Page 1 Service and Repair Manual Serial Number Range -135/70 ® from ZX13514-2533 to This manual includes: ZX13516H-3199 Repair procedures Includes: ZX13514-2463 Fault Codes ZX13514-2469 Electrical and ZX13514-2631 Hydraulic Schematics ZX135H-3200 to ZX135H-4000 For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.
Page 2: Introduction
Unrestricted with proper operation, inspection and scheduled maintenance. Copyright © 2015 by Terex Corporation 1268558GT Rev A, September 2015 First Edition, First Printing Genie and “ZX” are registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. ZX®-135/70 Part No. 1268558GT...
Page 3 March 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Initial Release 11/2015 Schematics Limit Switch Legend 5/2016 Repair Procedure 4-9 9/2016 Introduction Serial Number Legend 10/2016 Schematics Electrical / Hydraulic Schematics Display Module 3/2018 Repair...
Page 4: Serial Number Legend
Service and Repair Manual March 2018 Introduction Serial Number Legend To August 31, 2016 1 Model 1 Sequence number 2 Model year 2 Serial label (located under cover) 3 Facility code 3 Serial number (stamped on chassis) From September 1, 2016 1 Model 1 Serial label (located under cover) 2 Facility code...
Page 5: Safety Rules
March 2018 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
Page 6 Service and Repair Manual March 2018 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
Page 7: Table Of Contents
March 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
Page 8 March 2018 Table of Contents Section 3 Repair Procedures ....................19 Introduction ......................19 Platform Controls ....................21 Platform Controls ....................21 1-1 Platform Circuit Board ..................21 How to Remove the LED Circuit Board ............23 1-2 Joysticks - How to Calibrate a Joystick ............23 How to Reset a Proportional Valve Coil Default ..........
Page 9 March 2018 Table of Contents Jib Boom Components ..................40 3-1 Jib Boom Cable Track ..................41 How to Repair the Cable Track ............... 43 3-2 Jib Boom ......................44 3-3 Jib Boom Lift Cylinder ..................46 3-4 Jib Boom Level Cylinder ................47 3-5 Jib Boom Extension Cylinder .................
Page 10 March 2018 Table of Contents Ground Controls ....................85 6-1 Bypass/Recovery Key Switch................. 85 How to Use the Recovery Mode..............87 6-2 Circuit Boards ....................88 6-3 Membrane Decal .................... 90 6-4 Full Machine Calibration ................. 91 Display Module ....................92 Hydraulic Pumps ....................
Page 11 March 2018 Table of Contents Turntable Rotation Components ..............134 9-1 Turntable Rotation Assembly ............... 134 How to Adjust the Turntable Rotation Gear Backlash ........135 9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor..136 Axle Components ..................... 139 10-1 Steer Sensors ....................
Page 12 March 2018 Table of Contents Section 5 Schematics ......................191 Introduction ......................191 Wire Circuit Legend .................... 192 Wire Color Legend ....................196 Limit Switches and Angle Sensors ..............201 Circuit Connector Legend ................... 205 Drive Chassis and Platform Controller Pin Legend ..........208 Safety Controller Pin Legend ................
Page 13: Specifications
March 2018 Service and Repair 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 14: Hydraulic Oil Specifications
Service and Repair Manual March 2018 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.
Page 15 March 2018 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
Page 16 Service and Repair Manual March 2018 Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...
Page 17: Hydraulic Component Specifications
March 2018 Service and Repair Manual 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...
Page 18 Service and Repair Manual March 2018 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 19: Deutz Td 2.9 Engine Specifications
March 2018 Service and Repair Manual Specifications Deutz TD 2.9 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs 177 cu. in Displacement 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C 3.6 x 4.3 inches Bore and Stroke Oil Pressure switch 92 x 110 mm...
Page 20: Deutz Td2011L04I Engine Specifications
Service and Repair Manual March 2018 Specifications Deutz TD2011L04i Engine Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 220.9 cu. in Displacement 2.8 to 4.1 bar 3.62 liters Oil capacity (including filter) 12.8 quarts Number of cylinders 12.1 liters 3.78 x 4.92 inches Bore and Stroke...
Page 21 March 2018 Service and Repair Manual Specifications Deutz TD2011L04i cont. Fuel injection system Motorpal Injection pump pressure, maximum 15,000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Starter motor Current draw, normal load 140 - 200A...
Page 22: Perkins 854F-34T Engine Specifications
Service and Repair Manual March 2018 Specifications Perkins 854F-34T Oil Pressure switch Installation torque 18.4 ft-lbs 207 cu. in Displacement 25 Nm 3.4 liters Pressure switch point 12 psi Number of cylinders 0.82 bar 3.89 x 4.33 inches Bore and Stroke Oil Sensor Settings 99 x 110 mm 0 psi...
Page 23 March 2018 Service and Repair Manual Specifications Perkins 854F-34T cont. Engine coolant Capacity 16.5 quarts (50/50 extended life) 15.6 liters Coolant temperature switch Installation torque 18.4 ft-lbs 25 Nm Maximum continuous temperature 226°F 108°C Temperature Sensor Settings 215°F 37 ohms 102°C 170°F 78 ohms...
Page 24: Perkins 1104D-44T Engine Specifications
Service and Repair Manual March 2018 Specifications Perkins 1104D-44T Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 268.5 cu. in Displacement 2.8 to 4.1 bar 4.4 liters Oil capacity (including filter) 8.3 quarts Number of cylinders 7.9 liters 4.13 x 5 inches Bore and Stroke...
Page 25 March 2018 Service and Repair Manual Specifications Perkins 1104D-44T cont. Starter motor Current draw, normal load 115A Cranking speed 200 - 250 rpm Battery – Auxiliary power units Type 6V DC Quantity Battery capacity, maximum 285 AH Reserve capacity @ 25A rate 745 minutes Battery –...
Page 26: Machine Torque Specifications
Service and Repair Manual March 2018 Specifications Machine Torque Specifications Platform Rotator 1-8 center bolt, GR 5 480 ft-lbs (before SN 15-2475) 651 Nm 3/8 -16 bolts, GR 8 44 ft-lbs (before SN 15-2475) 60 Nm 1-8 center bolt, GR 5, dull gray 615 ft-lbs (from SN 15-2585) 824 Nm...
Page 27: Hydraulic Hose And Fitting Torque Specifications
March 2018 Service and Repair Manual 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 28: Torque Procedure
Service and Repair Manual March 2018 Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, Replace the O-ring.
Page 29 March 2018 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
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Page 31: Repair Procedures
March 2018 Service and Repair Manual Repair Procedures Section 3 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 32 Service and Repair Manual March 2018 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 33: Platform Controls
March 2018 Service and Repair 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 34 Service and Repair Manual March 2018 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 35: How To Remove The Led Circuit Board
March 2018 Service and Repair 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 36 Service and Repair Manual March 2018 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 37 March 2018 Service and Repair 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 38 Service and Repair Manual March 2018 Platform Controls Primary boom up/down functions: Jib boom up/down functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to...
Page 39: How To Reset A Proportional Valve Coil Default
March 2018 Service and Repair 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 40: How To Set The Function Thresholds And Default Functions Speeds
Service and Repair Manual March 2018 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...
Page 41 March 2018 Service and Repair 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 42: How To Adjust The Function Speeds
Service and Repair Manual March 2018 Platform Controls How to Adj ust the Functi on Speeds How to Adjust the Function Press the enter button to save the setting in memory. Speeds Press the enter or previous button on the Note: Perform this procedure with the boom in the LCD screen until EXIT is displayed.
Page 43: How To Adjust The Function Ramp Rate Setting
March 2018 Service and Repair Manual Platform Controls How to Adj ust the Functi on R amp R ate Setti ng How to Adjust the Function Ramp Press the previous button until the function to be adjusted is displayed. Rate Setting Press the plus button to increase the ramp The ramp rate setting of a joystick controls the time rate or press the minus button to decrease the...
Page 44: Platform Components
Service and Repair Manual March 2018 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 45: Platform Leveling Cylinder
March 2018 Service and Repair Manual 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 46: Platform Rotator
Service and Repair Manual March 2018 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 47: How To Bleed The Platform Rotator
March 2018 Service and Repair Manual Platform Components How to Bleed the Pl atform R otator How to Bleed the Platform Remove the hose and cable guide retaining fasteners and remove the guide from the Rotator platform support. Note: Do not start the engine. Use auxiliary power Remove the weld cable from the platform (if for all machine functions in this procedure.
Page 48: Platform Level Sensor - How To Calibrate The Platform Level Sensor
Service and Repair Manual March 2018 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 49: Platform Overload System (If Equipped)
March 2018 Service and Repair Manual 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 50 Service and Repair Manual March 2018 Platform Components Confirm the setting: Test all machine functions from the platform controls. Start the engine from the platform controls. Result: All platform control functions should Lift the test weight off the platform floor using a not operate.
Page 51: Platform Overload Recovery Message
March 2018 Service and Repair Manual Platform Components Press the buttons on the ground controls in the following sequence: Platform Overload Recovery (plus)(minus)(minus)(plus). Message (software V3.07 and Press the enter or previous button on the later) LCD screen until CLEAR OVERLOAD RECOVERY is displayed.
Page 52: Jib Boom Components
Service and Repair Manual March 2018 Jib Boom Components 1 primary extension boom 7 jib boom 2 jib boom manifold 8 jib extension boom 3 bellcrank 9 hose and cable junction box 4 cable track tube 10 jib boom lift cylinder 5 platform rotator 11 jib boom cable track 6 platform leveling cylinder...
Page 53: Jib Boom Cable Track
March 2018 Service and Repair Manual Jib Boom Components Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to Jib Boom Cable Track the platform manifold. Cap the fittings on the manifold. The jib boom cable track guides the cables and hoses running up the jib boom.
Page 54 Service and Repair Manual March 2018 Jib Boom Components Remove the hose and cable clamp retaining 17 Remove the fasteners from the cable track fasteners at the platform end of the jib boom tube guide at the platform end of the jib boom. cable track tube.
Page 55: How To Repair The Cable Track
March 2018 Service and Repair Manual Jib Boom Components How to R epair the C abl e Tr ack How to Repair the Cable Track Lift up the hoses and cables and carefully insert the new 4-link section of cable track. Component damage hazard.
Page 56: Jib Boom
Service and Repair Manual March 2018 Jib Boom Components Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to Jib Boom the platform manifold. Cap the fittings on the manifold. How to Remove the Jib Boom Bodily injury hazard.
Page 57 March 2018 Service and Repair Manual Jib Boom Components Place blocks between the upper and lower 13 Remove the jib boom angle sensor mounting cable tracks and secure the upper and lower bracket fasteners from the side of the primary tracks together.
Page 58: Jib Boom Lift Cylinder
Service and Repair Manual March 2018 Jib Boom Components 19 Secure the jib boom lift cylinder to the jib boom with a strap or other suitable device. Jib Boom Lift Cylinder 20 Raise the jib boom to a horizontal position using the overhead crane.
Page 59: Jib Boom Level Cylinder
March 2018 Service and Repair Manual Jib Boom Components Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Use a Jib Boom Level Cylinder soft metal drift to remove the pin and let the cylinder hang down. How to Remove the Jib Boom Attach a lifting strap from an overhead crane Level Cylinder...
Page 60: Jib Boom Extension Cylinder
Service and Repair Manual March 2018 Jib Boom Components Remove the external snap rings from the jib boom level cylinder barrel-end pivot pin. Use a Jib Boom Extension Cylinder soft metal drift to remove the pin. Tag, disconnect and plug the jib boom level How to Remove the Jib Boom cylinder hydraulic hoses from the jib boom Extension Cylinder...
Page 61 March 2018 Service and Repair Manual Jib Boom Components Extend the jib boom until the jib boom 10 Pull the electrical cables out of the lower cable extension cylinder rod-end pivot pin is track that lead to the primary boom. accessible.
Page 62: Angle Sensor
Service and Repair Manual March 2018 Jib Boom Components 17 Attach a lifting strap from an overhead crane to the barrel end of the jib boom extension Jib Boom Bellcrank Angle Sensor cylinder. The jib boom bellcrank angle sensor is monitored 18 Remove the pin retaining fasteners from the by the control system to keep the jib boom jib boom extension cylinder barrel-end pivot...
Page 63 March 2018 Service and Repair Manual 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.
Page 64 Service and Repair Manual March 2018 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.
Page 65 March 2018 Service and Repair Manual 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 66 Service and Repair Manual March 2018 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 67 March 2018 Service and Repair Manual 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.
Page 68: Boom Components
Service and Repair Manual March 2018 Boom Components 1 upper primary boom lift cylinder linkage 8 primary boom lift cylinder 9 number 1 secondary boom tube 2 primary boom 10 number 2 secondary boom tube 3 cable track 11 number 3 secondary boom tube 4 primary extension boom 12 lower primary boom lift cylinder linkage arm 5 jib boom manifold...
Page 69: Primary Boom Cable Track
March 2018 Service and Repair Manual Boom Components Pull the electrical cables out of the lower cable track that lead to the primary boom. Primary Boom Cable Track Component damage hazard. The primary boom cable track guides the cables Cables can be damaged if they and hoses running up the boom.
Page 70 Service and Repair Manual March 2018 Boom Components 10 Remove the retaining fasteners from the cable 15 Locate the two hydraulic hoses inside the end track guide at the platform end of the boom. of the secondary boom that lead to the primary Remove the cable track guide from the boom cable track.
Page 71: How To Repair The Primary Boom Cable Track
March 2018 Service and Repair Manual Boom Components How to R epair the Primary Boom C abl e Tr ack How to Repair the Primary Boom 20 Remove the mounting fasteners that attach the lower cable track to the primary boom lift Cable Track cylinder.
Page 72: Secondary Boom Cable Track
Service and Repair Manual March 2018 Boom Components Remove the upper rollers from the replacement section of cable track. Secondary Boom Cable Track Lift up the hoses and cables and carefully The secondary boom cable track guides the cables insert the new 4-link section of cable track. and hoses running up through the inside of the Component damage hazard.
Page 73 March 2018 Service and Repair Manual Boom Components Remove the cover retaining fasteners and 10 Pull the hydraulic hoses just removed through remove the cover from the secondary boom. the turntable bulkhead. Crushing hazard. The secondary Component damage hazard. boom end cover could become Hoses can be damaged if they unbalanced and fall when are kinked or pinched.
Page 74: How To Repair The Secondary Boom Cable Track
Service and Repair Manual March 2018 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 75: Primary Boom
March 2018 Service and Repair Manual Boom Components Remove the upper rollers from the replacement section of cable track. Primary Boom Lift up the hoses and cables and carefully insert the new 4-link section of cable track. How to Remove the Primary Component damage hazard.
Page 76 Service and Repair Manual March 2018 Boom Components Remove the primary boom cable track. Refer 10 Tag, disconnect and plug the primary boom to repair procedure, How to Remove the Cable extension cylinder hydraulic hoses. Cap the Track. fittings on the cylinder. Remove the end cover from the pivot end of Bodily injury hazard.
Page 77: Primary Boom Lift Cylinder
March 2018 Service and Repair Manual Boom Components 17 Use a soft metal drift to tap the pin halfway out and lower one of the linkage arms down. Tap Primary Boom Lift Cylinder the pin in the other direction and lower the other linkage arm down.
Page 78: Secondary Boom Lift Cylinder
Service and Repair Manual March 2018 Boom Components Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on Secondary Boom Lift Cylinder the cylinder. Bodily injury hazard. Spraying How to Remove the Secondary hydraulic oil can penetrate and Boom Lift Cylinder burn skin.
Page 79 March 2018 Service and Repair Manual Boom Components Remove the engine pivot plate retaining Tag, disconnect and plug the fuel hoses from fastener. Swing the engine pivot plate out the fuel tank. Clean up any fuel that may have away from the machine. spilled.
Page 80 Service and Repair Manual March 2018 Boom Components 13 Remove the turntable cover using a suitable 19 Attach an overhead crane or similar lifting lifting device. device to the battery box for the auxiliary power unit batteries. Crushing hazard. The turntable 20 Remove the battery box retaining fasteners cover may become unbalanced and carefully remove the battery box from the...
Page 81 March 2018 Service and Repair Manual Boom Components 24 Remove the secondary boom lift cylinder 29 Use a slide hammer to remove the barrel-end rod-end pivot pin retaining fasteners. Use a pivot pin. soft metal drift to remove the pin through the Component damage hazard.
Page 82: Primary Boom Extension Cylinder
Service and Repair Manual March 2018 Boom Components Remove the access cover from the pivot end of the primary boom. Primary Boom Extension Cylinder Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder. The primary boom extension cylinder extends and retracts the primary boom extension tube.The Bodily injury hazard.
Page 83: Secondary Boom Extension Cylinders
March 2018 Service and Repair Manual Boom Components Raise the primary boom approximately 10 feet / 3 m. Turn the machine off. Secondary Boom Extension Cylinders Working at the platform end of the secondary boom, support and secure the secondary boom end cover to a suitable lifting device.
Page 84 Service and Repair Manual March 2018 Boom Components Note: When installing the middle and upper Attach a lifting strap from an overhead crane secondary boom extension cylinders, be sure the to the rod end of the upper extension cylinder. grooved wear pads are correctly aligned with the Using the overhead crane, lift the extension channels on the top of the cylinders.
Page 85: Primary Boom Angle Sensor - How To Calibrate The Primary Boom Angle
March 2018 Service and Repair Manual Boom Components How to Calibrate the Primary Primary Boom Angle Sensor Boom Angle Sensor Note: If the axle sensor or secondary boom angle The primary boom angle sensor is used to limit the sensor have been removed or replaced, or the angle of the primary boom relative to the angle of turntable level sensor has been replaced, they the secondary boom and gravity.
Page 86 Service and Repair Manual March 2018 Boom Components 6 Point Calibration procedure Press and hold the enter button on the ground control panel while pulling out the ground Note: Use this procedure for software versions controls red Emergency Stop button to the on before 4.01.
Page 87 March 2018 Service and Repair Manual Boom Components 15 Press and hold a function enable/speed select 20 At the ground controls, press the plus button button and the primary boom down button and or minus button to adjust the display to the lower the primary boom down until the digital exact value shown on the digital level and level displays -50 degrees.
Page 88 Service and Repair Manual March 2018 Boom Components 2 Point Calibration procedure 25 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 89 March 2018 Service and Repair Manual Boom Components 43 Press the plus button to select YES, then 54 Turn the key back to the run position and remove the key from the bypass/recovery key press the enter button to accept. switch.
Page 90: Secondary Boom Angle Sensor - How To Calibrate The Secondary Boom Angle Sensor
Service and Repair Manual March 2018 Boom Components Note: For software versions 4.01 and higher, use the 2 Point Calibration procedure. For software Secondary Boom Angle Sensor versions before 4.01, use the 6 Point Calibration procedure. The software version is displayed on The secondary boom angle sensor is used to limit the LCD screen when the red Emergency Stop the angle of the primary boom relative to the angle...
Page 91 March 2018 Service and Repair Manual Boom Components 6 Point Calibration procedure Press the enter or previous button on the LCD screen until DELETE SECONDARY Note: Use this procedure for software versions BOOM ANGLE SENSOR CALIBRATION is before 4.01. displayed. Note: For the 2 Point Calibration procedure, 10 Press the plus button to select YES, then proceed to step 32.
Page 92 Service and Repair Manual March 2018 Boom Components 15 At the ground controls, press the plus button 20 Press and hold a function enable/speed select button and the secondary boom up button until or minus button to adjust the display to the the digital level displays 65 degrees.
Page 93 March 2018 Service and Repair Manual Boom Components 2 Point Calibration procedure 25 Press the enter or previous button on the LCD screen until EXIT is displayed. Note: Use this procedure for software versions 26 Press the plus button to select YES, then 4.01 and higher.
Page 94 Service and Repair Manual March 2018 Boom Components 39 Press the enter or previous button on the 49 Press the plus button to select YES, then LCD screen until DELETE SECONDARY press the enter button to accept. BOOM ANGLE SENSOR CALIBRATION is 50 Turn the key back to the run position and displayed.
Page 95: Engines
March 2018 Service and Repair 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 96: How To Install The Flex Plate
Service and Repair Manual March 2018 Engines How to Ins tall the Fl ex Plate Perkins engines: Torque the pump plate How to Install the 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 97: Ground Controls
March 2018 Service and Repair 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 98 Service and Repair Manual March 2018 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 99: How To Use The Recovery Mode
March 2018 Service and Repair 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...
Page 100: Circuit Boards
Service and Repair Manual March 2018 Ground Controls How to Remove the LCD Display Circuit Boards Screen Circuit Board Push in the red Emergency Stop button to the The ground control box contains a replaceable off position at both the ground and platform membrane decal with touch sensitive buttons for controls.
Page 101 March 2018 Service and Repair Manual Ground Controls How to Remove the ALC-1000 Tag and carefully disconnect the wire connectors from the circuit board. Circuit Board Carefully disconnect the LCD circuit board Note: If the ALC-1000 circuit board (TCON) has ribbon cable from the ECM circuit board.
Page 102: Membrane Decal
Service and Repair Manual March 2018 Ground Controls Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit Membrane Decal board. The membrane decal is a special decal that Electrocution/burn hazard. consists of a decal with an electronic membrane on Contact with electrically charged the backside.
Page 103: Full Machine Calibration
March 2018 Service and Repair Manual Ground Controls Note: Start this procedure with the booms in the fully stowed position and the axle retracted. Full Machine Calibration Full machine calibration must be completed in the Full machine calibration must be completed in the following sequence: proper sequence when the ALC-1000 circuit board •...
Page 104: Display Module
Service and Repair Manual March 2018 Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters. Tip-over hazard.
Page 105 March 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Machine Status With key switch on, press the Hydraulic pressure PSI 0-4500 PSI (plus)(minus) buttons at the same (English) time. Hydraulic pressure kPa 0-31000 kPa (metric) Primary boom to secondary +22°...
Page 106 Service and Repair Manual March 2018 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and hold Delete drive functions Default Reset the enter button and turn key switch to Software version Delete boom function speed on position.
Page 107 March 2018 Service and Repair Manual Display Module Screen or Procedure Description Range or Menu Selection Boom With key switch , press and hold Primary boom up speed stowed Function the enter button and turn key switch Speeds to on position. Release the enter button and press Primary boom up speed not stowed (plus)(plus)(minus)(minus)
Page 108 Service and Repair Manual March 2018 Display Module Screen or Menu Procedure Description Range or Selection Lift Functions With key switch , press and Primary boom up/down ramp acceleration % Ramps hold the enter button and turn key switch to on position. Primary boom up/down ramp Release the enter button and deceleration %...
Page 109 March 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Valve With key switch , press and hold the Delete drive valve calibration Calibration enter button and turn key switch to on position. Delete primary boom up/down Release the enter button and press valve calibration (minus)(minus)(enter)(enter).
Page 110 Service and Repair Manual March 2018 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 version Set unit Y-axis to gravity to on position.
Page 111 March 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Sensor Calibration With key switch , press and hold the Set unit X-axis to gravity enter button and turn key switch to on (software version Set unit Y-axis to gravity position.
Page 112 Service and Repair Manual March 2018 Display Module Screen or Procedure Description Range or Menu Selection Options With key switch , press and hold Boom Function Limit No LT= No limit; (NO LT/EXT LT) EXT LT= the enter button and turn key switch secondary boom to on position.
Page 113: Hydraulic Pumps
March 2018 Service and Repair 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.
Page 114: How To Prime The Function Pump
Service and Repair Manual March 2018 Hydraulic Pumps How to Prime the F uncti on Pump How to Adj ust the Functi on Pum p Standby Pr ess ure How to Prime the Function Pump How to Adjust the Function Pump Standby Pressure Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose...
Page 115: How To Adjust The Function Pump Pressure Compensator
March 2018 Service and Repair Manual Hydraulic Pumps Loosen the set screw for the pressure Adjust the function pump standby pressure. compensator adjustment screw. Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the set screw. Turn the engine off and remove the pressure gauge.
Page 116: Drive Pump
Service and Repair Manual March 2018 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 117: How To Prime The Drive Pump
March 2018 Service and Repair Manual Hydraulic Pumps How to Prime the Driv e Pum p How to Prime the Drive Pump Carefully pull the drive pump out until the pump coupler separates from the flex plate. Component damage hazard. Be Remove the drive pump from the machine.
Page 118: Manifolds
Service and Repair Manual March 2018 Manifolds Function Manifold Components The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.34 bar Prevents hydraulic pressure from 60 ft-lbs / 81 Nm flowing back into auxiliary pump Check valve, 5 psi / 0.34 bar...
Page 119 March 2018 Service and Repair Manual Manifolds Part No. 1268558GT ZX®-135/70...
Page 120 Service and Repair Manual March 2018 Manifolds Function Manifold Components, continued The function manifold is mounted to the turntable next to the ground controls. Index Description Schematic Item Function Torque Proportional solenoid Turntable rotate circuit 33-37 ft-lbs / 45-50 Nm valve Differential sensing valve, Turntable rotate circuit, regulates...
Page 121 March 2018 Service and Repair Manual Manifolds Part No. 1268558GT ZX®-135/70...
Page 122: Valve Adjustments - Function Manifold
Service and Repair Manual March 2018 Manifolds Simultaneously push and hold the auxiliary power button and the primary boom retract Valve Adjustments - button with the primary boom fully retracted. Function Manifold Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specification.
Page 123 March 2018 Service and Repair 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 124: Platform Manifold
Service and Repair Manual March 2018 Manifolds Platform Manifold The platform manifold is mounted to the platform mounting weldment. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform rotate left/right 20-25 ft-lbs / 27-34 Nm Proportional solenoid valve, 3 position 4 way Platform level up/down 20-25 ft-lbs / 27-34 Nm...
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Page 126: Jib Boom Manifold
Service and Repair Manual March 2018 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 127 March 2018 Service and Repair Manual Part No. 1268558GT ZX®-135/70...
Page 128: Flow Control Mainfold
Service and Repair Manual March 2018 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 129: Function Enable Valve
March 2018 Service and Repair 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...
Page 130: Turntable Rotation Manifold
Service and Repair Manual March 2018 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...
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Page 132: Steer And Axle Manifold
Service and Repair Manual March 2018 Manifolds Steer and Axle Manifold Components The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Flow control valve, 1.5 gpm / 5.7 L/min Right front steer cylinder retract 20-25 ft-lbs / circuit...
Page 133 March 2018 Service and Repair Manual Manifolds Part No. 1268558GT ZX®-135/70...
Page 134 Service and Repair Manual March 2018 Manifolds Steer and Axle Manifold, continued The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Pressure reducing valve, 2400 psi / 165 bar Axle extend/retract circuit 30-35 ft-lbs / 41-47 Nm...
Page 135 March 2018 Service and Repair Manual Manifolds Part No. 1268558GT ZX®-135/70...
Page 136: Valve Adjustments - Steer And Axle Manifold
Service and Repair Manual March 2018 Manifolds Turn the engine off. Valve Adjustments - Steer and Adjust the internal hex socket. Turn it Axle Manifold clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. How to Adjust the Axle Relief Component damage hazard.
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Page 138: Traction Manifold Components
Service and Repair Manual March 2018 Manifolds 8-10 Traction Manifold Components The traction manifold is mounted inside the manifold box at the blue triangle side of the machine. Index Schematic Description Function Torque Item 30-35 ft-lbs / Check valve, 5 psi / 0.3 bar Anti-cavitation 40.7-47.5 Nm 26-30 ft-lbs /...
Page 139 March 2018 Service and Repair Manual Manifolds Part No. 1268558GT ZX®-135/70...
Page 140 Service and Repair Manual March 2018 Manifolds Traction Manifold Components, continued The traction manifold is mounted inside the manifold box at the blue triangle side of the machine. Index Schematic Description Function Torque Item Flow control valve 2.2 gpm / Equalizes pressure on both sides of 30-35 ft-lbs / 8.3 L/m...
Page 141 March 2018 Service and Repair Manual Manifolds Part No. 1268558GT ZX®-135/70...
Page 142: Valve Adjustments - Traction Manifold
Service and Repair Manual March 2018 Manifolds 8-11 Hold the hot oil relief valve and remove the cap. Valve Adjustments - Traction Manifold Start the engine from the ground controls. 10 Press and hold the function enable/high rpm select button (rabbit symbol) position. How to Adjust the Hot Oil Relief 11 Adjust the internal hex socket until the Valve...
Page 143: Drive Oil Diverter Manifold Components (Welder Option)
March 2018 Service and Repair 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 144: Valve Coils
Service and Repair Manual March 2018 Manifolds Valve Coil Resistance 8-13 Specification Valve Coils Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...
Page 145 March 2018 Service and Repair Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.
Page 146: Turntable Rotation Components
Service and Repair Manual March 2018 Turntable Rotation Components Remove the drive hub mounting bolts and remove the turntable rotation assembly from Turntable Rotation Assembly the machine. Repeat steps 3 through 5 for the other How to Remove a Turntable turntable rotation assembly.
Page 147: How To Adjust The Turntable Rotation Gear Backlash
March 2018 Service and Repair 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 148: Turntable Level Sensor - How To Calibrate The Turntable Level Sensor
Service and Repair Manual March 2018 Turntable Rotation Components Note: Perform this procedure with the machine on a firm, level surface with the booms in the fully Turntable Level Sensor stowed position and the axles fully extended. Push in the ground controls red Emergency How to Calibrate the Turntable Stop button to the off position.
Page 149 March 2018 Service and Repair Manual Turntable Rotation Components Remove the key from the main key switch. Press the enter or previous button on the Insert the key into the bypass/recovery key LCD screen until SET UNIT X AXIS LEVEL switch and turn it to the bypass position.
Page 150 Service and Repair Manual March 2018 Turntable Rotation Components 11 Press the plus button or minus button to 14 Press the plus button or minus button to adjust the display to the exact value shown on adjust the display to the exact value shown on the digital level and press the enter button.
Page 151: Axle Components
March 2018 Service and Repair Manual Axle Components 10-1 Remove the steer sensor cover retaining fasteners. Remove the steer sensor assembly. Steer Sensors Note: If the sensor activator pin needs to be The steer sensors measure steer angle and replaced, install the new activator pin per communicates that information to the ground Illustration 1.
Page 152 Service and Repair Manual March 2018 Axle Components Left front (square-end, blue side) and right rear Install the steer sensor cover retaining (circle-end, yellow side) angle sensors: fasteners. Do not tighten the cover retaining fasteners. Connect the steer sensor assembly cable to the main harness.
Page 153: How To Calibrate A Replacement Steer Sensor
March 2018 Service and Repair Manual Axle Components How to C alibr ate a R epl acem ent Steer Sens or How to Calibrate a Replacement 10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable Steer Sensor angled away from the tire.
Page 154: How To Calibrate All Steer Sensors
Service and Repair Manual March 2018 Axle Components How to C alibr ate All Steer Sensors How to Calibrate All Steer Left front (square-end, blue side) and right rear (circle-end, yellow side) angle Sensors sensors: Rotate the sensor cover clockwise or counterclockwise until the voltage reading Note: This procedure will only need to be is between 1.4 to 1.6V DC.
Page 155 March 2018 Service and Repair Manual Axle Components Delete all Steer Sensor Calibrations Press and hold the enter button on the ground control panel while pulling out the ground 11 Press the enter or previous button on the controls red Emergency Stop button to the on LCD screen until DELETE ALL STEER position.
Page 156: Steer Cylinders
Service and Repair Manual March 2018 Axle Components 10-2 20 Push in the red Emergency Stop button to the off position. Steer Cylinders 21 Remove the fastener that was temporarily installed. Close the control box door and install How to Remove a Steer Cylinder the door retaining fasteners.
Page 157: Axle Extension Cylinders
March 2018 Service and Repair Manual Axle Components 10-3 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension Axle Extension Cylinders cylinder. Note: Connect the pressure hose from the power How to Remove an Axle unit to the "R"...
Page 158: Axle Angle Sensors - How To Calibrate The Axle Angle Sensors
Service and Repair Manual March 2018 Axle Components 10-4 Temporarily install a control box door retaining fastener between the door and the box to Axle Angle Sensors prevent the control box door from moving the toggle switch while calibrating the machine. The axle angle sensors measure the axle angle and communicates that information to the ground Remove the key from the main key switch.
Page 159 March 2018 Service and Repair Manual Axle Components Enter sensor calibration mode by pressing the 15 Wait approximately 20 seconds and turn the buttons at the ground controls in the following machine off by pressing the red Emergency Stop button in. sequence: (plus)(enter)(enter)(plus).
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Page 161: Fault Codes
March 2018 Service and Repair Manual Fault Codes Section 4 Before Troubleshooting: Faul t Codes  Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use.
Page 162: Control System Fault Codes
Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Primary Ext/Ret Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick. Check the connections to Value Too High ensure the connector terminals have not backed out.
Page 163 March 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up/Down Fault Check (both Primary Boom Up/Down disabled, Check ribbon and connector from buttons on TCON buttons pressed) display message on LCD membrane switch. If necessary replace membrane switch.
Page 164 Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Switch P3 Fault Check Display message on LCD P3 SAFETY Internal fault not on Z135 SWITCH FAULT Safety Switch P6R1 Fault Check Display message on LCD P6R1 Check wiring for circuit P53LS SAFETY SWITCH FAULT (white/black wire) for damage resulting...
Page 165 March 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Safety Switch P10 Fault Check Display message on LCD P10 Recycle power SAFETY SWITCH FAULT Safety Switch P11 Fault Check Display message on LCD P11 Recycle power and check wiring on SAFETY SWITCH FAULT circuit S140ENL (orange/black)
Page 166 Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Platform Overload Fault Check Display message on LCD. Disable all Check for an overload in the platform. (if active) functions from PCON. Limit functions Check the overload switch mounted on the platform support.
Page 167 March 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up/Down Not calibrated Normal function except threshold for Calibrate Thresholds. Flow Valve one or the other direction is zero. Display message on LCD. Just calibrated Initiate one second beep of audible Self-clearing (transient)
Page 168 Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Primary Boom Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
Page 169 March 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Secondary Boom Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring. Extend Valve zero and neutral, Alarm sounds. Check for an open or shorted valve coil.
Page 170 Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Secondary Boom Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Angle Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
Page 171 March 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick. Check the connections to ensure the connector terminals have Value Too High not backed out.
Page 172 Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Safety Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded Sensor Y Direction sounds Value Too High Replace SCON Value Too Low Value at 0 V...
Page 173 March 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Jib Level (Bellcrank) Not calibrated Normal function except threshold for Perform calibration procedure Up/Down Flow Valve(s) one or the other direction is zero. Display message on LCD. Just calibrated Initiate one second beep of audible Self-clearing (transient)
Page 174 Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Jib Extend/Retract Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick. Check the connections to ensure the connector terminals have not backed out.
Page 175 March 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Rear Axle Angle Sensor Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and Sensor is out of range.
Page 176 Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Left Front Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
Page 177 March 2018 Service and Repair Manual Fault Codes Error Source Error Type Effects Recovery Actions Right Rear Steer Angle Value at 5.0 V Primary up, Secondary up/down and Check for an open ground circuit going Sensor Extend disabled, Alarm sounds to the sensor Value Too High Primary up, Secondary up/down and...
Page 178 Service and Repair Manual March 2018 Fault Codes Error Source Error Type Effects Recovery Actions Secondary Boom Switch Too much time Inhibit Secondary Boom Extend if the If the fault occurs on extend, retract fault occurs. Timeout has elapsed from boom until LSS1RO is engaged and try when LSS1RO is again.
Page 179: Fault Matrix
March 2018 Service and Repair 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 180: Deutz Td 2.9 L4 Engine Fault Codes
Service and Repair Manual March 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN FMI Description SPN = Suspect Parameter Number 1022 Actuator error EGR-Valve; signal FMI = Failure Mode Identifier range check high KWP = Keyword Protocol 1224 Actuator EGR-Valve; over SPN FMI Description current...
Page 181 March 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Sensor error ambient air press.; KWP = Keyword Protocol signal range check high SPN FMI Description Sensor error ambient air press.;...
Page 182 Service and Repair Manual March 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier High low fuel temperature; KWP = Keyword Protocol warning threshold exceeded SPN FMI Description High Low fuel temperature;...
Page 183 March 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
Page 184 Service and Repair Manual March 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Starter relay high side; short KWP = Keyword Protocol circuit to battery SPN FMI Description Starter relay low side;...
Page 185 March 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature KWP = Keyword Protocol upstream turbine; shut off threshold exceeded SPN FMI Description...
Page 186 Service and Repair Manual March 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout error KWP = Keyword Protocol of short circuit to ground measurement cyl.
Page 187 March 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523008 Timeout error in Manipulation KWP = Keyword Protocol control FMI KWP Description 523009 Pressure Relief Valve (PRV) reached maximun allowed 4766...
Page 188 Service and Repair Manual March 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 Internal ECU monitoring detection reported error...
Page 189 March 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523615 Metering unit (Fuel-System); KWP = Keyword Protocol short circuit to battery low side FMI KWP Description 523615 Metering unit (Fuel-System);...
Page 190 Service and Repair Manual March 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523897 check of missing injector KWP = Keyword Protocol adjustment value programming (IMA) injector 3 (in firing order) FMI KWP Description 523898 check of missing injector...
Page 191 March 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523936 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame FMI KWP Description EEC3VOL2; Engine send messages 523922 1262 Burner Shut Off Valve;...
Page 192 Service and Repair Manual March 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524016 1259 Amount of air is not plausible to KWP = Keyword Protocol pump speed FMI KWP Description 524016 1260 Calculated amount of air is not...
Page 193 March 2018 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524108 9 1669 Timeout error of KWP = Keyword Protocol CAN-Transmit-Frame KWP Description ComEGRTVActr 524109 9 1679 Timeout error of 524035 12 1341 Injector diagnostics;...
Page 194 Service and Repair Manual March 2018 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol KWP Description 524120 9 1682 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag 524121 9 1683 Timeout error of CAN-Receive-Frame ComRxTrbChActr 524122 9...
Page 195: Perkins 854F-34T Engine Fault Code
March 2018 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Exhaust Gas Recirculation Valve Valve Position Sensor- Test Position :Voltage Above Normal Engine Exhaust Gas Recirculation Valve Valve Position Sensor - Test Position :Voltage Be- low Normal Accelerator Pedal Position 2 :Voltage Above...
Page 196 Service and Repair Manual March 2018 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Barometric Pressure :Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test Barometric Pressure :Voltage Below Normal Engine Pressure Sensor Open or Short Circuit - Test...
Page 197 March 2018 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit- Above Normal Test Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit -...
Page 198 Service and Repair Manual March 2018 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Injector Cylinder #02 :Current Below Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Current Above Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Data Drifted High Injector Data Incorrect- Test...
Page 199 March 2018 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test Valve :Erratic, Intermittent, or Incorrect 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test...
Page 200 Service and Repair Manual March 2018 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 2791 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve- Test Control:Current Below Normal 2791 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test Control :Current Above Normal...
Page 201 March 2018 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3219 After treatment #1 Intake Gas Sensor at Temperature : High- least Oxygen Level- Test severe (1) 3219 After treatment #1 Intake Gas Sensor at Temperature : Low - least...
Page 202 Service and Repair Manual March 2018 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3702 Diesel Particulate Filter Active Regeneration Inhibited Status : Current Indicator Lamp Circuit- Test Above Normal 4765 After treatment #1 Diesel Oxidation Catalyst Intake Gas...
Page 203: Schematics
March 2018 Service and Repair Manual Schematics Section 5 About This Section Schem atics There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.
Page 204: Wire Circuit Legend
Service and Repair Manual March 2018 Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the Control circuit prefix, circuit number and circuit suffix. Data The circuit prefix indicates the type of circuit. Engine The circuit number describes the function of Gauges the circuit.
Page 205 March 2018 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Auxiliary Boom Valve Engine Speed Select Alternator Field Axle Front Position Auxiliary Forward Valve Flashing Beacon Auxiliary Hydraulic Pump Function Enable Angle Fuel Select (gas/LP) Auxiliary Platform Valve Filter Restricted Auxiliary Reverse Valve Filter Switch...
Page 206 Service and Repair Manual March 2018 Wire Circuit Legend Suffix Definition Suffix Definition Jib Select Valve Platform Level Flow Control Jib Up Propel Lockout Jib Up/Down Control Primary Boom Extend/Retract Signal Load Sensor Platform Level Up Left Front Platform Rotate Control Left Front Steer Sensor Platform Rotate Flow Control Lockout...
Page 207 March 2018 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Right Rear Steer Sensor Starter Rotary Sensor Sec Boom Up/Down Flow Control Start Aid (Glow Plug or choke) Tilt Alarm X axis Secondary Boom Tilt Alarm Y axis Sec Boom Down Ground Control Sec Boom Extend...
Page 208: Wire Color Legend
Service and Repair Manual March 2018 Wire Color Legend Power Circuits Wire Coloring All cylinder extension colors are solid and all Primary boom down valve retract functions are striped black. When using Engine ignition / Fuel black wire, the stripe shall be white. Primary boom extend valve All rotations that are LEFT or CW are solid, Primary boom up valve...
Page 209 March 2018 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Primary boom up driver WH/RD Power to temp sender RD/BK Primary boom down driver Auxiliary Power RD/WH Primary boom up/down flow RD/BK Platform level alarm control proportional valve driver...
Page 210 Service and Repair Manual March 2018 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function GR/BK Axle oscillation Hydraulic Filter restricted Foot switch/TCON estop power Platform Level Safety Power RD/WH Boom down safety interlock RD/BK Platform Level Safety Output RD/BK Safety interlock to engine Platform Level Safety Ground...
Page 211 March 2018 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Flashing Beacon Primary Boom Angle Signal Safety Lift Speed Reduction Secondary Boom Angle Signal Hydraulic Pressure Sensor Safety Output BL/RD Drive Enable Left Oil Cooler Fan BL/WH Drive Enable Right...
Page 212 Service and Repair Manual March 2018 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Boom Length Signal Safety Safety cross check OR/BK Boom Length Signal Operational Data Receive BL/RD Primary Boom Hydraulic Valve BK/WH Data Transmit Lockout WH/RD Multi-Function Pressure Relief...
Page 213: Limit Switches And Angle Sensors
March 2018 Service and Repair Manual Limit Switches and Angle Sensors Limit Switch Legend 1 RSP1AO 14 Plat Angle Sensor 2 RSP1AS 15 PCON 3 LSP1RO 16 SCON 4 LST2O 17 RSRA1SO 5 LST1O 18 LSRA1ES 6 LST1S 19 RSLR1SO 7 LSS1RS 20 RSRR1SO 8 LSS1RO...
Page 214 Service and Repair Manual March 2018 Limit Switches and Angle Sensors Numbering Legend Types of Limit Switches Limit Front Circuit Load Operational There are two types of limit switches, found in Switch Axle Number moment Stringpot Rear Angle Safety various locations throughout the machine: Axle mechanical-type operational/safety switches and Rotary...
Page 215 March 2018 Service and Repair Manual Limit Switches and Angle Sensors Rotary Sensor Numbering LSFA1ES: Limit switch, Front Axle #1 Extended Safety. Prevents boom functions with the axles RSP1AO Primary boom angle sensor retracted. Switch closes when axles are fully extended.
Page 216 Service and Repair Manual March 2018 Limit Switches and Angle Sensors Rotary Sensor Functions RSRA1O: Rotary Sensor, Rear Axle #1 Operational. Provides front axle positioning RSP1AO: Rotary Sensor, Primary #1 Angle information for adjusting steering neutral setting Operational. Provides operational primary boom during axle extension.
Page 217: Circuit Connector Legend
March 2018 Service and Repair Manual Circuit Connector Legend Number Description Number Description Ribbon connector from TCON to membrane 2 pin Deutsch connector for primary boom up valve Ribbon connector from TCON to membrane 2 pin Deutsch connector for primary boom down valve Black 23 pin AMP connector on TCON 2 pin Deutsch connector for primary boom...
Page 218 Service and Repair Manual March 2018 Circuit Connector Legend Number Description Number Description 2 pin Deutsch connector for two-speed motor J121 12 pin Deutsch gray SCON connector stroke valve J122 12 pin Deutsch black SCON connector 2 pin Deutsch connector for right rear steer J124 2 pin Deutsch connector for drive enable right valve...
Page 219 March 2018 Service and Repair Manual Circuit Connector Legend Number Description Number Description J148 1 way Deutsch connector for platform J223 CAN Gateway 8 pin Molex connector ground jib/primary J224 Telematics connector J149 2 pin Deutsch connector, boom composite J228 Gateway to TCON interface connector J150 4 pin Deutsch connector, boom composite...
Page 220: Drive Chassis And Platform Controller Pin Legend
Service and Repair Manual March 2018 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 221: Safety Controller Pin Legend
March 2018 Service and Repair 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...
Page 222: Turntable Controller Pin Legend
Service and Repair Manual March 2018 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 223: Telematics Connector Pin Legend
March 2018 Service and Repair Manual Telematics Connector Pin Legend Genie installed Telematics connector is wired with an Active High digital input. Connector Pin Numbering Note: A Deutsch plug p/n DT06-08SA mates with the Genie Telematics connector Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case System Power 12 VDC...
Page 224: Engine Relay And Fuse Panel Legend - Deutz Td2011L04I
Service and Repair Manual March 2018 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 225: Engine Relay And Fuse Panel Legend - Deutz Td2.9
March 2018 Service and Repair Manual Engine Relay and Fuse Panel Legend - Deutz TD2.9 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...
Page 226: Engine Relay And Fuse Panel Legend - Perkins 1104D-44T
Service and Repair Manual March 2018 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...
Page 227: Engine Relay And Fuse Panel Legend - Perkins 854F-34T
March 2018 Service and Repair Manual Engine Relay and Fuse Panel Legend - Perkins 854F-34T 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...
Page 228: Electrical Symbols Legend
Service and Repair Manual March 2018 Electrical Symbols Legend Battery Motor Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid Connection - no Circuits crossing no Quick disconnect Circuit breaker with...
Page 229: Hydraulic Symbols Legend
March 2018 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve or motor) 3 way...
Page 230 Service and Repair Manual March 2018 This page intentionally left blank. ZX®-135/70 Part No. 1268558GT...
Page 231 March 2018 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic...
Page 232: Perkins 1104D Engine Electrical Schematic
Service and Repair Manual March 2018 Perkins 1104D-44T Engine Electrical Schematic ZX®-135/70 Part No. 1268558GT...
Page 233 March 2018 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic...
Page 234: Perkins 854F-34T Engine Electrical Schematic
Service and Repair Manual March 2018 Perkins 854F-34T Engine Electrical Schematic ZX®-135/70 Part No. 1268558GT...
Page 235: Perkins 854F-34T Engine Harness
March 2018 Service and Repair Manual Perkins 854F-34T Engine Harness Part No. 1268558GT ZX®-135/70...
Page 236 Service and Repair Manual March 2018 Perkins 854F-34T Engine Harness...
Page 237 March 2018 Service and Repair Manual Deutz TD2.9 Engine Electrical Schematic...
Page 238: Deutz Td2.9 Engine Electrical Schematic
Service and Repair Manual March 2018 Deutz TD2.9 Engine Electrical Schematic ZX®-135/70 Part No. 1268558GT...
Page 239: Deutz Td2.9 Engine Harness
March 2018 Service and Repair Manual Deutz TD2.9 Engine Harness Part No. 1268558GT ZX®-135/70...
Page 240 Service and Repair Manual March 2018 Deutz TD2.9 Engine Harness...
Page 241 March 2018 Service and Repair Manual Hydraulic Generator (Welder Option)
Page 242: Hydraulic Generator (Welder Option)
Service and Repair Manual March 2018 Hydraulic Generator (Welder Option) ZX®-135/70 Part No. 1268558GT...
Page 243: Generator Wiring Schematic
March 2018 Service and Repair Manual Generator Wiring Schematic Part No. 1268558GT ZX®-135/70...
Page 244 Service and Repair Manual March 2018 Generator Wiring Schematic...
Page 245 March 2018 Service and Repair Manual Hydraulic Schematic...
Page 246: Hydraulic Schematic (To Sn Zx13516H-2804)
Service and Repair Manual March 2018 Hydraulic Schematic (to SN ZX13516H-2804) ZX®-135/70 Part No. 1268558GT...
Page 247: Hydraulic Schematic (From Sn Zx13516H-2805)
March 2018 Service and Repair Manual Hydraulic Schematic (from SN ZX13516H-2805) Part No. 1268558GT ZX®-135/70...
Page 248 Service and Repair Manual March 2018 Hydraulic Schematic (from SN ZX13516H-2805)
Page 249: Electrical Schematic
OUT PWR ENABLE OPT GBOX OPER. REC. OR (~SM)+(AH) TO MICRO BOOM RET RECOVERY SIGNAL HARN SERV. OR Genie ZX-135/70 Vbb BTS621 BOOM DWN RECOVERY SIGNAL PWR IN SERV OR OUT 1 P22R RECOVERY PROVIDES ST OUT 2 BOOM EXT/RET FC RECOVERY SIGNAL...
Page 250: Electrical Schematic
OUT PWR ENABLE OPT GBOX OPER. REC. OR (~SM)+(AH) TO MICRO BOOM RET RECOVERY SIGNAL HARN SERV. OR Genie ZX-135/70 Vbb BTS621 BOOM DWN RECOVERY SIGNAL PWR IN SERV OR OUT 1 P22R RECOVERY PROVIDES ST OUT 2 BOOM EXT/RET FC RECOVERY SIGNAL...

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