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

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Service and Repair Manual
ZX
-135/70
®
Serial Number Range
ZX135H-4001
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. 1279835GT
Rev B1
April 2018

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Summary of Contents for Genie ZX-135/70

  • Page 1 Service and Repair Manual Serial Number Range -135/70 ® ZX135H-4001 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. 1279835GT Rev B1 April 2018...

  • Page 2: Introduction

    Copyright © 2017 by Terex Corporation 1279835 Rev B, June 2017 Second Edition, Second 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

    April 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 04/2017 Initial Release 6/2017 Repair Add Sections 4-3 to 4-9 Fault Codes Numeric Fault Codes 4/2018 Specifications Deutz TD2011 Engine Specifications Reference Examples: Electronic Version Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual April 2018 Introduction Serial Number Legend 1 Model 4 Serial label (located under cover) 2 Facility code 5 Serial number (stamped on chassis) 3 Sequence number ZX®-135/70 Part No. 1279835GT...

  • Page 5: Safety Rules

    April 2018 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 6 Service and Repair Manual April 2018 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    April 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History ....................iii Serial Number Legend ..................4 Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
  • Page 8 April 2018 Table of Contents Platform Components ..................29 2-1 Platform ......................29 2-2 Platform Leveling Cylinder ................30 2-3 Platform Rotator ..................... 31 How to Bleed the Platform Rotator ..............32 2-4 Platform Level Sensor - How to Calibrate the Platform Level Sensor ... 33 2-5 Platform Overload System ................
  • Page 9 April 2018 Table of Contents Engines ........................ 74 5-1 RPM Adjustment .................... 74 5-2 Flex Plate ....................... 74 How to Install the Flex Plate ................75 Ground Controls ....................76 6-1 Bypass/Recovery Key Switch ................ 76 How to Use the Recovery Mode ..............78 6-2 Circuit Boards ....................
  • Page 10 April 2018 Table of Contents Turntable Rotation Components ..............122 9-1 Turntable Rotation Assembly ............... 122 How to Adjust the Turntable Rotation Gear Backlash ........123 9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor ..124 Axle Components.....................
  • Page 11 April 2018 Table of Contents VEC Module - Deutz TD2011L04i and Perkins 1104D-44T Models ....206 VEC Module - Deutz TD2.9 Models ..............207 VEC Module - Perkins 854F Models ..............208 Electrical Symbols Legend ................. 209 Hydraulic Symbols Legend ................. 211 Perkins 1104D-44T Engine Electrical Schematic- View 1 .........

  • Page 13: Specifications

    Tires and wheels Hydraulic Fluid Specifications Tire size 445D50/710, 18PR Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic Tire ply rating systems, have the ability to perform over a wide Tire weight, new foam-filled...
  • Page 14 Service and Repair Manual April 2018 Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...
  • Page 15 April 2018 Service and Repair Manual Specifications Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46 Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C...

  • Page 16: Hydraulic Component Specifications

    Service and Repair Manual April 2018 Specifications UCON Hydrolube HP-5046 Fluid Hydraulic Component Properties Specifications ISO Grade Drive Pump Viscosity index Type: bi-directional variable displacement piston pump Kinematic Viscosity Displacement per revolution 2.8 cu in cSt @ 149°F / 65°C 46 cc cSt @ 104°F / 40°C Flow rate @ 2350 rpm...
  • Page 17 April 2018 Service and Repair Manual Specifications Auxiliary Pump Brakes Type: fixed displacement gear pump Brake relief pressure 190 psi 13 bar Displacement per revolution 0.15 cu in 2.47 cc Drive Motors Function manifold Displacement per revolution, high 0.8 cu in speed 13.3 cc System relief valve pressure, maximum...
  • Page 18 Service and Repair Manual April 2018 Specifications Manifold Component Specifications Plug torque SAE No. 2 36 in-lbs / 4 Nm SAE No. 4 10 ft-lbs / 13 Nm SAE No. 6 14 ft-lbs / 19 Nm SAE No. 8 38 ft-lbs / 51 Nm SAE No.

  • Page 19: Deutz Td 2.9 Engine Specifications

    April 2018 Service and Repair Manual Specifications Deutz TD 2.9 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs 177 cu. in Displacement 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C 3.6 x 4.3 inches Bore and Stroke Oil Pressure switch 92 x 110 mm...
  • Page 20 Service and Repair Manual April 2018 Specifications Deutz TD2011L04i Engine Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Displacement 220.9 cu. in 2.8 to 4.1 bar 3.62 liters Oil capacity (including filter) 12.8 quarts Number of cylinders 12.1 liters Bore and Stroke 3.78 x 4.92 inches...
  • Page 21 April 2018 Service and Repair Manual Specifications Deutz TD2011L04i cont. Fuel injection system Motorpal Injection pump pressure, maximum 15,000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Starter motor Current draw, normal load 140 - 200A...

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

    Service and Repair Manual April 2018 Specifications Perkins 854F-34T Oil Pressure switch Installation torque 18.4 ft-lbs 207 cu. in Displacement 25 Nm 3.4 liters Pressure switch point 12 psi Number of cylinders 0.82 bar 3.89 x 4.33 inches Bore and Stroke Oil Sensor Settings 99 x 110 mm 0 psi...
  • Page 23 April 2018 Service and Repair Manual Specifications Perkins 854F-34T cont. Engine coolant Capacity 16.5 quarts (50/50 extended life) 15.6 liters Coolant temperature switch Installation torque 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...

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

    Service and Repair Manual April 2018 Specifications Perkins 1104D-44T Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 268.5 cu. in Displacement 2.8 to 4.1 bar 4.4 liters Oil capacity (including filter) 8.3 quarts Number of cylinders 7.9 liters 4.13 x 5 inches Bore and Stroke...
  • Page 25 April 2018 Service and Repair Manual Specifications Perkins 1104D-44T cont. Starter motor Current draw, normal load 115A Cranking speed 200 - 250 rpm Battery – Auxiliary power units Type 6V DC Quantity Battery capacity, maximum 285 AH Reserve capacity @ 25A rate 745 minutes Battery –...

  • Page 26: Machine Torque Specifications

    Service and Repair Manual April 2018 Specifications Machine Torque Specifications Performance Specifications Platform Rotator Drive speed, maximum 1-8 center bolt, GR 5, dull gray 500 ft-lbs Stowed position, high speed 3.0 mph 678 Nm 4.8 km/h 40 ft / 9.1 sec 3/8-16 bolts, GR 8, gray coated 35 ft-lbs* 12.2 m / 9.1 sec...

  • Page 27: Hydraulic Hose And Fitting Torque Specifications

    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 be torqued to specification when they are removed 23 ft-lbs / 31.2 Nm...

  • Page 28: 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 29: About This Section

    April 2018 Service and Repair Manual Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 30: Platform Controls

    6 primary boom up/down, primary boom and provide proportional speed control over its extend/retract and turntable rotate left/right entire range of motion. joystick For further information or assistance, consult Genie Product Support. Platform Circuit Board Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury.
  • Page 31 April 2018 Service and Repair Manual Platform Controls How to Remove the Circuit Board Attach a grounded wrist strap to the ground screw inside the control box. Push in the red Emergency Stop button to the off position at both the ground and platform Electrocution/burn hazard.

  • Page 32: How To Remove The Led Circuit Board

    Service and Repair Manual April 2018 Platform Controls How to R emove the LED Circui t Board How to Remove the LED Circuit Board Joysticks Push in the red Emergency Stop button to the How to Calibrate a Joystick off position at both the ground and platform controls.
  • Page 33 April 2018 Service and Repair Manual Platform Controls Drive functions: Steer functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to platform controls.
  • Page 34 Service and Repair Manual April 2018 Platform Controls Secondary boom up/down and extend/retract Primary boom extend/retract functions: functions: Turn the key switch to the off position. 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 Press and hold the enter button on the ground control panel while turning the key switch to...
  • Page 35 April 2018 Service and Repair Manual Platform Controls Primary boom up/down functions: Jib boom up/down functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to...

  • Page 36: How To Reset A Proportional Valve Coil Default

    Service and Repair Manual April 2018 Platform Controls How to R es et a Proportional Valve Coil D efault How to Reset a Proportional Turntable rotate functions: Valve Coil Default Turn the key switch to the off position. Note: Use the following chart to identify the Press and hold the enter button on the ground description of each LCD screen control button used control panel while turning the key switch to...

  • Page 37: How To Set The Function Thresholds And Default Functions Speeds

    April 2018 Service and Repair Manual Platform Controls How to Set the F unc tion T hresholds and D efault Func tions Speeds How to Set the Function Slowly move the joystick off center in the opposite direction just until the machine Thresholds and Default function starts to move, then move the joystick Functions Speeds...
  • Page 38 Service and Repair Manual April 2018 Platform Controls Function speeds: Turntable rotate function, primary boom extended: Extend the primary boom Note: Be sure the machine is in the stowed position approximately 4 ft / 1.2 m. Move the rotate and the boom is rotated between the circle end joystick full stroke in either the left or right tires.

  • Page 39: How To Adjust The Function Speeds

    April 2018 Service and Repair Manual Platform Controls How to Adj ust the Functi on Speeds How to Adjust the Function Press the enter button to save the setting in memory. Speeds Press the enter or previous button on the Note: Perform this procedure with the boom in the LCD screen until EXIT is displayed.

  • Page 40: How To Adjust The Function Ramp Rate Setting

    Service and Repair Manual April 2018 Platform Controls How to Adj ust the Functi on R amp R ate Setti ng How to Adjust the Function Ramp Press the previous button until the function to be adjusted is displayed. Rate Setting Press the plus button to increase the ramp The ramp rate setting of a joystick controls the time rate or press the minus button to decrease the...

  • Page 41: Platform Components

    April 2018 Service and Repair Manual Platform Components Remove the weld cable from the platform (if equipped). Platform Electrocution/burn hazard. Contact with electrically charged How to Remove the Platform circuits could result in death or serious injury. Remove all rings, Separate the foot switch quick disconnect watches and other jewelry.

  • Page 42: Platform Leveling Cylinder

    Service and Repair Manual April 2018 Platform Components Place a block under the platform leveling cylinder for support. Platform Leveling Cylinder Remove the external snap rings from the The platform leveling cylinder keeps the platform barrel-end pivot pin. Use a soft metal drift to level through the entire range of boom motion.

  • Page 43: Platform Rotator

    April 2018 Service and Repair Manual Platform Components Remove the platform angle sensor retaining fasteners. Remove the platform angle sensor Platform Rotator from the platform rotator. The platform rotator is a hydraulically activated Component damage hazard. The helical gear assembly used to rotate the platform platform angle sensor is a very 160 degrees.

  • Page 44: How To Bleed The Platform Rotator

    Service and Repair Manual April 2018 Platform Components How to Bleed the Pl atform R otator How to Bleed the Platform Remove the hose and cable guide retaining fasteners and remove the guide from the Rotator platform support. Note: Do not start the engine. Use auxiliary power Remove the weld cable from the platform (if for all machine functions in this procedure.

  • Page 45: Platform Level Sensor - How To Calibrate The Platform Level Sensor

    April 2018 Service and Repair Manual Platform Components Locate the calibration toggle switch at the top of the ground control box. Activate calibration Platform Level Sensor mode by moving the toggle switch in the left direction. The platform level sensor is mounted to the side of the platform rotator.

  • Page 46: Platform Overload System

    Service and Repair Manual April 2018 Platform Components Turn the key switch to ground controls. Platform Overload System Open the ground control box. Locate the calibration toggle switch at the top Proper calibration of the platform overload system of the ground control box. Activate calibration is essential to safe machine operation.
  • Page 47 April 2018 Service and Repair Manual Platform Components Remove the key from the main key switch. 17 Press the enter or previous button on the Insert the key into the bypass/recovery key LCD screen until LOAD CELL FULL LOAD switch and turn it to the bypass position. LBS or LOAD CELL FULL LOAD KGS is displayed.

  • Page 48: How To Perform A Zero Load Cell Calibration

    Service and Repair Manual April 2018 Platform Components How to Per form a Z ero Load C ell C alibration How to Perform a Zero Load Cell 29 Add an additional test weight equal to 5% of the rated capacity onto the calibration weight Calibration to overload the platform.

  • Page 49: How To Replace The Platform Overload Load Cell

    April 2018 Service and Repair Manual Platform Components How to R eplac e the Platform Ov erload Load C ell How to Replace the Load Cell Sensor Platform Overload Recovery Message (software V3.07 and Note: The preload adjustment should only be later) performed after the load cell sensor has been replaced..
  • Page 50 Service and Repair Manual April 2018 Platform Components Press the buttons on the ground controls in the following sequence: (plus)(minus)(minus)(plus). Press the enter or previous button on the LCD screen until CLEAR OVERLOAD RECOVERY is displayed. Press the plus button or the minus button to select YES.

  • Page 51: Jib Boom Components

    April 2018 Service and Repair Manual Jib Boom Components 1 primary extension boom 7 jib boom 2 jib boom manifold 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...

  • Page 52: Jib Boom Cable Track

    Service and Repair Manual April 2018 Jib Boom Components Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to Jib Boom Cable Track the platform manifold. Cap the fittings on the manifold. The jib boom cable track guides the cables and hoses running up the jib boom.
  • Page 53 April 2018 Service and Repair Manual Jib Boom Components Remove the hose and cable clamp retaining 17 Remove the fasteners from the cable track fasteners at the platform end of the jib boom tube guide at the platform end of the jib boom. cable track tube.

  • Page 54: 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 55: Jib Boom

    April 2018 Service and Repair Manual Jib Boom Components Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to Jib Boom the platform manifold. Cap the fittings on the manifold. How to Remove the Jib Boom Bodily injury hazard.
  • Page 56 Service and Repair Manual April 2018 Jib Boom Components Place blocks between the upper and lower 13 Remove the jib boom angle sensor mounting cable tracks and secure the upper and lower bracket fasteners from the side of the primary tracks together.

  • Page 57: Jib Boom Lift Cylinder

    April 2018 Service and Repair Manual Jib Boom Components 19 Secure the jib boom lift cylinder to the jib boom with a strap or other suitable device. Jib Boom Lift Cylinder 20 Raise the jib boom to a horizontal position using the overhead crane.

  • Page 58: Jib Boom Level Cylinder

    Service and Repair Manual April 2018 Jib Boom Components Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Use a Jib Boom Level Cylinder soft metal drift to remove the pin and let the cylinder hang down. How to Remove the Jib Boom Attach a lifting strap from an overhead crane Level Cylinder...

  • Page 59: Jib Boom Extension Cylinder

    April 2018 Service and Repair Manual Jib Boom Components Remove the external snap rings from the jib boom level cylinder barrel-end pivot pin. Use a Jib Boom Extension Cylinder soft metal drift to remove the pin. Tag, disconnect and plug the jib boom level How to Remove the Jib Boom cylinder hydraulic hoses from the jib boom Extension Cylinder...
  • Page 60 Service and Repair Manual April 2018 Jib Boom Components Extend the jib boom until the jib boom 10 Pull the electrical cables out of the lower cable extension cylinder rod-end pivot pin is track that lead to the primary boom. accessible.

  • Page 61: Angle Sensor

    April 2018 Service and Repair Manual Jib Boom Components 17 Attach a lifting strap from an overhead crane to the barrel end of the jib boom extension Jib Boom Bellcrank Angle Sensor cylinder. The jib boom bellcrank angle sensor is monitored 18 Remove the pin retaining fasteners from the by the control system to keep the jib boom jib boom extension cylinder barrel-end pivot...
  • Page 62 Service and Repair Manual April 2018 Jib Boom Components Note: Use the following chart to identify the Enter sensor calibration mode by pressing the description of each LCD screen control button used buttons at the ground controls in the following in this procedure.
  • Page 63 April 2018 Service and Repair Manual Jib Boom Components 18 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings. Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved.

  • Page 64: Boom Components

    Service and Repair Manual April 2018 Boom Components 1 upper primary boom lift cylinder linkage 8 primary boom lift cylinder 9 number 1 secondary boom tube 2 primary boom 10 number 2 secondary boom tube 3 cable track 11 number 3 secondary boom tube 4 primary extension boom 12 lower primary boom lift cylinder linkage arm 5 jib boom manifold...

  • Page 65: Primary Boom Cable Track

    April 2018 Service and Repair Manual Boom Components Pull the electrical cables out of the lower cable track that lead to the primary boom. Primary Boom Cable Track Component damage hazard. The primary boom cable track guides the cables Cables can be damaged if they and hoses running up the boom.
  • Page 66 Service and Repair Manual April 2018 Boom Components 10 Remove the retaining fasteners from the cable 15 Locate the two hydraulic hoses inside the end track guide at the platform end of the boom. of the secondary boom that lead to the primary Remove the cable track guide from the boom cable track.

  • Page 67: 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 68: Secondary Boom Cable Track

    Service and Repair Manual April 2018 Boom Components Remove the upper rollers from the replacement section of cable track. Secondary Boom Cable Track Lift up the hoses and cables and carefully The secondary boom cable track guides the cables insert the new 4-link section of cable track. and hoses running up through the inside of the Component damage hazard.
  • Page 69 April 2018 Service and Repair Manual Boom Components Remove the cover retaining fasteners and 10 Pull the hydraulic hoses just removed through remove the cover from the secondary boom. the turntable bulkhead. Crushing hazard. The secondary Component damage hazard. boom end cover could become Hoses can be damaged if they unbalanced and fall when are kinked or pinched.

  • Page 70: How To Repair The Secondary Boom Cable Track

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

  • Page 71: Primary Boom

    April 2018 Service and Repair Manual Boom Components Remove the upper rollers from the replacement section of cable track. Primary Boom Lift up the hoses and cables and carefully insert the new 4-link section of cable track. How to Remove the Primary Component damage hazard.
  • Page 72 Service and Repair Manual April 2018 Boom Components Remove the primary boom cable track. Refer 10 Tag, disconnect and plug the primary boom to repair procedure, How to Remove the Cable extension cylinder hydraulic hoses. Cap the Track. fittings on the cylinder. Remove the end cover from the pivot end of Bodily injury hazard.

  • Page 73: Primary Boom Lift Cylinder

    April 2018 Service and Repair Manual Boom Components 17 Use a soft metal drift to tap the pin halfway out and lower one of the linkage arms down. Tap Primary Boom Lift Cylinder the pin in the other direction and lower the other linkage arm down.

  • Page 74: Secondary Boom Lift Cylinder

    Service and Repair Manual April 2018 Boom Components Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on Secondary Boom Lift Cylinder the cylinder. Bodily injury hazard. Spraying How to Remove the Secondary hydraulic oil can penetrate and Boom Lift Cylinder burn skin.
  • Page 75 April 2018 Service and Repair Manual Boom Components Remove the engine pivot plate retaining Tag, disconnect and plug the fuel hoses from fastener. Swing the engine pivot plate out the fuel tank. Clean up any fuel that may have away from the machine. spilled.
  • Page 76 Service and Repair Manual April 2018 Boom Components 13 Remove the turntable cover using a suitable 19 Attach an overhead crane or similar lifting lifting device. device to the battery box for the auxiliary power unit batteries. Crushing hazard. The turntable 20 Remove the battery box retaining fasteners cover may become unbalanced and carefully remove the battery box from the...
  • Page 77 April 2018 Service and Repair Manual Boom Components 24 Remove the secondary boom lift cylinder 29 Use a slide hammer to remove the barrel-end rod-end pivot pin retaining fasteners. Use a pivot pin. soft metal drift to remove the pin through the Component damage hazard.

  • Page 78: Primary Boom Extension Cylinder

    Service and Repair Manual April 2018 Boom Components Remove the access cover from the pivot end of the primary boom. Primary Boom Extension Cylinder Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. The primary boom extension cylinder extends and retracts the primary boom extension tube.The Bodily injury hazard.

  • Page 79: Secondary Boom Extension Cylinders

    April 2018 Service and Repair Manual Boom Components Raise the primary boom approximately 10 feet / 3 m. Turn the machine off. Secondary Boom Extension Cylinders Working at the platform end of the secondary boom, support and secure the secondary boom end cover to a suitable lifting device.
  • Page 80 Service and Repair Manual April 2018 Boom Components Note: When installing the middle and upper Attach a lifting strap from an overhead crane secondary boom extension cylinders, be sure the to the rod end of the upper extension cylinder. grooved wear pads are correctly aligned with the Using the overhead crane, lift the extension channels on the top of the cylinders.

  • Page 81: Primary Boom Angle Sensor - How To Calibrate The Primary Boom Angle Sensor

    April 2018 Service and Repair Manual Boom Components How to Calibrate the Primary Primary Boom Angle Sensor Boom Angle Sensor Note: If the axle sensor or secondary boom angle The primary boom angle sensor is used to limit the sensor have been removed or replaced, or the angle of the primary boom relative to the angle of turntable level sensor has been replaced, they the secondary boom and gravity.
  • Page 82 Service and Repair Manual April 2018 Boom Components Push in the ground controls red Emergency 11 Press the plus button to select YES, then Stop button to the off position. Do not turn the press the enter button to accept. key switch to the off position.

  • Page 83: Sensor

    April 2018 Service and Repair Manual Boom Components 22 Turn the key back to the run position and remove the key from the bypass/recovery key Secondary Boom Angle Sensor switch. Insert the key into the main key switch and turn it to ground controls. The secondary boom angle sensor is used to limit the angle of the primary boom relative to the angle Note: Be sure that the bypass/recovery key switch...
  • Page 84 Service and Repair Manual April 2018 Boom Components Turn the key switch to ground controls. Press the enter or previous button on the LCD screen until DELETE SECONDARY Open the ground control box. BOOM ANGLE SENSOR CALIBRATION is Locate the calibration toggle switch at the top displayed.
  • Page 85 April 2018 Service and Repair Manual Boom Components 18 Press the plus button to select YES, then press the enter button to accept. 19 Turn the key back to the run position and remove the key from the bypass/recovery key switch.

  • Page 86: Engines

    Service and Repair Manual April 2018 Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the engine Refer to Maintenance Procedure in the appropriate and the pump. It is bolted to the engine flywheel Service or Maintenance Manual for your machine, and has a splined center to drive the pump.

  • Page 87: 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 88: Ground Controls

    Service and Repair Manual April 2018 Ground Controls Bypass/Recovery Key Switch The turntable control box (TCON) is the communication and operations center for the machine. The turntable control box contains two key switches. The main key switch towards the top of the control box is for selection of ground or platform controls.
  • Page 89 April 2018 Service and Repair Manual Ground Controls How to Use the Bypass Mode Turn the bypass/recovery key switch to the bypass position. Tip-over hazard. Operating the Using auxiliary power, operate the ground machine outside of the operating control buttons to level the platform. envelope while in Bypass mode will result in death or serious Note: Only the auxiliary power unit can be used to...

  • Page 90: How To Use The Recovery Mode

    Service and Repair Manual April 2018 Ground Controls How to Us e the R ec ov ery Mode How to Use the Recovery Mode Turn the main key switch to ground controls. Remove the key from the main key switch and Recovery is only to be used as a last attempt to insert the key into the bypass/recovery key lower the platform when the operator in the...

  • Page 91: Circuit Boards

    April 2018 Service and Repair Manual Ground Controls How to Remove the LCD Display Circuit Boards Screen Circuit Board Push in the red Emergency Stop button to the The ground control box contains a replaceable off position at both the ground and platform membrane decal with touch sensitive buttons for controls.
  • Page 92 Service and Repair Manual April 2018 Ground Controls How to Remove the ALC-1000 Tag and carefully disconnect the wire connectors from the circuit board. Circuit Board Carefully disconnect the LCD circuit board Note: If the ALC-1000 circuit board (TCON) has ribbon cable from the ECM circuit board.

  • Page 93: Membrane Decal

    April 2018 Service and Repair Manual Ground Controls Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit Membrane Decal board. The membrane decal is a special decal that Electrocution/burn hazard. consists of a decal with an electronic membrane on Contact with electrically charged the backside.

  • Page 94: 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 95: Display Module

    April 2018 Service and Repair Manual Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters. Tip-over hazard.
  • Page 96 Delete boom function speed on position. Delete lift function ramps Release the enter button and press (minus)(minus)(previous)(previous) Delete all (Contact Genie Product Support before using this option) Clear Faults With key switch , press and hold...
  • Page 97 April 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and hold Forward extended drive 120% (max) 100% Drive Functions the enter button and turn key switch speed % (default) 50% (min) to on position.
  • Page 98 Service and Repair Manual April 2018 Display Module Screen or Procedure Description Range or Selection Menu Boom With key switch , press and hold Primary boom up speed stowed Function the enter button and turn key switch Speeds to on position. Release the enter button and press Primary boom up speed not stowed (plus)(plus)(minus)(minus)
  • Page 99 April 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and Primary boom up/down ramp Lift Functions hold the enter button and turn key acceleration % Ramps switch to on position. Primary boom up/down ramp Release the enter button and deceleration %...
  • Page 100 Service and Repair Manual April 2018 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and hold the Delete drive valve calibration Valve enter button and turn key switch to on Calibration position. Delete primary boom up/down Release the enter button and press valve calibration (minus)(minus)(enter)(enter).
  • Page 101 April 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Sensor Calibration With key switch , press and hold the Set unit X-axis to gravity enter button and turn key switch to on (software version Set unit Y-axis to gravity position.
  • Page 102 Service and Repair Manual April 2018 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and hold Boom Function Limit No LT= No limit; Options the enter button and turn key switch (NO LT/EXT LT) EXT LT= secondary to on position.

  • Page 103: 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 104: How To Prime The Function Pump

    Service and Repair Manual April 2018 Hydraulic Pumps How to Prime the F uncti on Pump How to Adj ust the Functi on Pum p Standby Pr ess ure How to Prime the Function Pump How to Adjust the Function Pump Standby Pressure Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose...

  • Page 105: How To Adjust The Function Pump Pressure Compensator

    April 2018 Service and Repair Manual Hydraulic Pumps Loosen the set screw for the pressure Adjust the function pump standby pressure. compensator adjustment screw. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. Turn the engine off and remove the pressure gauge.

  • Page 106: 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 107: How To Prime The Drive Pump

    April 2018 Service and Repair Manual Hydraulic Pumps How to Prime the Driv e Pum p How to Prime the Drive Pump Carefully pull the drive pump out until the pump coupler separates from the flex plate. Component damage hazard. Be Remove the drive pump from the machine.

  • Page 108: Manifolds

    Service and Repair Manual April 2018 Manifolds Function Manifold Components The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.34 bar Prevents hydraulic pressure from 60 ft-lbs / 81 Nm flowing back into auxiliary pump Check valve, 5 psi / 0.34 bar...
  • Page 109 April 2018 Service and Repair Manual Manifolds Part No. 1279835GT ZX®-135/70...
  • Page 110 Service and Repair Manual April 2018 Manifolds Function Manifold Components, continued The function manifold is mounted to the turntable next to the ground controls. Index Description Schematic Item Function Torque Proportional solenoid Turntable rotate circuit 33-37 ft-lbs / 45-50 Nm valve Differential sensing valve, Turntable rotate circuit, regulates...
  • Page 111 April 2018 Service and Repair Manual Manifolds Part No. 1279835GT ZX®-135/70...

  • Page 112: Valve Adjustments - Function Manifold

    Service and Repair Manual April 2018 Manifolds Simultaneously push and hold the auxiliary power button and the primary boom retract Valve Adjustments - button with the primary boom fully retracted. Function Manifold Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specification.
  • Page 113 April 2018 Service and Repair Manual Manifolds Simultaneously push and hold the function enable/high speed button and the primary How to Adjust the Primary Boom boom extend button with the primary boom Extend Relief Valve fully extended. Observe the pressure reading on the pressure gauge.

  • Page 114: Jib Boom Manifold

    Service and Repair Manual April 2018 Manifolds Jib Boom Manifold The jib boom manifold is mounted inside the primary extension boom at the platform end. Index Schematic Description Function Torque Item Pressure compensator valve, Jib boom up/down circuit, 30-35 ft-lbs / 41-47 Nm 150 psi / 10.3 bar regulates pressure drop across jib boom up/down proportional...
  • Page 115 April 2018 Service and Repair Manual Manifolds Part No. 1279835GT ZX®-135/70...

  • Page 116: Platform Manifold

    Service and Repair Manual April 2018 Manifolds Platform Manifold The platform manifold is mounted to the platform mounting weldment. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform rotate left/right 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...

  • Page 117: Flow Control Mainfold

    April 2018 Service and Repair Manual Manifolds Flow Control Manifold 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 Part No.

  • Page 118: Function Enable Valve

    Service and Repair Manual April 2018 Manifolds 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...

  • Page 119: Turntable Rotation Manifold

    April 2018 Service and Repair Manual Manifolds Turntable Rotation Manifold The turntable rotation manifolds are mounted to the turntable rotation drive hub motors. Index Schematic Description Function Torque Item Counterbalance valve Turntable rotate right 25-30 ft-lbs / 34-41 Nm Counterbalance valve Turntable rotate left 25-30 ft-lbs / 34-41 Nm...

  • Page 120: Steer And Axle Manifold

    Service and Repair Manual April 2018 Manifolds Steer and Axle Manifold Components The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Flow control valve, 2.1 gpm / 8 L/min Right front steer cylinder extend 20-25 ft-lbs / circuit...
  • Page 121 April 2018 Service and Repair Manual Manifolds Part No. 1279835GT ZX®-135/70...
  • Page 122 Service and Repair Manual April 2018 Manifolds Steer and Axle Manifold, continued The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Pressure reducing valve, 2400 psi / 165 bar Axle extend/retract circuit 30-35 ft-lbs / 41-47 Nm...
  • Page 123 April 2018 Service and Repair Manual Manifolds Part No. 1279835GT ZX®-135/70...

  • Page 124: Valve Adjustments - Steer And Axle Manifold

    Service and Repair Manual April 2018 Manifolds Turn the engine off. Valve Adjustments - Steer and Adjust the internal hex socket. Turn it Axle Manifold clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. How to Adjust the Axle Relief Component damage hazard.
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  • Page 126: Traction Manifold Components

    Service and Repair Manual April 2018 Manifolds 8-10 Traction Manifold Components The traction manifold is mounted inside the manifold box at the blue triangle side of the machine. Index Schematic Description Function Torque Item 30-35 ft-lbs / Check valve, 5 psi / 0.3 bar Anti-cavitation 40.7-47.5 Nm 26-30 ft-lbs /...
  • Page 127 April 2018 Service and Repair Manual Manifolds Part No. 1279835GT ZX®-135/70...
  • Page 128 Service and Repair Manual April 2018 Manifolds Traction Manifold Components, continued The traction manifold is mounted inside the manifold box at the blue triangle side of the machine. Index Schematic Description Function Torque Item Flow control valve 2.2 gpm / Equalizes pressure on both sides of 30-35 ft-lbs / 8.3 L/m...
  • Page 129 April 2018 Service and Repair Manual Manifolds Part No. 1279835GT ZX®-135/70...

  • Page 130: Valve Adjustments - Traction Manifold

    Service and Repair Manual April 2018 Manifolds 8-11 Hold the hot oil relief valve and remove the cap. Valve Adjustments - Traction Manifold Start the engine from the ground controls. 10 Press and hold the function enable/high rpm select button (rabbit symbol) position. How to Adjust the Hot Oil Relief 11 Adjust the internal hex socket until the Valve...

  • Page 131: Generator Manifold Component

    April 2018 Service and Repair Manual Manifolds 8-12 Generator Manifold Components The oil diverter manifold is mounted near the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item 19-21 ft-lbs / Check valve Controls flow to diverter valve 25.7-28.5 Nm 33-37 ft-lbs / Solenoid Valve...

  • Page 132: Valve Coils

    Service and Repair Manual April 2018 Manifolds Valve Coil Resistance 8-13 Specification Valve Coils Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...

  • Page 133: April

    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 134: Turntable Rotation Components

    Service and Repair Manual April 2018 Turntable Rotation Components Remove the drive hub mounting bolts and remove the turntable rotation assembly from Turntable Rotation Assembly the machine. Repeat steps 3 through 5 for the other How to Remove a Turntable turntable rotation assembly.

  • Page 135: How To Adjust The Turntable Rotation Gear Backlash

    April 2018 Service and Repair Manual Turntable Rotation Components How to Adj ust the Tur ntabl e R otati on Gear Backlas h Turn the adjustment bolt 1/2 to 3/4 turn How to Adjust the Turntable counterclockwise. Tighten the lock nut on the Rotation Gear Backlash adjustment bolt.

  • Page 136: 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 137 April 2018 Service and Repair Manual Turntable Rotation Components Remove the key from the main key switch. Press the enter or previous button on the Insert the key into the bypass/recovery key LCD screen until SET UNIT X AXIS LEVEL switch and turn it to the bypass position.
  • Page 138 Service and Repair Manual April 2018 Turntable Rotation Components 11 Press the plus button or minus button to 14 Press the plus button or minus button to adjust the display to the exact value shown on adjust the display to the exact value shown on the digital level and press the enter button.

  • Page 139: Axle Components

    April 2018 Service and Repair Manual Axle Components 10-1 Remove the steer sensor cover retaining fasteners. Remove the steer sensor assembly. Steer Sensors Note: If the sensor activator pin needs to be The steer sensors measure steer angle and replaced, install the new activator pin per communicates that information to the ground Illustration 1.
  • Page 140 Service and Repair Manual April 2018 Axle Components Left front (square-end, blue side) and right rear Install the steer sensor cover retaining (circle-end, yellow side) angle sensors: fasteners. Do not tighten the cover retaining fasteners. Connect the steer sensor assembly cable to the main harness.

  • Page 141: How To Calibrate A Replacement Steer Sensor

    April 2018 Service and Repair Manual Axle Components How to C alibr ate a Repl acem ent Steer Sens or How to Calibrate a Replacement 10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable Steer Sensor angled away from the tire.

  • Page 142: How To Calibrate All Steer Sensors

    Service and Repair Manual April 2018 Axle Components How to C alibr ate All Steer Sensors How to Calibrate All Steer Left front (square-end, blue side) and right rear (circle-end, yellow side) angle Sensors sensors: Rotate the sensor cover clockwise or counterclockwise until the voltage reading Note: This procedure will only need to be is between 1.4 to 1.6V DC.
  • Page 143 April 2018 Service and Repair Manual Axle Components Delete all Steer Sensor Calibrations Press and hold the enter button on the ground control panel while pulling out the ground 11 Press the enter or previous button on the controls red Emergency Stop button to the on LCD screen until DELETE ALL STEER position.

  • Page 144: Steer Cylinders

    Service and Repair Manual April 2018 Axle Components 10-2 20 Push in the red Emergency Stop button to the off position. Steer Cylinders 21 Remove the fastener that was temporarily installed. Close the control box door and install How to Remove a Steer Cylinder the door retaining fasteners.

  • Page 145: Axle Extension Cylinders

    April 2018 Service and Repair Manual Axle Components 10-3 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension Axle Extension Cylinders cylinder. Note: Connect the pressure hose from the power How to Remove an Axle unit to the "R"...

  • Page 146: Axle Angle Sensors - How To Calibrate The Axle Angle Sensors

    Service and Repair Manual April 2018 Axle Components 10-4 Temporarily install a control box door retaining fastener between the door and the box to Axle Angle Sensors prevent the control box door from moving the toggle switch while calibrating the machine. The axle angle sensors measure the axle angle and communicates that information to the ground Remove the key from the main key switch.
  • Page 147 April 2018 Service and Repair Manual Axle Components Enter sensor calibration mode by pressing the 15 Wait approximately 20 seconds and turn the buttons at the ground controls in the following machine off by pressing the red Emergency Stop button in. sequence: (plus)(enter)(enter)(plus).
  • Page 148 Service and Repair Manual April 2018 This page intentionally left blank. ZX®-135/70 Part No. 1279835GT...

  • Page 149: Fault Codes

    April 2018 Service and Repair Manual Fault Codes Section 4 Before Troubleshooting: Faul t Codes  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.

  • Page 150: Control System Fault Codes

    Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Primary Ext/Ret Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick. Check the connections to Value Too High ensure the connector terminals have not backed out.
  • Page 151 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up/Down Fault Check (both Primary Boom Up/Down disabled, Check ribbon and connector from buttons on TCON buttons pressed) display message on LCD membrane switch. If necessary replace membrane switch.
  • Page 152 Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Switch P3 Fault Check Display message on LCD P3 SAFETY Internal fault not on Z135 SWITCH FAULT Safety Switch P6R1 Fault Check Display message on LCD P6R1 Check wiring for circuit P53LS SAFETY SWITCH FAULT (white/black wire) for damage resulting...
  • Page 153 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Safety Switch P10 Fault Check Display message on LCD P10 Recycle power SAFETY SWITCH FAULT Safety Switch P11 Fault Check Display message on LCD P11 Recycle power and check wiring on SAFETY SWITCH FAULT circuit S140ENL (orange/black)
  • Page 154 Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Platform Overload Fault Check Display message on LCD. Disable all Check for an overload in the platform. (if active) functions from PCON. Limit functions Check the overload switch mounted on at TCON to AUX Power.
  • Page 155 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up/Down Not calibrated Normal function except threshold for Calibrate Thresholds Flow Valve one or the other direction is zero. Display message on LCD Just calibrated Initiate one second beep of audible Self-clearing (transient)
  • Page 156 Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Primary Boom Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
  • Page 157 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Secondary Boom Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring. Extend Valve zero and neutral, Alarm sounds Check for an open or shorted valve coil.
  • Page 158 Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Secondary Boom Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Angle Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
  • Page 159 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick. Check the connections to ensure the connector terminals have Value Too High not backed out.
  • Page 160 Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded Sensor Y Direction sounds Value Too High Replace SCON Value Too Low Value at 0 V...
  • Page 161 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Jib Level (Bellcrank) Not calibrated Normal function except threshold for Perform calibration procedure Up/Down Flow Valve(s) one or the other direction is zero. Display message on LCD Just calibrated Initiate one second beep of audible Self-clearing (transient)
  • Page 162 Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Jib Extend/Retract Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick. Check the connections to ensure the connector terminals have not backed out.
  • Page 163 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Rear Axle Angle Sensor Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and Sensor is out of range.
  • Page 164 Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Left Front Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
  • Page 165 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Right Rear Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
  • Page 166 Service and Repair Manual April 2018 Fault Codes Error Source Error Type Effects Recovery Actions Secondary Boom Switch Too much time Inhibit Secondary Boom Extend if the If the fault occurs on extend, retract fault occurs. Timeout has elapsed from boom until LSS1RO is engaged and try when LSS1RO is again.
  • Page 167 April 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Platform load cell Not calibrated Calibrate the load cell. Zero load not calibrated: overloaded Alarm sounds indicating a fault. Overload LED is on. Functions disabled, engine shutdown Auxiliary functions enabled except extend.

  • Page 168: Fault Code Source

    Service and Repair Manual April 2018 Fault Codes Fault Source and Type will display as: Fault Source Description Source Type SCON Controller Area Network “ ID XXX_xx FAULT “ Primary Boom Angle Zone Where XXX is the one to three digit Fault Source and xx is the two digit Fault Type.
  • Page 169 April 2018 Service and Repair Manual Fault Codes Fault Source Fault Source Description Description Turntable Level Sensor X-Direction Enable Output Power P7R Turntable Level Snesor Y-Direction Primary Down Power P9A Boom Length Sensors Cross-Check (SCON) IGN/Fuel Power P9B Boom Safety Envelope (SCON) Primary Extend Power P10 Turntable Controller - Platform Controller Primary Up Power P11...
  • Page 170 Service and Repair Manual April 2018 Fault Codes Fault Source Description Brake Valve Motor Shift Valve Chassis Tilt Sensors Cross-Check (SCON) Jib Bellcrank Level Sensor Jib Bellcrank Level Flow Valve AUX Relay Platform Level Toggle Switch Platform Rotate Toggle Switch Platform Level Flow Valve Platform Rotate Valve Boom Length Sensor...

  • Page 171: Fault Matrix

    April 2018 Service and Repair Manual Fault Codes Platform Overload P_39 - P_10 P_11 - P_9B - P_30 - (SCON pin #1) Turnta Primary Ignition/F Secondar Prop Prima Secondary Boom OFF OFF OF Rotate Second Extend/Do length Boom ary Up (crosscheck Exten LSS1RS and...

  • Page 172: Deutz Td 2.9 L4 Engine Fault Codes

    Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN FMI Description SPN = Suspect Parameter Number 1022 Actuator error EGR-Valve; signal FMI = Failure Mode Identifier range check high KWP = Keyword Protocol 1224 Actuator EGR-Valve; over SPN FMI Description current...
  • Page 173 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Sensor error ambient air press.; KWP = Keyword Protocol signal range check high SPN FMI Description Sensor error ambient air press.;...
  • Page 174 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier High low fuel temperature; KWP = Keyword Protocol warning threshold exceeded SPN FMI Description High Low fuel temperature;...
  • Page 175 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
  • Page 176 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Starter relay high side; short KWP = Keyword Protocol circuit to battery SPN FMI Description Starter relay low side;...
  • Page 177 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature KWP = Keyword Protocol upstream turbine; shut off threshold exceeded SPN FMI Description...
  • Page 178 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout error KWP = Keyword Protocol of short circuit to ground measurement cyl.
  • Page 179 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523008 Timeout error in Manipulation KWP = Keyword Protocol control FMI KWP Description 523009 Pressure Relief Valve (PRV) reached maximun allowed 4766...
  • Page 180 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 Internal ECU monitoring detection reported error...
  • Page 181 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523615 Metering unit (Fuel-System); KWP = Keyword Protocol short circuit to battery low side FMI KWP Description 523615 Metering unit (Fuel-System);...
  • Page 182 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523897 check of missing injector KWP = Keyword Protocol adjustment value programming (IMA) injector 3 (in firing order) FMI KWP Description 523898 check of missing injector...
  • Page 183 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523936 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame FMI KWP Description EEC3VOL2; Engine send messages 523922 1262 Burner Shut Off Valve;...
  • Page 184 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524016 1259 Amount of air is not plausible to KWP = Keyword Protocol pump speed FMI KWP Description 524016 1260 Calculated amount of air is not...
  • Page 185 April 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524108 9 1669 Timeout error of KWP = Keyword Protocol CAN-Transmit-Frame KWP Description ComEGRTVActr 524109 9 1679 Timeout error of 524035 12 1341 Injector diagnostics;...
  • Page 186 Service and Repair Manual April 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol KWP Description 524120 9 1682 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag 524121 9 1683 Timeout error of CAN-Receive-Frame ComRxTrbChActr 524122 9...

  • Page 187: Perkins 854F-34T Engine Fault Code

    April 2018 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Exhaust Gas Recirculation Valve Valve Position Sensor- Test Position :Voltage Above Normal Engine Exhaust Gas Recirculation Valve Valve Position Sensor - Test Position :Voltage Be- low Normal Accelerator Pedal Position 2 :Voltage Above...
  • Page 188 Service and Repair Manual April 2018 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Barometric Pressure :Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test Barometric Pressure :Voltage Below Normal Engine Pressure Sensor Open or Short Circuit - Test...
  • Page 189 April 2018 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit- Above Normal Test Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit -...
  • Page 190 Service and Repair Manual April 2018 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Injector Cylinder #02 :Current Below Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Current Above Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Data Drifted High Injector Data Incorrect- Test Engine Injector Cylinder #02 :Data Drifted Low...
  • Page 191 April 2018 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test Valve :Erratic, Intermittent, or Incorrect 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test...
  • Page 192 Service and Repair Manual April 2018 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 2791 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve- Test Control:Current Below Normal 2791 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test Control :Current Above Normal...
  • Page 193 April 2018 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3219 After treatment #1 Intake Gas Sensor at Oxygen Level- Test Temperature : High- least severe (1) 3219 After treatment #1 Intake Gas Sensor at Oxygen Level- Test...
  • Page 194 Service and Repair Manual April 2018 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3702 Diesel Particulate Filter Active Regeneration Indicator Lamp Circuit- Test Inhibited Status : Current Above Normal 4765 After treatment #1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit -...

  • Page 195: Schematics

    April 2018 Service and Repair Manual Schematics Section 5 About This Section Schem atics There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.

  • Page 196: Wire Circuit Legend

    Service and Repair Manual April 2018 Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the Control circuit prefix, circuit number and circuit suffix. Data The circuit prefix indicates the type of circuit. Engine The circuit number describes the function of Gauges the circuit.
  • Page 197 April 2018 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Auxiliary Boom Valve Engine Speed Select Alternator Field Axle Front Position Auxiliary Forward Valve Flashing Beacon Auxiliary Hydraulic Pump Function Enable Angle Fuel Select (gas/LP) Auxiliary Platform Valve Filter Restricted Auxiliary Reverse Valve Filter Switch...
  • Page 198 Service and Repair Manual April 2018 Wire Circuit Legend Suffix Definition Suffix Definition Jib Select Valve Platform Level Flow Control Jib Up Propel Lockout Jib Up/Down Control Primary Boom Extend/Retract Signal Load Sensor Platform Level Up Left Front Platform Rotate Control Left Front Steer Sensor Platform Rotate Flow Control Lockout...
  • Page 199 April 2018 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Right Rear Steer Sensor Starter Rotary Sensor Sec Boom Up/Down Flow Control Start Aid (Glow Plug or choke) Tilt Alarm X axis Secondary Boom Tilt Alarm Y axis Sec Boom Down Ground Control Sec Boom Extend...

  • Page 200: Wire Color Legend

    Service and Repair Manual April 2018 Wire Color Legend Power Circuits Wire Coloring All cylinder extension colors are solid and all Primary boom down valve retract functions are striped black. When using Engine ignition / Fuel black wire, the stripe shall be white. Primary boom extend valve All rotations that are LEFT or CW are solid, Primary boom up valve...
  • Page 201 April 2018 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Primary boom up driver WH/RD Power to temp sender RD/BK Primary boom down driver Auxiliary Power RD/WH Primary boom up/down flow RD/BK Platform level alarm control proportional valve driver...
  • Page 202 Service and Repair Manual April 2018 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function GR/BK Axle oscillation Hydraulic Filter restricted Foot switch/TCON estop power Platform Level Safety Power RD/WH Boom down safety interlock RD/BK Platform Level Safety Output RD/BK Safety interlock to engine Platform Level Safety Ground...
  • Page 203 April 2018 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Flashing Beacon Primary Boom Angle Signal Safety Lift Speed Reduction Secondary Boom Angle Signal Hydraulic Pressure Sensor Safety Output BL/RD Drive Enable Left Oil Cooler Fan BL/WH Drive Enable Right...
  • Page 204 Service and Repair Manual April 2018 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Boom Length Signal Safety Safety cross check OR/BK Boom Length Signal Operational Data Receive BL/RD Primary Boom Hydraulic Valve BK/WH Data Transmit Lockout WH/RD Multi-Function Pressure Relief...

  • Page 205: Limit Switches And Angle Sensors

    April 2018 Service and Repair Manual Limit Switches and Angle Sensors Limit Switch Legend 1 RSP1AO 14 Plat Angle Sensor 2 RSP1AS 15 PCON 3 LSP1RO 16 SCON 4 LST2O 17 RSRA1SO 5 LST1O 18 LSRA1ES 6 LST1S 19 RSLR1SO 7 LSS1RS 20 RSRR1SO 8 LSS1RO...
  • Page 206 Service and Repair Manual April 2018 Limit Switches and Angle Sensors Types of Limit Switches Numbering Legend There are two types of limit switches, found in Limit Front Circuit Load Operational various locations throughout the machine: Switch Axle Number moment mechanical-type operational/safety switches and Stringpot Rear...
  • Page 207 April 2018 Service and Repair Manual Limit Switches and Angle Sensors Rotary Sensor Numbering LSFA1ES: Limit switch, Front Axle #1 Extended Safety. Prevents boom functions with the axles RSP1AO Primary boom angle sensor retracted. Switch closes when axles are fully extended.
  • Page 208 Service and Repair Manual April 2018 Limit Switches and Angle Sensors Rotary Sensor Functions RSRA1O: Rotary Sensor, Rear Axle #1 Operational. Provides front axle positioning RSP1AO: Rotary Sensor, Primary #1 Angle information for adjusting steering neutral setting Operational. Provides operational primary boom during axle extension.

  • Page 209: Circuit Connector Legend

    April 2018 Service and Repair Manual Circuit Connector Legend Number Description Number Description Ribbon connector from TCON to membrane 2 pin Deutsch connector for primary boom up valve Ribbon connector from TCON to membrane 2 pin Deutsch connector for primary boom down valve Black 23 pin AMP connector on TCON 2 pin Deutsch connector for primary boom...
  • Page 210 Service and Repair Manual April 2018 Circuit Connector Legend Number Description Number Description 2 pin Deutsch connector for two-speed motor J121 12 pin Deutsch gray SCON connector stroke valve J122 12 pin Deutsch black SCON connector 2 pin Deutsch connector for right rear steer J124 2 pin Deutsch connector for drive enable right valve...
  • Page 211 April 2018 Service and Repair Manual Circuit Connector Legend Number Description Number Description J148 1 way Deutsch connector for platform J223 CAN Gateway 8 pin Molex connector ground jib/primary J224 Telematics connector J149 2 pin Deutsch connector, boom composite J228 Gateway to TCON interface connector J150 4 pin Deutsch connector, boom composite...

  • Page 212: Drive Chassis And Platform Controller Pin Legend

    Service and Repair Manual April 2018 Drive Chassis and Platform Controller Pin Legend Pin Numbering - 23 pin connector Pin Numbering - 35 pin connector ZX®-135/70 Part No. 1279835GT...
  • Page 213 April 2018 Service and Repair Manual Drive Chassis and Platform Controller Pin Legend Plat Controller Plat Controller Drive Chassis Drive Chassis GNDPCON - BR VLVRET1 - BR VLVRET1 - BR GND-DCON - BR P52PCON - WH P21DCON - WH V61AXRT - GR V153JBE - BK (UNUSED) P53LS - WH/BK...

  • Page 214: Safety Controller Pin Legend

    Service and Repair Manual April 2018 Safety Controller Pin Legend J121 Safety Controller Pin Numbering for 12 pin connectors J122 Safety Controller S132LDS - BL/WH P21DCON - WH S73SLE - BL/RD C142SBS - OR (UNUSED) C141PBS - RD C145CAL - RD/WH C60AXE - GR/WH (UNUSED) S12SB - BL/WH...

  • Page 215: Turntable Controller Pin Legend

    April 2018 Service and Repair Manual Turntable Controller Pin Legend Pin Numbering - 35 pin connector Pin Numbering - 23 pin connector Pin Numbering - 4 pin connector Part No. 1279835GT ZX®-135/70...
  • Page 216 Service and Repair Manual April 2018 Turntable Controller Pin Legend Turntable Turntable Turntable Turntable Controller Controller Controller Controller VLVRET4 - BR GNDPCON - BR GNDSCON - BR (UNUSED) V03PUD - RD/WH P52PCON - WH P21DCON - WH C35RPM - BK/RD V09PER - BK/RD C46HN - WH V06TRF - WH/RD...

  • Page 217: Telematics Connector Pin Legend

    April 2018 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 218: Vec Module - Deutz Td2011L04I And Perkins 1104D-44T Models

    Service and Repair Manual April 2018 VEC Module - Deutz TD2011L04i and Perkins 1104D-44T Models Number Component Description CR15B Glow Plugs CR15A Glow Plugs CR28 Fuel Power SPARE Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler F22A...

  • Page 219: Vec Module - Deutz Td2.9 Models

    April 2018 Service and Repair Manual VEC Module - Deutz TD2.9 Models Number Component Description CR15B Glow Plugs CR15A Glow Plugs CR28 Fuel Power CR39 Deutz Aux. Shutdown Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler F22A...

  • Page 220: Vec Module - Perkins 854F Models

    Service and Repair Manual April 2018 VEC Module - Perkins 854F Models Number Component Description CR81B ECU Power CR81A ECU Power Starter SPARE Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler F27A Fuse 30A, ECU Power F27C...

  • Page 221: Electrical Symbols Legend

    April 2018 Service and Repair Manual Electrical Symbols Legend Battery Motor Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid Connection - no Circuits crossing no Quick disconnect Circuit breaker with...
  • Page 222 Service and Repair Manual April 2018 Electrical Symbols Legend ZX®-135/70 Part No. 1279835GT...

  • Page 223: Hydraulic Symbols Legend

    April 2018 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve or motor) 3 way...
  • Page 224 Service and Repair Manual April 2018 Perkins 1104D-44T Engine Electrical Schematic...

  • Page 225: Perkins 1104D-44T Engine Electrical Schematic- View 1

    April 2018 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic- View 1 Part No. 1279835GT ZX®-135/70...

  • Page 226: Perkins 1104D-44T Engine Electrical Schematic- View 2

    Service and Repair Manual April 2018 Perkins 1104D-44T Engine Electrical Schematic- View 2 ZX®-135/70 Part No. 1279835GT...
  • Page 227 April 2018 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic- View 2...
  • Page 228 Service and Repair Manual April 2018 Perkins 854F-34T Engine Electrical Schematic- View 1...

  • Page 229: Perkins 854F-34T Engine Electrical Schematic- View 1

    April 2018 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic- View 1 Part No. 1279835GT ZX®-135/70...
  • Page 230 Service and Repair Manual April 2018 Perkins 854F-34T Engine Electrical Schematic- View 2...

  • Page 231: Perkins 854F-34T Engine Electrical Schematic- View 2

    April 2018 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic- View 2 Part No. 1279835GT ZX®-135/70...

  • Page 232: Perkins 854F-34T Engine Harness

    Service and Repair Manual April 2018 Perkins 854F-34T Engine Harness ZX®-135/70 Part No. 1279835GT...
  • Page 233 April 2018 Service and Repair Manual Perkins 854F-34T Engine Harness...

  • Page 234: Deutz Td2.9 Engine Electrical Schematic- View 1

    Service and Repair Manual April 2018 Deutz TD2.9 Engine Electrical Schematic- View 1...
  • Page 235 April 2018 Service and Repair Manual Part No. 1279835GT ZX®-135/70...
  • Page 236 Service and Repair Manual April 2018 Deutz TD2.9 Engine Electrical Schematic- View 1 ZX®-135/70 Part No. 1279835GT...

  • Page 237: Deutz Td2.9 Engine Electrical Schematic- View 2

    April 2018 Service and Repair Manual Deutz TD2.9 Engine Electrical Schematic- View 2 Part No. 1279835GT ZX®-135/70...
  • Page 238 Service and Repair Manual April 2018 Deutz TD2.9 Engine Electrical Schematic- View 2...
  • Page 239 April 2018 Service and Repair Manual Deutz TD2.9 Engine Harness...

  • Page 240: Deutz Td2.9 Engine Harness

    Service and Repair Manual April 2018 Deutz TD2.9 Engine Harness ZX®-135/70 Part No. 1279835GT...

  • Page 241: Contact Alarm Schematic

    April 2018 Service and Repair Manual Contact Alarm Schematic Part No. 1279835GT ZX®-135/70...
  • Page 242 Service and Repair Manual April 2018 Contact Alarm Schematic...
  • Page 243 April 2018 Service and Repair Manual Generator Wiring Diagram- ANSI...

  • Page 244: Generator Wiring Diagram- Ansi

    Service and Repair Manual April 2018 Generator Wiring Diagram- ANSI ZX®-135/70 Part No. 1279835GT...

  • Page 245: Generator Wiring Diagram- Aus

    April 2018 Service and Repair Manual Generator Wiring Schematic Part No. 1279835GT ZX®-135/70...
  • Page 246 Service and Repair Manual April 2018 Generator Wiring Schematic...
  • Page 247 April 2018 Service and Repair Manual Hydraulic Schematic...

  • Page 248: Hydraulic Schematic

    Service and Repair Manual April 2018 Hydraulic Schematic ZX®-135/70 Part No. 1279835GT...

  • Page 249: Electrical Schematic

    MULTI FUNCTION VLV RECOVERY SIGNAL TIER IV ENG OUT PWR ENABLE OPT GBOX OPER. REC. OR (~SM)+(AH) TO MICRO BOOM RET RECOVERY SIGNAL Genie ZX-135/70 HARN SERV. OR Vbb BTS621 BOOM DWN RECOVERY SIGNAL PWR IN SERV OR OUT 1 P22R...

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