Terex Genie ZX-135/70 Bedienungsanleitung

Service Manual

Serial Number Range

ZX-135/70

From ZX13513-2001

to ZX13514-

2532

(does not include

ZX13514-

2463,

ZX13514-2469

and

ZX13514-2531)

Part No.

218700

Rev F

September 2015

Service Manual September 2015

Introduction

ii ZX-135/70Part No. 218700

Intr od ucti on Intr od ucti on

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

maintenance procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also 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 Operator's, Parts,

Maintenance, and Service and Repair manuals.

218700 Rev F, September 2015

First Edition, 6L[WK Printing

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries.

“ZX” is a trademark of Terex South Dakota, Inc..

September 2015 Service Manual

Introduction

Part No. 218700 ZX-135/70 iii

Revision History

Revision Date Section Procedure / Page / Description

A 12/2012

Initial Release

A1 9/2013 Schematics Electrical Schematic

B 9/2013 Maintenance

Schematics

B-18, D-1

Electrical Schematic

B1 12/2013 Repair 4-8

C 4/2014 Specifications

Repair

Perkins 1104D-44T

4-8, 4-9

D 4/2014 Fault Codes

Specifications

Fault Codes

Performance Specifications

D1 6/2014 Maintenance B-19

D2 8/2014 Maintenance

Repair

Added B-20, Moved D-9 to C-8, C-1, C-3

1-2

D3 10/2014 Specifications

Repair

Deutz TD2011L04i

6-1

D4 11/2014 Specifications

Repair

Machine Specifications

Display Module, 4-8, 4-9

D5 11/2014 Specifications Performance Specifications

E 2/2015 Maintenance Checklist B, B-3, B-19, B-20, B-21, B-22, B-23, B-24

Repair 1-1, 3-6, 4-8, 4-9, 6-1, 6-2, 6-4, 8-5, 9-2

Display Module

Fault Codes Fault Matrix

Schematics Hydraulic Schematic

E1 5/2015 Maintenance B-23

Repair 6-1 (Recovery mode)

Reference Examples:

Section – Maintenance, B-3

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 Manual September 2015

Introduction

iv ZX-135/70 Part No. 218700

Revision History

Revision Date Section Procedure / Page / Description

F 9/2015 Repair 3-6, 4-8, 4-9, 6-1

Fault Codes Added Deutz TD2.9 L4, Perkins 854F-34T

Schematics Updated Perkins 1104D-44T

Added Perkins 854F-34T

Added Deutz TD2.9 L4

Electrical schematic

Reference Examples:

Section – Maintenance, B-3

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

September 2015 Service Manual

Introduction

Part No. 218700 ZX-135/70 v

Serial Number Legend

1 Model

2 Model year

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

Service Manual September 2015

Safety Rules

vi ZX-135/70 Part No. 218700

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.

September 2015 Service Manual

Safety Rules

Part No. 218700 ZX-135/70 vii

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 result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

y 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

approve

d 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, over

head 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.

September 2015

Table of Contents

viii ZX-135/70 Part No. 218700

Introduction Introduction .......................................................................................................... ii

Important Information ..............................................................................................ii

Find a Manual for this Model...................................................................................ii

Revision History .....................................................................................................iii

Serial Number Legend ........................................................................................... v

Section 1Safety Rules......................................................................................................... vi

General Safety Rules .............................................................................................vi

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

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

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

Hydraulic Specification........................................................................................... 2

Hydraulic Component Specifications ..................................................................... 4

Deutz TD2011L04i Engine Specifications ............................................................. 6

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

Perkins 1104D-44T Engine Specifications ............................................................ 8

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

Machine Torque Specifications............................................................................ 11

Hydraulic Hose and Fitting Torque Specifications ............................................... 12

Torque Procedure ................................................................................................ 13

SAE and Metric Fasteners Torque Charts........................................................... 14

September 2015

Table of Contents

Part No. 218700 ZX-135/70 ix

Section 3 Scheduled Maintenance Procedures ...............................................................15

Introduction...........................................................................................................15

Pre-Delivery Preparation Report ..........................................................................19

Maintenance Inspection Report............................................................................21

Checklist A Procedures .....................................................................................23

A-1 Inspect the Manuals and Decals....................................................................23

A-2 Perform Pre-operation Inspection..................................................................24

A-3 Perform Function Tests .................................................................................24

A-4 Perform Engine Maintenance – Perkins Models ...........................................25

A-5 Perform Engine Maintenance – Deutz Models ..............................................25

A-6 Check the Hydraulic Return Filter Condition Indicator ..................................26

A-7 Perform 30-Day Service ................................................................................27

A-8 Grease the Turntable Rotation Bearing and Rotate Gear .............................27

A-9 Replace the Drive Hub Oil .............................................................................28

September 2015

Table of Contents

x ZX-135/70 Part No. 218700

Checklist B Procedures..................................................................................... 29

B-1 Inspect the Batteries...................................................................................... 29

B-2 Inspect the Electrical Wiring .......................................................................... 30

B-3 Test the Key Switches ................................................................................... 32

B-4 Inspect the Engine Air Filter .......................................................................... 34

B-5 Check the Oil Cooler and Cooling Fins - Deutz Models................................ 35

B-6 Check the Exhaust System ........................................................................... 36

B-7 Confirm the Proper Brake Configuration ....................................................... 37

B-8 Inspect the Tires, Wheels and Lug Nut Torque............................................. 38

B-9 Check the Drive Hub Oil Level and Fastener Torque ................................... 38

B-10 Test the Platform Self-leveling .................................................................... 39

B-11 Test the Engine Idle Select Operation ........................................................ 40

B-12 Test the Ground Control Override ............................................................... 41

B-13 Test the Drive Brakes.................................................................................. 42

B-14 Test the Drive Speed – Stowed Position..................................................... 42

B-15 Test the Drive Speed – Raised or Extended............................................... 43

B-16 Test the Drive Speed – Raised and Extended ............................................ 44

B-17 Test the Alarm and Optional Flashing Beacon............................................ 44

B-18 Perform Hydraulic Oil Analysis.................................................................... 45

B-19 Test the Turntable Level Sensor ................................................................. 45

B-20 Test the Secondary Boom Angle Sensor .................................................... 47

B-21 Test the Primary Boom Angle Sensor ......................................................... 49

B-22 Test the Safety Envelope Limit Switches .................................................... 51

B-23 Test the Recovery Mode System ................................................................ 55

B-24 Inspect the Calibration Decal ...................................................................... 56

B-25 Inspect for Turntable Bearing Wear ............................................................ 57

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