Page 1 Service Manual Serial Number Range ZX-135/70 From ZX13513-2001 to ZX13514-2532 (does not include ZX13514-2463, ZX13514-2469 and ZX13514-2531) Part No. 218700 Rev F September 2015...
Page 2: Introduction
Unrestricted with proper operation, inspection and First Edition, Printing scheduled maintenance. 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.. ZX-135/70 Part No. 218700...
Page 3: Table Of Contents
September 2015 Service Manual Introduction Revision History Revision Date Section Procedure / Page / Description 12/2012 Initial Release 9/2013 Schematics Electrical Schematic 9/2013 Maintenance B-18, D-1 Schematics Electrical Schematic 12/2013 Repair 4/2014 Specifications Perkins 1104D-44T Repair 4-8, 4-9 4/2014 Fault Codes Fault Codes Specifications Performance Specifications...
Page 4: Revision History
Service Manual September 2015 Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Repair 3-6, 4-8, 4-9, 6-1 Fault Codes Added Deutz TD2.9 L4, Perkins 854F-34T Schematics Updated Perkins 1104D-44T Added Perkins 854F-34T Added Deutz TD2.9 L4 Electrical schematic Reference Examples: Section –...
Page 5: Serial Number Legend
September 2015 Service Manual Introduction Serial Number Legend 1 Model 2 Model year 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) Part No. 218700 ZX-135/70...
Page 6: Safety Rules
Service Manual September 2015 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 7 September 2015 Service Manual 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 8 September 2015 Table of Contents Introduction Introduction ......................ii Important Information ....................ii Find a Manual for this Model ................... ii Revision History ..................... iii Serial Number Legend ................... v Section 1 Safety Rules ......................vi General Safety Rules ..................... vi Section 2 Specifications .......................
Page 9 September 2015 Table of Contents Section 3 Scheduled Maintenance Procedures ............... 15 Introduction ......................15 Pre-Delivery Preparation Report ................19 Maintenance Inspection Report................21 Checklist A Procedures ..................23 A-1 Inspect the Manuals and Decals..............23 A-2 Perform Pre-operation Inspection ..............24 A-3 Perform Function Tests .................
Page 10 September 2015 Table of Contents Checklist B Procedures ..................29 B-1 Inspect the Batteries ..................29 B-2 Inspect the Electrical Wiring ................30 B-3 Test the Key Switches ................... 32 B-4 Inspect the Engine Air Filter ................34 B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ........ 35 B-6 Check the Exhaust System ................
Page 11 September 2015 Table of Contents Checklist C Procedures ..................58 C-1 Perform Engine Maintenance - Deutz Models..........58 C-2 Perform Engine Maintenance - Deutz Models..........58 C-3 Perform Engine Maintenance - Perkins Models ..........59 C-4 Replace the Engine Air Filter Element ............59 C-5 Grease the Platform Overload Mechanism (if equipped) ......
Page 12 September 2015 Table of Contents Section 4 Repair Procedures ..................... 83 Introduction ......................83 Platform Controls ....................85 Platform Controls ....................85 1-1 Platform Circuit Board ..................85 How to Remove the LED Circuit Board ............87 1-2 Joysticks - How to Calibrate a Joystick ............87 How to Reset a Proportional Valve Coil Default ..........
Page 13 September 2015 Table of Contents Boom Components ..................117 4-1 Primary Boom Cable Track ................118 How to Repair the Primary Boom Cable Track ..........120 4-2 Secondary Boom Cable Track ..............120 How to Repair the Secondary Boom Cable Track ........122 4-3 Primary Boom....................
Page 14 September 2015 Table of Contents Manifolds ......................164 8-1 Function Manifold Components ..............164 8-2 Valve Adjustments - Function Manifold ............168 8-3 Platform Manifold ..................170 8-4 Jib Boom Manifold ..................172 8-5 Flow Control Mainfold .................. 174 8-6 Function Enable Valve ................. 175 8-7 Turntable Rotation Manifold .................
Page 15 September 2015 Table of Contents Section 5 Fault Codes ....................... 203 Introduction ......................203 Control System Fault Codes ................204 Fault Matrix ......................221 Deutz TD 2.9 L4 Engine Fault Codes .............. 222 Perkins 854F-34T Engine Fault Code ............. 237 Section 6 Schematics ......................
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Page 17: Specifications
September 2015 Service Manual Specifications Section 2 Specific ati ons Machine Specifications Performance Specifications Tires and wheels Drive speed, maximum Tire size 445D50/710, 18PR Stowed position, high speed 3.0 mph 4.8 km/h Tire ply rating 40 ft / 9.1 sec Tire weight, new foam-filled 800 lbs 12.2 m / 9.1 sec...
Page 18: Hydraulic Specification
Service Manual September 2015 Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. 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 19: Specifications
September 2015 Service Manual Specifications Chevron Rando HD Premium Oil Continued use of Chevron 5606A hydraulic fluid, or MV Fluid Properties equivalent, when ambient temperatures are consistently ISO Grade above 32°F / 0°C may result in Viscosity index component damage Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C...
Page 20: Hydraulic Component Specifications
Service Manual September 2015 Specifications Hydraulic Component Auxiliary Pump Specifications Type: fixed displacement gear pump Displacement per revolution 0.15 cu in Drive Pump 2.47 cc Type: bi-directional variable displacement piston pump Function manifold Displacement per revolution 2.8 cu in System relief valve pressure, maximum 3100 psi 46 cc (measured at test port)
Page 21 September 2015 Service Manual Specifications Brakes Manifold Component Specifications Brake relief pressure 190 psi Plug torque 13 bar SAE No. 2 36 in-lbs / 4 Nm Drive Motors SAE No. 4 10 ft-lbs / 13 Nm Displacement per revolution, high 0.8 cu in SAE No.
Page 22: Deutz Td2011L04I Engine Specifications
Service Manual September 2015 Specifications Deutz TD2011L04i Engine Oil temperature switch Installation torque 8 - 18 ft-lbs 220.9 cu. in Displacement 11 - 24 Nm 3.62 liters Temperature switch point 275°F Number of cylinders 135°C 3.78 x 4.92 inches Bore and Stroke Oil Pressure switch 96 x 125 mm Installation torque...
Page 23: Deutz Td 2.9 Engine Specifications
September 2015 Service 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 24: Perkins 1104D-44T
Service Manual September 2015 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 Oil viscosity requirements...
Page 25 September 2015 Service 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: Perkins 854F-34T Engine Specifications
Service Manual September 2015 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 10 ohms...
Page 27: Machine Torque Specifications
September 2015 Service Manual Specifications Machine Torque Specifications Perkins 854F-34T cont. Engine coolant Ethylene Glycol Platform Rotator Capacity 16.5 quarts 1-8 center bolt, GR 5 480 ft-lbs (50/50 extended life) 15.6 liters 651 Nm Coolant temperature switch 3/8 -16 bolts, GR 8 44 ft-lbs Installation torque 18.4 ft-lbs...
Page 28: Hydraulic Hose And Fitting Torque Specifications
Service Manual September 2015 Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (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 be torqued to specification when they are removed...
Page 29: Torque Procedure
September 2015 Service Manual Specifications Torque Procedure Seal-Lok™ fittings Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. Illustration 1 Note: The O-ring in Parker Seal Lok™...
Page 30: Sae And Metric Fasteners Torque Charts
Service Manual September 2015 Specifications ZX-135/70 Part No. 218700...
Page 31: Scheduled Maintenance Procedures
September 2015 Service Manual Scheduled Maintenance Procedures Section 3 Machine Configuration: Schedul ed Mai ntenance Pr ocedures  Unless otherwise specified, perform each procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed ...
Page 32 Service Manual September 2015 Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards.
Page 33 September 2015 Service Manual Scheduled Maintenance Procedures Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in this The pre-delivery preparation report contains manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
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Page 35: Pre-Delivery Preparation Report
September 2015 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.
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Page 37: Maintenance Inspection Report
September 2015 Service Manual Maintenance Inspection Report Model Y N R Y N R Checklist A Checklist B Inspect the manuals Batteries Serial number and decals Electrical wiring Pre-operation Key switches Date inspection Inspect air filter Function tests Hour meter Oil cooler and fins - Engine maintenance Deutz models...
Page 38 Service Manual September 2015 Maintenance Inspection Report Model Y N R Y N R Checklist C Checklist E Engine maintenance - Hydraulic oil Deutz models Serial number Engine maintenance - Engine maintenance - Perkins models Deutz models Date Engine maintenance - Engine maintenance - Deutz models Perkins models...
Page 39: Checklist A Procedures
September 2015 Service Manual Checklist A Procedures Open the operator's manual to the decals inspection section. 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 comes Result: The machine is equipped with all first.
Page 40: Perform Pre-Operation Inspection
Service Manual September 2015 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 comes performed every 8 hours or daily, whichever comes first.
Page 41: Perform Engine Maintenance - Perkins Models
September 2015 Service Manual Checklist A Procedures Perform Engine Maintenance – Perform Engine Maintenance – Perkins Models Deutz Models Engine specifications require that this procedure be Engine specifications require that this procedure be performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes first.
Page 42: Check The Hydraulic Return Filter Condition Indicator
Service Manual September 2015 Checklist A Procedures Open the ground control side turntable cover and inspect the filter condition indicator gauge 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.
Page 43: Perform 30-Day Service
September 2015 Service Manual Checklist A Procedures 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 one time procedure to be performed after the first 30 days or Perform this procedure more often if dusty 40 hours of usage.
Page 44: Replace The Drive Hub Oil
Service Manual September 2015 Checklist A Procedures Replace the Drive Hub Oil Drive hub specifications require that this one-time procedure be performed after the first 100 hours of usage. After this interval, refer to the maintenance checklist for continued scheduled maintenance. Failure to replace the drive hub oil may cause the machine to perform poorly and continued use may result in component damage.
Page 45: Checklist B Procedures
September 2015 Service Manual Checklist B Procedures Remove the cover from the auxiliary power unit batteries located at the ground controls Inspect the Batteries side of the machine. Note: Perform the remaining steps on the auxiliary power unit batteries and the engine starting battery. Genie specifications require that this procedure be Be sure that the battery cable connections are performed every 250 hours or quarterly, whichever...
Page 46: Inspect The Electrical Wiring
Service Manual September 2015 Checklist B Procedures Perform an equalizing charge OR fully charge the battery(s) and allow the battery(s) to rest at Inspect the Electrical Wiring least 6 hours. Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer.
Page 47 September 2015 Service Manual Checklist B Procedures Install the bolt that was just removed into the 11 Start the engine from the ground controls and anchor hole to secure the engine pivot plate raise the secondary boom above the turntable from moving.
Page 48: Test The Key Switches
Service Manual September 2015 Checklist B Procedures When the Bypass/Recovery key switch is turned and held to the recovery position, the auxiliary Test the Main Key Switch power units will turn on and fully retract the secondary boom, then the primary boom and then Genie specifications require that this procedure be lower the primary boom.
Page 49 September 2015 Service Manual Checklist B Procedures 11 Raise the primary boom 3 ft / 1 m. Note: Perform this procedure with the machine on a firm, level surface with the booms in the fully Result: The primary boom should raise. stowed position and the axles fully extended.
Page 50: Inspect The Engine Air Filter
Service Manual September 2015 Checklist B Procedures Release the latches on the air cleaner cap. Remove the end cap from the air cleaner Inspect the Engine Air Filter canister. Remove the filter element. Use a damp cloth to wipe the filter sealing Genie specifications require that this procedure be surface and the inside of the outlet tube.
Page 51: Check The Oil Cooler And Cooling Fins - Deutz Models
September 2015 Service Manual Checklist B Procedures Cooling and blower fins: Check the Oil Cooler and Cooling Inspect the fan blower fins for physical Fins - Deutz Models damage. Clean the fan blower fins of debris and foreign material. Using a flashlight, inspect the head cooling Genie requires that this procedure be performed passages and fins for physical damage or every 250 hours or quarterly, whichever comes...
Page 52: Check The Exhaust System
Service Manual September 2015 Checklist B Procedures Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate. Check the Exhaust System Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving.
Page 53: Confirm The Proper Brake Configuration
September 2015 Service Manual Checklist B Procedures Be sure the free-wheel valve on the drive pump is closed (clockwise). Confirm the Proper Brake Note: The free-wheel valve should always remain Configuration closed. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first.
Page 54: Inspect The Tires, Wheels And Lug Nut Torque
Service Manual September 2015 Checklist B Procedures Inspect the Tires, Wheels and Check the Drive Hub Oil Level Lug Nut Torque and Fastener Torque Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.
Page 55: Test The Platform Self-Leveling
September 2015 Service Manual Checklist B Procedures Turntable rotate drive hubs: B-10 Test the Platform Self-leveling Open the cover at the ground controls side of the machine. Remove the plug located on the top 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...
Page 56: Test The Engine Idle Select Operation
Service Manual September 2015 Checklist B Procedures Press and hold a function enable/speed select B-11 button and fully lower the primary boom. Test the Engine Idle Select Result: The platform should remain level at all Operation times to within ±2 degrees. Genie specifications require that this procedure be Note: If the platform becomes out of level, the tilt performed every 250 hours or quarterly, whichever...
Page 57: Test The Ground Control Override
September 2015 Service Manual Checklist B Procedures Push and release the rpm select button until B-12 low rpm is selected (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.
Page 58: Test The Drive Brakes
Service Manual September 2015 Checklist B Procedures B-13 B-14 Test the Drive Brakes Test the Drive Speed – Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first.
Page 59: Test The Drive Speed - Raised Or Extended
September 2015 Service Manual Checklist B Procedures Lower the boom to the stowed position. B-15 Test the Drive Speed – Raised or Extend the primary boom 12 inches / 0.3 m. Extended Position 10 Choose a point on the machine (i.e., contact patch of a tire) as a visual reference for use when crossing the start and finish lines.
Page 60: Test The Drive Speed - Raised And Extended
Service Manual September 2015 Checklist B Procedures B-16 B-17 Test the Drive Speed – Raised Test the Alarm and Flashing and Extended Position Beacon Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever An alarm and/or flashing beacon are installed to...
Page 61: Perform Hydraulic Oil Analysis
September 2015 Service Manual Checklist B Procedures B-18 B-19 Perform Hydraulic Oil Analysis Test the Turntable Level Sensor Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever A properly functioning level sensor (SCON) is comes first.
Page 62 Service Manual September 2015 Checklist B Procedures Note: Perform this procedure with the booms in the Turn the key switch to ground control and pull fully stowed position and the axles fully extended. out the red Emergency Stop button to the on position at both ground and platform controls.
Page 63: Test The Secondary Boom Angle Sensor
September 2015 Service Manual Checklist B Procedures Place a digital level that has been calibrated to B-20 gravity on the Y axis of the turntable. Test the Secondary Boom Angle Result: The reading at the display and digital Sensor level is within ± 1° of each other. Genie specifications require that this procedure be Result: The reading at the display and digital performed every 250 hours or quarterly, whichever...
Page 64 Service Manual September 2015 Checklist B Procedures Start the engine from the ground controls. Lower the secondary boom to 65°. Press the plus and minus buttons at the Result: The reading at the display and digital same time on the LCD screen to enter the level is within ±...
Page 65: Test The Primary Boom Angle Sensor
September 2015 Service Manual Checklist B Procedures 11 Fully lower the secondary boom until it stops B-21 at approximately -3.5°. Test the Primary Boom Angle Result: The reading at the display and digital Sensor level is within ± 2° of each other and of -3.5°. Genie specifications require that this procedure be Result: The reading at the display and digital performed every 250 hours or quarterly, whichever...
Page 66 Service Manual September 2015 Checklist B Procedures Start the engine from the ground controls. Fully raise the secondary boom. The boom is fully raised when the cylinder is fully extended Press the enter or previous button on the and the boom stops moving. LCD screen until PRIMARY BOOM ANGLE TO GRAVITY DEGREES is displayed.
Page 67: Test The Safety Envelope Limit Switches
September 2015 Service Manual Checklist B Procedures B-22 Raise the primary boom to -20°. Test the Safety Envelope Limit Result: The reading at the display and digital level is within ± 2° of each other and of -20°. Switches Result: The reading at the display and digital Genie specifications require that this procedure be level is greater than ±...
Page 68 Service Manual September 2015 Checklist B Procedures Remove the lower cover retaining fasteners 10 Remove the multimeter leads and connect the and remove the lower cover from turntable. Deutsch connector to the limit switch. 11 Start the engine from the ground controls. Crushing hazard.
Page 69 September 2015 Service Manual Checklist B Procedures 14 Re-connect the Deutsch connector to Turntable Rotate Safety Limit Switch, LST1S LSS1RS. Locate the turntable rotate safety limit switch Result: The LCD screen displays SEC (LST1S) at the center of the turntable. LSS1RS FAULT.
Page 70 Service Manual September 2015 Checklist B Procedures Axle Extended Safety Limit Switches, LSFA1ES 10 Choose an axle extend safety limit switch to and LSRA1ES test. 11 Locate and disconnect the Deutsch connector Start the engine from the ground controls and to the axle extend limit switch.
Page 71: Test The Recovery Mode System
September 2015 Service Manual Checklist B Procedures Turn the key switch to the ground control and B-23 pull out the red Emergency Stop button to the Test the Recovery System on position. Start the engine. Genie specifications require that this procedure be Fully raise the secondary boom then extend it performed every 250 hours or quarterly, whichever approximately 4 ft / 1.2 m.
Page 72: Inspect The Calibration Decal
Service Manual September 2015 Checklist B Procedures Note: Contact your authorized Genie distributor or B-24 Genie if a replacement is required. Inspect the Calibration Decal Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the safety decal in good condition is mandatory for safe machine operation.
Page 73: Inspect For Turntable Bearing Wear
September 2015 Service Manual Checklist B Procedures B-25 Inspect for Turntable Bearing Wear Genie requires that this one-time procedure be performed after the first 3 months of usage. After this interval, refer to the maintenance checklist for continued scheduled maintenance. Grease the turntable bearing.
Page 74: Checklist C Procedures
Service Manual September 2015 Checklist C Procedures Perform Engine Maintenance – Perform Engine Maintenance – Deutz Models Deutz Models Engine specifications require that this one–time Engine specifications require that this procedure be procedure be performed at 500 hours. performed every 500 hours. •...
Page 75: Perform Engine Maintenance - Perkins Models
September 2015 Service Manual Checklist C Procedures Perform Engine Maintenance – Replace the Engine Air Filter Perkins Models Element Engine specifications require that this procedure be Genie specifications require that this procedure be performed every 500 hours or annually. performed every 500 hours or six months, whichever comes first.
Page 76: Grease The Platform Overload Mechanism (If Equipped)
Service Manual September 2015 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. Application of lubrication to the platform overload mechanism is essential to safe machine operation.
Page 77: Test The Platform Overload System (If Equipped)
September 2015 Service Manual Checklist C Procedures As weight is added to the platform, the spring will compress until, when the platform is overloaded, Test the Platform Overload the lower arm contacts a limit switch and thereby System (if equipped) activating the overload signal.
Page 78 Service Manual September 2015 Checklist C Procedures Using a suitable lifting device, place a test Add an additional 15 lbs / 6.8 kg test weight to weight equal to that of the available capacity in the original test weight to overload the one of the locations shown.
Page 79: Check And Adjust The Engine Rpm
September 2015 Service Manual Checklist C Procedures Test all machine functions from the platform controls. Check and Adjust the Engine Result: All platform control functions should operate using the auxiliary pump except for boom lift and extend which are disabled. Turn the key switch to ground controls.
Page 80 Service Manual September 2015 Checklist C Procedures Skip to step 5 if the low idle rpm is correct. Perkins models: Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine. 1 engine pivot plate anchor hole 2 engine pivot plate retaining fastener Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate.
Page 81 September 2015 Service Manual Checklist C Procedures Press the enter or previous button on the Press and hold the function enable/high speed LCD screen until engine rpm is displayed. button. Note the engine rpm on the display. Result: Low idle should be 1300 rpm. Result: High idle should be 2350 rpm.
Page 82: Inspect For Turntable Bearing Wear
Service Manual September 2015 Checklist C Procedures Note: To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from Inspect for Turntable Bearing the turntable rotation bearing. Wear Genie requires that this procedure be performed every 500 hours or six months, whichever comes first.
Page 83 September 2015 Service Manual Checklist C Procedures Move the boom sections to the positions indicated in step 3. Visually inspect the dial indicator to be sure the needle returns to the “zero” position. Remove the dial indicator and rotate the turntable 90°.
Page 84: Checklist D Procedures
Service Manual September 2015 Checklist D Procedures Primary boom wear pad specifications Minimum 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)
Page 85: Check The Free-Wheel Configuration
September 2015 Service Manual Checklist D Procedures Manually rotate each wheel at the square-end of the machine. Check the Free-wheel Result: Each wheel at the square-end of the Configuration machine should rotate with minimum effort. Re-engage the drive hubs by turning over the drive hub disconnect caps.
Page 86: Replace The Drive Hub Oil
Service Manual September 2015 Checklist D Procedures 11 Manually rotate each wheel at the circle-end of the machine. Replace the Drive Hub Oil Result: Each wheel at the circle-end of the machine should rotate with minimum effort. 12 Re-engage the drive hubs by turning over the Genie specifications require that this procedure be drive hub disconnect caps.
Page 87 September 2015 Service Manual Checklist D Procedures Turntable Rotate Drive Hub: Secure the turntable from rotating with the turntable rotation lock pin. Tag, disconnect and plug the hydraulic hoses to the drive hub drive motor and brake for each drive hub assembly. Bodily injury hazard.
Page 88: Adjust The Turntable Rotatation Gear Backlash
Service Manual September 2015 Checklist D Procedures Turn the adjustment bolt clockwise until it contacts the backlash pivot plate. Adjust the Turntable Rotation Gear Backlash Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Properly adjusted turntable rotation gear backlash is essential for good machine performance and service life.
Page 89: Replace The Hydraulic Filter Elements
September 2015 Service Manual Checklist D Procedures Hi pressure filter and drive motor case drain filter: Replace the Hydraulic Filter Elements Note: The high pressure filter is for all machine functions except the drive functions. The drive motor case drain filter is used to filter oil returning to the hydraulic tank from the drive motors.
Page 90: Perform Engine Maintenance - Deutz Models
Service Manual September 2015 Checklist D Procedures 15 Install the new high pressure filter element into the housing. Install the filter housing onto the Perform Engine Maintenance – filter head and tighten it securely. Deutz Models 16 Clean up any oil that may have spilled during the installation procedure.
Page 91: Perform Engine Maintenance - Perkins Models
September 2015 Service Manual Checklist D Procedures Perform Engine Maintenance – Check the Turntable Rotation Perkins Models Bearing Bolts Engine specifications require that this procedure be Genie specifications require that this procedure be performed every 1000 hours. performed every 1000 hours or annually, whichever comes first.
Page 92 Service Manual September 2015 Checklist D Procedures Confirm that each turntable mounting bolt is Remove the engine pivot plate retaining torqued in sequence to specification. Refer to fastener from the engine pivot plate anchor Specifications, Machine Torque hole at the pivot end of the engine pivot plate. Specifications.
Page 93: Machine Specifications
September 2015 Service Manual Checklist E Procedures Close the two hydraulic tank shut-off valves at the hydraulic tank. Test or Replace the Hydraulic Oil Component damage hazard. 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.
Page 94 Service Manual September 2015 Checklist E Procedures Remove the cover from the auxiliary power 15 Support the hydraulic tank with 2 lifting straps. unit batteries. Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate 10 Tag and disconnect the cables from the lifting device.
Page 95: Perform Engine Maintenance - Perkins Models
September 2015 Service Manual Checklist E Procedures Perform Engine Maintenance – Perform Engine Maintenance – Perkins Models Deutz Models Engine specifications require that this procedure be Engine specifications require that this procedure be performed every 2000 hours. performed every two years. •...
Page 96: Perform Engine Maintenance - Perkins Models
Service Manual September 2015 Checklist E Procedures Perform Engine Maintenance – Perform Engine Maintenance – Perkins Models Perkins Models Engine specifications require that this procedure be Engine specifications require that this procedure be performed every 3000 hours. performed every 3000 hours. •...
Page 97: Perform Engine Maintenance - Deutz Models
September 2015 Service Manual Checklist E Procedures Perform Engine Maintenance – Perform Engine Maintenance – Deutz Models Perkins Models Engine specifications require that this procedure be Engine specifications require that this procedure be performed every 3000 hours. performed every 4000 hours. TD 2011L04i Models: All Models: •...
Page 98: Perform Engine Maintenance - Deutz Models
Service Manual September 2015 Checklist E Procedures Perform Engine Maintenance – Deutz Models Engine specifications require that this procedure be performed every 6,000 hours. TD 2011L04i Models: • Toothed belt - replace Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual OR the Deutz D 2.9 L4 Series Operation Manual.
Page 99: Repair Procedures
September 2015 Service Manual Repair Procedures Section 4 Machine Configuration: Repair Pr oc edures  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed ...
Page 100 Service Manual September 2015 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 101: Platform Controls
September 2015 Service Manual Platform Controls Platform Controls The platform controls contains two printed circuit boards: The LED circuit board is mounted to the underside of the control box lid which contains the LEDs. The LED circuit board sends the input from the operator to the platform controls circuit board (PCON).
Page 102 Service Manual September 2015 Platform Controls Attach a grounded wrist strap to the ground screw inside the control box. Platform Circuit Board Electrocution/burn hazard. Electrocution/burn hazard. Contact with electrically charged Contact with electrically charged circuits could result in death or circuits could result in death or serious injury.
Page 103: How To Remove The Led Circuit Board
September 2015 Service Manual 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 104 Service Manual September 2015 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 105 September 2015 Service Manual 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 106 Service Manual September 2015 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 platform controls.
Page 107: How To Reset A Proportional Valve Coil Default
September 2015 Service Manual 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 108: How To Set The Function Thresholds And Default Functions Speeds
Service Manual September 2015 Platform Controls How to Set the F unction 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 very slowly towards the neutral or center...
Page 109 September 2015 Service Manual 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 110: How To Adjust The Function Speeds
Service Manual September 2015 Platform Controls How to Adj ust the Functi on Speeds How to Adj ust the Functi on R amp R ate Setti ng How to Adjust the Function How to Adjust the Function Ramp Speeds Rate Setting Note: Perform this procedure with the boom in the The ramp rate setting of a joystick controls the time stowed position.
Page 111: Platform Components
September 2015 Service 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 112: Platform Leveling Cylinder
Service Manual September 2015 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 113: Platform Rotator
September 2015 Service 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 114: How To Bleed The Platform Rotator
Service Manual September 2015 Platform Components Remove the weld cable from the platform (if How to Bleed the Pl atform R otator How to Bleed the Platform equipped). Rotator Electrocution/burn hazard. Note: Do not start the engine. Use auxiliary power Contact with electrically charged for all machine functions in this procedure.
Page 115: Platform Level Sensor - How To Calibrate The Platform Level Sensor
September 2015 Service 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 116: Platform Overload System (If Equipped)
Service Manual September 2015 Platform Components Determine the limit switch trigger point: Platform Overload System (if Gently move the platform up and down by equipped) hand, so it bounces approximately 1 to 2 inches / 2.5 to 5 cm. Allow the platform to settle.
Page 117: Platform Overload Recovery Message
September 2015 Service Manual Platform Components Confirm the setting: Platform Overload Recovery Start the engine from the platform controls. Message (software V3.07 and Lift the test weight off the platform floor using a later) suitable lifting device. Place the test weight back onto the center of If the ground controls LCD screen displays the platform floor using a suitable lifting OVERLOAD RECOVERY, the emergency lowering...
Page 118 Service Manual September 2015 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 119: Jib Boom Components
September 2015 Service 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 12 jib boom leveling cylinder...
Page 120: Jib Boom Cable Track
Service Manual September 2015 Jib Boom Components Pull the hoses out of the plastic hose guide located on the primary extension boom near Jib Boom Cable Track the jib boom manifold. Tag, disconnect and plug the jib boom lift The jib boom cable track guides the cables and cylinder hydraulic hoses.
Page 121: How To Repair The Cable Track
September 2015 Service Manual Jib Boom Components 15 Pull the two hydraulic hoses just removed and How to R epair the C abl e Tr ack How to Repair the Cable Track all of the cables through the hose and cable guide at the platform support.
Page 122: Jib Boom
Service Manual September 2015 Jib Boom Components Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses from the jib boom Jib Boom manifold. Cap the fittings on the manifold. Bodily injury hazard. Spraying How to Remove the Jib Boom hydraulic oil can penetrate and burn skin.
Page 123 September 2015 Service Manual Jib Boom Components 11 Disconnect the electrical connector from the 19 Secure the jib boom lift cylinder to the jib boom jib boom angle sensor located at the jib boom with a strap or other suitable device. pivot pin on the engine side of the machine.
Page 124: Jib Boom Lift Cylinder
Service Manual September 2015 Jib Boom Components Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Use a Jib Boom Lift Cylinder soft metal drift to remove the pin and let the cylinder hang down. How to Remove the Jib Boom Lift Attach a lifting strap from an overhead crane Cylinder...
Page 125: Jib Boom Level Cylinder
September 2015 Service Manual Jib Boom Components Remove the external snap rings from the jib boom level cylinder barrel-end pivot pin. Use a Jib Boom Level 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 Level Cylinder...
Page 126: Jib Boom Extension Cylinder
Service Manual September 2015 Jib Boom Components Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to Jib Boom Extension Cylinder the platform manifold. Cap the fittings on the manifold. How to Remove the Jib Boom Bodily injury hazard.
Page 127: Angle Sensor
September 2015 Service Manual Jib Boom Components 13 Remove the pin retaining fastener from the jib boom pivot pin. Do not remove the pin. Jib Boom Bellcrank Angle Sensor 14 Use a soft metal drift to tap the pin halfway out in one direction and lower one side of the jib The jib boom bellcrank angle sensor is monitored boom bellcrank.
Page 128 Service Manual September 2015 Jib Boom Components Note: Use the following chart to identify the Locate the calibration toggle switch at the top description of each LCD screen control button used of the ground control box. Activate calibration in this procedure. mode by moving the toggle switch in the left direction.
Page 129 September 2015 Service Manual Jib Boom Components 13 Press and hold a function enable/speed select 16 Press and hold a function enable/speed select button and the platform level up button. Fully button and the platform level down button until extend the jib boom level cylinder. the digital level displays approximately 34 ±...
Page 130 Service Manual September 2015 Jib Boom Components 21 Press and hold a function enable/speed select 24 At the ground controls, press the plus button button and the platform level down button until or minus button to adjust the display to the the digital level displays approximately 18 ±...
Page 131 September 2015 Service Manual Jib Boom Components 2 Point Calibration procedure 27 Press and hold the engine start button for approximately 5 seconds to shut off the Note: Use this procedure for software versions engine and to save the calibration settings. 4.01 and higher.
Page 132 Service Manual September 2015 Jib Boom Components 41 Enter sensor calibration mode by pressing the 50 Press and hold the engine start button for buttons at the ground controls in the following approximately 5 seconds to shut off the engine and to save the calibration settings. sequence: (plus)(enter)(enter)(plus).
Page 133: Boom Components
September 2015 Service Manual 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 134: Primary Boom Cable Track
Service Manual September 2015 Boom Components Tag and disconnect the electrical connectors from the jib boom manifold located at the Primary Boom Cable Track platform end of the primary extension boom. Tag, disconnect and plug the two hydraulic The primary boom cable track guides the cables hoses from the jib boom manifold that lead to and hoses running up the boom.
Page 135 September 2015 Service Manual Boom Components 12 Remove the hose and cable clamps from the 19 Attach a lifting strap to each end of the cable primary boom lift cylinder. track from an overhead crane for support. Do not apply any lifting pressure. 13 At the counterweight end of the secondary boom, support and secure the secondary 20 Remove the mounting fasteners that attach...
Page 136: How To Repair The Primary Boom Cable Track
Service Manual September 2015 Boom Components How to R epair the Primary Boom C abl e Tr ack How to Repair the Primary Boom Cable Track Secondary Boom Cable Track Component damage hazard. The secondary boom cable track guides the cables The boom cable track can be and hoses running up through the inside of the damaged if it is twisted.
Page 137 September 2015 Service 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 138: How To Repair The Secondary Boom Cable Track
Service Manual September 2015 Boom Components How to R epair the Sec ondary Boom C able Tr ack How to Repair the Secondary 17 Working at the counterweight end of the secondary boom, attach a lifting strap from an Boom Cable Track overhead crane to the secondary boom cable track.
Page 139: Primary Boom
September 2015 Service 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 140 Service Manual September 2015 Boom Components 11 Place blocks under both ends of the primary Remove the primary boom cable track. Refer boom lift cylinder for support. to repair procedure, How to Remove the Cable Track. 12 Attach a lifting strap from an overhead crane to the rod end of the primary boom lift cylinder.
Page 141: Primary Boom Lift Cylinder
September 2015 Service Manual Boom Components Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on Primary Boom Lift Cylinder the cylinder. The primary boom lift cylinder raises and lowers Bodily injury hazard. Spraying the primary boom. The primary boom lift cylinder is hydraulic oil can penetrate and equipped with a counterbalance valve to prevent burn skin.
Page 142: Secondary Boom Lift Cylinder
Service Manual September 2015 Boom Components Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out Secondary Boom Lift Cylinder away from the machine. How to Remove the Secondary Boom Lift Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop.
Page 143 September 2015 Service Manual Boom Components Close the two hydraulic tank shut-off valves at 15 Remove the hydraulic tank retaining fasteners. the hydraulic tank. 16 Remove the cover from the auxiliary power unit batteries. Component damage hazard. The engine must not be started 17 Tag and disconnect the cables from the with the hydraulic tank shut-off auxiliary power unit batteries.
Page 144 Service Manual September 2015 Boom Components 22 Remove the hydraulic tank from the machine. 29 Use a slide hammer to remove the barrel-end pivot pin. Crushing hazard. The hydraulic tank could become unbalanced Component damage hazard. and fall if not properly supported Hoses and cables can become when removed from the damaged if the barrel end of the...
Page 145: Primary Boom Extension Cylinder
September 2015 Service Manual 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 146: Secondary Boom Extension Cylinders
Service Manual September 2015 Boom Components Remove the cover retaining fasteners and remove the cover from the secondary boom. Secondary Boom Extension Crushing hazard. The secondary Cylinders boom end cover could become unbalanced and fall when The secondary boom extension cylinders extend removed from the secondary and retract the secondary boom.
Page 147: Sensor
September 2015 Service Manual Boom Components Support and slide the upper extension cylinder out of the secondary boom and place it on a Primary Boom Angle Sensor structure capable of supporting it. Crushing hazard. The extension The primary boom angle sensor is used to limit the cylinder could fall when removed angle of the primary boom relative to the angle of from the secondary boom if not...
Page 148 Service Manual September 2015 Boom Components How to Calibrate the Primary 6 Point Calibration procedure Boom Angle Sensor Note: Use this procedure for software versions before 4.01. Note: If the axle sensor or secondary boom angle sensor have been removed or replaced, or the Note: For the 2 Point Calibration procedure, turntable level sensor has been replaced, they proceed to step 33.
Page 149 September 2015 Service Manual Boom Components Press and hold the enter button on the ground 15 Press and hold a function enable/speed select control panel while pulling out the ground button and the primary boom down button and controls red Emergency Stop button to the on lower the primary boom down until the digital level displays -50 degrees.
Page 150 Service Manual September 2015 Boom Components 20 At the ground controls, press the plus button 25 Press and hold the engine start button for approximately 5 seconds to shut off the or minus button to adjust the display to the engine and to save the calibration settings.
Page 151 September 2015 Service Manual Boom Components 2 Point Calibration procedure 43 Press the plus button to select YES, then press the enter button to accept. Note: Use this procedure for software versions 4.01 and higher. 44 Lower the primary boom to the stowed position.
Page 152: Secondary Boom Angle Sensor - How To Calibrate The Secondary Boom Angle Sensor
Service Manual September 2015 Boom Components 54 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 153: (I) 6 Point Calibration Procedure
September 2015 Service Manual Boom Components 6 Point Calibration procedure 10 Press the plus button to select YES, then press the enter button to accept. Note: Use this procedure for software versions 11 Place a digital level that has been calibrated to before 4.01.
Page 154 Service Manual September 2015 Boom Components 15 At the ground controls, press the plus button 21 At the ground controls, press the plus button or minus button to adjust the display to the or minus button to adjust the display to the exact value shown on the digital level and exact value shown on the digital level and press the enter button.
Page 155 September 2015 Service Manual Boom Components 25 Press the enter or previous button on the 35 Locate the calibration toggle switch at the top LCD screen until EXIT is displayed. of the ground control box. Activate calibration mode by moving the toggle switch in the left 26 Press the plus button to select YES, then direction.
Page 156 Service Manual September 2015 Boom Components 44 Press the enter or previous button on the SECONDARY BOOM SCREEN UNTIL FULLY RAISED is displayed. 45 Press the plus button to select YES, then press the enter button to accept. 46 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings.
Page 157: Engines
September 2015 Service Manual 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 158: How To Install The Flex Plate
Service Manual September 2015 Engines How to Ins tall the Fl ex Plate Perkins engines: Torque the pump plate How to Install a Flex Plate mounting bolts in sequence to 23 ft-lbs / 31 Nm. Then torque the pump plate mounting Install the flex plate onto the engine flywheel bolts in sequence to 47 ft-lbs / 63 Nm.
Page 159: Ground Controls
September 2015 Service Manual 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 160 Service Manual September 2015 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 161: Recovery Mode)
September 2015 Service Manual 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 switch.
Page 162: Circuit Boards
Service Manual September 2015 Ground Controls How to Remove the LCD Display Screen Circuit Board Circuit Boards 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 163 September 2015 Service Manual Ground Controls Tag and carefully disconnect the wire How to Remove the ALC-1000 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. been replaced, the entire machine must be Carefully disconnect the two ribbon cables calibrated in a specific order.
Page 164: Membrane Decal
Service Manual September 2015 Ground Controls Carefully remove the membrane decal from the control box lid while guiding the ribbon Membrane Decal cables out of the control box lid. Remove any decal adhesive from the control The membrane decal is a special decal that box lid with a mild solvent.
Page 165: Full Machine Calibration
September 2015 Service Manual Ground Controls Full machine calibration must be completed in the following sequence: Full Machine Calibration • Select engine configuration. Refer to Repair Section, Display Module. Unit of Measure Full machine calibration must be completed in the and Language.
Page 166: Display Module
Service Manual September 2015 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. Calibration and parameter settings must be completed by a person trained and qualified on the repair of this machine.
Page 167: Display Module
September 2015 Service Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch on, press the Hydraulic pressure PSI (English) 0-4500 PSI Machine Status (plus)(minus) buttons at the Hydraulic pressure kPa (metric) 0-31000 kPa same time. Primary boom to secondary boom +22°...
Page 168 Service Manual September 2015 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and Forward extended drive speed % 120% (max) 100% Drive Functions hold the enter button and turn (default) 50% (min) key switch to on position. Forward not stowed drive speed % 120% (max) 100% Release the enter button and (default) 50% (min)
Page 169 September 2015 Service Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and Primary boom up speed stowed Boom Function hold the enter button and turn Speeds key switch to on position. Primary boom up speed not Release the enter button and stowed press...
Page 170 Service Manual September 2015 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 acceleration % Ramps key switch to on position. Primary boom up/down ramp Release the enter button and deceleration %...
Page 171 September 2015 Service Manual Display Module Screen or Menu Procedure Description Range or Selection Valve Calibration With key switch , press and Delete drive valve calibration hold the enter button and turn Delete primary boom up/down key switch to on position. valve calibration Release the enter button and Delete primary boom...
Page 172: Display Module
Service Manual September 2015 Display Module Screen or Menu Procedure Description Range or Selection Sensor Calibration With key switch , press and hold Set unit X-axis to gravity the enter button and turn key switch (before software Set unit Y-axis to gravity to on position.
Page 173 September 2015 Service Manual Display Module Sensor With key switch , press and hold Set unit X-axis to gravity the enter button and turn key switch Calibration to on position. (software version Set unit Y-axis to gravity Release the enter button and press 4.01 and higher) (plus)(enter)(enter)(plus).
Page 174 Service Manual September 2015 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and Boom Function Limit No LT= No limit; EXT LT= Options hold the enter button and turn (NO LT/EXT LT) secondary boom extend key switch to on position.
Page 175: Hydraulic Pumps
September 2015 Service Manual Hydraulic Pumps Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying The function pump is a pressure compensated, hydraulic oil can penetrate and variable displacement piston pump. Any internal burn skin.
Page 176: How To Prime The Function Pump
Service Manual September 2015 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 Connect a 0 to 5000 psi / 0 to 350 bar...
Page 177 September 2015 Service Manual Hydraulic Pumps How to Adjust the Function Pump Adjust the pressure compensator pressure. Turn the adjustment screw clockwise to Pressure Compensator increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. Note: Two people will be required to perform this procedure.
Page 178: Drive Pump
Service Manual September 2015 Hydraulic Pumps Locate the two hydraulic tank valves at the hydraulic tank. Close the valves. Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump.
Page 179: How To Prime The Drive Pump
September 2015 Service 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. sure to open the two hydraulic tank valves before performing Component damage hazard.
Page 180: Manifolds
Service Manual September 2015 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 Prevents hydraulic pressure from...
Page 181 September 2015 Service Manual Manifolds Part No. 218700 ZX-135/70...
Page 182 Service Manual September 2015 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 30-35 ft-lbs / 41-47 Nm 150 psi / 10.3 bar...
Page 183 September 2015 Service Manual Manifolds Part No. 218700 ZX-135/70...
Page 184: Valve Adjustments - Function Manifold
Service Manual September 2015 Manifolds Simultaneously push and hold the auxiliary power button and the primary boom retract Valve Adjustments - Function button with the primary boom fully retracted. Manifold Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specification.
Page 185 September 2015 Service Manual Manifolds How to Adjust the Primary Boom Simultaneously push and hold the function enable/high speed button and the primary Extend Relief Valve boom extend button with the primary boom fully extended. Observe the pressure reading Note: Perform this procedure with the axles on the pressure gauge.
Page 186: Platform Manifold
Service Manual September 2015 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...
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Page 188: Jib Boom Manifold
Service Manual September 2015 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 189 September 2015 Service Manual Part No. 218700 ZX-135/70...
Page 190: Flow Control Mainfold
Service Manual September 2015 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 ZX-135/70...
Page 191: Function Enable Valve
September 2015 Service Manual 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 Part No.
Page 192: Turntable Rotation Manifold
Service Manual September 2015 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 Shuttle valve.
Page 193: Steer And Axle Manifold
September 2015 Service Manual Manifolds Steer and Axle Manifold 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, 1.5 gpm / 5.7 L/min Right front steer cylinder retract 20-25 ft-lbs / circuit...
Page 194 Service Manual September 2015 Manifolds ZX-135/70 Part No. 218700...
Page 195 September 2015 Service Manual 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 196 Service Manual September 2015 Manifolds ZX-135/70 Part No. 218700...
Page 197: Valve Adjustments - Steer And Axle Manifold
September 2015 Service Manual 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.
Page 198: Traction Manifold Components
Service Manual September 2015 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 199 September 2015 Service Manual Manifolds Part No. 218700 ZX-135/70...
Page 200 Service Manual September 2015 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 divider/combiner valve B...
Page 201 September 2015 Service Manual Manifolds Part No. 218700 ZX-135/70...
Page 202: Valve Adjustments - Traction Manifold
Service Manual September 2015 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 11 Adjust the internal hex socket until the Relief Valve...
Page 203: Drive Oil Diverter Manifold Components (Welder Option)
September 2015 Service Manual Manifolds 8-12 Drive Oil Diverter Manifold (welder option) The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item Directional valve Diverter valve 80-90 ft-lbs / 108-122 Nm Orifice, 0.030 inch / 0.080 cm Delays shift to drive Solenoid Valve...
Page 204: Valve Coils
Service Manual September 2015 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 205: How To Test A Coil Diode
September 2015 Service Manual Manifolds How to T est a Coil Di ode How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.
Page 206: Turntable Rotation Components
Service Manual September 2015 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. Rotation Assembly Tip-over hazard.
Page 207: How To Adjust The Turntable Rotation Gear Backlash
September 2015 Service Manual Turntable Rotation Components How to Adj ust the Tur ntabl e R otati on Gear Backlash 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 208: Turntable Level Sensor - How To Calibrate The Turntable Level Sensor
Service Manual September 2015 Turntable Rotation Components Temporarily install a control box door retaining fastener between the door and the box to Turntable Level Sensor prevent the control box door from moving the toggle switch while calibrating the machine. How to Calibrate the Turntable Turn the key switch to ground controls.
Page 209 September 2015 Service Manual Turntable Rotation Components Press the enter or previous button on the 11 Press the plus button or minus button to LCD screen until SET UNIT X AXIS LEVEL adjust the display to the exact value shown on TO GRAVITY is displayed.
Page 210 Service Manual September 2015 Turntable Rotation Components 14 Press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured...
Page 211: Axle Components
September 2015 Service Manual Axle Components 10-1 Steer Sensors The steer sensors measure steer angle and communicates that information to the ground controls ECM. The steer sensor on the ground controls side of the machine at the square-end acts as the lead sensor when in front wheel steer mode. In rear wheel steer mode, the steer sensor on the ground controls side of the machine at the circle-end acts as the lead sensor.
Page 212 Service Manual September 2015 Axle Components Position the new steer sensor assembly over 10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable the sensor activator pin with the sensor cable angled towards the tire. Refer to Illustration 2. angled away from the tire.
Page 213: How To Calibrate A Replacement Steer Sensor
September 2015 Service Manual Axle Components How to C alibr ate a R epl acem ent Steer Sens or How to C alibr ate All Steer Sensors How to Calibrate a Replacement How to Calibrate All Steer Steer Sensor Sensors Note: If a steer angle sensor has been removed or Note: This procedure will only need to be replaced, the steer angle sensors will need to be...
Page 214 Service Manual September 2015 Axle Components Left front (square-end, blue side) and right Press and hold the enter button on the ground control panel while pulling out the ground rear (circle-end, yellow side) angle controls red Emergency Stop button to the on sensors: Rotate the sensor cover clockwise or counterclockwise until the voltage reading position.
Page 215: Steer Cylinders
September 2015 Service Manual Axle Components 10-2 Delete all Steer Sensor Calibrations Steer Cylinders 11 Press the enter or previous button on the LCD screen until DELETE ALL STEER SENSORS CALIBRATION is displayed.Press How to Remove a Steer Cylinder the plus button to select YES, then press the enter button to accept.
Page 216: Axle Extension Cylinders
Service Manual September 2015 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" port of the cylinder and the return Extension Cylinder hose from the power unit to the "E"...
Page 217: Axle Angle Sensors - How To Calibrate The Axle Angle Sensors
September 2015 Service Manual 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 218 Service Manual September 2015 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). 16 Remove the fastener that was temporarily Press the enter or previous button on the LCD screen until DELETE AXLE ANGLE...
Page 219: Fault Codes
September 2015 Service Manual Fault Codes Section 5 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 220: Control System Fault Codes
Service Manual September 2015 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 221 September 2015 Service 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 222 Service Manual September 2015 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 223 September 2015 Service 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) between SCON and TCON.
Page 224 Service Manual September 2015 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 225 September 2015 Service 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) warning device...
Page 226 Service Manual September 2015 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 Sensor is out of range.
Page 227 September 2015 Service 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 228 Service Manual September 2015 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 Sensor is out of range.
Page 229 September 2015 Service 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 230 Service Manual September 2015 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 Out of Tolerance...
Page 231 September 2015 Service 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 232 Service Manual September 2015 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 233 September 2015 Service 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 234 Service Manual September 2015 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 Sensor is out of range.
Page 235 September 2015 Service 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 Sensor is out of range.
Page 236 Service Manual September 2015 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 Timeout has elapsed from fault occurs. boom until LSS1RO is engaged and try when LSS1RO is again.
Page 237: Fault Matrix
September 2015 Service Manual Fault Codes P_38 - Propel P_39 - Turntable P_10 - Primary P_11 - Primary / P_9B - P_30 - Secondary Rotate Boom Extend Secondary Up Ignition/Fuel Extend/Down P_38 P_39 P_10 P_11 P_30 P_9B Turntable tilt Y axis (+5°, secondary boom not stowed) Primary Boom angle (crosscheck) Secondary Boom angle (crosscheck) Secondary Boom safety (not retracted and not raised)
Page 238: Deutz Td 2.9 L4 Engine Fault Codes
Service Manual September 2015 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1022 Actuator error EGR-Valve; signal KWP = Keyword Protocol range check high SPN FMI Description 1224 Actuator EGR-Valve;...
Page 239 September 2015 Service 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 240 Service Manual September 2015 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; shut off threshold exceeded 1180 Physical range check high for...
Page 241 September 2015 Service 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 Sensor error EGR cooler...
Page 242 Service Manual September 2015 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; short circuit to battery Injector 1 (in firing order);...
Page 243 September 2015 Service 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 1180 3...
Page 244 Service Manual September 2015 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 245 September 2015 Service 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 1029 Physical range check high for...
Page 246 Service Manual September 2015 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 523470 Maximum rail pressure in limp...
Page 247 September 2015 Service 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 248 Service Manual September 2015 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 249 September 2015 Service 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 250 Service Manual September 2015 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 plausible to HFM reading...
Page 251 September 2015 Service 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 252 Service Manual September 2015 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 253: Perkins 854F-34T Engine Fault Code
September 2015 Service 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 254 Service Manual September 2015 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 Engine Coolant Temperature :Voltage Above...
Page 255 September 2015 Service 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 - Below Normal...
Page 256 Service Manual September 2015 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 257 September 2015 Service 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 258 Service Manual September 2015 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 2791...
Page 259 September 2015 Service 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 260 Service Manual September 2015 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 261: Electrical Schematic
September 2015 Service Manual Schematics Section 6 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. Remove all rings, ...
Page 262: Wire Circuit Legend
Service Manual September 2015 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 263 September 2015 Service 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 Auxiliary Steer/Drive Valve...
Page 264 Service Manual September 2015 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 Platform Rotate Left (CCW)
Page 265 September 2015 Service 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 Ground Control Panel...
Page 266: Wire Color Legend
Service Manual September 2015 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 267 September 2015 Service Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function WH/RD Power to temp sender Primary boom up driver Auxiliary Power RD/BK Primary boom down driver RD/BK Platform level alarm RD/WH Primary boom up/down flow control proportional valve driver RD/WH Drive Motor shift (speed)
Page 268 Service Manual September 2015 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 269 September 2015 Service 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 270 Service Manual September 2015 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 Envelope Active LED...
Page 271: Limit Switches And Angle Sensors
September 2015 Service Manual Limit Switches and Angle Sensors Limit Switch Legend 1 RSP1AO 14 Plat Angle Sensor 2 RSP1AS 15 PCON 3 LSP1RO 16 SCON 4 LST20 17 RSRA1SO 5 LST10 18 LSRA1ES 6 LST1S 19 RSLR1SO 7 LSS1RS 20 RSRR1SO 8 LSS1RO 21 DCON...
Page 272 Service Manual September 2015 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 Angle...
Page 273 September 2015 Service 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. RSP1AS Primary boom angle sensor, safety RSJ1AO Jib boom angle sensor...
Page 274 Service Manual September 2015 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 275: Circuit Connector Legend
September 2015 Service 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 ext/ret flow control valve...
Page 276 Service Manual September 2015 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 277 September 2015 Service 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 J231...
Page 278: Drive Chassis And Platform Controller Pin Legend
Service Manual September 2015 Drive Chassis and Platform Controller Pin Legend Pin Numbering - 23 pin connector Pin Numbering - 35 pin connector Plat Controller Plat Controller Drive Chassis Drive Chassis GNDPCON - BR VLVRET1 - BR VLVRET1 - BR GND-DCON - BR P52PCON - WH V153JBE - BK...
Page 279: Safety Controller Pin Legend
September 2015 Service Manual 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 D82CAN (+) - YL...
Page 280: Turntable Controller Pin Legend
Service Manual September 2015 Turntable Controller Pin Legend Pin Numbering - 35 pin connector Pin Numbering - 23 pin connector Pin Numbering - 4 pin connector Turntable Turntable Turntable Turntable Controller Controller Controller Controller VLVRET4 - BR GNDPCON - BR GNDSCON - BR (UNUSED) V03PUD - RD/WH...
Page 281: Telematics Connector Pin Legend
September 2015 Service 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) Telematics Use Case System Power 12 VDC...
Page 282: Deutz Td2011L04I
Service Manual September 2015 Engine Relay and Fuse Panel Legend - Deutz TD2011L04i Deutz TD2011L04i Models Number Component Description CR28 Start Relay CR17 Hydraulic Oil Cooler Fan Relay CR41 Flashing Beacon Relay Horn Relay CB10 Circuit Breaker, 20A, Hydraulic Oil Cooler / Horn Fuse, 30A, Eng / Start / Alt Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler / Horn...
Page 283: Engine Relay And Fuse Panel Legend- Deutz Td2.9 Models
September 2015 Service Manual Engine Relay and Fuse Panel Legend- Deutz TD2.9 Models Deutz TD2.9 Models Number Component Description CR77 PCE #1 Engine Alt. Relay CR17 Hydraulic Oil Cooler / Fan Relay CR28 Fuel Pump CR41 Flashing Beacon Relay Horn Relay Fuse, 30A, ECU Power Fuse, 30A, Eng / Start/ Alt Fuse, 60A, Glow Plug...
Page 284: Engine Relay And Fuse Panel Legend - Perkins 1104D-44T
Service Manual September 2015 Engine Relay and Fuse Panel Legend - Perkins 1104D-44T Perkins 1104D Models Number Component Description CR77 Function Enable Relay CR28 Start Relay CR17 Hydraulic Oil Cooler Fan Relay CR41 Flashing Beacon Relay Horn Relay CB10 Circuit Breaker, 20A, Hydraulic Oil Cooler / Horn Fuse, 30A, Eng / Start / Alt Fuse, 60A, Glow Plug Fuse, 20A, Hydraulic Oil Cooler / Horn...
Page 285: Engine Relay And Fuse Panel Legend- Perkins 854F Models
September 2015 Service Manual Engine Relay and Fuse Panel Legend- Perkins 854F Models Perkins 854F-34T Models Number Component Description CR77A PCE#1 Engine Alt CR17 Hydraulic Oil Cooler Fan Relay Fuse, 30A, ECU Power Fuse, 20A, Key Switch Power CR41 Flashing Beacon Relay Horn Relay Fuse, 20A, RPM Solenoid Fuse, 30A, Eng / Start / Alt...
Page 286: Electrical Symbols Legend
Service Manual September 2015 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 Battery separator...
Page 287: Hydraulic Symbols Legend
September 2015 Service 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 288 Service Manual September 2015 This page intentionally left blank. ZX-135/70 Part No. 218700...
Page 289 September 2015 Service Manual Perkins 1104D-44T Engine Electrical Schematic...
Page 290: Perkins 1104D Engine Electrical Schematic
Service Manual September 2015 Perkins 1104D-44T Engine Electrical Schematic ZX-135/70 Part No. 218700...
Page 291 September 2015 Service Manual Perkins 854F-34T Engine Electrical Schematic...
Page 292: Perkins 854F-34T Engine Electrical Schematic
Service Manual September 2015 Perkins 854F-34T Engine Electrical Schematic ZX-135/70 Part No. 218700...
Page 293: Perkins 854F-34T Engine Harness
September 2015 Service Manual Perkins 854F-34T Engine Harness Part No. 218700 ZX-135/70...
Page 294 Service Manual September 2015 Perkins 854F-34T Engine Harness...
Page 295 September 2015 Service Manual Deutz TD2.9 Engine Electrical Schematic...
Page 296: Deutz Td2.9 Engine Electrical Schematic
Service Manual September 2015 Deutz TD2.9 Engine Electrical Schematic ZX-135/70 Part No. 218700...
Page 297: Deutz Td2.9 Engine Harness
September 2015 Service Manual Deutz TD2.9 Engine Harness Part No. 218700 ZX-135/70...
Page 298 Service Manual September 2015 Deutz TD2.9 Engine Harness...
Page 299: Generator Wiring Schematic
September 2015 Service Manual Generator Wiring Schematic Part No. 218700 ZX-135/70...
Page 300 Service Manual September 2015 Generator Wiring Schematic...
Page 301 September 2015 Service Manual Hydraulic Generator (Welder Option)
Page 302: Hydraulic Generator (Welder Option)
Service Manual September 2015 Hydraulic Generator (Welder Option) ZX-135/70 Part No. 218700...
Page 303: Hydraulic Schematic
September 2015 Service Manual Hydraulic Schematic Part No. 218700 ZX-135/70...
Page 304 Service Manual September 2015 Hydraulic Schematic...
Page 305: Electrical Schematic (Includes Deutz Engine)
September 2015 Service Manual Electrical Schematic (Includes Deutz Engine) ZX-135/70 Part No. 218700 Servic e M anual September 2015...
Page 306 OUT PWR ENABLE OPT GBOX OPER. REC. OR (~SM)+(AH) TO MICRO BOOM RET RECOVERY SIGNAL HARN SERV. OR Genie ZX-135/70 Vbb BTS621 BOOM DWN RECOVERY SIGNAL PWR IN SERV OR OUT 1 P22R RECOVERY PROVIDES ST OUT 2 BOOM EXT/RET FC RECOVERY SIGNAL...

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Terex Genie ZX-135/70 Service Manual

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