Terex Genie ZX-135/70 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

ZX®-135/70

from ZX13514-2533 to

ZX13516H-

3199

Includes:

ZX13514-

2463

ZX13514-

2469

ZX13514-

2631

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

ZX135H-3200 to

ZX135H-

4000

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your

machine.

Part No. 1268558GT

Rev A5

March 2018

Service and Repair Manual March 2018

Introduction

ii ZX®-135/70 Part No. 1268558GT

Intr od ucti o n Intr od ucti o n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

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.

March 2018 Service and Repair Manual

Introduction

Part No. 1268558GT ZX®-135/70 iii

Revision History

Revision Date Section Procedure / Page / Description

A 9/2015

Initial Release

A1 11/2015 Schematics Limit Switch Legend

A2 5/2016 Repair Procedure 4-9

A3 9/2016 Introduction Serial Number Legend

A4 10/2016 Schematics Electrical / Hydraulic Schematics

3/2018

Repair Display Module

Reference Examples:

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual March 2018

Introduction

iv ZX®-135/70 Part No. 1268558GT

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

1 Sequence number

2 Serial label (located under cover)

3 Serial number (stamped on chassis)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

1 Serial label (located under cover)

2 Serial number (stamped on chassis)

March 2018 Service and Repair Manual

Safety Rules

Part No. 1268558GT ZX®-135/70 v

Section 1 Safet y R ul es

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.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual March 2018

Safety Rules

vi ZX®-135/70 Part No. 1268558GT

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol

—

used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates a imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could res

ult in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to

wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved

steel

-toed shoes.

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an

approved fire extinguisher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine

components and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are

in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self

-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

March 2018

Table of Contents

Part No. 1268558GT ZX®-135/70 vii

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 2Specifications .......................................................................................................1

Machine Specifications...........................................................................................1

Performance Specifications....................................................................................1

Hydraulic Oil Specifications....................................................................................2

Hydraulic Component Specifications......................................................................5

Deutz TD 2.9 Engine Specifications.......................................................................7

Deutz TD2011L04i Engine Specifications ..............................................................8

Perkins 854F-34T Engine Specifications .............................................................10

Perkins 1104D-44T Engine Specifications ...........................................................12

Machine Torque Specifications ............................................................................14

Hydraulic Hose and Fitting Torque Specifications ...............................................15

Torque Procedure ................................................................................................16

March 2018

Table of Contents

viii ZX®-135/70 Part No. 1268558GT

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..............................................27

How to Set the Function Thresholds and Default Functions Speeds..............28

How to Adjust the Function Speeds ................................................................30

How to Adjust the Function Ramp Rate Setting..............................................31

Platform Components ........................................................................................32

2-1 Platform ..........................................................................................................32

2-2 Platform Leveling Cylinder .............................................................................33

2-3 Platform Rotator .............................................................................................34

How to Bleed the Platform Rotator..................................................................35

2-4 Platform Level Sensor - How to Calibrate the Platform Level Sensor ...........36

2-5 Platform Overload System (if equipped) ........................................................37

2-6 Platform Overload Recovery Message ..........................................................39

March 2018

Table of Contents

Part No. 1268558GT ZX®-135/70 ix

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 .........................................................................48

3-6 Jib Boom Bellcrank Angle Sensor - How to Calibrate the Jib Boom Bellcrank

Angle Sensor ................................................................................................50

Boom Components ............................................................................................56

4-1 Primary Boom Cable Track ............................................................................57

How to Repair the Primary Boom Cable Track ...............................................59

4-2 Secondary Boom Cable Track .......................................................................60

How to Repair the Secondary Boom Cable Track ..........................................62

4-3 Primary Boom.................................................................................................63

4-4 Primary Boom Lift Cylinder ............................................................................65

4-5 Secondary Boom Lift Cylinder........................................................................66

4-6 Primary Boom Extension Cylinder .................................................................70

4-7 Secondary Boom Extension Cylinders...........................................................71

4-8 Primary Boom Angle Sensor - How to Calibrate the Primary Boom Angle

Sensor ..........................................................................................................73

4-9 Secondary Boom Angle Sensor - How to Calibrate the Secondary Boom Angle

Sensor ..........................................................................................................78

Engines................................................................................................................83

5-1 RPM Adjustment ............................................................................................83

5-2 Flex Plate .......................................................................................................83

How to Install the Flex Plate............................................................................84

March 2018

Table of Contents

x ZX®-135/70 Part No. 1268558GT

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 ..............................................................................................101

7-1 Function Pump .............................................................................................101

How to Prime the Function Pump .................................................................102

How to Adjust the Function Pump Standby Pressure ...................................102

How to Adjust the Function Pump Pressure Compensator...........................103

7-2 Drive Pump...................................................................................................104

How to Prime the Drive Pump .......................................................................105

Manifolds ...........................................................................................................106

8-1 Function Manifold Components....................................................................106

8-2 Valve Adjustments - Function Manifold........................................................110

8-3 Platform Manifold .........................................................................................112

8-4 Jib Boom Manifold........................................................................................114

8-5 Flow Control Mainfold...................................................................................116

8-6 Function Enable Valve .................................................................................117

8-7 Turntable Rotation Manifold .........................................................................118

8-8 Steer and Axle Manifold ...............................................................................120

8-9 Valve Adjustments - Steer and Axle Manifold ..............................................124

8-10 Traction Manifold Components ..................................................................126

8-11 Valve Adjustments - Traction Manifold.......................................................130

8-12 Drive Oil Diverter Manifold Components (welder option)...........................131

8-13 Valve Coils .................................................................................................132

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