-135/70 Part No. 218700...
  • Page 262 August 2014 Service Manual Perkins 1104D-44T Engine Electrical Schematic...

  • Page 263: Perkins 1104D Engine Electrical Schematic

    Service Manual August 2014 Perkins 1104D-44T Engine Electrical Schematic ZX-135/70 Part No. 218700...

  • Page 264: Generator Wiring Schematic

    August 2014 Service Manual Generator Wiring Schematic Part No. 218700 ZX-135/70...
  • Page 265 Service Manual August 2014 Generator Wiring Schematic...
  • Page 266 August 2014 Service Manual Hydraulic Generator (Welder Option)

  • Page 267: Hydraulic Generator (Welder Option)

    Service Manual August 2014 Hydraulic Generator (Welder Option) ZX-135/70 Part No. 218700...

  • Page 268: Hydraulic Schematic

    August 2014 Service Manual Hydraulic Schematic Part No. 218700 ZX-135/70...
  • Page 269 Service Manual August 2014 Hydraulic Schematic...

  • Page 270: Electrical Schematic (Includes Deutz Engine)

    KEY SWITCH PRI BOOM LENGTH 100' STATUS PLAT PRI BOOM RETRACTED STATUS AUXILIARY HYD RECOVERY SIGNAL AUXILIARY HYD RECOVERY SIGNAL Genie ZX-135/70 MULTI FUNCTION VLV RECOVERY SIGNAL MULTI FUNCTION VLV RECOVERY SIGNAL GROUND BOOM RET RECOVERY SIGNAL BOOM RET RECOVERY SIGNAL...

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