from 13-2001 to 14-2532, ZX
Contents
1.2.
3. A B C D E F G H I J K L M TER AA A PRIMA
4. A A A AA AA AA AAA A AAA nn Qol o ojoo D2 w D wit o o EIER EISE S IER GRIES x 2 1 o e zri r EE a Q e ES HYD WELDER PROPEL BYPA
5. P Te O T 5 0 6 7 8 E T eo p O 2 O FR cop Gem eege e caz or CRI7 SCH e em F p Ke 1 2 3 4 B3BAT ra T 101200070 a a OHO r ETE O O 8 E l 17 7 ye Os VI ena Idi cms y O O b cri cns E OL NAN E r1 p NN au Number Component Description 1 CR77A PCE 1 2 CR2 Engine Alt 3 CR17 Hydraulic Oil Cooler Fan Relay 4 FX1 Fuse 30A ECU Power 5 FX2 Fuse 20A Key Switch Power 6 CR41 Flashing Beacon Relay 7 CR5 Horn Relay 8 F27 Fuse 20A RPM Solenoid 9 F23 Fuse 30A Eng Start Alt 10 F22 Fuse 60A Glow Plug 11 F7 Fuse 20A Hydraulic Oil Cooler Horn 12 B3BAT Fused Power from B1 13 B1BAT Power from Battery 14 R21PIGN Ignition 15 02PGND Ground 16 CR1 Engine Starter 17 CR81 ECU Power Genie Part No 218700 ZX 135 70 269 Service Manual September 2015 Electrical Symbols Legend t F Battery Motor Horn or alarm Flashing beacon Gauge F1 FS de ele BK 5 25A SCH Diode Hour meter LED
6. een Ee O PAS Li Ly A AAA L O pe mom OA L L L oe Il cms CRI7 A ee P oe 1 2 3 4 B1PBAT OCHO EE HO C S OO O O So S ei O Ohi 4 CR41 CR5 CR1 CR15 OS AO ES S 2 r A H u ur KO 2 Number Component Description 1 CR77 Function Enable Relay 2 CR28 Start Relay 3 CR17 Hydraulic Oil Cooler Fan Relay 4 CR41 Flashing Beacon Relay 5 CR5 Horn Relay 6 CB10 Circuit Breaker 20A Hydraulic Oil Cooler Horn 7 F23 Fuse 30A Eng Start Alt 8 F22 Fuse 60A Glow Plug 9 F7 Fuse 20A Hydraulic Oil Cooler Horn 10 B3PBAT Fused Power from B1 11 B1PBAT Power from Battery 12 R21PIGN Ignition Fuse 20A RPM Solenoid 13 02PGND Ground 14 CR1 Start Relay 15 CR15 Glow Plug Relay Genie A TEREX BRAND 268 ZX 135 70 Part No 218700 September 2015 Service Manual Engine Relay and Fuse Panel Legend Perkins 854F Models Perkins 854F 34T Models
7. p e O T 5 0 D 7 8 e O p O d pF27 Cd Q Pes y Pt CR77 CR2 CRIT O y deed E PH 99 O 120 0400 cH O nTe O cH O C OTOH R21PIGN 4 losa e h e CR28 CR41 CR5 CR39 CR15 OS 7A V oda E mi o L1 dn p xd yo ee u ues Component Description CR77 PCE 1 CR2 Engine Alt Relay CR17 Hydraulic Oil Cooler Fan Relay CR28 Fuel Pump CR41 Flashing Beacon Relay CR5 Horn Relay F27 Fuse 30A ECU Power F23 Fuse 30A Eng Start Alt F22 Fuse 60A Glow Plug F7 Fuse 20A Hydraulic Oil Cooler Horn B3BAT Fused Power from B1 B3BAT Fused Power from B1 R21IGN Ignition 02GND Ground CR39 Engine Shutdown CR15 Glow Plug Relay Genie Part No 218700 ATEREX BRAND ZX 135 70 267 Service Manual September 2015 Engine Relay and Fuse Panel Legend Perkins 1104D 44T Perkins 1104D Models
8. SA O qu Lg Y Lr a n UII D a mA E 5 6 7 8 N O a eBio ATS BIPBAT E O L e CY EL J DT M CR28 CR17 up Ip FK D I 1 2 3 4 B asrar OHOOHO C E FOO e 3 E e EON 13 53 il 1 O O i i 1 CR41 CR5 De CR1 CR15 B eran Hr E yl EN Z n nun O O Number Component Description 1 CR28 Start Relay 2 CR17 Hydraulic Oil Cooler Fan Relay 3 CR41 Flashing Beacon Relay 4 CR5 Horn Relay 5 CB10 Circuit Breaker 20A Hydraulic Oil Cooler Horn 6 F23 Fuse 30A Eng Start Alt 7 F22 Fuse 60A Glow Plug 8 F7 Fuse 20A Hydraulic Oil Cooler Horn 9 B1PBAT Power from Battery 10 B3PBAT Fused Power from B1 11 R21PIGN Ignition Fuse 20A RPM Solenoid 12 02PGND Ground 13 CR1 Start Relay 14 CR15 Glow Plug Relay Genie 266 ZX 135 70 Part No 218700 September 2015 Service Manual Engine Relay and Fuse Panel Legend Deutz TD2 9 Models Deutz TD2 9 Models Number ON Oo Om 50 MM A c 11 12 13 14 15 16
9. ees Boom Components 44 Press the enter or previous button on the LCD SCREEN UNTIL SECONDARY BOOM FULLY RAISED is displayed 45 Press the plus button to select YES then press the enter button to accept 46 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 47 Press the enter or previous button on the LCD screen until EXIT is displayed 48 Press the plus button to select YES then press the enter button to accept 49 Turn the key back to the run position and remove the key from the bypass recovery key Switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine 50 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 51 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 52 Pull out the red Emergency Stop button Start the engine and lower the boom
10. z U en DU 9 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 10jib boom lift cylinder 5 platform rotator 11 jib boom cable track 6 platform leveling cylinder 12 jib boom leveling cylinder Genie ATEREX BRAND Part No 218700 ZX 135 70 103 Service Manual September 2015 Jib Boom Components 3 1 5 Pullthe hoses out of the plastic hose guide located on the primary extension boom near Jib Boom Cable Track the jib boom manifold The jib boom cable track guides the cables and 6 Tag disconnect and plug the jib boom lift hoses running up the jib boom It can be repaired cylinder hydraulic hoses Cap the fittings on link by link without removing the cables and hoses the cylinder that run through it Removing the entire jib boom Bodily int rv hazard Soravif cable track is only necessary when performing A WARNING y injury Spray ng A f hydraulic oil can penetrate and major repairs that involve removing the jib boom burn skin Loosen hydraulic connections very slowly to allow How to Remove the Jib Boom the oil pressure to dissipate gradually Do not allow oil to Cable Track a Note When removing a hose assembly or fitting D the O ring if equipped on the fitting and or hose 7 Remove the hose and cable clamp retaining end
11. Checklist A Checklist B R A 1 Inspect the manuals B 1 Batteries and decals x B 2 Electrical wiring A 2 Pre operation a inspection B 3 Key switches A 3 Function tests B 4 Inspect air filter A 4 Engine maintenance B 5 Oil cooler and fins Perkins models Deutz models A 5 Engine maintenance B 6 Exhaust system Deut del SE B 7 Brake configuration A 6 Filter condition indicator B 8 Tires and wheels Perform after 40 hours B 9 Drive hub oil A 7 30 day service B 10 Platform leveling Perform after 100 hours B 11 Engine idle select A 8 Rotation Bearing B 12 Ground control override Perform after 150 hours B 13 Drive brakes AT Drive Nubo B 14 Drive speed stowed B 15 Drive speed raised or extended B 16 Drive speed raised and extended B 17 Alarm package B 18 Hydraulic oil analysis B 19 Turntable level sensor B 20 Secondary boom angle sensor B 21 Primary boom angle sensor B 22 Safety envelope limit switches B 23 Recovery mode B 24 Calibration decal Perform after 3 months B 25 Turntable bearing wear Comments Genie ZX 135 70 21 Service Manual Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions e Make copies of this report to use for each inspection e Select the appropriate checklist s for the type of inspection s to perf
12. D CO N V60AXEX GR WH Ans Y99 AXLE EXTEND J99 I EE zl V61AXRT GR libs Y100 AXLE RETRACT J100 VLVRET1 BR 16 N co st LO co N co O EN Gi Y at Genie Sweden Phone 0046 3157 5101 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 900 808 110 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 810 Fax 0049 4221 491 820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
13. Pump prime mover engine or motor Shuttle valve 2 position 3 way Differential sensing valve valve 200 psi __ 13 8 bar 1 Relief valve with pressure setting Priority flow regulator EN Solenoid operated proportional valve I bowel Pressure reducing valve 50 50 N Flow divider combiner valve AN Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional Counterbalance valve with pressure and pilot ratio Solenoid operated 3 position 4 way directional valve Part No 218700 Genie ATEREX BRAND Pilot operated 2 position 2 way directional valve e valve EE a H Es di eo uei Sick ES Lt Se Lot i Eom T Ae e se 1 T 2 position 2 way solenoid valve ZX 135 70 271 Service Manual September 2015 c NON MA U A I This page intentionally left blank Genie ATEREX BRAND 272 ZX 135 70 Part No 218700 273 September 2015 Service Manual lll 1 Perkins 1104D 44T Engine Electrical Schematic September 2015 Service Manual
14. Note There are four hydraulic filters on the machine one tank return filter one medium EE pressure filter one high pressure filter and one Result The needle on the gauge should be drive motor case drain filter Only the tank return operating in the green area filter has a condition indicator amp i Result If the needle is in the red area the hydraulic filter is being bypassed and the filter needs to be replaced Refer to Maintenance 2 Press and release the engine idle select Procedure Replace the Hyaraulic Filter button to change the engine rpm to high idle Elements 1 Start the engine from the ground controls Genie ATEREX BRAND 26 ZX 135 70 Part No 218700 September 2015 Service Manual A 7 Perform 30 Day Service The 30 day maintenance procedure is a one time procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Berform the following maintenance procedures e A 8 Grease the Turntable Rotation Bearing and Rotate Gear e B 8 Inspect the Tires Wheels and Lug Nut Torque e B 9 Check the Drive Hub Oil Level and Fastener Torque e D 5 Replace the Hydraulic Filter Elements e D 8 Check the Turntable Rotation Bearing Bolts Part No 218700 Genie ATEREX BRAND ZX 135 70 27 Checklist A Procedures A 8 Grease the Turntable Rotation Bearing and Rotate Gea
15. i e Plus Minus Previous Enter Activation of the enter or previous buttons scrolls through the screens To change parameter values or select a setting use the plus button to increase or scroll forward and the minus button to decrease or scroll backwards Then press the enter button to save the new value to memory An audible beep will indicate a save to memory Use the enter and previous buttons to scroll to the ExIT menu Use the plus button to change to YES and use the enter button to exit Screen or Menu Procedure Description Range or Selection Operator Default Hourmeter on power up Engine speed Engine oil pressure PSI English Engine oil pressure kPa metric Engine temperature F Engiish engine temp will not display until temp is gt 100 F Engine temperature C metric engine temp will not display until temp is gt 38 C Primary boom angle to gravity Turntable level sensor X direction Turntable level sensor Y direction Platform level sensor degree Battery volts Genie A TEREX BRAND 150 ZX 135 70 Part No 218700 September 2015 Service Manual AA AA A A A A Display Module Screen or Menu Procedure Description Range or Selection Machine Status With key switch on press the plus minus buttons at the same time Hydraulic pressure PSI English Hydraulic pressure kPa metric Primary boom t
16. HORN PWR RD 5 1 Q e 30 gt VLVRET2 BR lt VLVRET3 BUBK a cc a z z z z 5 n S 38 amp VLVRET2 BL amp ES amp Er e 2 ER lt lt VLVRETI GR E E E zou o N D a n BSR 4 GEN ON OFF GRIWH aoe zZ d p 5 CHANNEL 2 NOT USED O 2 2 2 5 suzet 5 RI 8 R 8 5 E 2928 R 2 E E OTT x E 5 Sz amp zr E 3 amp yaw G gt P HORN RTN GR NOT useo zz 8 8 3 3 we 5 VALVE RETURN P22 34 C148JBS BL WH 5 GRIBK gt gt YL E SE o di ELEVATED E NEIBETZER P110JBS BK WHBK II BK 2 oe E p22 8 P109JBS GRIWH nk WH a qmm a JIB SENSOR SIGNAL P22 322 C148JBS BL WH 2 a x HORN PWR RD l m E 5 gt JIB SENSOR GROUND P22 31 P110JBS BK V147JBD BLIBK 2 lt lt RDIBK A Y86 JIB BELLCRANK DOWN J136 gt JIB SENSOR POWER P22 30 P109JBS GR WH V146JBU BL amp RD Cares Y85 JIB BELLCRANK UP J135 O De JIB BELLCRANK LEVEL DOWN P22 29 V147JBD BL BK LL 4 Rs BELLCRANK LEVEL UPP22 28 V146JBU BL NOT USED P2227 i 6 GND1 BR SAFETY CUTOUT E NOT USED P222 amp Sa 5 C158STC BL RD WS 7 Z C160 PL WHIRD NOTUSED E x 5 4 o Ox 3 Gegen NOT USED 22 242 ar Fer Power re 22 T w p C Z P162JPW OR SAFE PLTILT PWR P22 23 P87PTS RD 10 DEG O 5 E amp 2 5 d E a Ede 1 JSGND1 BR U20 SAFE PLTILT GND P22 22 P87RET BR E om kon 35 pE E Cis PLTILT SNSR PWR P2221 P85PTS GR 0 20 DEG Y AX
17. Auxiliary Pump Specifications Type fixed displacement gear pump Displacement per revolution 0 15 cu in Drive Pump 2 47 cc Type bi directional variable displacement piston pump Function manifold Displacement per revolution 2 8 cu in System relief valve pressure maximum 3100 psi 46 cc measured at test port 213 7 bar Flow rate 2350 rpm 28 5 gpm Primary boom extend relief pressure 2600 psi 108 L min measured at ptest port 179 bar Drive pressure maximum 3625 psi Jib and platform manifolds 290 par Platform rotate and platform level flow 0 2 gpm Charge Pump regulator 0 76 L min Type gerotor Jib manifold flow regulator 2 gpm Displacement per revolution 0 85 cu in 7 6 L min 13 9cc Steer Axle Manifold Flow rate 2350 rpm 9gpm Axle extend relief pressure 2400 psi 34 L min 165 bar Charge pressure 2350 rpm 315 ps Traction Manifold Neutral position 21 7 bat Hot oil relief pressure 250 psi Function pump 17 2 bar Type variable displacement piston pump Hydraulic Filters Displacement per revolution 0 to 2 75 cu in High pressure filter Beta 3 gt 200 to 4 oa High pressure filter bypass pressure 102 psi Flow rate 2350 rpm 0 to 28 gpm 7 bar to 1 i E Medium pressure filter Beta 3 2 200 Pressure maximum 2900 psi s Medium pressure filter bypass pressure 51 psi 200 bar 3 5 bar Gene SD SANE SC har Hydraulic tank return filter 10 micron with 25 psi Standby pressure 250 psi 1 7
18. September 2015 Service Manual Fault Codes Error Source Error Type Effects Recovery Actions Rear Axle Angle Sensor Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Value at 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Out of Tolerance Primary up Secondary up down and Extend disabled Alarm sounds Recalibrate sensor Not calibrated Primary up only active from TCON activate alarm Perform calibration procedure per service manual Just calibrated Initiate one second beep of audible warning device Self clearing transient Propel Joystick Value at 5 0 V Value Too High Value Too Low Value at 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrat
19. 6 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 1 Run 2 Bypass 3 Recovery 7 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 8 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus Part No 218700 September 2015 Service Manual Aa A A A AA EE AA MNT Turntable Rotation Components 9 Press the enter or previous button on the LCD screen until SET UNIT X AXIS LEVEL TO GRAVITY is displayed 10 Place a digital level that has ben calibrated to gravity on the X axis of the turntable Note Illustrations shown at the platform end of the machine negative degree side slope Genie ATEREX BRAND 11 Press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown
20. WHT NEUTRAL L 120V AC gt AUTO e RESET CB 4 L BLK 120VAC e e 15A 5 6 7 8 Genie ZX 135 70 283 Service Manual September 2015 AE Generator Wiring Schematic 284 September 2015 Service Manual Be Hydraulic Generator Welder Option 285 Service Manual September 2015 Tr a a U Hydraulic Generator Welder Option A B C D E F G H J K L M PIN D DR ow Bu mee t WH O30EDO S WH BK Sr 4 BR ND2 5 BR GND3 6 WH csopor 9159 7 WHK C31EDC A 8 GR WH CASGEN A GRANH ee E A s ECH 11 RD B3ENG TCON E E 5 5 2 tp a J amp n 23 con 3 i A EN d Et E A mon mn mom mm nommen x _ TIME DELAY MODULE A A 4 SECOND ek kb i eg e DL LL roses 1 SECONI 3 8 B GROUND 2 di 2 SENSOR POWER 5 DG Se U36 T E E 124 ohma E 200M E a V151HG GR a VABET SC GOIL T t m g D V150HG GR BK B3 DIGITAL OUTPUT BYPASS OMRON SSWINEUT i A a gt A gt RS232DD 01 TD d a a 3128 BS RS232mD 02 AD E e E o d Ca BOOT g 3 rese 4 Se ls H RO 8 kri V 4 Hl 3 4 a 8 in Di ANALOG 0 JOYSTICK 5 8 DIO lt CR5
21. 176 271 270 366 280 379 380 515 320 433 298 300 406 310 420 420 569 350 474 433 430 583 450 610 610 827 sio 691 474 470 637 500 678 670 908 560 759 640 867 680 922 910 1233 770 1044 718 710 962 750 1016 990 1342 840 1139 800 908 1138 1120 1518 1360 1844 1820 2467 1530 2074 1260 1979 tose 200 2379 3218 3180 do a a 3620 2223 3000 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 4 6 Class 8 8 Class 10 9 3 Class 12 9 23 D e amp 711 37 57 64 muda I e 14 20 2 L 2 120 el 12 18 a 110 18 130 10 200 16 220 9 EW 8 112 Zeep 12 7 320 350 530 7 670 7 840 1 14 42 930 a ES 7460 2 1640 Co o p N gt c D m i S x r c D m D i di d D r 2 L dm c D m d S L o Qo Co Co 00 ka Si Sl o So o O 5 Ins colo we BERN BER E lola C2 food Kors PIN le o m lala lo alo o en oo EM ole o le wo a m E ci elo ual NIRI R Silvia a NIA Ko co I o u INS ou IND Nm 32 6 7 81 110 108 147 202 274 269 365 610 525 3 715 970 210 285 420 570 562 762 583 791 778 1055
22. 2 Remove the filter element 3 Use a damp cloth to wipe the filter sealing surface and the inside of the outlet tube Make sure that all contaminant is removed before the filter is inserted Genie part number 123702 4 Check new filter element gasket for damage before installing 5 Install the new filter element 6 Install the end cap on the canister and secure Note Be sure the discharge slot is pointing down Genie Part No 218700 ZX 135 70 59 Service Manual September 2015 Checklist C Procedures C 5 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent A TEREX BRAND 60 ZX 135 70 Genie Part No 218700 September 2015 Service Manual C 6 Test the Platform Overload System if equipped Genie specificatio
23. ATIRDI vi ZX 135 70 Part No 218700 September 2015 Service Manual 8 Test all machine functions from the platform controls O Result All platform control functions should operate using the auxiliary pump except for boom lift and extend which are disabled 9 Turn the key switch to ground controls 10 Test all machine functions from the ground controls O Result All platform control functions should operate using the auxiliary pump except for boom lift and extend which are disabled 11 Lift the test weights off the platform floor using a suitable lifting device O Result The platform overload indicator light and alarm should turn off at both the ground and platform controls Note There may be an 2 second delay before the overload indicator lights and alarm turn off 12 Test all machine functions from the ground controls Result All ground control functions should operate normally 13 Turn the key switch to platform controls 14 Test all machine functions from the platform controls O Result All platform control functions should operate normally Note If the platform overload system is not operating properly Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped Part No 218700 Genie ATEREX BRAND ZX 135 70 63 Checklist C Procedures C 7 Check and Adjust the Engine RPM Genie specifications require that this procedure be performed
24. Install the steer sensor cover retaining fasteners Do not tighten the cover retaining fasteners Connect the steer sensor assembly cable to the main harness Calibrate the steer sensor Refer to Repair Procedure How to Calibrate a Replacement Steer Sensor Note Be sure the yoke pivot pin retaining plate is fully engaged into the pivot pin and that the fasteners are securely tightened Right front square end yellow side and left rear circle end blue side angle sensors I A GG Li Dei AD Illustration 3 installed position starting position sensor cover rotation arrow bona 196 10 11 Position the new steer sensor assembly over the sensor activator pin with the sensor cable angled away from the tire Refer to Illustration 3 Align the sensor with the pin and install the sensor on to the pin Note Be sure the sensor activator pin is engaged into the sensor 12 13 14 15 Rotate the sensor housing in a clockwise direction until the sensor cable is pointing away from the machine Refer to Illustration 2 Install the steer sensor cover retaining fasteners Do not tighten the cover retaining fasteners Connect the steer sensor assembly cable to the main harness Calibrate the steer sensor Refer to Repair Procedure How to Calibrate a Replacement Steer Sensor Note Be sure the y
25. Tighten the low idle lock nut and confirm the rpm A 4 Ades OJO 1 low idle adjustment screw 2 solenoid boot 3 yoke lock nut Checklist C Procedures 7 Press and hold the function enable high speed button Note the engine rpm on the display Result High idle should be 2350 rpm If the high idle is correct disregard adjustment step 8 8 Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm Note Be sure the solenoid fully retracts when activating high idle 9 Check for excessive movement in the linkage bar pins W Result If there is excessive wear in the linkage the linkage bar should be replaced 10 Remove the engine pivot plate retaining fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 11 Swing the engine pivot plate in towards the machine 12 Install the bolt that was just removed into the original hole to secure the engine pivot plate AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Genie ATEREX BRAND Part No 218700 ZX 135 70 65 Service Manual September 2015 Checklist C Procedures C 8 Inspect for Turntable Bearing Wear Genie requ
26. fasteners Remove the platform control box and set it aside Remove the air line to platform bracket retaining fasteners if equipped Remove the power to platform cover plate from the electrical outlet box Do not disconnect the wiring AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry mounting weldment may become unbalanced and fall if it is not properly supported 8 Remove the power to platform electrical outlet box from the platform and lay it to the side Genie Part No 218700 ZX 135 70 95 Service Manual September 2015 Platform Components 2 2 Platform Leveling Cylinder The platform leveling cylinder keeps the platform level through the entire range of boom motion The platform is maintained level to the turntable To accomplish this the ECM at the ground controls compares the difference in readings between the platform angle sensor and the turntable level sensor which then sends a signal to the platform controls to open or close the appropriate platform level proportional valve on the platform manifold to maintain a level platform The platform leveling cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Cylinder Note When removing a hose assembly or fitting the O ring if equipped
27. Ground or Return Wire Color Legend Color Circuit Primary Function Color OR 166 Boom Length Signal Safety GR OR BK 167 Boom Length Signal Operational BK BL RD 168 Primary Boom Hydraulic Valve BK WH Lockout WH RD GR 169 Envelope Active LED WH BK WH RD 170 Load Sense Relay Source WH RD WH BK 171 Load Sense Relay Sink WH RD BL 172 UP DN Flow Control Ground OR RD BK 173 Ext Ret Flow Control Ground YL WH 174 Key Switch Power Ground WH Position WH BK 175 Load Sensor Signal Operational BD GR WH 176 Secondary Extend Retract FC ne BL RD 177 Extend Retract Lockout ee BK 178 Control Module Status Light SN GR 179 Drive Power Relay YL BK 180 Lift Power Relay OR 181 48 Volt Alternator field or Battery BR RD 182 24 Volt Battery BL 183 Envelope or Load Sense Recovery WH 184 Program setup Enable WH 185 Encode A BL 186 Encode B BL 187 Bootstrap or Program Enable Genie 254 ZX 135 70 Part No 218700 September 2015 Service Manual Limit Switches and Angle Sensors Limit Switch Legend 100 Hp A SR No N A j 17 A CO A b NS PCON SS AO DCON L K Z 1 RSP1AO 14 Plat Angle Sensor 2 RSP1AS 15PCON 3 LSP1RO 16 SCON 4 LST20 17 RSRA1SO 5 L
28. Normal Test 110 4 Engine Coolant Temperature Voltage Below Engine Temperature Sensor Open or Short Circuit Normal Test 110 15 Engine Coolant Temperature High least Coolant Temperature Is High severe 1 110 16 Engine Coolant Temperature High moderate Coolant Temperature Is High severity 2 152 2 Number Of ECU Resets Erratic Intermittent or ECM Memory Test Incorrect 157 0 Engine Injector Metering Rail 1Pressure High Fuel Rail Pressure Problem most severe 3 157 2 Engine Injector Metering Rail 1 Pressure Fuel Rail Pressure Problem Erratic Intermittent or Incorrect 157 3 Engine Injector Metering Rail 1 Pressure Engine Pressure Sensor Open or Short Circuit Voltage Above Normal Test 157 4 Engine Injector Metering Rail 1 Engine Pressure Sensor Open or Short Circuit Pressure Voltage Below Normal Test 157 10 Engine Injector Metering Rail 1 Pressure Engine Pressure Sensor Open or Short Circuit Abnormal Rate of Change Test 157 16 Engine Injector Metering Rail 1 Pressure High Fuel Rail Pressure Problem moderate severity 2 157 17 Engine Injector Metering Rail 1Pressure Low Fuel Rail Pressure Problem least severe 1 157 18 Engine Injector Metering Rail 1Pressure Low Fuel Rail Pressure Problem moderate severity 2 168 3 Battery Potential Power Input 1 Voltage Above Ignition Keyswitch Circuit and Battery Supply Circuit Normal Test 166 2 Engine Rated Power Erratic Intermittent or ECM Memory Test
29. Platform Angle Sensor Measures the angle of the platform The range of measurement is 20 degrees The safety cutout is set at 10 degrees from gravity and will disable the primary and secondary boom up down functions and the platform level up down functions Jib Bell Crank Angle Sensor Measures the angle of the jib bell crank The range of measurement is 60 70 degrees Safety Controller SCON Redundant dual axis tilt sensors measuring the X and Y tilt angles of the turntable Also provides safety switch logic for function cut off Alarm sounds at 4 5 degrees Part No 218700 Genie ATEREX BRAND ZX 135 70 LSFA1ES Limit switch Front Axle 1 Extended Safety Prevents boom functions with the axles retracted Switch closes when axles are fully extended LSRA1ES Limit switch Rear Axle 1 Extended Safety Prevents boom functions with the axles retracted Switch closes when axles are fully extended LST10 Limit switch Turntable 1 Operational Activates the drive enable zone when the turntable is rotated in the left direction LST20 Limit switch Turntable 2 Operational Activates the drive enable zone when the turntable is rotated in the right direction LST1S Limit switch Turntable 1 Safety Prevents the turntable from rotating out past either rear tire when axles are retracted LSS1RO Limit switch Secondary Boom 1 Retracted Operational NOHC when secondary boom is fully retracted Us
30. Safety Rules 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 M 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 AN 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 gt Be sure to properly dispose of old oil or o other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area a is properly ventilated and well lit September 2015 ECC EE A A Table of Contents Introduction INtFOUCtION coastal ii Important Information did ii Find a Manual for this Model ii Revision History 0 00 eee cece ee ceeeee ee nono eter noo nn cnn rn ene nn rra iii Serial Nu
31. YES NO jib level calibration deg to gravity 60 jib level calibration deg to gravity 34 jib level calibration deg to gravity 8 jib level calibration deg to gravity 18 jib level calibration deg to gravity 44 jib level calibration deg to gravity 70 Screen or Menu Procedure Description Range or Selection Genie ATEREX BRAND 156 ZX 135 70 Part No 218700 September 2015 Service Manual AA AA A A A A Display Module Sensor With key switch OFF press and hold Set unit X axis to gravity Calibration the enter button and turn key switch to on position Release the enter button and press plus enter enter plus software version 4 01 and higher Set unit Y axis to gravity Set platform level to gravity YES NO Platform level sensor millivolts degree Delete axles angle sensors calibration YES NO YES Axle angle fully retracted YES NO YES Axle angle fully extended YES NO Delete all steer sensors calibrations YES NO Delete blue end blue side steer sensor FL calibration YES NO Delete yellow end blue side steer sensor RL calibration YES NO Delete blue end yellow side steer Use buttons to adjust sensor FR calibration YES NO Delete yellow end yellow side steer sensor RR calibration YES NO Delete secondary boom angle sensor calibration YES NO Secondary boom fully lowered YES NO Secondary boom fully
32. 10 Check the ambient air temperature and adjust ne SEENEN the specific gravity reading for each cell as follows Maintaining electrical wiring in good condition is e Add 0 004 to the reading of each cell for essential to safe operation and good machine every 10 F 5 5 C above 80 F 26 7 C performance Failure to find and replace burnt chafed corroded or pinched wires could result in e Subtract 0 004 from the reading of each cell unsafe operating conditions and may cause for every 10 F 5 5 C below 80 F 26 7 component damage C Result All battery cells display a specific A WARNING EC oe emat itv of 1 277 ter The battery is full Contact with electrically charged a a Pr a SEH Ke circuits could result in death or A IA serious injury Remove all rings Result One or more battery cells display a watches and other jewelry specific gravity from 1 218 to 1 269 The battery is still usable but at a lower 1 Remove the engine pivot plate retaining performance The battery will need to be fastener Swing the engine pivot plate out recharged more often Proceed to step 11 away from the machine Result One or more battery cells display a H specific gravity from 1 217 to 1 173 The en battery is approaching the end of it s life A vam Proceed to step 11 De A p EE CT a E b zen amp Result The difference in specific gravity n Cea readings between cells is greater than 0 1 OR the specific gravity of one or more ce
33. 6 Inspect the following areas for burnt chafed e Cable track on the boom corroded pinched and loose wires e Cables on the boom jib boom and jib boom e Inside of the ground control box pivot area e Hydraulic manifold wiring e Jib boom platform rotate manifold e Battery area wiring e Platform control box e Hydraulic oil cooler wiring e Inside of the platform control box 7 Inspect for a liberal coating of dielectric grease 15 t for a liberal coating of dielectri in ihe following locations nspect for a liberal coating of dielectric grease in the following locations s All wire harness connectors to ground e All wire harness connectors to platform control box control box e Wire harness connectors to SCON module 16 Remove the engine pivot plate retaining 8 Open the hydraulic manifold box covers at fastener from the engine pivot plate anchor both sides of the drive chassis hole at the pivot end of the engine pivot plate 9 Inspect the following areas for burnt chafed 17 Swing the engine pivot plate in towards the corroded pinched and loose wires machine e Hydraulic manifold wiring 18 Install the bolt that was just removed into the original hole to secure the engine pivot plate 10 Inspect for a liberal coating of dielectric grease in the following locations AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury e Wire harne
34. CALIBRATED it will be necessary to enter the valve calibration menu 12 Start the engine from the platform controls 13 Select a function that needs the function speed set 14 Primary boom up down and extend retract functions Move the joystick full stroke in the up or extend direction When the alarm sounds move the joystick in the opposite direction full stroke until the alarm sounds again Return the joystick to center Secondary boom up and down functions Starting from the stowed position move the joystick full stroke in the up direction When the alarm sounds move the joystick in the down direction full stroke until the alarm sounds again Return the joystick to center Turntable rotate function fully retracted Move the rotate joystick full stroke in either the left or right direction until the alarm sounds Return the joystick to center Part No 218700 Genie ATEREX BRAND ZX 135 70 93 Platform Controls Turntable rotate function primary boom extended Extend the primary boom approximately 4 ft 1 2 m Move the rotate joystick full stroke in either the left or right direction until the alarm sounds Return the joystick to center Turntable rotate function primary and jib booms extended With the primary boom extended approximately 4 ft 1 2 m extend the jib boom approximately 1 ft 0 3 m Move the rotate joystick full stroke in either the left or right direction until the alarm sounds Return
35. GLP NN He As ms m el ow del ri Ge i me E RFB ooo of A B 6 D FSRR E STEER AXLE f NUM tid ME Zu 4 4 th MANIFOLD i Z PLATFORM ROTATE 6 i s i E 50 IN Ta Y pi 930 GPM 71 1 LPM a Y Ze A DU agy d Sale m lz n E f E IN S ax nx A A E E E o n am WW Ss SC COUNTERBALANGE VALVES IE E ee a P PE 5 Maps ERE E 1 Gil WELDER MANIFOLD WELDER OPTION RATIO PRESS pte i i xt 0 I 5 22GPM 83LPM li A i af I Gr 3 1 1000 PSI AG bs PRR owl E om ipe URB L oso 8 i ILB EE A PMPA IMRA 4 CA c8 3 1 1250 PSI IS Tee a Ee z 8 Mela E i i F i poa 3 1 1500 PSI l NNI tw dE UMP DRIVE ET HYDRAULIC 45 1 2000 PSI PLATFORM LEVEL 7 LLIT l 1 y A i l L fill PUMP 15 8 BAR W ROTARY em CP 1 1 2500 PSI 0 9 0 7 GPM 3 4 2 6 LPM i L A l DO w d m A Ee X COUPLER aeoea 3 1 2500 PSI x ie I I as II LEFT M K P FRONT jil I GE GF pg pc l AS BLU W e l REAR LRAT 404 0 a B PMPB Se T MRB 8 DD DE Gv cw 3 1 3000 PSI Pi ZS A AAA TIP AT AAA Ji EN E se cH 0N 45 1 3000 PSI T i E 1 BY 3 EE s eco TL ler er herren ee esp ZIP Velo 3 1 3300 PSI E PLD L HL i r Ben ao 24 GENERATOR oncooen eea 1 53 3500 PSI NE i Lx m EOS ae EE S Lauter LE an a 2 1 4000 PSI PLATFORM MANIFOLD oe Loo RRB U EE RBK ol J 0 et S ene 45
36. Genie A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Fault Codes SAFETY SWITCH FAULT Error Source Error Type Effects Recovery Actions Safety Switch P10 Fault Check Display message on LCD P10 Recycle power SAFETY SWITCH FAULT Safety Switch P11 Fault Check Display message on LCD P11 Recycle power and check wiring on SAFETY SWITCH FAULT circuit S140ENL orange black between SCON and TCON Check SCON chart for possible faults Safety Switch P12 Fault Check Display message on LCD P12 Recycle power SAFETY SWITCH FAULT Safety Switch P14 Fault Check Display message on LCD P14 Recycle power SAFETY SWITCH FAULT Safety Switch P18 Fault Check Display message on LCD P18 Recycle power SAFETY SWITCH FAULT Safety Switch P22 Fault Check Display message on LCD P22 Re level platform Check for wiring SAFETY SWITCH FAULT damage on circuit PS6PRV red white Safety Switch P22R Fault Check Display message on LCD P22R Re level platform Repair or replace SAFETY SWITCH FAULT PCON Safety Switch P30 Fault Check Display message on LCD P30 Recycle power and check wiring on SAFETY SWITCH FAULT circuit S140ENL orange black between SCON and TCON Check SCON chart for possible faults Safety Switch P38 Fault Check Display message on LCD P38 Recycle power and check wiring on SAFETY SWITCH FAULT circuit S137PLL red white between SCON and TCON Check SCON chart for possible faults Safety Sw
37. Genie A TEREX BRAND 2 ZX 135 70 Do not top off with incompatible hydraulic fluids Hydraulic fluids may be incompatible due to the differences in base additive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in component damage Note Do not operate the machine when the ambient air temperature is consistently above 120 F 49 C Hydraulic Fluid Temperature Range 40 22 4 40 30 20 10 0 14 32 50 68 86 104 122 F 10 20 30 40 50 C Ambient air temperature Chevron hydraulic oil 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046D Chevron Rando HD premium oil MV E oa h A Part No 218700 September 2015 Service Manual Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C 7 5 cSt 104 F 40 C 33 5 Brookfield Viscosity cP 4 F 20 C 1040 cP 22 F 30 C 3310 Flash point 375 F 190 C Pour point 58 F 50 C Maximum continuous operating 171 F 77 C temperature Note An hydraulic oil heating system is recommended when the ambient temperature is consistently below O F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Prem
38. In this case it is the wire that feeds the relay coil for the work lamp All other numbers remain the same V61AXR V stands for valve power Number 61 stands for axle retracted circuit AXR stands for Axle retracted R46HRN R stands for Relay output supplying power to the horn HRN Number 46 is the circuit number for the horn Genie A TEREX BRAND 246 ZX 135 70 Circuit prefix Control Data Engine Gauges Neutral Power Relay Output Safety e 0 2 0 SZ om OO Valve Part No 218700 September 2015 Service Manual Suffix ABV AF AFV AH ANG APV ARV ASV AXE AXO AXR BAT BEX BRK BST BV CAL CAN CAT CNK DCN DE DEL DER DTH DTL EDC ENL ENV ERL ESL Definition Auxiliary Boom Valve Alternator Field Auxiliary Forward Valve Auxiliary Hydraulic Pump Angle Auxiliary Platform Valve Auxiliary Reverse Valve Auxiliary Steer Drive Valve Axle Extend Valve Axle Oscillate Axle Retract Valve Battery Boom Extended Brake Boom Stowed Bypass Valves Calibrate CAN Signal CATS Module Chain Break Drive Chassis Controller Drive Enable Drive Enable Left Drive Enable Right Data High Data Low Electrical Displacement Control Envelope Lockout Envelope Light Extend Retract Lockout Engine Status Lamp Suffix ESP FAP FB FE FL FLR FLT FP FS FSL FTS FWD GEN GND HG HRN HS IGN JBD JBE JBR JBS JBU JD JER JFC JPL JPW JRL JRR e Genie Par
39. Incorrect 166 14 Engine Rated Power Special Instruction ECM Memory Test 168 4 Battery Potential Power Input 1 Voltage Below Ignition Keyswitch Circuit and Battery Supply Circuit Normal Test Genie 238 A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Dece sacma TG EIT Perkins 854F 34T Engine Fault Code SPN Suspect Parameter Number FMI Failure Mode Identifier Service Manual SPN FMI Description Refer to Engine Manual 172 3 Engine Air Inlet Temperature Sensor Voltage Engine Temperature Sensor Open or Short Circuit Above Normal Test 172 4 Engine Air Inlet Temperature Sensor Voltage Engine Temperature Sensor Open or Short Circuit Below Normal Test 173 3 Engine Exhaust Gas Temperature Voltage Engine Temperature Sensor Open or Short Circuit Above Normal Test 173 4 Engine Exhaust Gas Temperature Voltage Engine Temperature Sensor Open or Short Circuit Below Normal Test 174 3 Engine Fuel Temperature Voltage Above Engine Temperature Sensor Open or Short Circuit Normal Test 174 4 Engine Fuel Temperature 1 Voltage Below Engine Temperature Sensor Open or Short Circuit Normal Test 190 8 Engine Speed Abnormal Frequency Pulse Engine Speed Timing Sensor Circuit Test Width or Period 190 15 Engine Speed High least severe 1 Engine Over speeds 558 2 Accelerator Pedal1Low Idle Switch Erratic Idle Valida
40. N e seanuya Y LO N o NOWONN 4153 VLVRETO6 BR C155PCE OR RD 98 m D Y74A FUNCTION 8 RI55PCE OR RD Ty ENABLE VALVE e Qu 2 168A a a EZ zZ C28TSR WT RD Sea DE WATER TEMP SENDER m C2BPSRWT BK z ru OIL PRESSURE m E 2 ul 3 z 6 R21GNWH wane o S HOD o a a 4 E L 9 FUEL SHUTDOWN Li a a Th T S o OR g Ra 11GNWH et dt BAT GND BR COLD START g ADVANCE x eo 855 e Saiz m iE a R21IGN WH EE 06GND BR FUEL LIFT PUMP ul Le ET iB e Ls Ke CR2 RELAY x i SENDER TE GN FUEL m m ex e 5 U EL 3 H a 5
41. Note Use this procedure for software versions 4 01 and higher 33 Fully extend the axles with the booms in the stowed positions 34 Raise the jib boom to a slightly less than horizontal position 35 Push in the ground controls red Emergency Stop button to the off position Do not turn the key switch to the off position 36 Open the ground control box 37 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 38 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 39 Remove the key from the main key switch Insert the key into the bypass recovery key Switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 40 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it Genie ATEREX BRAND ZX 135 70 115 Part No 218700 Service Manual i ees Jib Boom Components 41 42 43 45 46 47 Enter sensor calibration mode by pressing the buttons at the ground controls in the fo
42. Replace SCON Just calibrated Initiate one second beep of audible warning device Self clearing transient Safety Turntable Level Sensor X Direction Value at 5 0 V Value Too High Value Too Low Value at 0 V Out of Tolerance Flash unit out of level icon and LED and activate alarm Check that SCON is grounded Replace SCON Just calibrated Initiate one second beep of audible warning device Self clearing transient 212 Genie A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Joystick Value at 5 0 V Value Too High Value Too Low Value at 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Joystick Just calibrated Initiate one second beep of audible warning device Self clearing transient Turntable Rotate Buttons on TCON Fault Check both buttons pressed Turntable rotate disabled Display message on LCD Check ribbon and connector from membrane switch If necessary replace membrane s
43. Secondary 1 Angle Safety Backup safety angle sensor for RSS1AO Cuts power to circuits P9B P_11 and P_30 if the secondary boom drifts down while still extended RSFA10 Rotary Sensor Front Axle 1 Operational Provides front axle positioning information for adjusting steering neutral setting during axle extension Genie ATEREX BRAND 258 ZX 135 70 RSRA10 Rotary Sensor Rear Axle 1 Operational Provides front axle positioning information for adjusting steering neutral setting during axle extension RSLF1SO Rotary Sensor Left Front 1 Steer Operational Provides wheel position information during steering Master wheel in all steer modes except rear steer RSRF1SO Rotary Sensor Right Front 1 Steer Operational Provides wheel position information during steering RSLR1SO Rotary Sensor Left Rear 1 Steer Operational Provides wheel position information during steering Master wheel for rear steer mode RSRR1SO Rotary Sensor Right Rear 1 Steer Operational Provides wheel position information during steering Part No 218700 September 2015 A _ gt AAA M MU QUUM Number Description J9 J10 J11 J12 J13 J14 J15 J17 J20 J21 J22 J23 J24 J25 J28 J29 J31 J32 J46 J49 J55 J57 J58 Ribbon connector from TCON to membrane 1 Ribbon connector from TCON to membrane 2 Black 23 pin AMP connector on TCON Black 35 pin AMP connector on TCON White 23 pin AMP connec
44. Secondary up down and Extend disabled Alarm sounds Genie ATEREX BRAND ZX 135 70 Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Part No 218700 September 2015 Service Manual Fault Codes Error Source Error Type Effects Recovery Actions Right Rear Steer Angle Sensor Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate RR zero and neutral Alarm sounds Value at 0 V Primary up Secondary up down and Check for 5 0 VDC at the sensor Extend disabled Alarm sounds Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Steer Valves LF RF LR Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Part No 218700 enie ATEREX BRAND ZX 135 70 219 Service Manual September 2015 EE Fault Codes Error Source Error Type Effects Recovery Acti
45. t E 25 a TO 14 32 s 5 amp 2 MEXAVAZO WHITE 35 PIN A S 9 gg S S 3 E Tad ul za 8 S 4 pi i e AUX HYD PUMP BE iE ARN ERE THd x 4 zz E lt lt STARTER RELAY AE AMANOVA 10814 Yuva g E vos ER ONO naa ya o sid lt Ne qNO e D E E E zz S yeunseey o cB ONS 1V8 SAS 20 914 Z HONG e fus 3 voe 5 CN wars ERAS S e e a STARTER 9 9 NMd VI SAS L0 Sid AV e CRRA w y YA m 423 sE 11001931983 5 vor E X amp auivaig eo PE AUX MAIN a t smurta Gillet ELECTRONICS BAT oO 2 2 YN 5 Er A d er AUX HYD 1111 amp BATTERY oe qu Quuvacg Bn o o ES Ww Mo1NvO 80 P224_ lt HO CINVORzza HOIH NVO Z F Zd A Nvoszza 2 18VSI0 BLOWS 909224 Z 181319220 E m SNLWLS HOLIMSLOOS SOPZZE 4 ADS E 2 O SniviS IIMOLS 02d 4 we NODd zd ES S c SN 1VLS NOLLINOI E FZzd 4 HMTELLZO 3 I 3 Lu ONNOYO Zee 4 ug aN9TaL E M3MOd SAS Lebada 4 QRHIVS THL 2 eo ER a A SE x ae 3 N F iay ib P a 5 S FETE N gt m N eo lt Te o N o Part No 218700 ZX 135 70 280 September 2015 Service Manual AE EE Deutz TD2 9 Engine Harness A D E F G H K L M e v 2 a d f RER fr w aum 592 a 8 EEES 3 3 DETAIL B DU
46. the joystick to center 15 Once the function speeds have been set press and hold the engine start button until the engine shuts off Do not press the red Emergency Stop button Note Approximately 3 seconds after the engine shuts off the alarm at the ground controls will sound to indicate the settings are being saved in memory 16 At the ground controls turn the key switch to the off position wait a moment and then turn the key switch to platform controls 17 Check the display at the ground controls to be sure there are no calibration faults Note There should be no calibration faults shown on the display If calibration faults exist repeat this procedure Service Manual September 2015 Platform Controls How to Adjust the Function Speeds Note Perform this procedure with the boom in the stowed position Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 Enter 4 Plus Minus Previous 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the plus button twice then press the minus button twice 4 Press the previous button until the function to be adjusted is di
47. unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device 3 Working at the platform end of the secondary boom support and secure the secondary boom end cover to a suitable lifting device Part No 218700 September 2015 Service Manual EENEG Boom Components 4 Remove the cover retaining fasteners and 10 Pull the hydraulic hoses just removed through AWARNING remove the cover from the secondary boom Crushing hazard The secondary oom end cover could become unbalanced and fall when removed from the secondary the turntable bulkhead Component damage hazard Hoses can be damaged if they are kinked or pinched boom if not properly supported 11 Working at the counterweight end of the and secured to the lifting device secondary boom tag disconnect and plug the hydraulic hoses from the unions that lead to Working at the platform end of the secondary the cable track boom remove the hose and cable U bolt fasteners near the upper cable track tube 127 Working al tiie CoUntanwelgt SE secondary boom tag and disconnect the Working at the platform end of the secondary electrical connectors to all of the cables that boom remove the upper cable track tube lead to the secondary boom cable track ere EE UI GUINGOHIDSS 13 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on Working at the platform end of the secondary the
48. 030 inch 0 762 mm S Brake and two speed circuit a 8 Check valve 5 psi 0 3 bar N Drive motor anti cavitation Ec p E 9 Check valve 5 psi 0 3 bar M Drive motor anti cavitation EN S 10 Flow divider combiner valve C dees an end drive motors in en oi 11 Check valve 5 psi 0 3 bar L Drive motor anti cavitation re 42 Flow control valve 2 gpm 7 6 H Equalizes pressure on both sides of 30 35 ft Ibs L min divider combiner valve 40 7 47 5 Nm Genie 182 ZX 135 70 Part No 218700 Service Manual Manifolds September 2015 o OZA CoN Y d a e o Ma A p LARA E ura NA Fi ED Le 3 EE iA Nt AN c ip OE gt NV NU Y A v Genie ZX 135 70 183 Part No 218700 Service Manual September 2015 ee aa Zst IG r 2 Manifolds Traction Manifold Components continued The traction manifold is mounted inside the manifold box at the blue triangle side of the machine Index Schematic No Description Ham Function Torque 13 Flow control valve 2 2 gpm G Equalizes pressure on both sides of 30 35 ft lbs 8 3 L m divider combiner valve B 40 7 47 5 Nm 14 Flow control valve 4 0 gpm F Equalizes pressure on both sides of 30 35 ft Ibs 15 1 L m divider combiner valve A 40 7 47 5 Nm i m 20 25 ft lbs 15 Check valve 5 psi 0 3 bar J Drive motor anti cavitation 27 1 33 9 Nm 18 Fl
49. 1 4000 PSI 8 TRACTION MANIFOLD E Es eu 2 1 3000 PSI HS0080T a Genie Part No 218700 ZX 135 70 287 Service Manual September 2015 e E Hydraulic Schematic 288 September 2015 Service Manual lll Electrical Schematic Includes Deutz Engine 289 J153 J153 C27AUX RD
50. 10 degrees 133 Service Manual September 2015 Boom Components 20 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 21 Press and hold a function enable speed select button and the primary boom up button until the digital level displays 40 degrees 22 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 23 Press and hold a function enable speed select button and the primary boom up button until the primary boom is fully raised The boom is fully raised when the cylinder is fully extended and the boom stops moving The angle will be 70 degrees 24 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown
51. 1104D 44T 268 Engine Relay and Fuse Panel Legend Perkins 854F Models 269 Electrical Symbols Legend cocooonncccinnnconiccnnicc 270 Hydraulic Symbols Legend orseson EE Ea 271 Perkins 1104D Engine Electrical Schematic 4snneennnneneennnnennenn 274 Perkins 854F 34T Engine Electrical Schematic uennnennennnnennenn 276 Perkins 854F 34T Engine Harness sse 277 Deutz TD2 9 Engine Electrical Schematic sene 280 Deutz TD2 9 Engine Harness iecit aiii an nee 281 Generator Wiring Schematic ssssssseeeene nennen 283 Hydraulic Generator Welder Option 286 Hydraulic Schematic sess eene nennen 287 Electrical Schematic Includes Deutz Engine sees 289 Genie ATEREX BRAND Part No 218700 ZX 135 70 XV Service Manual September 2015 Ss This page intentionally left blank Genie ATEREX BRAND 16 ZX 135 70 Part No 218700 September 2015 Service Manual A 2222222 A Specifications Machine Specifications Performance Specifications Tires and wheels Drive speed maximum Tire size 445D50 710 18PR Stowed position high speed 3 0 mph 2 4 8 km h Tire ply rating 18 40 f 9 4 sec Tire weight new foam filled 800 Ibs 12 2 m 9 1 sec E a02 kg Raise
52. 2 o V36LRS BL X 5 Y57 LR STEER RIGHT J93 N D E O 4 eo V37RRS BL BK Ip CA Y56 RR STEER LEFT J92 N22 d Y55 RR STEER RIGHT J91 o 93 3 gg E vt ae m Sar E d MN NN LF STEER LEFT P3223 V37LFS BLIBK X LF STEER RIGHT P32 22 V36LFS BL 527 BK DO L N LLI MB NER RF STEER LEFT P3221 37RFS BUBK E DIR 7 il V O VE Z e STEER SNSR PWR 5 0 VDC P32 20 P109ANG GR WH P109ANG GR WH RD AN S14 LF STEER RIGHT O STEER SNSR GND P32 19 P110RT BK P110RT BK d dp FT MEN RF STEER RIGHT P32 18 V36RFS BL LR STEER LEFT P32 17 V37LRS BL BK e 37 BK l LR STEER RIGHT zeg V36LRS BL m CMARFS OR Zr BL Y BRAKE P32 15 V32BRK WH RD 3 22 RD S19 RF STEER RIGHT 8 VALVE RTN2 P32 14 VLVRET2 BR 5 LF STEER SNSR P32 13 C111LFS OR RF STEER SNSR P3212 C111RFS OR t 32 8K a LR STEER SNSR P32 11 C111LRS OR C111LRS OR BL Y RR STEER SNSR P32 10 C111RRS OR 3 22 RD WV S124R STEER RIGHT ef RR STEER LEFT P32 09 V37RRS BLIBK RR STEER RIGHT P32 08 V36RRS BL e SPARE P32 07 3 BK a SPARE P32 06 M ERROR BL SPARE P32 05 _ IR E S11 RR STEER RIGHT SNSR MOTOR SPEED P32 04 S V29MS RD WH E AXLE EXTEND P32 03 V60AXEX GR WH AXLE RETRACT P32 02 V61AXRT GR VALVE RTNA P32 01 VIVRETUBR AV S2BRK WH RD AS Y2 BRAKE RELEASE J106 V29MS RD WH libs Y27 TWO SPEED MOTOR STROKE J87
53. 3 position 4 way W Turntable rotate circuit 33 37 ft lbs 45 50 Nm 15 Relief valve 3100 psi 214 bar BB System relief 30 35 ft lbs 41 47 Nm 16 Differential sensing valve 150 psi Q Secondary boom up down 50 55 ft lbs 68 75 Nm 10 3 bar circuit regulates pressure drop across secondary boom up down proportional valve Genie 164 ZX 135 70 Part No 218700 September 2015 Service Manual Manifolds AN SS Se Das c 3 fj x Q CC o ON Hie T 2 m Genie ATEREX BRAND Part No 218700 ZX 135 70 165 Service Manual SS TS ees Manifolds September 2015 Function Manifold Components continued The function manifold is mounted to the turntable next to the ground controls Index No Description Schematic Item Function Torque 17 Proportional solenoid R Turntable rotate circuit 33 37 ft lbs 45 50 Nm valve 18 Differential sensing valve DD Turntable rotate circuit regulates 30 35 ft lbs 41 47 Nm 150 psi 10 3 bar pressure drop across turntable rotate proportional valve 19 Proportional solenoid U Secondary boom up down circuit 50 55 ft lbs 68 75 Nm valve 20 Check valve 5 psi V Pump circuit 90 100 ft Ibs 122 136 Nm 0 34 bar 21 Proportional solenoid GG Secondary boom extend retract 50 55 ft Ibs 68 75 Nm valve circuit 22 Proportional solenoid T Primary boom extend retract circuit 33 37 ft Ibs 45 50 Nm valve 23 Differenti
54. 35 pin connector Drive Chassis VLVRET1 BR V61AXRT GR V60AXEX GRIWH V29MS RD WH UNUSED UNUSED UNUSED V36RRS BL V37RRS BL BK C111RRS OR C111LRS OR C111RFS OR C111LFS OR VLVRET2 BR V32BRK WH RD V36LRS BL V37LRS BL BK V36RFS BL P110RT BK P109ANG GR WH V37RFS BL BK V36LFS BL V37LFS BL BK J31 o o so Oc RON ba qo No K aa a E wb if cio 2X x on gt O O DAN oO Oc bk WHY o Drive Chassis GND DCON BR P21DCON WH P53LS WH BK UNUSED S56PRV RD C61AXRT GR UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED D81CAN GR D82CAN YL UNUSED C60FAP GR WH C60RAP GR WH UNUSED P61LSA GR Part No 218700 September 2015 A FT zT ZZ Safety Controller Pin Legend J121 oa A O N o N O 11 12 Safety Controller S132LDS BL WH S73SLE BL RD UNUSED C145CAL RD WH UNUSED D82CAN YL D81CAN GR S59CNK GRIWH S56PRV RD 137PLL RD WH S139TRF WH RD GNDSCON BR Pin Numbering for 12 pin connectors S Genie Part No 218700 J122 a 0 N CoN Oo 11 12 Service Manual Safety Controller P21DCON WH C142SBS OR C141PBS RD C60AXE GR WH S12SB BL WH S13DE BL RD P53LS WH BK S140ENL OR RD P54ENG BK WH P58LS RD BK S56PRV RD C61AXR GR ATEREX B
55. 83 bar Injection pressure 23000 psi 1600 bar Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Glow plugs Initial load 0 10 sec 80A Continuous load gt 10 sec 40A Starter motor Current draw normal load 68A Cranking speed 130 200 rpm Battery Auxiliary power units Type 6V DC Quantity 2 Battery capacity maximum 285 AH Reserve capacity 25A rate 745 minutes Battery Engine starting and control system Type 12V DC Group 31 Quantity 1 Battery capacity maximum 1000A Reserve capacity 25A rate 200 Minutes Part No 218700 September 2015 Perkins 854F 34T cont Engine coolant Ethylene Glycol Service Manual A _ _ __ _ 2 A ee Specifications Machine Torque Specifications Platform Rotator Capacity 16 5 quarts 50 50 extended life 15 6 liters 1 8 center bolt GR 5 pes m Coolant t t itch ii di 3 8 16 bolts GR 8 44 ft lbs Installation torque 18 4 ft lbs 60 Nm 25 Nm Turntable rotate assembly Maximum continuous temperature 226 F 108 C Rotate bearing mounting bolts lubricated 320 ft lbs 7 3 4 10 SHC 434 Nm el ee sens Rotate bearing mounting bolts lubricated 180 ft lbs 215 37 ohms 5 8 11 SHC 244 Nm AS Rotate drive hub mounting bolts lubricated 80 ft lbs 170 F 78 ohms 108 Nm 82 C a Drive motor mounting bolts d
56. Auxiliary power units Type 6V DC Quantity 2 Battery capacity maximum 285 AH Reserve capacity 25A rate 745 minutes Battery Engine starting and control system Type 12V DC Group 31 Quantity 1 Battery capacity maximum 1000A Reserve capacity 25A rate 200 Minutes Alternator output 80A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Genie A TEREX BRAND 6 ZX 135 70 Part No 218700 September 2015 Service Manual Deutz TD 2 9 Engine Displacement 177 cu in 2 9 liters Number of cylinders 4 Bore and Stroke 3 6 x 4 3 inches 92 x 110 mm Horsepower net intermittent 74 2 hp 2600 rpm 55 kW Induction system turbocharged Firing order 1 3 4 2 Low idle 1000 rpm High idle 2500 rpm Compression ratio 17 4 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Specifications Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil Pressure switch Installation torque 8 18 ft lbs 11 24Nm Pressure switch point 22 psi 1 5 bar 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 Governor electronic Starter motor Lubrication system i Current draw norm
57. 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 Section Repair Procedure 4 2 Electronic Version 7 Click on any content or procedure in the Table of Contents to view Section Fault Codes All charts the update Section Schematics Legends and schematics Genie Part No 218700 e ATEREX BRAND ZX 135 70 iii Service Manual September 2015 A AAA ssi Introduction 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 Section Repair Procedure 4 2 Electronic Version 7 Click on any content or procedure in the Table of Contents to view Section Fault Codes All charts the update Section Schematics Legends and schematics Genie A TEREX BRAND iv ZX 135 70 Part No 218700 September 2015 Service Manual Introduction Serial Number Legend Genie A TEREX BRAND Model ZX 135 70 Serial number ZX13513 12345 Model year 2013 Manufacture date 04 12 13 Electrical schematic nu
58. Carefully remove the membrane decal from the control box lid while guiding the ribbon cables out of the control box lid Remove any decal adhesive from the control box lid with a mild solvent Note Do not allow any solvent to come in contact with the LCD display screen machine functions The membrane contains touch sensitive areas that activate the machine functions 7 How to Replace the Membrane 8 Decal 9 1 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the ground control box lid fasteners Open the ground control box 4 Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit board Electrocution burn hazard A WARNING Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap Genie 148 ZX 135 70 Install the new membrane decal while guiding the ribbon cables through the control box lid Connect the ribbon cables to the ECM circuit board Close the control box lid and install the retaining fasteners Part No 218700 September 2015 Service Man
59. Display message on LCD P6R1 Check wiring for circuit P53LS SAFETY SWITCH FAULT white black wire for damage resulting in shorts or opens Repair wiring or replace TCON Safety Switch P6R2 Fault Check Display message on LCD P6R2 Check wiring for circuit PS4ENG SAFETY SWITCH FAULT black white wire for damage resulting in shorts or opens Repair wiring or replace TCON Safety Switch P7 Fault Check Display message on LCD P7 SAFETY Check wiring for circuit S56PRV red SWITCH FAULT wire for damage resulting in shorts or opens Repair wiring or replace TCON Safety Switch P7R Fault Check Display message on LCD P7R Function enable button was held down SAFETY SWITCH FAULT during startup Recycle power with the function button released Safety Switch DCON P7R Fault Check Display message on LCD DCON P7R Check wiring for circuit S56PRV red SAFETY SWITCH FAULT wire for damage resulting in shorts or opens Repair wiring or replace DCON Safety Switch P9A Fault Check Display message on LCD P9A Check wiring for circuit P53LS SAFETY SWITCH FAULT white black wire for damage resulting in shorts or opens Repair wiring or replace TCON Safety Switch P9B Fault Check Display message on LCD P9B Boom has violated the safety limits resulting in the engine being shut off as a safety feature Use aux to get the boom back into operational limits Check P54ENG and P58LS between SCON and TCON for damage Check SCON chart for possible fault conditions 206
60. Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 8 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 9 Press the enter or previous button on the LCD screen until DELETE PRIMARY BOOM ANGLE SENSOR CALIBRATION is displayed 10 Press the plus button to select YES then press the enter button to accept 11 Place a digital level that has been calibrated to gravity on top of the primary boom and note the angle displayed on the digital level 12 Atthe PRIMARY BOOM ANGLE TO GRAVITY 0 0 DEG screen press the plus button or minus button to adjust the display to the exact value shown on the digital level then press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 13 Start the engine from the ground controls Note If the system exits out of calibration mode when the engine is started repeat step 8 and then continue with step 14 14 Fully raise the secondary boom The boom is fully raised when the cylinder is fully extended and the boom stops moving Part No 218700 Genie ATEREX BRAND ZX 135 70 Boom Components 15 Press and
61. Free wheel configuration D 3 Drive hub oil D 4 Turntable rotation gear backlash D 5 Hydraulic filter D 6 Engine maintenance Deutz models D 7 Engine maintenance Perkins models D 8 Turntable bearing bolts Genie Comments 22 A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible
62. P1 13 C26TSR WH RD 2 Set 4 ES OIL_PRESSURE P1 12 C25PSR WH BK B3BAT 14 RD PER Ka EDC REV P1 11 C31EDC WH BK BAT GND BR HORN P15 ECU POWER Sa EDCEWD C30EDC WH C41RPM OR BK lt TO HORN a BUTTON ES c STARTER RELAY Pi 09 C33STR BK z C107AF RD lt E g LP 33 8 n SERVICE HRN P1 07 C46HRN WH ig amp P_7R 4 REV PWMIP1 06 E IS ALTERNATOR 9 KZ FWD PWM P1 05 m C 5 E i 5 2 P_6R1 START AID RLY P1 04 C34SA BK WH 5 i9 H e IGN FUEL P1 03 C2TEL WH C21IGN WH f a I lo THROTTLE P1 02 C35RPM BK RD a aj lt o n x D o E D lt gt d ju gt 3 valve RTNM PT O7 5 2348 RK a d z o z 3 mal Y aH lt pr 3 2 z lz Q og 8 zus Y sea E s Es m Fa a ges ol g I I Re 3 2 ol CG 2 o us guts 5 SM AH z On ET OSFAZ FTE m 2 ES o e u 2 fouz El x Zo 2 eo x o LO H lt Zl on S T c g 25 Blas apuro iz 585 r E ES a ES 265 Y Or gu Oo m u a oun Zo E ea 9 3 Ze 203 209005 SERE C35RPM BKIRD d An elk alle oa qvos t F ER dle esz 8225 EN EM a L lt w OO E 2 2 B Je HHI ES u 8 wees aida Lco S T E 2 Se 5 F Plogkes CES T 8 els elias 2 SEO lais 5 EM N r o e 8 a S uy C33STR BK w E e Z 5 m on y B1ENG RD EIE 25 EI z u ES Pioa BIENG RD T RT g Es E E BATECU GND P1 03 deum sz Ae 52 Vv 3 t SYS BAT GND P1 02 GND BR e DKE 304 e se STARTER ii S amp 4 Teee pee T on SYS_BAT_PWRIP1 01 B1BAT RD B1BA
63. Receive Frame temperature upstream DOC PrHtEnCmd pre heat command signal range check high engine command 4768 4 1045 Sensor error exhaust gas 523240 9 179 Timeout CAN message temperature upstream DOC FunModCtl Function Mode signal range check low Control 4769 2 1026 Sensor exhaust gas temperature 523350 4 565 Injector cylinder bank 1 short downstream DOC plausibility circuit error 523352 4 566 Injector cylinder bank 2 short 4769 3 1034 Sensor error exhaust gas circuit temperature downstream DOC 523354 12 567 Injector powerstage output defect signal range check high 523470 2 826 Pressure Relief Valve PRV 4769 4 1035 Sensor error exhaust gas forced to open performed by temperature downstream DOC pressure increase signal range check low 523470 2 827 Pressure Relief Valve PRV 523006 3 34 Controller mode switch short forced to open performed by circuit to battery pressure shock 523006 4 35 Controller mode switch short circuit to ground 523008 1 648 Manipulation control was triggered Ganie Part No 218700 ZX 135 70 229 Service Manual Deutz TD 2 9 L4 Engine Fault Codes September 2015 Ex AAA AAA A SPN Suspect Parameter Number SPN FMI KWP Description Ce 523612 12 613 Internal ECU monitoring BEE detection reported error SPN FMI KWP Description E 523612 12 614 Internal ECU monitoring 523470 7 876 Maximum rail pressure in limp
64. Selection Sensor Calibration With key switch OFF press and hold Set unit X axis to gravity the enter button and turn key switch to on position Release the enter button and press plus enter enter plus Set platform level to gravity YES NO Platform level sensor millivolts degree before software version 4 01 Set unit Y axis to gravity Delete axles angle sensors calibration YES NO YES Axle angle fully retracted YES NO YES Axle angle fully extended YES NO Delete all steer sensors calibrations YES NO Delete blue end blue side steer sensor FL calibration YES NO Delete yellow end blue side steer sensor RL calibration YES NO Delete blue end yellow side steer sensor Use buttons to adjust FR calibration YES NO Delete yellow end yellow side steer sensor RR calibration YES NO Delete secondary boom angle sensor calibration YES NO secondary boom angle to gravity 3 5 secondary boom angle to gravity 20 secondary boom angle to gravity 35 secondary boom angle to gravity 50 secondary boom angle to gravity 65 secondary boom angle to gravity 76 Delete primary boom angle sensor calibration YES NO primary boom angle to gravity 0 primary boom angle to gravity 50 primary boom angle to gravity 207 primary boom angle to gravity 10 primary boom angle to gravity 40 primary boom angle to gravity 70 Delete level angle sensor calibration
65. Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Sensor Extend disabled Alarm sounds Value at 0 V Primary up Secondary up down and Check for 5 0 VDC at the sensor Extend disabled Alarm sounds Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Right Front Steer Angle Value at 5 0 V Primary up Secondary up down and Check for an open ground circuit going to the sensor Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Sensor 218 Extend disabled Alarm sounds Value at 0 V Primary up Secondary up down and Check for 5 0 VDC at the sensor Extend disabled Alarm sounds Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Left Rear Steer Angle Value at 5 0 V Primary up Secondary up down and Check for an open ground circuit going to the sensor Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Value at 0 V Primary up
66. Startthe engine from the platform controls 3 Pressthe engine rpm select button until the foot switch activated high idle rabbit symbol is selected 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications Part No 218700 Service Manual September 2015 B 15 8 Test the Drive Speed Raised or Extended Position 10 11 Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function is essential to safe machine 12 operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit symbol
67. Suspect Parameter Number SPN FMI KWP Description leede 51 6 1022 Actuator error EGR Valve signal KWP Keyword Protocol range check high SPN FMI KWP Description 51 6 1224 Actuator EGR Valve over 51 3 1019 EGR Valve short circuit to current battery 51 6 1230 Actuator error EGR Valve 51 3 1024 Position sensor error of actuator Overload by short circuit Be E signal range check 51 7 1016 Actuator position for EGR Valve Ig not plausible 91 3 1226 en circuit to 51 11 1231 Actuator error EGR Valve Power attery stage over temp due to high 51 3 1227 EGR Valve short circuit to current battery A67 51 12 1018 Actuator EGR Valve powerstage 51 4 1020 EGR Valve short circuit to over temperature ground 51 12 1021 Mechanical actuator defect 51 4 1025 Position sensor error actuator EGR Valve in signal range check 51 12 1225 Actuator EGR Valve over Ow temperature 51 4 1228 EGR Valve short circuit to 94 1 474 Low fuel pressure warning ground A02 threshold exceeded 51 4 1229 2 circuit to 94 1 475 Low fuel pressure shut off ground A67 threshold exceeded 1 4 1232 Actuator error EGR Valve 94 3 472 Sensor error low fuel pressure Voltage below threshold signal range check high 51 5 1015 Actuator error EGR Valve signal 94 A 473 Sensor error low fuel pressure range check low signal range check low 51 5 1017 Actuator EGR Valve open load 97 3 464 Sensor error water in fuel signal 51 5 1023 Actuator error EGR Valve signal range check high range c
68. They are not standard size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Besure the O ring face seal is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm 2 Usinga permanent ink marker make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting Refer to Illustration 1 Part No 218700 Gen ATEREX BRAND ZX 135 70 13 Specifications T DET S Illustration 1 1 hex nut 2 reference mark 3 body hex fitting 3 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 Note The marks indicate the correct tightening
69. WH aC s 3 rex g IGN FUEL P1 03 C21 TEL WH C21IGN WH a bee THROTTLE pi 92 lt C35RPM BKRD COSRPM BK RD i M D yi 5 ul VALVE RTN 1 P1 01 lt H 1 E ES J 38 ag SC E gus 3 SIRO EN o zZ He E P BES 8 E L 1878 x d D Ee de E E a amp EE 882 a E amp i KC of GE E 5 5 Se 2 ES 3 8 AUX HYD PUMP SE i muon CSSRPM BK RD o EE E FEER B 8332 O T EEEE sroii o ERE js P1 04 a 2 Zi R33STR BK STARTER RELAY S BATECU GND P103 lt GND BR BIENG AD SYS BAT GND 51 99 ZGND BR A E STARTER N x SYS_BAT_PWA Ten lt BIBATRD 20A BIBATRD 55 CB P35APM BK AD SEE 9 i E m ENGINE BLOCK g D u o ag F 28 Zell ENG START e a g CONTROLS BATTERY o 3 De U Oo e c a e PEE LU s sg lee An E Y v 5 un ag w pu of E RE E 2E st om CAN LOW P1 08 lt NC as S gE T CAN HIGH 9 P7 Zne v4 ER EK S Q REMOTE DISABLE P1 06 lt C226TEL BL set FOOTSWITGH STATUS P1 05 lt S56PRV RD e STOWED STATUS P1 04 C P23PCON BK S1S7PLLEAD WH IGNITION STATUS P1 03 C21TEL WH v GROUND P1 02 GND BR aw 0 SYS POWER P1 01 lt B1BAT RD on c et Vu 2 d wi s 25 e iur y gt g x 53 8g 53 o 28 82 gag 83 seg D a em lt 10 o N o Part No 218700 ZX 135 70 274 275 September 2015 Service Manual AAA Perkins 854F 34T Engine Electrical Schematic September 2015 Perkins 854F 34T Engine Electrical Schematic Service Manu
70. ZX 135 70 Service Manual September 2015 Specifications Hydraulic Oil Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level ISO 15 13 minimum Water content 250 ppm maximum Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Shell Tellus S2 V 32 Shell Tellus S2 V 46 Shell Tellus S4 VX 32 Shell Shell Donax TG Dexron III Chevron 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Mineral based Biodegradable Fire resistant Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the hydraulic fluid temperature consistently exceeds 200 F 90 C an optional oil cooler may be required
71. after the secondary boom was raised Genie ATEREX BRAND 220 ZX 135 70 Part No 218700 September 2015 Service Manual EE Fault Codes P 38 Propel Pp 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 OFF OFF OFF OFF Primary Boom angle crosscheck OFF OFF OFF OFF OFF Secondary Boom angle crosscheck OFF OFF OFF OFF Secondary Boom safety not retracted and not raised OFF OFF OFF Axle safety not stowed not faulted primary and secondary OFF OFF OFF OFF stowed Axle crosscheck angle sensor versus safety switch OFF OFF OFF OFF Axle not fully extended and Turntable rotate stowed and in drive OFF OFF disable zone Turntable tilt angle crosscheck SCON internal sensors 3 in a OFF OFF OFF OFF OFF delta configuration Primary Boom safety max angle OFF OFF OFF OFF OFF Loss of CAN OFF OFF OFF OFF OFF OFF LSS1RS disconnected SCON pin 2 OFF OFF Platform Overload SCON pin 1 OFF Secondary Boom length OFF OFF OFF crosscheck LSS1RS and LSS1RO Genie Part No 218700 ZX 135 70 221 Service Manual September 2015 Deutz TD 2 9 L4 Engine Fault Codes SPN
72. as presented and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts NA WN RH Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Genie Machine Configuration Unless otherwise specified perform each procedure with the machine in the following configuration e Machine parked on a firm level surface e Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked e All external AC power supply disconnected from the machine e Boom in the stowed position e Turntable secured with the turntable rotation lock ATEREX BRAND Part No 218700 ZX 135 70 15 Service Manual September 2015 AAA AAA 2 9 lt ii Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert A personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Indicat
73. bar 17 bar bypass Drive motor case drain return filter Beta 1022 Genie 4 ZX 135 70 Part No 218700 September 2015 Brakes Service Manual A _ _ _ _____ 2 RT Specifications Manifold Component Specifications Brake relief pressure Drive Motors Displacement per revolution high speed Displacement per revolution low speed square end Displacement per revolution low speed circle end Part No 218700 190 psi Plug torque EE SAE No 2 36 in Ibs 4 Nm SAE No 4 10 ft lbs 13 Nm OS cil SAE No 6 14 ft lbs 19 Nm 13 3 cc 8 SAE No 8 38 ft lbs 51 Nm 2 7 cuin a 45 cc SAE No 10 41 ft lbs 55 Nm 1 5 cu in SAE No 12 56 ft Ibs 76 Nm 25cc Valve coil resistance specifications Solenoid valve 3 position 4 way 7 20 schematic item A B C D W Solenoid Valve 2 position 3 way 5 60 schematic items D E F G Z Solenoid Valve 2 position 3 way 7 20 schematic items P Q Solenoid Valve 2 position 3 way 8 80 schematic items AE Proportional solenoid valve 3 position 4 way 8 80 schematic items Y and AF Solenoid Valve 2 position 3 way 7 10 schematic items AD Solenoid valve 2 position 2 way 3 5 to schematic item A 5 50 Genie ZX 135 70 5 Service Manual September 2015 Specifications Deutz TD2011L04i Engine Displacement 220 9 cu in 3 62 liters Number of cylinders 4 Bore and Stroke 3 78 x 4 92 inches 96
74. be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the machine on a firm level surface and in the stowed position with the axles extended 1 Raise the primary boom approximately 10 feet 3 m Turn the machine off 2 Working at the platform end of the secondary boom support and secure the secondary boom end cover to a suitable lifting device Genie A TEREX BRAND 130 ZX 135 70 3 Remove the cover retaining fasteners and remove the cover from the secondary boom A WARNING Crushing hazard The secondary oom end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device 4 Remove the retaining fasteners from both secondary boom extend limit switches and remove the limit switches Do not disconnect the wiring Note Label the location of each limit switch as they are not the same and their mounting locations cannot be exchanged 5 Tag disconnect and plug all hydraulic hoses for the 3 secondary boom extension cylinders Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the upper extension
75. boom between the circle end tires and with the machine on a firm level surface 1 Secure the turntable from rotating with the turntable rotation lock pin 2 Remove the ground controls side fixed turntable cover 3 Tag disconnect the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Attach a lifting strap from an overhead crane or other suitable lifting device to the lifting eye on the turntable rotation assembly Genie A TEREX BRAND 190 ZX 135 70 5 Remove the drive hub mounting bolts and remove the turntable rotation assembly from the machine 6 Repeatsteps 3 through 5 for the other turntable rotation assembly ADANGER Tip over hazard If the turntable rotation lock pin is not properly installed machine stability is compromised and the machine could tip over when the drive hub is removed from the machine which could result in death or serious injury Crushing hazard The drive hub could become unbalanced and fall if not properly supported by an overhead crane or lifting device when removed from the machine AWARNING Note When installing a turntable rotation assembly the rotation gear backlash must be adjusted Refer to Repair Procedure Adjust th
76. controls Hold the enter button for approximately 5 seconds 8 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 9 Press the enter or previous button on the LCD screen until SET PLATFORM LEVEL SENSOR TO GRAVITY is displayed 10 Press the plus button to select YES then press the enter button to accept 11 Press the enter or previous button on the LCD screen until EXIT is displayed 12 Press the plus button to select YES then press the enter button to accept 13 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode Genie ATEREX BRAND ZX 135 70 99 Part No 218700 Service Manual September 2015 Platform Components 2 5 Platform Overload System if equipped Proper calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over How to Calibrate the Platform Overload System if equipped Note Perform this procedure with the machine on a firm level surface 1 Level the platform 2 Determine the max
77. cylinder Eun nm the lower cable track retaining 14 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses at the Working at the counterweight end of the unions located above the primary boom lift secondary boom remove the lower cable cylinder Cap the fittings on the unions EENEG 15 Pull the hydraulic hoses for the primary boom Tag disconnect and plug the hydraulic hoses lift cylinder and extension cylinder out through from the following ports of the function the hole in the number 4 secondary boom manifold PE PR P2 T1 PU and PD Cap the tube fittings on the manifold Component damage hazard AWARNING Bodily injury hazard Spraying Hoses can be damaged if they hydraulic oil can penetrate and are kinked or pinched burn skin Loosen hydraulic connections very slowly to allow 16 Working at the platform end of the secondary the oil pressure to dissipate boom place blocks between the upper and gradually Do not allow oil to lower cable tracks for support squirt or spray Ganie Part No 218700 ZX 135 70 121 Service Manual September 2015 Boom Components 17 Working at the counterweight end of the secondary boom attach a lifting strap from an overhead crane to the secondary boom cable track 18 Carefully pull the secondary boom cable track out of the counterweight end of the boom 19 Remove the secondary boom cable track from the machine and place it on a structure capable of supporting it 4 WARNI
78. cylinder retainers from the saddle blocks 7 Attach a lifting strap from an overhead crane to the rod end of the upper extension cylinder 8 Using the overhead crane lift the extension cylinder to clear the saddle blocks Part No 218700 September 2015 Service Manual 9 Support and slide the upper extension cylinder out of the secondary boom and place iton a structure capable of supporting it AWARNING Crushing hazard The extension cylinder could fall when removed from the secondary boom if not properly supported Note During removal the overhead crane strap will need to be adjusted for proper balancing 10 Repeat steps 6 through 9 for the remaining secondary boom extension cylinders Note The secondary boom extension cylinders must be installed in the same order they were removed Note When installing the middle and upper secondary boom extension cylinders be sure the grooved wear pads are correctly aligned with the channels on the top of the cylinders 1 upper extension cylinder 1 middle extension cylinder 2 bottom extension cylinder 3 cylinder grooved wear pads channels ah Ga M A Boom Components 4 8 Primary Boom Angle Sensor The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity The primary boom maximum angle is gradually reduced as the downhill slope positive degree Y axis is increase
79. disconnect and plug the hydraulic hose at the return filter Cap the fitting on the return filter housing 7 Remove the turntable cover using a suitable lifting device AWARNING Crushing hazard The turntable cover may become unbalanced and fall if not properly supported and secured to a suitable lifting device 8 Remove the ground control box mounting fasteners Move the ground control box out of the way Genie ATEREX BRAND ZX 135 70 77 Part No 218700 Service Manual oe nri Checklist E Procedures September 2015 9 Remove the cover from the auxiliary power 15 Support the hydraulic tank with 2 lifting straps unit batteries Place one lifting strap at each end of the tank 10 Tag and disconnect the cables from the KEE die ee auxiliary power unit batteries 16 Remove the hydraulic tank from the machine AWARNING Electrocution burn hazard Contact with electrically charged AWARNING Crushing hazard The hydraulic circuits could result in death or tank could become unbalanced serious injury Remove all rings and fall if not properly supported watches and other jewelry when removed from the machine 11 Tag and disconnect the cables from the engine starting battery located on the engine 17 Remove the suction strainers from the tank side of the machine and clean them using a mild solvent AWARNING _ Electrocution burn hazard 18 Rinse out the inside of the tank using a mild Contact with electrical
80. engine from the ground controls 4 Pushandrelease the rpm select button until high rpm is selected rabbit symbol Result The engine should change to high idle Part No 218700 September 2015 Service Manual 5 Push and release the rpm select button until low rpm is selected turtle symbol Result The engine should return to low idle om 0 1 low idle indicator light 2 foot switch activated high idle indicator light 3 engine rpm select button Oo Turn the key switch to platform controls Push the engine rpm select switch until low idle turtle symbol is selected Result The engine should remain at low idle Press down the foot switch Result The engine should remain at low idle o oo Push the engine idle select switch until high idle rabbit symbol is selected Result The engine should change to high idle Checklist B Procedures B 12 Test the Ground Control Override Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls c
81. everiodin ground 523988 5 1243 Charging lamp open load 524034 3 1438 ao short circuit to 523988 12 1244 Charging lamp over temp 524034 4 1439 Disc separator short circuit to 523998 4 1327 Injector cylinder bank 2 slave ground short circuit 524034 5 1436 Disc Separator open load 523999 12 1328 Injector powerstage output Slave 524034 12 1437 Disc Separator powerstage over defect temperature 524014 1 1254 Air pressure glow plug flush line below limit Genie 234 ZX 135 70 Part No 218700 September 2015 Service Manual Deutz TD 2 9 L4 Engine Fault Codes SPN Suspect Parameter Number SPN FMI KWP Description EE d 524108 9 1669 Timeout error of oe CAN Transmit Frame SPN FMI KWP Description ComEGRTVActr 524035 12 1341 Injector diagnostics time out 524109 9 1679 Timeout error of error in the SPI communication CAN Receive Frame 524057 2 1505 Electric fuel pump fuel pressure ComRxEGRTVActr build up error 524110 9 1670 Timeout error of 524097 9 1663 Timeout error of a aa CAN Transmit Frame om E DPFBrnAirPmpCtl 524111 9 1680 Timeout error of 524098 9 1664 Timeout error of a CAN Transmit Frame E xd ComDPFBrnPT 524112 9 1671 Timeout ComITVActr 524099 9 1665 Timeout error of 524113 9 1681 Timeout error of CAN Transmit Frame CAN Receive Frame ComDPFC1 ComRxITVActr 524100 9 1666 Timeout error of 524114 9 1659 Timeout error of CAN Transmit Frame CAN Trans
82. ground control and pull out the red Emergency Stop button to the on position Start the engine 2 Fully raise the secondary boom then extend it approximately 4 ft 1 2 m 3 Raise the primary boom approximately 15 then extend it approximately 4 ft 1 2 m 4 Turn the key switch to the off position to turn off the engine Turn the key switch back to ground controls Note If this procedure is performed with the main key switch in the off position an active latched safety fault will be set and will have to be cleared 5 Remove the key from the main key switch and insert the key into the bypass recovery key switch 6 Turn and hold the key switch to the recovery position The key switch must be held in the recovery position O Result The auxiliary power unit will turn on and the boom will begin the following recovery sequence e The primary boom will retract e The secondary boom will retract e The primary boom will lower Note It is not necessary to fully lower the primary boom 7 Turn the bypass recovery key switch to the run position 8 Remove the key from the bypass recovery key switch and insert the key into the main key switch 9 Start the engine and return the boom to the stowed position e le Service Manual September 2015 Checklist B Procedures B 24 Inspect the Calibration Decal Genie specifications require that this procedure be performed every 250 hours or quarterly whichever
83. hold a function enable speed select button and the primary boom down button and lower the primary boom down until the digital level displays 50 degrees 16 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note Be sure the number entered at the ground controls is a negative number Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 17 Press and hold a function enable speed select button and the primary boom up button until the digital level displays 20 degrees 18 At the ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note Be sure the number entered at the ground controls is a negative number Note Ifthe measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 19 Press and hold a function enable speed select button and the primary boom up button until the digital level displays
84. in the stowed position 1 Align the remaining wheels on the machine so they are visually parallel to the chassis as close as possible 2 Disconnect the steer sensor assembly cable from the main harness to be replaced 3 Remove the steer sensor cover retaining fasteners Remove the steer sensor assembly Note If the sensor activator pin needs to be replaced install the new activator pin per Illustration 1 Part No 218700 Genie ATEREX BRAND ZX 135 70 Axle Components HH Illustration 1 square end yellow side and circle end blue side shown Left front square end blue side and right rear circle end yellow side angle sensors Sb Ca 2202 OHO Illustration 2 1 starting position 2 installed position 3 sensor cover 4 rotation arrow 195 Service Manual September 2015 Axle Components Position the new steer sensor assembly over the sensor activator pin with the sensor cable angled towards the tire Refer to Illustration 2 Align the sensor with the pin and install the sensor on to the pin Note Be sure the sensor activator pin is engaged into the sensor 6 Rotate the sensor housing in a clockwise direction until the sensor cable is pointing away from the machine Refer to Illustration 2
85. level cylinder fully retracted the jib boom bellcrank angle should be at approximately 70 degrees Part No 218700 September 2015 Service Manual 27 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 28 Press the enter or previous button on the LCD screen until EXIT is displayed Press the plus button to select YES then press the enter button to accept 29 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine 30 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 31 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 32 Pull out the red Emergency Stop button Start the engine and lower the boom to the stowed position Be sure there are no calibration faults shown on the display Jib Boom Components 2 Point Calibration procedure
86. message on LCD Check ribbon and connector from membrane switch If necessary replace membrane switch Jib Up Down Joystick Value at 5 0 V Value Too High Value Too Low Value at 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Not calibrated Joystick Speed and Direction frozen at zero and neutral Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Just calibrated Initiate one second beep of audible warning device Self clearing transient Part No 218700 enie ATEREX BRAND ZX 135 70 215 Service Manual September 2015 EE Fault Codes Error Source Error Type Effects Recovery Actions Jib Extend Retract Joystick Value at 5 0 V Value Too High Value Too Low Value at 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Joystick Just calibrated Initiate one second beep of audible warning device Self clearing transient Platform Rota
87. must be replaced All connections must be fasteners from the jib boom cable track torqued to specification during installation Refer to junction box Remove the clamps Specifications Hydraulic Hose and Fitting Torque 8 Gut the jib boom lift cylinder hydraulic hoses Specifications out of the jib boom cable track junction box 1 Raise the jib boom to a horizontal position 9 Remove the hose and cable clamp retaining Turn the machine off fasteners at the platform end of the jib boom 2 Remove the cover from the hose and cable cable track tube Remove the clamps junction box under the jib boom cable track 10 Tag and disconnect the electrical connectors 3 Tagand disconnect the electrical connectors EES inside the cable track junction box 11 Tag and disconnect the electrical connectors 4 Tag disconnect and plug the two hydraulic EE hoses from the jib boom manifold that lead to 12 Tag and disconnect the electrical connector the platform manifold Cap the fittings on the from the foot switch manifold 13 Tag and disconnect the electrical connector AWARNING Bodily injury hazard Spraying from the platform angle sensor hydraulic oil can penetrate and 14 Tag disconnect and plug the hydraulic hoses burn skin Loosen hydraulic f the P and T port the olatfi connections very slowly to allow ci ii an BEN the oil pressure to dissipate manne gradually Do not allow oil to squirt or spray Note The jib boom manifold is located at the platfo
88. not apply any lifting pressure 10 Remove the eight mounting bolts from the platform mounting weldment 11 Remove the center bolt and slide the platform mounting weldment off of the platform rotator AWARNING Crushing hazard The platform mounting weldment may become unbalanced and fall if it is not properly supported 12 Support the platform rotator with a suitable lifting device Do not apply any lifting pressure 13 Place a block under the platform leveling cylinder for support 14 Remove the pin retaining fasteners from the platform leveling cylinder rod end pivot pin Do not remove the pin 15 Remove the pin retaining fasteners from the jib boom to platform rotator pivot pin Do not remove the pin 16 Use a soft metal drift to remove both pins and remove the platform rotator from the machine AWARNING Crushing hazard The platform rotator could fall when removed from the machine if not properly supported Genie A TEREX BRAND 98 ZX 135 70 How to Bleed the Platform Rotator Note Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Rotate the platform full right then full left until air is completely out of the rotator Bleeding the valve is not necessary Part No 218700 September 2015 Service Manual 2 4 Platform Level Sensor The platform level sensor is mounted to the side of the platform rotator The platform level sensor is monitored by t
89. on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 12 Press the enter or previous button on the LCD screen until SET UNIT Y AXIS LEVEL TO GRAVITY is displayed 13 Place a digital level that has been calibrated to gravity on the Y axis of the turntable negative degree uphill slope Part No 218700 ZX 135 70 193 Service Manual September 2015 x EA Turntable Rotation Components 14 Press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 15 Press the enter or previous button on the LCD screen until EXIT is displayed 16 Press the plus button to select YES then press the enter button to accept 17 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key
90. on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Extend the jib boom until the platform leveling cylinder barrel end pivot pin is accessible 2 Raise the jib boom slightly and place blocks under the platform 3 Lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks Genie A TEREX BRAND 96 ZX 135 70 4 Place a block under the platform leveling cylinder for support 5 Remove the external snap rings from the barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin 6 Support the rod end of the platform level cylinder 7 Remove the pin retaining fasteners from the platform leveling cylinder rod end pivot pin Use a soft metal drift to remove the barrel end pivot pin 8 Carefully pull the platform leveling cylinder out of the boom to access the hydraulic hoses 9 Tag disconnect and plug the hydraulic hoses from the platform leveling cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Remove the platform leveling cyli
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92. operating the machine Unless otherwise specified perform each procedure with the machine in the following configuration e Machine parked on a firm level surface e Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked All external AC power supply disconnected from the machine e Boom in the stowed position Turntable secured with the turntable rotation lock e Welder disconnected from the machine if equipped with the weld cable to platform option Part No 218700 Genie ATEREX BRAND ZX 135 70 203 Fault Codes Before Troubleshooting VI Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine VI Be sure that all necessary tools and test equipment are available and ready for use MI Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous conditions VI Be aware of the following hazards and follow generally accepted safe workshop practices A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Two persons will be required to safely perform some troubleshooting procedures Service Manual BEE Fault Codes September 2015 Error Source Error Type Effe
93. or replace the limit switch ramp bracket to ensure the limit switch roller arm remains centered with the limit switch ramp bracket through the entire length of travel Result The roller arm of the limit switch is damaged Replace the limit switch roller arm or limit switch Note The limit switch ramp bracket is attached to the number 4 boom tube 13 Locate and disconnect the Deutsch connector to LSS1RS Result The alarm should sound Result The LCD screen should display the message SEC BOOM RETRACTED SAFETY SWITCH DISCONNECTED FAULT Result The alarm doesn t sound and the LCD screen doesn t display a Fault message The limit switch is faulty and needs to be replaced Note A P30 Power Fault and a P11 Power Fault will also display as a result of this test Genie A TEREX BRAND ZX 135 70 Part No 218700 September 2015 A A OA EA ZZ 14 Re connect the Deutsch connector to LSS1RS Result The LCD screen displays SEC 1 LSS1RS FAULT Result The LCD screen doesn t display the Fault message The limit switch is faulty and needs to be replaced 15 Turn the engine off 16 With the key switch off press and hold the 2 enter button and turn the key switch to the on position Release the enter button after five 3 seconds and press the minus minus previous previous buttons in that order 17 Press the previous button until clear all safety switch faults appears 18 Select YES then pre
94. plus button to select YES then press the enter button to accept 14 Proceed to step 20 Delete a Single Steer Sensor Calibration 15 To calibrate a single steer sensor delete the specific steer sensor calibration 16 Press the enter or previous button on the LCD screen until DELETE STEER SENSORS CALIBRATION is displayed Example DELETE BLUE END BLUE SIDE STEER SENSORS CALIBRATION FL 17 Press the plus button to select YES then press the enter button to accept 18 Press the enter or previous button on the LCD screen until EXIT is displayed 19 Press the plus button to select YES then press the enter button to accept 20 Push in the red Emergency Stop button to the off position 21 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 22 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine Part No 218700 Gen ATEREX BRAND ZX 135 70 199 le Axle Components 10 2 Steer Cylinders How to Remove a Steer Cylinder Note When removing a hose assembly or fitting the O rin
95. previous button twice 4 Press the previous button until the function to be adjusted is displayed 5 Press the plus button to increase the ramp rate or press the minus button to decrease the ramp rate 6 Press the enter button to save the setting in memory 7 Press the enter or previous button on the LCD screen until EXIT is displayed 8 Press the plus button or minus button to select YES and then press the enter button Part No 218700 September 2015 A lt a A 2 1 9 Platform Service Manual Platform Components Remove the weld cable from the platform if equipped AWARNING Electrocution burn hazard How to Remove the Platform 1 Separate the foot switch quick disconnect plug Support the platform with an appropriate lifting 10 device Locate the cables that connect to the bottom 11 of the control box Number each cable and its location at the platform control box Disconnect the cables from the bottom of the 12 platform control box Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Support the platform but do not apply any lifting pressure Remove the four mounting bolts and two U bolts securing the platform to the platform mounting weldment Remove the platform from the platform mounting weldment Remove the platform control box mounting AWARNING Crushing hazard The platform
96. prior to machine operation The jib boom bellcrank angle sensor is mounted to the bellcrank pivot pin on the engine side of the machine How to Calibrate the Jib Boom Bellcrank Angle Sensor Note If the primary boom or secondary boom angle sensors have been removed or replaced or the turntable level sensor has been replaced they must be calibrated before the jib boom bellcrank angle sensor Refer to Repair Procedures How to Calibrate the Primary Boom Angle Sensor or How to Calibrate the Secondary Boom Angle Sensor or How to Calibrate the Turntable Level Sensor Note For software versions 4 01 and higher use the 2 Point Calibration procedure For software versions before 4 01 use the 6 Point Calibration procedure The software version is displayed on the LCD screen when the red Emergency Stop button is pulled out to the on position Note Perform this procedure with the machine on a firm level surface Note A digital level will only be required to perform the 6 Point Calibration procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Service Manual September 2015 Jib Boom Components Note Use the following chart to identify the 5 description of each LCD screen control button used in this procedure t a oc Plus Minus Previous Enter 7 Digital levels
97. side 1 drive hub plugs 2 Remove both plugs and check the oil level O Result The oil level should be even with the bottom of the plug holes 3 Ifnecessary add oil until the oil level is even with the bottom of the plug holes Refer to Specifications Fluid Capacity Specifications 4 Install the plug in the drive hub 5 Check the torque of the drive hub mounting fasteners Refer to Specifications Machine Torque Specifications 6 Repeatthis procedure for each drive hub Part No 218700 September 2015 Service Manual Turntable rotate drive hubs 1 Openthe cover at the ground controls side of the machine 2 Remove the plug located on the top of the hub and check the oil level Result The oil level should be even with the bottom of the plug hole 1 drive hub mounting bolt 2 drive hub fill plug 3 drive hub drain plug 3 If necessary add oil until the oil level is even with the bottom of the plug hole Refer to Specifications Fluid Capacity Specifications 4 Apply pipe thread sealant to the plug and install the plug in the drive hub 5 Repeat steps 2 through 4 for the other turntable rotate drive hub Part No 218700 Gen ATEREX BRAND ZX 135 70 39 Checklist B Procedures B 10 Test the Platform Self leveling Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling thro
98. steer cylinder 20 25 ft lbs from moving when not steering 27 34 Nm 20 Flow control valve 1 5 gpm 5 7 L min O Right rear steer cylinder retract 20 25 ft lbs circuit 27 34 Nm 21 Flow control valve 1 5 gpm 5 7 L min L Left front steer cylinder retract 20 25 ft lbs circuit 27 34 Nm 22 Flow control valve 2 1 gpm 8 L min H Left front steer cylinder extend 20 25 ft lbs circuit 27 34 Nm 23 Flow control valve 2 1 gpm 8 L min I Right front steer cylinder extend 20 25 ft Ibs circuit 27 34 Nm 24 Solenoid valve 3 position 4 way A Steer left right left front steer 20 25 ft Ibs cylinder 27 34 Nm 25 Solenoid valve 3 position 4 way B Steer left right right front steer 20 25 ft Ibs cylinder 27 34 Nm Genie Part No 218700 ZX 135 70 179 Service Manual September 2015 Manifolds Genie 180 ZX 135 70 Part No 218700 September 2015 Service Manual 8 9 Valve Adjustments Steer and Axle Manifold How to Adjust the Axle Relief Valve Note Perform this procedure with the machine on a firm level surface and in the stowed position with the axles extended Note Refer to Steer and Axle Manifold list to locate the axle relief valve Note Two people will be required to perform this procedure 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the steer and axle m
99. switches RD BL WH 65 Low fuel indication BK BL 66 Drive Enable WH BL 67 Secondary boom not stowed BK RD 68 a lowered WH RD BL 69 Primary boom 1 extended ER BL WH 70 Primary boom 2 retracted Se BL BK 71 Primary boom 2 extended ARO BL WH 72 Secondary boom extended BERN BL RD 73 Secondary boom retracted BK RD RD 74 Primary 1 Lockout RD WH 75 Primary 2 Lockout GR BL 76 Primary boom 3 extended RD WH 77 Lower Angle 1 operational BL WH WH BK 78 Upper Angle 2 operational GR WH BK 79 Power from TCON ESTOP BK N A 80 Can 2 0 J1939 Shield OR GR 81 Can 2 0 J1939 Low RD YL 82 Can 2 0 J1939 High OR RD GR WH 83 Tilt signal X axis BK RD GR BK 84 Tilt signal Y axis RD BK GR 85 Tilt sensor power OR Genie 252 ZX 135 70 Part No 218700 September 2015 Service Manual Wire Color Legend Color Circuit Primary Function Color Circuit Primary Function RD 117 Flashing Beacon RD 141 Primary Boom Angle Signal OR 118 Lift Speed Reduction Satety BL 119 Hydraulic Pressure Sensor OR 142 Secondary Boom Angle Signal Output Safety OR 120 Oil Cooler Fan BL RD 143 Drive Enable Left GR 124 Axle Oscillate Left BL WH 144 Drive Enable Right GR BK 122 Axle Oscillate Right RDIWH an EE RD BK 123 Primary Boom Angle Signal BL 146 Jib Bellcrank Up Flow Control Operational BL BK 147 Jib Bellcrank Down Flow Control RD WH 124 Secondary Boom Angle Signal BL WH 148 Jib Bellcrank Sensor Operational GR WH 149 Jib Up Down Flow Control WH RD 1
100. test weight back onto the center of the platform floor using a suitable lifting device O Result The alarm should be off The platform overload indicator light should be off at the platform controls and there should be no error message on the LCD display at the ground controls Note There may be an 2 second delay before the overload indicator lights and alarm turn off 8 Add an additional 15 Ibs 6 8 kg test weight to the original test weight to overload the platform Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and platform overload should be displayed on the LCD screen at the ground controls Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 9 Test all machine functions from the platform controls O Result All platform control functions should not operate 10 Turn the key switch to ground controls 11 Test all machine functions from the ground controls O Result All ground control functions should not operate Part No 218700 Genie ATEREX BRAND ZX 135 70 101 Platform Components 2 6 Platform Overload Recovery Message software V3 07 and later If the ground controls LCD screen displays OVERLOAD RECOVERY the emergency lowering system has been used while the platform was overloaded How to Clear the Platform Overload Recovery Message Note This message sh
101. the zero position 6 Raise the secondary riser but do not extend it Move the primary boom and jib to horizontal and fully extend N Note the reading on the dial indicator O Result The measurement is less than 0 118 inch 3 0 mm The bearing is good D Result The measurement is more than 0 118 inch 3 0 mm The bearing is worn and needs to be replaced Part No 218700 September 2015 Service Manual a FT A A AA Checklist C Procedures 8 Move the boom sections to the positions indicated in step 3 Visually inspect the dial indicator to be sure the needle returns to the Zero position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the boom to the stowed position and turn the machine off 12 Remove the dial indicator from the machine Genie ATEREX BRAND Part No 218700 ZX 135 70 67 Service Manual September 2015 Checklist D Procedures D 1 Check the Boom Wear Pads Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extreme
102. the engine Locate the secondary boom up down and extend retract joystick Move the secondary boom up down and extend retract joystick full stroke in the up extend direction and hold for 5 seconds then return to the center or neutral position Move the secondary boom up down and extend retract joystick full stroke in the down retract direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Part No 218700 Service Manual Platform Controls Primary boom extend retract functions 1 2 Genie ATEREX BRAND ZX 135 70 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 platform controls Hold the enter button for approximately 5 seconds Press the minus button twice then press the enter button twice Use the scroll button to scroll through the menu until DELETE PRIMARY BOOM EXTEND RETRACT JOYSTICK DEFAULTS is displayed Press the plus button to select YES then press the enter button Do not start the engine Locate the thumb rocker switch on top of the primary boom turntable rotate joystick Move the primary boom extend retract thumb rocker switch full stroke in the extend direction and hold for 5 seconds then return to thecenter or neutral position Move the primary boom extend retract thumb rocker switch
103. the ground and platform controls Add an additional 15 Ibs 6 8 kg test weight to the original test weight to overload the platform Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls Result If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations the platform overload system needs to be calibrated Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 7 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and PLATFORM OVERLOAD should be displayed on the LCD screen at the ground controls Result If the alarm does not sound and the platform overload indicator light does not come on with the test weights in any of the platform locations the platform overload system needs to be calibrated Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Genie
104. the ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 20 Press and hold a function enable speed select button and raise the jib boom above horizontal to provide additional ground clearance for the remaining calibration points Service Manual September 2015 Jib Boom Components 21 Press and hold a function enable speed select button and the platform level down button until the digital level displays approximately 18 2 degrees 70 60 44 8 ge 18 Calibration angles 22 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note Be sure the number entered at the ground controls is a negative number Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 23 Press and hold a function enable spee
105. the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Support the rod end of the jib boom lift cylinder with a suitable lifting device Genie A TEREX BRAND 108 ZX 135 70 4 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Use a Soft metal drift to remove the pin and let the cylinder hang down 5 Attach a lifting strap from an overhead crane to the barrel end of jib boom lift cylinder 6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin 7 Remove the jib boom lift cylinder from the machine A WARNING Crushing hazard The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane Part No 218700 September 2015 Service Manual 3 4 Jib Boom Level Cylinder How to Remove the Jib Boom Level Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation R
106. the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 36 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 37 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 38 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 39 Press the enter or previous button on the LCD screen until DELETE SECONDARY BOOM ANGLE SENSOR CALIBRATION is displayed 40 Lower the secondary boom to the stowed position 41 Press the enter or previous button on the LCD SCREEN UNTIL SECONDARY BOOM FULLY LOWERED is displayed 42 Press the plus button to select YES then press the enter button to accept 43 Fully raise the secondary boom until it stops at the end of the cylinder stroke e le Service Manual September 2015 PF
107. to Remove the Jib Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the platform mounting weldment and the platform rotator Refer to Repair Procedure How to Remove the Platform Rotator 3 Tag disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to the platform manifold Cap the fittings on the 4 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses from the jib boom manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Remove the cotter pin from the upper cable track tube at the platform end of the jib boom Not
108. to select YES then press the enter button to accept 52 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine 53 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 54 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners 55 Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 56 Pull out the red Emergency Stop button Start the engine and lower the boom to the stowed position Be sure there are no calibration faults shown on the display ZX 135 70 Part No 218700 September 2015 Service Manual Boom Components 1 upper primary boom lift cylinder linkage arm 2 primary boom 3 cable track 4 primary extension boom 5 jib boom manifold 6 secondary boom lift cylinder 7 secondary boom cable track inside of secondary boom e Genie 8 primary boom lift cylinder 9 number 1 secondary boom tube 10 number 2 secondary boom tube 11 number 3 secondary boom
109. tube 12 lower primary boom lift cylinder linkage arm 13 number 4 secondary boom tube ATEREX BRAND Part No 218700 ZX 135 70 117 Service Manual September 2015 Boom Components 4 1 Primary Boom Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom How to Remove the Primary Boom Cable Track Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the machine on a firm level surface Note Perform this procedure with the boom in the stowed position 1 Remove the cover from the lower jib boom cable track 2 Tag and disconnect the electrical connectors inside the lower cable track 3 Remove the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom Remove the clamps 4 Pullthe electrical cables out of the lower cable track that lead to the primary boom 5 Tagand disconnect the electrical connectors from the jib boom manifold located at the platform end of the prim
110. until EXIT is displayed 6 Press the plus button or minus button to select YES and then press the enter button Service Manual September 2015 Platform Controls How to Set the Function Thresholds and Default Functions Speeds Note Before the threshold and default function speeds can be set the boom function proportional valve coil defaults must be set first Refer to Repair Procedure How to Reset a Proportional Valve Coil Default Note If a boom function proportional valve coil has not been replaced and just want to reset the function speed to original factory settings proceed to Function speeds procedure 1 Start the engine from the platform controls 2 Press down the foot switch Note Be sure the engine rpm is set to foot switch activated high idle Function threshold 3 Selecta joystick controlled function that needs to have the threshold set 4 Slowly move the joystick off center in either direction just until the machine function starts to move then move the joystick very slowly towards the neutral or center position just before the machine function stops Do not let go of the joystick 5 While holding the joystick in position press the engine start button at the platform controls to set the joystick controller threshold Genie A TEREX BRAND 92 ZX 135 70 6 Slowly move the joystick off center in the opposite direction just until the machine function starts to move then move the joys
111. with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Pre delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Funct
112. zuuvrvrotztgs EE 533552545065 t 289292 E ESSERE 25 SCONGND BR SCONGND BR SEREZ28888 5 S139TRF WH RD E a S137PLL RD WH 9 EK e S56PRV RD e S56PRV RD o S59CNK GR WH S59CNK GR WH D81CAN GR D82CAN YL C145CAL RD WHP121 04 CALIBRATION IN P121 03 TD RS232 S73SLE BL RD P121 02 SEC SW CONNECTION u sl S132LDS BLIWH SP121 01 LOAD SENSE gt Ix nc tc ul o c Ed os ix Kei E ge 28 2 BE SS SE d 3 5 amp poi o amp 8 ga OG E 4B Z 838 EX 8 Je 28 iz zu 9 2g 5 5 d amp 8 g Ss S82 22 Y CRM NN Te 5 5a So 2 5 oo g e TO AS A NZ o NZ on Sa BM UID FCO BM E R FC O PLD BM DWN O BM RETO 2 MLT FNC VLV O eas AUX HYD O x 9 gs SZZ PRIBMRETSTI G amp S Zu f We gree BM3 1 ES2uoOs BM90 1 Ett SERVICE OR RECOVERY MODE PRI LO 1 O Onarar M a uj s m SS SS SS a a ipu de sh ng E Ez ES 2 o af 28 a 2 es ul a zZz x mm er E 5 98 r amp r9 E 5 e SBS SE mmEBEE ef S2e S 5 a Soe F CH 8 TCON ESTOP II E B e o BL BK lz BC BC E Z SNE BB BB xu NAVY o BA BA G P MODE GRBK ER syys WH BK as slele o be lt p m ls Q Z lt lt H m PWR TO TCON ESTOP BL BK i Sg i FE PESE UU d 5 o0 P ba TCON ESTOP BL WH TETESTOPRET PT2 E z tu Qe E u oet u Denk u Dr E WN SE ot A 25 25 sl a 5 z A 5 3 55 2 83 SERV CAL MODE DIAG TETHER PWR P11 22 lt gas 33 a 2 9 g Q Q L c470UT WHIBK ECU POW
113. 0 Genie ATEREX BRAND ZX 135 70 105 Service Manual Jib Boom Components How to Repair the Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Service Parts Department 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Carefully remove the snap rings and pins from each end of the damaged section of cable track 3 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 4 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 5 Remove the upper rollers from the replacement section of cable track 6 Lift up the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 7 Connect the ends of the replacement cable track section to the existing cable track using the pins and snap rings 8 Install the rollers onto the new section of cable track 9 Operate the jib boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track Service Manual September 2015 Jib Boom Components 3 2 Jib Boom How
114. 0 Heian El 5 D2 ANALOG NC E 2 Bp ES OMRON ao 2 D8 DIG INS NG 2 m 3 RELAY A R l 5 El NOT USED S m 2 la eee op 4 ES NOT USED 2 bg m 3 d C57 1 D mm 3 WELDER OPTION A Ga m AS 4 ney SEAN A A G1 WELDER MANIFOLD 5 t PRESSURE SWITCH F3 DONS 3 H EE a E E P o inui 200 Pl SX CONTROLLER 1 T BV ZG 5 p 2 Ze ree E dg A PMPA MTRA 4 E S g NO e SCH E S gt SR d 31504 5 DRIVE HYDRAULIC Co En PUMP e COUPLER TTH LZ Z LZ Z ALL LL SSS SS O 6 4 DIVERTER MANIFOLD 2 030 IN NE SIL B PMPB X TT IMRB 3 BY l 1 oa DA GENERATOR SE l OIL COOLER pF TO APU SUCTION ro 7 Lol G2 p CLR lt gt e Lee em Genie ATEREX BRAND 286 ZX 135 70 Part No 218700 September 2015 Service Manual Hydraulic Schematic
115. 0 Part No 218700 September 2015 A _ 2 AAA ET Perkins 854F 34T Engine Fault Code SPN Suspect Parameter Number FMI Failure Mode Identifier Service Manual SPN FMI Description Refer to Engine Manual 27 3 Engine Exhaust Gas Recirculation Valve Valve Position Sensor Test Position Voltage Above Normal 27 4 Engine Exhaust Gas Recirculation Valve Valve Position Sensor Test Position Voltage Be low Normal 29 3 Accelerator Pedal Position 2 Voltage Above Analog Throttle Position Sensor Circuit Test Normal 29 4 Accelerator Pedal Position 2 Voltage Below Analog Throttle Position Sensor Circuit Test Normal 51 3 Engine Throttle Valve 1Position Voltage Above Valve Position Sensor Test Normal 51 4 Engine Throttle Valve 1 Position Voltage Below Valve Position Sensor Test Normal 91 3 Accelerator Pedal Position 1 Voltage Above Analog Throttle Position Sensor Circuit Test Normal 91 4 Accelerator Pedal Position 1 Voltage Below Analog Throttle Position Sensor Circuit Test Normal 97 15 Water In Fuel Indicator High least severe Fuel Contains Water 100 2 Engine Oil Pressure Erratic Intermittent or Switch Circuits Test Incorrect 100 17 Engine Oil Pressure Low least severe 1 Oil Pressure Is Low 102 3 Engine Intake Manifold 1 Pressure Voltage Engine Pressure Sensor Open or Short Circuit Test Above Normal 102 4 Engine Intake Manifold 1 Pressur
116. 109 Service Manual September 2015 Jib Boom Components 3 5 5 Tag disconnect and plug the two hydraulic g hoses from the jib boom manifold that lead to Jib Boom Extension Cylinder the platform manifold Cap the fittings on the manifold How to Remove the Jib Boom AWARNING Bodily injury hazard Spraying Extension Cylinder hydraulic oil can penetrate and burn skin Loosen hydraulic Bodily injury hazard This connections very slowly to allow AWARNING procedure requires specific repair the oil pressure to dissipate skills lifting equipment and a gradually Do not allow oil to suitable workshop Attempting squirt or spray this procedure without these skills and tools could result in death or 6 Tag disconnect and plug the jib boom lift serious injury and significant cylinder and jib boom extension cylinder component damage Dealer hydraulic hoses from the jib boom manifold service is strongly recommended Cap the fittings on the manifold Note Perform this procedure with the boom in the AWARNING Bodily injury hazard Spraying stowed position hydraulic oil can penetrate and burn skin Loosen hydraulic Note When removing a hose assembly or fitting connections very slowly to allow the O ring if equipped on the fitting and or hose the oil pressure to dissipate end must be replaced All connections must be gradually Do not allow oil to torqued to specification during installation Refer to squirt or spray Sp
117. 2 DRIVE E AUXILIARY l n PIS Fa ED Fa FADE Fa a XX F3 E Fo xc E ZC e Ve t4 9 TE 1 p idet M acc CN e c pa E n JE IE L 2137 X XH I X X E X i 38 oap EN l at IT Y T D gt s n i M2 s l BAR dl si T E HTC SI Ce m vi 3 8 LPM d x S BEE 4 TANK 5 A O BS pe R i L D T We el 1 T B i cu l 25 oe ES __ Ll S E Lo ze SC _ B SEN Pal Pal e m FUNCTION MANIFOLD FRONT AXLE REAR AXLE m 4 7 EXTENSION EXTENSION BELLORANK LEVEL TANK oL See d SC 3 6 1 6 GPM 16 6 6 LPM COOLE AF i ais cm LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR i eg wn WE la 4 la 1 l STEERING STEERING STEERING STEERING ELO NE I AS I te pet PIS 1 pa 1 I E EE TES eS au ze mt NOT mc en an au m if l K 28 E D 3 18 i M i E 1JLD yE A SE pi peces NH Y cce pa mace euo 1 le Je mum RFE_ RR LRE LAR RRE RRR LEA FAE FAR RAE RAR o cw 5 ee pig er ye ee eg A d x x 3 x Pa T2 DE E Ge T TEST A B a GM OR Be d 22 00 mz i E mI P NE TN Po RIGHT st Parce T mu a f usn U cnn A PLATFORM RIGHT RRA S IU RFA FRONT Su L gw pam Gut gin gauL LCE MANIFOLD T REAR 90 t E ie em Tom TE IPM LPM LPM E RECIRCULATION SAFE a c Do Du Dhd bue ail DOR bg pus CUP RECIRCU ET RR l i l F Keen gt Per in Ne ee pae tj H H H I ri ot UA E
118. 2 Remove the hose and cable clamps from the 19 Attach a lifting strap to each end of the cable primary boom lift cylinder track from an overhead crane for support Do 13 At the counterweight end of the secondary EENEG boom support and secure the secondary 20 Remove the mounting fasteners that attach boom lower end cover to a suitable lifting the lower cable track to the primary boom lift device cylinder 14 Remove the cover retaining fasteners and 21 Remove the mounting fasteners that attach remove the cover from the end of the the cable track to the primary boom SEAN 22 Carefully remove the cable track from the Crushing hazard The secondary machine and lay H on a structure capable of AWARNING boom lower end cover could supporting it become unbalanced and fall Crushing h d Th when removed from the AWARNING eid dees ee secondary boom H not properly unbalanced Gad tall when ae secured to the removed from the primary boom j if not properly supported by the 15 Locate the two hydraulic hoses inside the end overhead crane of the secondary boom that lead to the primary Component damage hazatd b ble track een The boom cable track can be 16 Tag disconnect and plug the hydraulic hoses damaged if it is twisted from the unions Cap the fittings on the unions Bodily injury h ds Component damage hazard AWARNING 271 Injury hazard Spraying Cables and hoses can be hydraulic oil can penetrate and damaged if they are kinked or burn sk
119. 215 F 37 ohms 102 C 170 F 78 ohms 82 C Alternator output 85A 12V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Genie Part No 218700 ZX 135 70 9 Service Manual September 2015 Specifications Perkins 854F 34T Displacement 207 cu in 3 4 liters Number of cylinders 4 Bore and Stroke 3 89 x 4 33 inches 99 x 110 mm Horsepower net intermittent 2500 rpm 74 hp 55 2 kW Induction system turbocharged Firing order 1 3 4 2 Standby speed 1000 rpm Low idle 1500 rpm High idle 2500 rpm Compression ratio 17 0 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Governor Electronic Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Minimum oil pressure 12 psi 0 82 bar Oil capacity including filter 7 7 quarts 7 3 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Genie A TEREX BRAND 10 ZX 135 70 Oil Pressure switch Installation torque 18 4 ft Ibs 25 Nm Pressure switch point 12 psi 0 82 bar Oil Sensor Settings 0 psi 10 ohms 50 psi 120 ohms Fuel injection system Transfer pump pressure 10 12 psi 0 69 0
120. 25 A i E al A A o osaNp BR e WBRA m S S 8 gs M OIL COOLER FAN E lu E E 5 8 TE apen I uro e C116HYD OR e 03GND BR COOLER RELAY SS BUM z Es E TEMP SW E oz E M s E gt 5 es 288 AAL A ooo z I E Wi H d dl R34SA BK WH GLOW PLUG S 3 58 H EER f 5 Oppe i E L C34SA BKAWH Ne O2GND BR 3 GLOW PLUG RELAY E A C31EDC WH BK a D o 93 DUAL B i gt COIL I E EDC C30EDG WH Ge 33 VALVE RTN 3 P123 lt O4GND BR AG GENERATOR P1 22 lt C45GEN GRWH TT_TILT_Y AXIS P1221 lt ES 5 Geen NT TT TILT X AXIS P1 20 lt S E WH PULLIN ay WH NITINd e HILO SPEED P 38 POWER TO TTROT FC P1 19 S139TRF WH RD ES ADDED M B TOH SOLENOID om ALTERNATOR RPM P1 18 lt C41RPM OR BK d Ed B P 88 PWR TO PROPEL P1 17 4 8197PLL RD WH D VALVE RTN 2 P1 16 lt y TE D TT TILT SNSR FWR P1 15 lt e SE SERVICE TT_TILT_SNSR_GND P1 14 lt E 02 ND BR E Se OILWATER_TEMP P1 13 lt C26TSRWH RD Je tU Si FABHRN WH HORN RELAY OIL PRESSURE P1 12 lt C25PSRANH BK B3BAT 14 RD E EDC REV P1 11 lt GS1EDC WH BK BAT GND BR 9 EDC FWD P1 10 C30EDC WH OA1RPM OR BK CATRPM OR BK uL STARTER RELAY P1 08 C33STR BK CS1EDC WH BK CIO7AF RD LP Pros C30EDO WH 2235 E SERVICE HRN P497 Z C46HANWH CASHRNWH i 82 LEE B g REV PWM P108 lt Eng Yi 5 FWD PWM P105 lt Brett x ALTERNATOR CHOKE GLOW PLUG RELAY P1 04 CS4SA BK
121. 25 ee Lockout SC E E WH BK 126 Secondary Boom Lockout Riser Gen M Down Enable BK 152 Injector Retard GR 127 ECU Test Switch BK 153 Jib Extend OR RD 128 Low Engine Speed BKIWH 154 Jib Retract RD BK 129 Descent Alarm OR RD 155 Pressure Comp Enable WH RD 130 Travel Alarm GR WH 156 Jib Up Down BL 131 Motion Alarm BK RD 157 Jib Extend Retract GR 132 Platform Load Input BL RD 158 Steer Signal Rocker GR WH 133 Platform Load Alarm BL WH 159 Steer Joystick Signal GR BK 134 Key Switch power WH RD 160 Propel Joystick Signal BL WH 135 Fuel Pump WH BK 161 Secondary Boom Joystick Signal RD 136 Power to Safety Module OR 162 Joystick 5V DC power RD WH 137 Drive Power P 38 BL WH 163 Primary Extend Retract Signal RD BK 138 Primary Boom Up Secondary RD WH 164 Primary Up Down Signal Boom Down Extend P_11 30 WH RD 165 TT Rotate Signal WH RD 139 Turntable Rotate Flow Control Safety P_39 OR RD 140 Boom Envelope Safety Genie ATEREX BRAND Part No 218700 ZX 135 70 253 Service Manual September 2015 Circuit 188 189 190 191 192 193 194 195 196 197 198 199 226 227 228 N A Primary Function Safety cross check Data Receive Data Transmit Multi Function Pressure Relief Jib Rotate Left Jib Rotate Right Speed Select Input Electric Brake Source 2 5V Sensor Power Hour Meter 12V Sensor Power Thermal Switch Telematics Remote Disable Engine Control CAN 2 0 41939 Low Engine Control CAN 2 0 41939 High
122. 30 ft lbs CB 34 41 Nm 3 Shuttle valve 2 position 3 way Turntable rotation brake release 8 10 ft lbs CC 11 14 Nm 4 Orifice Plug 0 030 inch 0 76 mm CD Turntable rotation brake release Genie 176 A TEREX BRAND ZX 135 70 Part No 218700 September 2015 A A 1 Manifolds 8 8 Steer and Axle Manifold The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine Service Manual Index E Schematic No Description Item Function Torque 1 Flow control valve 1 5 gpm 5 7 L min Right front steer cylinder retract 20 25 ft lbs M circuit 27 34 Nm 2 Check valve Prevents right front steer cylinder 20 25 ft lbs S from moving when not steering 27 34 Nm 3 Pilot operated piston Y Z AA BB 4 Check valve Prevents left front steer cylinder 20 25 ft lbs Q from moving when not steering 27 34 Nm 5 Check valve Prevents right front steer cylinder 20 25 ft lbs T from moving when not steering 27 34 Nm 6 Check valve Prevents left front steer cylinder 20 25 ft lbs R from moving when not steering 27 34 Nm 7 Flow control valve 2 1 gpm 8 L min Right rear steer cylinder extend 20 25 ft lbs K circuit 27 34 Nm 8 Solenoid valve 3 position 4 way Steer left right right rear steer 20 25 ft lbs D cylinder 27 34 Nm 9 Check valve Prevents right rear steer cylinder 20 25 ft lbs A from moving when not steering 27 34
123. 4 J157 J160 J161 J162 J163 J164 J165 J166 J168 J169 J175 Description 1 way Deutsch connector for platform ground jib primary 2 pin Deutsch connector boom composite 4 pin Deutsch connector boom composite 3 pin Deutsch connector CAN connector jib primary 3 pin SAE Deutsch tee 2 pin Deutsch connector for engine and manifold harness 6 pin Deutsch connector for secondary boom angle sensor 2 pin Deutsch connector for PCON manifold boom composite harness 4 pin Deutsch connector for front axle angle sensor 4 pin Deutsch connector for rear axle angle sensor 3 pin Deutsch connector for jib bellcrank angle sensor 2 pin Deutsch connector for secondary boom up down flow control 2 pin Deutsch connector for secondary boom extend retract flow control 12 pin Deutsch connector located at PCON 6 pin Deutsch connector for jib bellcrank sensor 1 way 0 25 inch slide terminal for belt generator excite 20 pin Molex connector for circuit board to joystick and switches 2 2 pin Deutsch connector Part No 218700 Genie ATEREX BRAND ZX 135 70 Number J223 J224 J228 J231 J232 J233 e Service Manual Description CAN Gateway 8 pin Molex connector Telematics connector Gateway to TCON interface connector Tier IV A1 or D2 1 ECU connector Tier IV K1 or D2 2 ECU connector Tier IV engine interface connector 261 Service Manual September 2015 Drive Chassis an
124. 4 Nm 3 Flow control valve 0 2 gpm 0 76 L min AG Platform rotate left right circuit 20 25 ft lbs 27 34 Nm AB 3 AL 02 OS Ur iS Genie A TEREX BRAND 170 ZX 135 70 Part No 218700 September 2015 Service Manual A e _ lt _ e 1 This page intentionally left blank Genie ATEREX BRAND Part No 218700 ZX 135 70 171 Service Manual EN 8 4 Jib Boom Manifold The jib boom manifold is mounted inside the primary extension boom at the platform end September 2015 Index TEM Schematic 2 No Description item Function Torque 1 Pressure compensator valve X 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 valve Solenoid Valve 2 position 3 way AE Jib boom retract 20 25 ft lbs 27 34 Nm 3 Solenoid Valve 2 position 3 way AD Jib boom extend 20 25 ft lbs 27 34 Nm 4 Flow regulator valve 2 gpm 7 6 AC Jib boom extend retract circuit 20 25 ft lbs 27 34 Nm L min 5 Orifice 0 040 inch 1 mm AB Jib boom extend retract circuit 6 Check valve 25 psi 1 7 bar AA Holds oil in jib boom manifold 20 25 ft lbs 27 34 Nm 7 Shuttle valve Z Jib boom up down circuit 10 12 ft lbs 14 16 Nm 8 Proportional solenoid valve Jib boom up down 20 25 ft lbs 27 34 Nm 3 position 4 way 9 Proportional solenoid valve AF Jib boom bellcrank level 20 25 ft lbs 27 34 Nm 3
125. 49 5 Nm 4 10 ft lbs 13 6 Nm _ 6 30 ft Ibs 40 7 Nm c ES 8 40 ft lbs 54 2 Nm IMAI 10 60 ft lbs 81 3 Nm 12 85 ft Ibs 115 Nm 16 110 ft lbs 150 Nm 20 140 ft lbs 190 Nm D Adjustable Fitting Non adjustable fitting 24 180 ft lbs 245 Nm JIC 37 Fittings swivel nut or hose connection 1 jam nut SAE O ring Boss Port SAE Dash Size Thread Size Flats tube fitting installed into Steel 4 7116 20 2 SAE Dash Size Torque 6 9 16 18 1 4 ORFS 37 Adj 15 ft lbs 20 3 Nm 8 3 4 16 1 ORFS Non adj 26 ft lbs 35 3 Nm T ey l 37 Non adj 22 ft lbs 30 Nm 12 1 116 12 7 Sr Ad Novad 295 393 Nm 716 15 16 12 1 8 ORFS Adj Non adj 60 ft Ibs 81 3 Nm 20 1 5 8 12 1 37 Adj Non adj 52 ft lbs 70 5 Nm 24 1 7 8 12 1 10 ORFS Adj Non adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft lbs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft Ibs 413 5 Nm Genie 12 ZX 135 70 Part No 218700 September 2015 Service Manual Torque Procedure Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O ring in Parker Seal Lok fittings and hose end are custom size O rings
126. 571 7 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem Relief Valve Not Responding Properly 5571 10 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem Relief Valve Abnormal Rate of Change 5571 14 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem Relief Valve Special Instruction 5571 16 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem Relief Valve High moderate severity 2 5826 16 Emission Control System Operator Inducement Refer to Operator Inducement Codes Severity High moderate severity 2 Genie 244 ZX 135 70 Part No 218700 September 2015 Service Manual Observe and Obey Schematics About This Section There are two groups of schematics in this section Electrical Schematics A WARNING VI Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine before operating the machine Before Troubleshooting V Immediately tag and remove from service a damaged or malfunctioning machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics A WARNING V Repair any machine damage or malfunction VI Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine M Be sure that a
127. 9 14 84 CAN Bus 0 BusOff Status 411 4 381 Physical range check low for EE 280 SE 1 in firing order short EGR differential pressure 411 4 796 Sensor error differential pressure St A SH SCH Side ih Eh Ss en Venturiunit EGR signal range in the injector 1 in firing order check low Genie Part No 218700 ZX 135 70 225 Service Manual AAA AAA AAA a Deutz TD 2 9 L4 Engine Fault Codes September 2015 SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier 677 3 956 Starter relay high side short KWP Keyword Protocol circuit to battery SPN FMI KWP Description 677 3 960 Starter relay low side short 651 5 568 Injector 1 in firing order circuit to battery interruption of electric connection 677 4 957 Starter relay high side short 652 3 581 Injector 2 in firing order short circuit to ground circuit 677 4 961 Starter relay low side short 652 4 587 High side to low side short circuit circuit to ground in the injector 2 in firing order 677 5 958 Starter relay no load error 652 5 569 Injector 2 in firing order 677 12 959 Starter relay powerstage over interruption of electric connection temperature 653 3 582 Injector 3 in firing order short 703 3 426 Engine running lamp short circuit circuit to battery 653 4 588 High side to low side short circuit 703 4 427 Engine running lamp short circuit in the injector 3 in firing ord
128. 909 1233 e gt l T _ N iv E A vo M o N N w M o wo w o9 a N e o 2 _ o a gt Ny wech gt EN _ so a N N to Wi S Co w J N Q o co a gt D a C ho j ajo unico pr AS LS Jo um la ala AIN N Co ZE N gt co o s o Ne o e Fe un oo o _ 4A o NI Sin O wW O o Co o SSIs En N O1 N DIO io O O1 N 2 NIDO S O 0 gt 00 N A N o al N A c Q Q e N OH Golal AlLAkKa leja Sol 1 o alo ln re Nana a E Melo e o om o ico 1 6 5 e ops oi N Or Ga E e 00 oo o r c D m i 2 L E c D m i 2 L E G D m D 7 lt E c D m D 2 L mi co ne Ajos fo le NS iol N ole on B N a E al e A N 214 Genie A TEREX BRAND 14 ZX 135 70 Part No 218700 September 2015 Service Manual Scheduled Maintenance Procedures EN Observe and Obey MI Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine MI Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified of the Maintenance inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations A WARNING Failure to perform each procedure
129. A A4 V AA GND BR Ki4 lt ECU GND OIL PRESSURE SWITCH A 6 C25PSR lt C28PSR A06 4 ENGINE CAN BUS I R20PWR RD Kiss ECU PWR TVA MOTOR POSITION PWR TVAPOSPWR Se lt TVAPOSPWR A08 TO CAN GATEWAY e GND BR K16 ECU GND EGR POSITION PWR EGRPOSPWR X EGRPOSPWR A09 LHEAT Ki 7_ lt LAMBDA SENSOR HEAT BOOST PRES PWR P A 10 BOOSTPWR EIC T7 BGOSTPWR A10 L CRTR START REQUEST RAIL PRES SUPPLY GA RAILPPWR BEZ RAILPPWR An AIR INLET TEMP SENSOR DELTAPWR K1 14 4 DPF DELTA PRESURE PWR EXHAUST GAS PRES PWR EGPRESPWR ElC21 EGPRESPWR A12 ATEMPSIG K19 BLIRD gt gt ATEMPSIG K1 18 AIR INLET TEMP SIGNAL CAM SPEED PWR A 13 CAMSPDPWR HO CAMSPDPWRA13 ATEMPGND K20 0R gt gt 2 ATEMPGND Ki 20 AIR INLET TEMP RETURN CAM SPEED SIG DA 14__ gt CAMSPDSIG EICH CAMSPDSIG A14 WATER IN FUEL SENSOR L GPCDIAG K122 GLOW PLUG CONTROLER DIAG FUEL METERING UNIT SUPPLY DA 15 P135FMU EICH PIaBFMU A15 RISKSP GRIBK gt gt C33RET EZ ENGINE START RELAY GND INJECTOR 1 HIGH DA TE Mir 5 OBGND BR gt gt 2 C20RET K1 28_ lt EGR PWR RELAY GND INJECTOR 3 HIGH A 17 INJ3HI WIFSW K30 RD WH gt WIFSW Kan X WATER IN FUEL SWITCH FUEL TEMP SENSOR GND 4 23 FTEMPRET EIC 15 lt FrEMPRET A23 PERKINS DIAGNOSTICS DELTAGND K138 lt DPF DELTA PRESURE GND EGR POSITION GND EGRPOSGND E C 35 eGRPOSGND A24 08GND BR gt DIAGB GPCGND K141_ lt GLOW PLUG CONTROLER GND BOOST PRES GND gt A 25 BOOSTGND ElC 19 lt BOOSTGND A25 RXPWRRD DIAS
130. A RAIL PRES GND gt 4 28 RAILPGND EICS RAILPGNA2E D228CAN YL gt DAGG d D228CAN K1 46 4 ENGINE CAN COMM HIGH EXHAUST GAS PRES GND EGRPOSGND BEZ EGPRESGND az D227CAN GR DAGF D227CAN K1 47 ENGINE CAN COMM LOW 129 CAM SPEED GND CAMSPDGND 2108 lt CAMSPDGND A28 E SENSON GPCSIG K152 lt GLOW PLUG CONTROLER SIG INJECTOR 2 LOW gt 4 31 INJ2LO 6 DELTAPAR KH AKT C33STR K1 53 ENGINE START RELAY SIGNAL INJECTOR 1 LOW gt 4 32 INJLO E DELTAGND K35 BUBK 55 2 C134KSP Ki 54 4 SWITCHED BATTERY KEY SWITCH TVA MOTOR D A 34 TVAMO SSES lt TVAMO A34 DELTASIG K58 WHIRD A DELTASIG K1 58_ lt DPF DELTA PRESURE SIG EGR MOTOR 24 35 EGRMO ti lt EGRMO A35 02GND EEN INTERLOCK GROUND TVA MOTOR POSITION GND DA 37 TVAPOGND CH TVAPOSGND A37 FUEL TEMP SENSOR ee A38 FTEMPSIG EE PrEMPSIG A38 LNERN Ki 88 4 LAMBDA VOLTAGE NERNST EGR POSITION ae A 38 EGRPOSSIG EICH FGRPOSSIG A39 DOC INLET TEMP SENSOR LPUMP Ki 64_ lt LAMBDA CURENT PUMP BOOST PRES SIG S 4 40 BOOTSIG EICHE BOOSTSIG A40 DOCRET K79 6RS gt 1 DOCRET K1 78 lt DOC INLET TEMP GND RAIL PRES SIG gt A 41 RAILPSIG EICH RAILPSIG A41 DOCSIG kat enn 2 DOCSIG K1 80 4 DOC INLET TEMP SIG EXHAUST GAS PRES SIG gt A43 EGPRESSIG EIC2 EGPRESSIG A43 7 TATEMPRET K181 T3 TEMP GND CRANK SPEED SIG D A44 CRNKSPD BO CRNKSPD A44 DPF INLET TEMP SENSOR T3TEMPSIG K1 82 d T3 TEMP SIG INJECTOR 4 LOW gt 4 46 INJALO DPFRET Va oe A DPFRET K1 83 lt DPF INLET TEMP GND INJECTOR 3 LOW gt 4 48 INISLO Eat DP
131. Aid glow plug or choke High Engine speed select Steer clockwise Steer counterclockwise Gasoline LPG Limit switch signal stowed RPM signal Boom retracted signal Jib Up Jib Down AC Generator Horn Output Power Enable Work Lamp Motion Lamp Auxiliary Boom Auxiliary Steer Auxiliary Platform Boom envelope safety valve cutoff Power to safety interlock switches engine Color Circuit Primary Function Color RD 1 Primary boom up driver WH RD RD BK 2 Primary boom down driver RD RD WH 3 Primary boom up down flow RD BK control proportional valve driver RD WH WH 4 Turntable rotate left valve driver WH WH BK 5 Turntable rotate right valve WH BK driver Hae WH RD 6 Turntable rotate flow control proportional valve driver BK BK 7 Primary boom extend BK WH BK WH 8 Primary boom retract BK RD BK RD 9 Primary boom Extend Retract BL proportional valve driver BL BK BL 10 Secondary boom up valve driver BL WH BL BK 11 Secondary boom down valve BL RD driver OR BL WH 12 Secondary boom up down flow OR BK control proportional valve driver BL RD 13 Drive enable GERD OR 14 Platform level up valve GR OR BK 15 Platform level down valve DEE GR WH OR RD 16 Platform up down flow control proportional valve driver WH GR 17 Platform rotate left valve driver WH BK GR BK 18 Platform rotate right valve driver WH RD GR WH 19 Jib select valve driver circuit WH BK RD 20 12V DC battery supply BL WH 21 12V DC ignition supply BL WH BK 22 Key switch power to
132. CAN YL Toes ENGINE CAN BUS nOz 2 2 2 GE 3 2 2 nu Q ENGINE CAN LOW P223 04 D227CAN GR 2207 el TO ENGINE HARNESS lt z MACHINE CAN HIGH P223 05 D82CAN YL 383 lt D82CAN YL ER Q e gt MACHINE CAN LOW Ez D81CAN GR IER D81CAN GR Se E x E DIGITAL IN 1 P223 07q x d m BA 2E aS P E 2 lt o 3 y 8 Ez d e Z z Y RE DIGITALIN 2 P2230 Yx S SS ez S ez x S 8 S 33 gt o pl E EE 202 a o ajaja a oz N e o Hi 20z a t c 25 O ag e R a o a o on ES 2 B88 SOS 32 eoo D lt a a2 Sad ow I az A HE E F PWR PCON ESTOP P21 23X P23PCN BK KEES NOT USED P21 22 AA NOT USED P21 2 ZF a NOT USED P27 2 amp E 5 S 2 5 Es oy NOT USED P21 1 bi SE i J151A C SHE SPARE WH CAN H P271 Z D82CAN YL EIAS D82CAN YL a CAN L P21 1 D81CAN GR D81CAN GR S STR MODE R OR BK 4 Jis S s HRN RLY CNTRL P21 162 C46HN WH ER lt C46HN WH coq us OUT PWR ENBL P21 1 C470UT WH BK C470UT WT BK pee E STRMODELOR AE Si TES NOT USED P21 14 lt J150A 4 BOOT P21 1 W I NOT USED P21 1X z zu ESE DRV SPEED RD WH 4 NOT USED P21 1 a CAN SHIELD P21 10 8 8 z NOT USED P21 08 S amp E y 7 Z E ES Bs NOT USED P21 0K E H E Ese ENG SPEED BK RD GND2 BR 20 z 3 P_22 P21 0 P56PRV RD WH ETE RAS 3 S S n NoT USED us A NOT USED P27 0K E i 8 8 g MLEEXTGRWH L SPAREWH 18 S
133. D the joystick controllers will need to be calibrated Wee h can damage printed circuit board Refer to Repair Procedure How to Calibrate a Maintain fi Joystick components aintain firm i contact with a metal part of the machine that is grounded at all How to Remove the Circuit Board times when handling printed circuit boards OR use a 1 Push in the red Emergency Stop button to the grounded wrist strap off position at both the ground and platform controls 8 Tag and carefully disconnect the wire 2 Locate the cables that connect to the bottom EE of the control box Number each cable and its 9 Tag and disconnect the ribbon cable from the location at the control box LED circuit board 3 Disconnect the cables from the bottom of the 10 Remove the circuit board mounting fasteners platform control box X 11 Carefully remove the circuit board from the 4 Remove the control cable receptacle retaining control box fasteners from the bottom of the platform control box 5 Remove the platform control box lid retaining fasteners Open the control box lid 6 Locate the circuit board mounted to the inside of the platform control box Genie 86 ZX 135 70 Part No 218700 September 2015 Service Manual How to Remove the LED Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Locate the circuit b
134. Deutsch connector for secondary boom up valve 2 pin Deutsch connector for secondary boom down valve 2 pin Deutsch connector for turntable rotate flow control 2 pin Deutsch connector for turntable rotate CW valve 2 pin Deutsch connector for turntable rotate CCW valve 2 pin Deutsch DT platform rotate CW valve Y70 2 pin Deutsch connector for jib boom up valve 2 pin Deutsch connector for jib boom down valve 2 pin Deutsch connector for prox kill 2 pin Deutsch connector for platform footswitch 259 Service Manual E Circuit Connector Legend Number September 2015 Description 12 pin Deutsch gray SCON connector 12 pin Deutsch black SCON connector 2 pin Deutsch connector for drive enable right limit switch LST10 2 pin Deutsch connector for drive enable left limit switch LST20 4 pin Deutsch connector for drive enable safety limit switch LST1S 6 pin Deutsch connector for primary boom up down ext ret and turntable joystick 6 pin Deutsch connector for jib boom up down ext ret and platform rotate 2 pin Deutsch connector for boom composite lower limit switch harness 2 pin Deutsch connector for jib boom bellcrank up 2 pin Deutsch connector for jib boom bellcrank down 2 pin Deutsch connector for front axle safety switch 2 pin Deutsch connector for rear axle safety switch 2 pin Deutsch connector for jib extend 2 pin Deutsch connector for jib retract 2 way Deutsch connector for l
135. EE i P109ANG GRWH P109ANG SRIWH lt S OR gt gt WH l n SRER C141PBS RD lt G BL 53 YL ou SNSR GND BR fs WH BK P BK S18 PRI BM ES Z A ANG SAFETY LSP1EO P1220 C71PBE BLIBK P109ANG GRWH lt RD gt gt RD PRI BOOM LENGTH 3 STATUS Gei A LSP1RO C70PBR BL WH 8 E Oa LSB2RO C64LS OR BK g LSP1AO C67SBD BL PRI BOOM LENGTH 100 STATUS tp LSS1RO P12 16 C73SBR BURD E bs PRI BOOM RETRACTED STATUS LST10 DR ENBL R P12 15 C144DER BLIWH ER oa 9 PED FST1S LOW FUEL 12 142 C65LOF BL IWH x P f zis gt OPER SW PWR P12 13 C64LS OR BK 3 g 40 P_18 Az P_14 TES P 12 PT2 10 C61AXR GR C61AXR GR 9P122 12 P12 e P_11 P12 09 S140ENL OR RD 4 S56PRV RD P 10 P 10 P12 08 S59CNK GR WH P58LS RD BK P58LS RD BK P_9B P_9B P58LS RD BK PS4ENG BKIWH P_9A P53LS WH BK S140ENL OR RD St40ENL ORRO 3P122 08 P11 P30 87 UH y PR S56PRV RD P53LS WH BK gt P122 07 P6R1 H zz P 6R2 U30 P 6R2 P12 04 P54ENG BK WH P54ENG BK WH S13DE BL RD ENA 22 33 9 P 01 Eed S12SB BLIWH 3 PIE EEE DCON ECU PWR P12 02 P21DCN WH C60AXE GRWH 382288858 ooo Bo S88 SCON ECU GND P7201 SCONGND BR PA P53LS WHIBK C141PBS RD onSHSSeEE BB B3BAT 14 RD C142SBS OR REZTOUSSES CO K IERE z P21DCN WH P21DCN WH T GUE rury amp
136. ELAY BOOM EXT gt 13 EA 0m SEC_DWN_VLV V11SBD BL BK V11SBD BL BK UNUSED P VLVRET5 BR A DON 214 PRI_RET_VALVE V08PBR BK WH VO8PBR BK WH 0559 Y80 PRI RET VLV J63 y bu et PRI EXTEND VLV VO7PBE BK VO7PBE BK 9 YT9 PRI EXT VLV J62 O BOOMRET 215 SS PRI DOWN VLV VO2PBD RD BK V02PBD RD BK x gt Y21 PRI DWN VLV 460 Po 9 gt d rs PRI UP VLV VO1PBU RD VO1PBU RD lily A Y22 PRI UP VLV J59 o y Li F I SEC BMEIR FC VLV V176SER GR WH V176SER GR WH Se Y78 SEC BM ER F C J164 u Gr BM U D FC VLV V12SUD BL WH V12SUD BL WH 54 Y46 SEC BM UD F C J163 y D N t a Se TTROTFC VLV P VOSTRF WH RD VOGTRF WH RD EUA Y77 TT ROT CWICCW F C J69 e On nz PRI BM E R FC VLV VO9PER BK RD VO9PER BK RD E54 Y76 PRI BM EXT RET F C 461 Sus PRI BM U D FC VLV VO3PUD RD WH VO3PUD RD WH EY Y45 PRI BM UPIDWN F C 58 51 gs VALVE RTNA EI VLVRET4 BR VLVRET4 BR gt lg TOPLD D 2 e z E E EE ewe OIL TEMP SENDER s es si S e 3 wa p JIB EXT ar gt ES 9 c C25PSR WTIBK ewe OIL PRESSURE 3 L TO PLD z5 CERES E 3 zt H Z Beer 24 22 68 EE 3 Skaar EC Ss o2zrzzt e a su ii e tl BOOM UP 685583 o N BAT GND BR FUEL SOLENOID SZ e EK Bg Wo B1ENG RD SIGE g o 253 e o gt 5 SEEEER 5 ES SEC UP e S P E Sie d E HS we est bel z2 e S Sen QE 9 AUXILIARY zx 2022555 E 227 2583333 le
137. ER DIAG TETHER GND P11 21 lt 2 I ER E S M E P23PCON BK PCON MODE TETHER FUNC ENBL P11 20 lt e 2 Z 2 2 TCON MODE OUTPUT PWR ENABLE NOT USED P11 1 X P6R1 CAN HIGH P11 18 D82CAN YL BA lt N S56PRV RD BK P7R CAN LOW P11 172 D81CAN GR DH 8 SRV REC WH SERV OR OPER REC CAL FREQ 2 PIT TX BA P56PRV RDO 10 P22 TET ESTOP PWR P11 15 A Bo D OR BK gt 11 OPER REC CAL FREQ 1 EI E 55 slalg e 4 GRIWH 12 P7 GN WH A NOT USED ZS SS x 2 8 gt 13 len NOT USED P11 12 ap xp gt Ae P RDIWH 14 TcoN MODE L SERV CAL MODE P11 112 C145CAL RD WH BL 15 ALARM PWR CAN SHIELD 1939 11 P11 10Q z or E r y ya gt 16 ALARM GND FLASHING BEACON RLY P11 09 R117FB RD ee gt S SPARE FTS al 3 R P_22 P56PRV RD WH gt E 2 U30 E P_7 PLAT GR WH 2 092 ho P7 SS6PRV RD A 2 C470UT WH BK 50 ero PWR PCON ESTOP P11 05 P23PCON BK e P 15 OR BK 22 E 288 OUT PWR ENBL P71 04Z C47OUT WH BK 28 O fee HORN RELAY COIL P CA6HN WH ALM PWR BL So zx amp 28 z PCON POWER P11 02 P52PCON WH lt io gt gt ALM GND BR Sa T woo J147C if 22 2d B PCON GND P77 072 GNDPCON BR lt S 3 fo e J148C SS wg CS GES pi e m aoa S 220 1200 ENGINE CAN TCON Sab LL 2 GROUND P223 01 ALM GND BR BUSTO ES Slab RARRR AA B colo TELEMATICS E EE SSS SS SS SS SS SS i STuno TTT Pos PL z can sito PER RRA Te WS Goo 2 a 88 318 SS alo za ENGINE CAN HIGH P223 03 D228
138. ETZ 2 9L TURBO TIER IV ENGINE DATEN X173_ STARTER RELAY SIGNAL X172 X STARRTER RELAY GND 1231 021 REN P20PWR RD ECUPWR pomeo INJECTOR 3 D D212 gt INJ3A02 BK TE INJECTOR 3 A02 GND BR ECU GND INJECTOR 2 INJ2 A03 OR X1741 lt INJECTOR 2 A03 P20PWR RD ECU PWR MPROP MPROP A04 WH X17 19 L MPROP A04 GND BR ECU GND MPROP MPROP A05 WH BK X17 20 PROP A05 L P20PWR RD ECU PWR RAIL PRES RAILP A07 RD X17 32 RAIL PRESSURE A07 GND BR ECU GND INJECTOR 1 WI A16 GR X17 35 INJECTOR 1 A16 C26LVL WH RD COOLANT LEVEL 1 INJECTOR A INJ4 A18 BL X12 37 INJECTOR 4 A18 COOLANT LEVEL CLSWJPR OR CLUTCH EGR SOL PWR EGRSOLPWR OR RD X1747 EGR SOLENOID POWER C28 VL WHIRDO S CIS5RETWH FUEL PUMP RELAY GND EGR SOL GNDD D2 1 20 gt EGRSOLGND BR X175 EGR SOLENOID GROUND PHORETBI 2 P33RET BK STARTER RELAY GND STARTASSISTD D2 1 23 gt R34SA RD UBATT WHS UBATT WH COOLANT PWR M SENS PWR D B2 1 24 gt MSENPWR GRANH X1722 M SENSOR POWER RARET WH AUX ENGINE STOP RAIL PRES RAILP A25 RDWH II RAIL PRESSURE A25 C33STR BK ENGINE START RAIL PRES RAILPSIG A26 RD BK X1725 RAIL SIGNAL A20 X17 29 EGRPOPWR RD EGR PWR BOOST SIG gt D2 1 27 BTSIG A27 GR BK lt BOOST SIGNAL A27 C25SEN D2 1 28 C25SEN A28 WH RD X17 24 lt C25SEN A28 WATER IN FUEL D228CAN YL lt P2244 CUSTOMER CAN HIGH MSENS GND MSENGND OR m lt M SENSOR GROUND CHSSWF GR C135WIF G
139. EX BRAND xii ZX 135 70 Part No 218700 September 2015 Bee Table of Contents Boom Components 4 eiu niei ite cxi e FER ORE EE EFURER ER 117 4 1 Primary Boom Cable Track 118 How to Repair the Primary Boom Cable Track 120 4 2 Secondary Boom Cable Track 120 How to Repair the Secondary Boom Cable Track 122 4 3 Primary BOOM EE 123 4 4 Primary Boom Lift Cylinder AA 125 4 5 Secondary Boom Lift Cylinder 126 4 6 Primary Boom Extension Cylinder oooocccccnnoccccnnnocccccononcccconancccnnnancccnnnnnnccinno 129 4 7 Secondary Boom Extension Cvlmders see 130 4 8 Primary Boom Angle Sensor How to Calibrate the Primary Boom Angle SENSO 131 4 9 Secondary Boom Angle Sensor How to Calibrate the Secondary Boom Angle SIDE 136 i 6 Point Calibration procedure e 137 Laus UE 141 5 1 RPMAQJUS Met tacto ta ctr toad o 141 9 2 Flex Plate cocina aa 141 How to Install the Flex Plate 142 Ground Controls sssaaa eerte aii 143 6 1 Bypass Recovery Key Switch 143 How to Use the Recovery Mode menn 145 6 2 Circuit Boards aka nen 146 6 3 Membrane Detales ii 148 6 4 Full Machine Calibration seen eene 149 Display Module ees KREE eee RED rop eo ie e ce Ru RE Ce ic 150 Hydraulic Pumps esee eene nennen nnne nene nnne nnne natnra rasero 159 7 1 Function PUMP TE 159 How to Prime the Function Pump enne 160 How to Adjust the Function Pu
140. Ee NOT USED 270 u E Eg e o STR MODE R OR BK 3 17 gt P 7 P21 04 S56PRV RD a LE S56PRV RD je fo ep weg z J149A 1 PR m ERR NOT USED gt 16 NOT USED P27 0 AAA NA NN NOT USED gt 15 PCON PWRP2T 0 amp P52PCN WH PS2PCN WH lt ald a 3 L STR MODE LOR S 14 HES uj PCON GND P21 0 GNDPCN BR GNDPCN BR ung e J148A 1 ES DRV SPEED RD WH 5 13 Ir 1 gt 5 zx cE8 a2 gt 5 d dk 4 ES 2553 Sat DRV ENBL BL WH AXLE EXEGR WH ze z 2 W L ENG SPEED BK RD S 11 g az ER 2 E H y GND1 BR S 10 5 202 z amp o o lt 5 id a Sl zh e e NX m z E 25 z o 6 co z Zi me g GC TIY S we o OS z OS 2285 SEB e AXLE RETGR S 9 S www gee zo 5 ES zz ES 2 888i iS amp tak ENG START BK COLON N oz ole x ENS 3 22 g oF one Ae 5 AAA AAA NOT USED 2 8 s dad Sos ze 2 25 E E S E e 2 DRV ENBLBLANH 5 7 eee 53 Bz 888 99 899999 EBS ENG STARTBK 6 e 8 oa 8 E ques E 3 DO 5 Bae STARTASSTBKIWH START ASSTBKWH s Y Y 5 ERD S e o I zx Gee ao amp a l AUX PUMP RD gt 4 To Tin 3 I E C56PTS RD EG R o E de E II GEN ON OFF GR WH gt 3 4 a tt a6 E lt a H alala Ha alol of z E a z HORN RET GR S 2 amp as 3 L RAR RARER RE 22 AUXPUMP RD Ww M g 3 x e o ANS il el 2
141. FSIG KB4 ORIBK DPFSIG Ki 84 DPF INLET TEMP SIG TVA MOTOR D 4 49 TVAMO Sen lt TVMO A48 LAMBDA SENSOR EGR MOTOR gt 4 0 EGRMO lt EGRMO A50 bas gt e 0 eet KEE Gs es a 4 Se FR LAMBDA CURRENT ADJUST COOLANT SENSOR SIGD A 57 C26TSR EIC 14 X CO8TSR ABT SEA GET Ass MERKT qr ee en EES Cep Ase mq 8 ben 1 on ee ee FUEL METERING UNIT gt A60 C135FMU BEZ C1335FMUASO Genie ATEREX BRAND Part No 218700 ZX 135 70 277 Service Manual September 2015 LSS E E S Perkins 854F 34T Engine Harness 278 September 2015 Service Manual De Deutz TD2 9 Engine Electrical Schematic 279 September 2015 Service Manual ke N e Ut LO Ge N eo 38 5z x Uu Ka z 2 9 E 5 D YO O1 LSA 8 El 523 ori 8 3 OH SMS H Y74 al BL oumo a0as91 In a FUNCTION ENABLE VALVE J166 E 5 gt EEN E Sao 9 8 z HM
142. Fuse with amperage Foot switch AKA A B C EE LS3 S A E me N C H O I Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid Connection no terminal AUX MAIN Circuits crossing no connection E a Quick disconnect terminal CB1 ri Ns 15A Circuit breaker with amperage Main Key switch T a 1 1 i L Service Bypass Key yo MM la ls 2x m m a Steer sensor RD o Tilt sensor Oil temperature switch normally open Coolant temperature switch normally open Oil pressure switch normally closed switch 2 my E ARR EOM X eas F LN GE tr cor 5 l4 ARS E ume Emergency Stop Hydraulic oil cooling e Relay Power relay Dutton fan Gauge sending unit n s P i N O N C NO Control relay contact normally open Diode starting aid glow plug or flame ignitor Genie 270 A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Hydraulic Symbols Legend 0 087 incn 0 94 mm A N Orifice with size Check valve X Shut off valve Brake Pump fixed displacement Pump bi directional variable displacement Motor bi directional Motor 2 speed bi directional Cylinder double acting
143. GR 10 C30EDC WH 41 UNUSED 11 UNUSED 11 C31EDC WH BK 12 V11SBD BL BK 12 UNUSED 12 C25PSR WH BK 13 UNUSED 13 C64LS OR BK 13 C26TSR WH RD 14 VLVRET5 BR 14 C65LOF BL WH 14 UNUSED 15 UNUSED 15 C144DER BL WH 15 UNUSED 16 UNUSED 16 C73SBR BL RD 16 UNUSED 17 VLVRET5 BR 17 C67SBD BL 17 S137PLL RD WH 18 VLVRETS BR 18 C64LS OR BK 18 C41RPM OR BK 19 V10SBU BL 19 C7OPBR BL WH 19 S139TRF WH RD 20 V73SBR GR BK 20 C71PBE BL BK 20 UNUSED 21 V72SBE GR 21 UNUSED 21 UNUSED 22 UNUSED 22 UNUSED 22 C45GEN GR WH 23 UNUSED 23 UNUSED 23 UNUSED 24 UNUSED 24 UNUSED 25 VO4TRL WH 25 SNSR GND BR 26 VOSTRR WH BK 26 P109ANG GR WH 27 VLVRET7 BR 27 UNUSED 28 UNUSED 28 C143DEL BL RD 29 UNUSED 29 UNUSED 30 VLVRET6 BR 30 UNUSED 31 UNUSED 31 UNUSED 32 C27AUX RD 32 C123PBS RD BK 33 UNUSED 33 C124SBS OR BK 34 V155PCE OR RD 34 S140ENL OR RD 35 V150HG GR BK 35 GND16 BR Genie ZX 135 70 Part No 218700 September 2015 Service Manual AAA A R Telematics Connector Pin Legend Genie installed Telematics connector is wired with an Active High digital input Connector Pin Numbering aN ee 8 v 6 15 y fa 2 t YODA pos Note A Deutsch plug p n DT06 08SA mates with the Genie Telematics connector Pin Circuit Type Circuit Properties Genie Machine Function s Telematics Use Case 1 System Power 12 VDC Battery Posit
144. Genie A TEREX BRAND Service Manual Serial Number Range From ZX13513 2001 ZX 135 70 E does not include ZX13514 2463 ZX13514 2469 and ZX13514 2531 Part No 218700 Rev F September 2015 Service Manual September 2015 Introduction 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 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 Contact Us Internet www genielift com E mail awp techpub tere
145. How to Adjust the Function Pump Standby Pressure 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 2 Startthe engine from the ground controls and allow the engine to run at low idle 3 Observe the pressure reading on the pressure gauge Result The gauge should show 250 psi 17 bar Result If the gauge does not show 250 psi 17 bar proceed with step 4 to adjust the function pump standby pressure 4 Loosen the set screw for the standby pressure adjustment screw 1 standby pressure set screw 2 standby pressure adjustment screw 5 Adjustthe function pump standby pressure Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure Tighten the set screw 6 Turn the engine off and remove the pressure gauge Part No 218700 September 2015 a AA EA A How to Adjust the Function Pump 7 Pressure Compensator Note Two people will be required to perform this procedure 1 Confirm the system relief pressure is set to specification Refer to Repair Procedure Valve Adjustments Function Manifold Connect a 0 to 5000 psi O to 350 bar 8 pressure gauge to the test port on the function manifold Start the engine from the ground controls and change the rpm to high idle Push and hold the high speed function enable button rabbit symbol Do not activate any boom functions Observe the pressure reading
146. IS Ss gos E L JSGNDI BR 3 46 PL TILT SNSR P22 20 C84TAY GR BK 5 do oo 6 d GND2 BR ISGND4 BR 5 15 PL TILT SNSR GND P22 IX P85RET BR PLAT TILT SNSR E 52718 i zo ES lt Pis21Pw oR 12 JIB NOT RETRACTED P22 18C C154JBR BK WH C154JBR BK WH Sp LEST C161SB WHBK _preqspw or S3 LLL FOOT SW RTN P22 417 C56FTS RD C56FTS RD E 3 5 T S zb 3 Leem wen SS LIMIT SWITCH 0 C64LS OR BK C64LS OR BK eS 2 g P amp 258 a C164PLS RDWH S 11 SAFE PL TILT OUT P22 15 C88PTS RD BK e 3 zo 5 au 2 p 7 o ES E LOAD SNSR PWR P22 142 BK BK ol amp Ee x gt 5 7 P 8 Ci618B WHIBK 5 9 LOAD SNSR IN P22 13 OR AA L jo 325 FERE D DS O E y ES GND3 BR C160JPL WHIRD gt 8 LOAD SNSR GND P22 12 GR YL at ES 2 ze 5 g 22355 SO DB cis7JeR BK RD 4 C159STC BLWHI 7 n E PROX KILL CMD P2211 C90PXS RD BK C90PXS RD BK S euo SE 59 4 C16PRL OR RD C158STC BURD gt 6 eee E JIB RETRACT J141 E gt P22 09 y g Y83 K 3 C156JUD GRIWH 5357 4 a JIB RETRACT P22 09 V154JBR BK WH V154JBR BK WH e OR BK J141 25 d 5 EE 2 x 5 8 T gt e or ZS 2 P162JPW OR P162JPW OR 5 4 PLAT LEVEL DOWN P22 08 V15PLD OR BK ans Y19 PLAT LEVEL DN J81 ii g 3 3 E Szor dc T JSGND3 BR P162JPW OR gt 3 OBBATEEVEEUE EE Ts lee S Ez amp 8 ae2223 E L e ae Sa J18 JSGND3 BR gt 2 JIB DWN P22 06 v44JD GR BK V44JD GR BK
147. ND OR gt FUELPRES BL gt gt MSENPWR GRIWH gt ENGINE BLOCK 7 8 Genie ATEREX BRAND Part No 218700 ZX 135 70 281 Service Manual September 2015 Aa ESE Deutz TD2 9 Engine Harness 282 September 2015 Service Manual B C D E F G 120V AC W REGULATOR CB FON 874 3 X RD e vi 4 m i 30A 30 E RD 12VDC lt o r RED d 87 lt zm WT km WH 5 WH 2 9 5 p H BRN BRN GND lt BRN BAN 2 m e PPN BK gt T BK 2 1 GR BK WH LJ BK WH WHT NEUTRAL 120V AC c x AUTO RESET CB AN L BLK 120VAC e e 15A 220V AC W REGULATOR x 87a 3 gt RD e s 4 gd 30A Es ect E RED 12V lt 5 RED E WT e P WH 3 IT WH 2 86 85 5 5 tl BRN BRN u BRN o PRES T lt a ES BK S BK g A BK WH e BKH MD WHT NEUTRAL 220V AC Ce AUTO c RESET CB BLK 220VAC e e 12 5A Generator Wiring Schematic Part No 218700 J K L M 1 120V AC W O REGULATOR B wa 3 RD e N e s 30A 1130 4 87 2 WT 2 B78 s BRN 3
148. NG Crushing hazard The secondary boom cable track could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Component damage hazard The secondary boom cable track can be damaged if it is twisted Note During removal the overhead crane strap will need to be adjusted for proper balancing Genie A TEREX BRAND 122 ZX 135 70 How to Repair the Secondary Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Service Parts Department 1 Remove the secondary boom cable track Refer to Repair Procedure How to Remove the Secondary Boom Cable Track 2 Visually inspect the cable track and determine which 4 link section needs to be replaced 3 Carefully remove the snap rings and pins from each end of the damaged section of cable track 4 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 5 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Note If the section of cable track being replaced has clamps or wear pads those items will need to be transferred to the replacement
149. NSILZO H 3 m pa gt 8 Se ESTE x ES MENO E 9 s amp 5 3 8 8 E Y HO LAMPE QY VSPEH o E an N e 25 t MS N z S 29 GLOW PLUG 9 d ret gt zl Ek amp 558 a m Sa P u g m PETA 8 8 o 2 H e Y ui z as i n a I Seg 8 k280 x 3 dE 835 HYD OIL E ue NO CAHSLLY Gy A A aoe 2 S ll COOLER E P 5 i T E ur N 5 YO GAH9LLO ei EE e z 2 x 5 E J 52 g 3 cou orar 3 8 7 3 ren 4 HMHO L3MbeO f E L asten ENLY SATWA EZEld 8 HMNYH9 pY e HOLVAJNIO Ov SE SL E 3 ns HORN SKY A DU LU rzea L E I SV X DU LL Oe Shed lt HAWVTE d49ELO 23 LOULLOL YIMOd EE d GEI lt AUHM AMLBELS 8 5 Wed MOL BETA lt T seo AE E i se Bache OU Md Sz a ZEIT lt HWARTIALEIS e i HA ease ra Dr PUMP c Wu ZATVA SEI lt E N u i MMd YSNS LW LU Gerd C S E 3 4 GNO USNS LWL 11 Fred 5 i E DUAL 2 YE Y00NO c COIL L HALE LZ d H len EIEI lt 3 L amp i EDC Eeer sunsssua wWo Zi ld lt Maniwodaieo ER 1 m 1 L HMAF dS O ABU od3 t te L NIHAO ED M RUNS i Jen i QM DQ3 Oz HM DQ3089 mee Jl HA Leese AVIS HSLNVIS 60 814 NEULSEEO ATULSEEI MG HLSEEO Y3MOd HOLIMS ADA OEL Z NAMO ISNPELY MSRIO dSMFELO ME MO dSMbeL2 NaH 20 38 20 614 HM NAHSPO u uMd zd ouumaoza Aza 3083 C eh Q Jv40L0 EEES n BE isissv iuvis t0 tid lt Bas i B S of LL TANAN 018 HAP TELIZO aS B ee YE UN9ZO FILLONHL 201g 4 S be m E ALTERNATOR LEN AWA FO Ela lt sU 5 ex g T TE R PES
150. Nm 10 Check valve Prevents left rear steer cylinder 20 25 ft lbs V from moving when not steering 27 34 Nm 11 Solenoid valve 3 position 4 way Steer left right left rear steer 20 25 ft lbs C cylinder 27 34 Nm 12 Flow control valve 2 1 gpm 8 L min Left rear steer cylinder extend 20 25 ft lbs J circuit 27 34 Nm 13 Flow control valve 7 gpm 26 5 L min Axle extend retract circuit 50 55 ft lbs G 68 75 Nm 14 Solenoid Valve 2 position 3 way Axle retract 50 55 ft lbs F 68 75 Nm 15 Solenoid Valve 2 position 3 way Axle extend 50 55 ft lbs E 68 75 Nm Genie Part No 218700 ZX 135 70 177 Service Manual September 2015 Manifolds Genie 178 ZX 135 70 Part No 218700 September 2015 A AA A Manifolds Steer and Axle Manifold continued Service Manual The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine Index Schematic No Description Hai Function Torque 16 Pressure reducing valve 2400 psi 165 bar P Axle extend retract circuit 30 35 ft lbs 41 47 Nm 17 Check valve U Prevents left rear steer cylinder 20 25 ft lbs from moving when not steering 27 34 Nm 18 Flow control valve 1 5 gpm 5 7 L min N Left rear steer cylinder retract 20 25 ft lbs circuit 27 34 Nm 19 Check valve W Prevents right rear
151. OR BK gt 8 PLATLVL DN l NOT USED pex e D S16 Ss y PLAT LVL DN OR BK PLAT LVL UP OR 3 7 1 PLAT LVL UP REAR AXLE POSITION SENSOR P31 21 C60RAP GR WH C60RAP GR WH J161 Eu GND6 BR GND6 BR S 6 GND FRONT AXLE POSITION SENSOR P31 20 C60FAP GR WH C60FAP GRIWH 4 lt gt T a E PLAT LVL upon GND3 BR 3 5 GND RS232 GND P31 1 C157JER BK RD S_4_ JIB EXT RET CAN P31 1 D82CAN YL C156JUD GR WH 3 JiB UP DWN CAN P31 17 D81CAN GR GND4 SR I_2 GND NOT USED Oe C16ePRL ORRD 3 1 PLAT ROT AXLE NOT EXT SIG P31 1 EL au oo NOT USED P31 14 D ALARM RD BK 169 PstI BL 23 gt BOOT E NOT USED ad GND12 BR ER RS232 TXD P31 1 o WH RS232 RXD P31 17 e ESEAT CAN SHIELD P31 10 ae 4 FRONT AXLE SENSOR AXLE NOT RET RTN P31 0 aa ag GE DIGIN AXLE RET GND NOT USED P31 0 amp NOT USED P31 0X P12 P31 06 C61AXRT GR P_7R P31 0 S56PRV RD Nor USED P31 0 O P eR1 P31 03 P53LS WH BK Sei DCON ECU PWR P31 0 P21DCN WH C5 o DCON ECU GND P31 0R GND DCN BR e Sech s CH Xo N CH 2 o 26 d VLVRET2 BR eo HI 2 LO d E Z amp V37LFS BL BK else A v62 LF STEER LEFT J98 co C m ET V36LFS BL Y61 LF STEER RIGHT J97 O c O V37RFS BL BK X CA Y60 RF STEER LEFT J96 o V36RFS BL A Y59 RF STEER RIGHT J95 A CO ER er N o E E I6 V37LRS BL BK is A Y58 LR STEER LEFT J94 I amp gl 2 ex 5 10 eo ala
152. R WATER IN FUEL 2 INJECTOR 3 INJ3 AS2 BKWH 4 INJECTOR 3 432 PI3SSEN GRAWH O FUELPRES BL FUEL PRES SIGNAL INJECTOR 1 INJ1 A33 GR WH X17 62 INJECTOR 1 433 P135SEN GR WH WATER IN FUEL 1 CRET p D2 135 gt C34RET GR WH e L CLSWJPR OR CLUTCH A C21ENG WH IGN ON LAMP CAM SPD CAMSPD A37 WH BK CRANK SPD SHD CRNKSPD SHD WH X174 CAM SPEED A37 X171 lt lt CRANK SPEED SHIELD R33STR WH STARTER RELAY PWR CRANK SPEED CRNKSPD A39 BLAWH XT7 15 CRANK SPEED A39 ENGINE CAN BUS as D BOOST SIG BSTSIG A40 WH BK X1728 ROOST SIGNAL A40 TO CAN ENER e D227CAN GR CUSTOMER CAN LOW BST PRES TEMP BSTPT A43 WHIRD HIER BOOST PRESSURE TEMP EGRPOGND BR EGR GND P25SEN P25SEN A44 BK WH X17 28 lt P25SEN A44 EGRPOSIG RD EGR SIGNAL INJECTOR 2 INJ2 A46 OR BK XITAY INJECTOR 2 A46 PTIORET BK COOLANT GND INJECTOR 4 INJ4 A48 BL WH XITAZ INJECTOR 4 A48 C134KSP GRIBK KEY SW PWR CAM SPEED CAMSPD AS2 BK WH II CAM SPEED A52 C135FP BLWH FP RELAY PWR CAM SPEED SHIELD CAMSPD SHD WH X17 9_ GAM SPEED SHIELD DEUTZ DIAGNOSTICS X17 21 DIAGM CRANK SPEED CRNKSPD A54 BL RD lt CRANK SPEED A54 DN e X1746 EGR POSITION SIGNAL D227CAN GRY DIAG F 26 EL EGR SOLENOID GROUND GND BRY gt DIAGB TE EGR SOLENOID POWER CISAKSP GRIER DIGA XITAZ FUEL PRESSURE X17 6Y GROUND FUEL PRESSURE MSENG
153. RAND ZX 135 70 263 Service Manual September 2015 Turntable Controller Pin Legend 1 H D E et CC I CX XX XO COOL ee XC XX OCOG9COCOCOCOCOG9 Pin Numbering 35 pin connector Pin J11 Turntable Controller 1 GNDPCON BR 2 P52PCON WH 3 C46HN WH 4 C470UT WH BK 5 P23PCON BK 6 S56PRV RD 7 P56PRV RD WH 8 UNUSED 9 R117FB RD 10 UNUSED 11 C145CAL RD WH 12 UNUSED 13 UNUSED 14 UNUSED 15 UNUSED 16 UNUSED 17 D81CAN GR 18 D82CAN YL 19 UNUSED 20 UNUSED 21 UNUSED 22 UNUSED 23 UNUSED J15 Turntable Controller 1 B1BAT RD 2 GND BR 3 GND BR 4 UNUSED 00800001 1 OOOO g ge a 264 Numbering 23 pin connector Pin Numbering 4 pin connector J12 Turntable J13 Turntable J14 Turntable Controller Controller Controller 4 VI VRET BR 1 GNDSCON BR 1 UNUSED 2 VO3PUD RD WH 2 P21DCON WH 2 C35RPM BK RD 3 VO9PER BK RD 3 P53LS WH BK 3 C21IGN WH 4 VO6TRE WH RD 4 P54ENG BK WH 4 C34SA BK WH 5 V12SUD BL WH 5 S56PRV RD 5 UNUSED 6 V176SER GR WH 6 P53LS WH BK 6 UNUSED 7 VO1PBU RD 7 P58LS RD BK f C46HRN WH 8 VO2PBD RD BK 8 S59CNK GR WH 8 UNUSED 9 VO7PBE BK 9 S140ENL OR RD 9 C33STR BK 10 VOSPBR BK WH 10 C61AXR
154. RY LIFT PRIMARY EXT RET SECONDARY LIFT CHARGE FILTER ENABLE T p SN 9072 am in um E EX TPM SOS REGEN 165 50 GPM 397 189 LPM SECONDA TR a ONERE CYLINDERS 4 VALVE 65 GPM 24 8 LPM iid Ix SS dE ENS Ed Mus mpr ET Blech A el CA cB CA CE cr 68 oH a ej SI cM oO ea oP ca I ex T l A kG I 1 f A l pd l 4 A E er IW t t L Ae l HIGH 1 proa l L TJ J EE J pa ll 1 is ER PRESSURE OMR ail Io IE GEM e oM Lol low bf oM Eo x aj pM 92 p UE TEE FILTER 1 I II x IE If x I LIT wr X5 ja i pe Seea ML Ce De Lev eT LL De 1 1 t re 4 i i CS Len P j 8 LP To ON CH e Li a EE ah P po I d ETT mE 1 E D we jx IL eco 03 eo 60 HOM THER RR zu Hu Sn e Ban B T E TI fs OE DE zu E JIB UP DWN 2 i ris AN 4 NM r nd LC L JIB MANIFOLD 8 8112 GPM 12 5 4 5 LPM rot oy LE Ke PIED i poi 4 oR TKD mM F3 I X PMP Jeer TRL TAR _ PU Pb Greet PE PR SU e Jee sr ge Zu lr os D F IO em QU e S HT SUE PSI O eus d I ij gt A A E o usd o Wi WI XM i ip ar 20 T MALE s ALE LP E T i O A SCH e Leit S li l v T BAR l s I 1 I zZ l Ld PS L gs T e w an HEE e OA er CR NEP Pl y B qq LES 249 9 Si I 100 69 T T I Y 6 cs _ JBAR L EN PSI BAR it E EI m SE I 3 GC AUXILIARY D D M A A D D D 4 IB EXT RI 3 E 72005 9 FUNCTION PUMP 1 po HH 9 S FF 2 0 GPM 3 8 REGEN Dez Ip
155. SS P14 3 V150HG GR BK V150HG GR BK X Y75 WELDER GEN BYPASS VLV J167 m Z gt 2 e PRESS COMP ENABLE VLV P1434 V155PSE OR RD V155PSE OR RD de gt J Y74 FUNCTION ENABLE VALVE J166 Boom cw oa m RS SPARE E e eaan 2 AUX_RELAY AUR _ _ _ __ _ _____ _ _Q gt zCTAUX RD z on FS H gt JEOOWN gt 4 Toso VALVE RTN6 P14 30 VLVRET6 BR VLVRTN6 BR e P14 2K e o gt 5 PROPEL POWER INPUT P14 28 PLTFRM DOWN SCH VALVE_RTN7 P14 27 VLVRET7 BR VLVRTN7 BR a u GER gt 6 ES mec VOSTRR WH BK CO5TRR WH BK Tb Y53 TT ROT CCW VLV J71 L SCH ROTATE_CW_VLV P VO4TRLWH CO4TRL WH x lt b gt Y52 TT ROT CW VLV J70 e E gt 7 B UNUSED P1424 MULTI_FUNCT_VLV P14 2 on Oa V72SBE GR V72SBE GR e e gt 8 UNUSED P1422 PLTFRM CCW za FS ma o E V73SBR GR BK V73SBR GR BK 4 gt SEC_EXT_VLV P14 21 V72SBE GR V10SBU BL V10SBU BL e acer gt 9 TO PLD Sa SEC RET VLV EE V73SBR GR BK id rc L SsEC UP VV Fos 3 V10SBU BL o wi ie STE gt 10 F 53 BOOM OVERLOAD DI P14 182 VLVRETS BR libs eebe BOOM REVERSE LOAD DI P14 17 VLVRET8 BR Brite 965 ER EE 21 soe HYD_FILTER2 DI ES tel vos SECRET vv es Oa 3 HYD FILTER DI ere dido Y81 SEC UP VLV J67 ar 512 ES VALVE_RTNS ViURETS BR lib 4 Y82 SEC DWN VLV J68 d gs DRIVE LIGHT R
156. ST10 18LSRA1ES 6 LST1S 19 RSLR1SO 7 LSS1RS 20 RSRR1SO 8 LSS1RO 21 DCON 9 RSS1AO 22RSRF1SO 10 RSS1AS 23RSLF1SO 11LSP1EO 24 LSFA1ES 12RSJ1AO 25 RSFA1SO 13LSJ1RO Genie ATEREX BRAND Part No 218700 ZX 135 70 255 Service Manual September 2015 Limit Switches and Angle Sensors Types of Limit Switches There are two types of limit switches found in various locations throughout the machine mechanical type operational safety switches and rotation or angle sensors As in aircraft which features redundant safety systems each mechanical operational switch is backed up with a separate independently functioning safety switch The mechanical type operational or safety switches are used to sense a positive displacement or movement of the limit switch actuator or arm as the machine moves through its range of operational functions The rotation or angle sensors utilize Hall Effect technology and must be calibrated when replaced Included in this group are envelope limit Numbering Legend LS LS Limit Switch LT Stringpot RS Rotary Sensor FA LR RF RR FA Front Axle Rear Axle Left Front Left Rear Right Front Right Rear Jib Boom Boom Turntable 1 Circuit Number L A D L O Load O Operational moment Angle S Safety Down Extend Retract Limit Switch Numbering Primary boom length retracted Primary boom length fully extended Second
157. T RD F20 EZ ES E E N Te P35RPM BKRD z o Paz ENGINE BLOCK Fett Ep A 38 amp Onn ESE 3 IR a z_ Bc 3 83d is 2 EE z SE START BAT 1 EIS A B1BAT RD ELECTRONICS les AUXMAINA B1BAT RD BATTERY La B1BAT RD B1BAT RD a V AUX HYD a 2 B2BAT RD 9 B2BAT RD BATTERY on S SEPARATE 4 GAWIRE SEPARATE 4 GAWIRE oS a a4 a Su E SE S139TRF WH RD Hei Es EI 25 CAN LOW et 38 NC S137PLL RD WH 8 CAN HIGH PLOTENC wi wB Ir zu Z olle REMOTE DISABLE P1062C226TEL BL lt Se 82 Z LA wor 8 FOOTSWITCH STATUS ETE S56PRV RD du Y Y 8 2 e x er STOWED STATUS _P1 04 P23PCON BK ag l IGNITION STATUS Pro3 C21TEL WH Sz 8 S GROUND ErGz GND BR d 1 E 2 2 5 SYS POWER P1 01 B1BAT RD lt 25 33 C64LS OR BK C64LS OR BK rot Tepes LSSiRo 2E Lag E C67SBD BL C67SBD BL BR T Ved SEC RET Sm a2 2 2 C64LS OR BK C64LS OR BK K 2 ar OPER 235566 e C73SBR BL RD C73SBR BL RD We z 19 amp go 8G 5 822888 9 m LST20 H o e SS 322 H a C64LS OR BK C64LS OR BK pL Tel DRV SS SS lt 2 C143DEL BL RD C143DEL BURD BR FX p ENABLE se E XE UAT STU LEFT 255553 Bx HRS quas Ze S S Z gt 80 555883888 0228 o LST10 TIRA GEFF 1 C64LS ORIBK Cous app TER Los oa C144DER BL WH C144DER BUWH R IT A OD ENABLE S Nu ZAR LR 2 RIGHT S 124 C64LS OR BK C64LS OR BK 4 V FST1S LOW F
158. TD2011 Operation Manual Deutz TD2011 Operation Manual Genie part number 139320 Genie part number 139320 Deutz D 2 9 L4 Series Operation Manual Genie part number 1251561 Genie A TEREX BRAND 58 ZX 135 70 Part No 218700 September 2015 Service Manual C 3 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 500 hours or annually e Engine oil and filter replace e Fuel system primary filter water separator element replace e Fuel system secondary filter replace e Crankcase breather canister replace e Hoses and clamps inspect replace e Radiator clean e V belts inspect adjust replace Required maintenance procedures and additional engine information is available in the Perkins 1100D Operation and Maintenance Manual Perkins 1100D Operation and Maintenance Manual Checklist C Procedures C 4 Replace the Engine Air Filter Element Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Note Perform this procedure with the engine off 1 Release the latches on the air cleaner cap Remove the end cap from the air cleaner canister
159. UEL C65LOFL BL WH C65LOFL BLIWH eat a a VLVRET BR 3 3 VLVRET BR e amp E 0 1248BS OR BK C124SBS ORIBK BL _ EE 2 ul a o 2 3 3 S a e 2 d E 2 SNSR GND BR SNSR GND BR 52 GR A 519 SEC BM SIS 8 E 5 SE 8 a al al 8 P109ANG GR WH e P109ANG GR IWH 3 gt WH ANG OPER 3 E Nm p ge x C1428BS OR I gt Y_ _ a e 532 003 SNSR GND BR lt gt gt BK ee a o ap L P109ANG GR WH A N ANG SAFETY 14 wo E E 8 8 C64LS OR BK C64LS OR BK D RES istis S13DE BL RD BR ag V D DRVEN BK SI xIzao WH Zeg 3126 o 4 C64LS OR BK RDE T see C64LS OR BK 2 SM E SAA LSSIRS C LLS ORBKSS SBR oy al SP 3 EX S73SLE BURD S SWH mej 46 T Eaz RDH TREES ispiro dup c A C64LS OR BK C64LS OR BK ORIBK Sd dist 3 EXT P_30 P 30 P12 34 S140ENL OR RD C70PBR BL WH C70PBR BL WH a RD BK WHi H z 44 SEC ANG INPUT P12332 C124SBS OR BK PRI ANG INPUT P12322 C123PBS RD BK eof Pe LSPIEO S BR 3 FROM FULLY BOOM STOWED P1231 ett C6ALS ORIBK A C64LS OR BK BK a el p Jl EXTENDED LSB14A0 P1230 C71PBE BL BK C71PBE BL BK BL BK WH B J45 LSB13AO PT2 29 LST20 DR ENBL L P1228 C143DEL BLIRD kan ps PRESSURE GA P1227 4 SNSR PWR P12262 P109ANG GR WH On SNSR GND P1225 SNSR GND BR gt C123PBS RD BK C123PBS RD BK Wu 4 BL Fs TO PLD SNSR GND BR e SNSR GND BR FR GR p gt cR S17 PRI BM LOCKOUT N
160. aced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom in the Boom Components 4 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Attach a lifting strap from an overhead crane to the rod end of the primary boom lift cylinder Do not apply any lifting pressure 6 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin and rest the cylinder on the block 7 Attach a lifting strap from a second overhead crane to the barrel end of the primary boom lift cylinder Do not apply any lifting pressure 8 Remove the primary boom lift cylinder barrel end pivot pin retaining fasteners 9 Use a soft metal drift to remove the barrel end pivot pin Carefully remove the primary boom lift cylinder from the machine stowed position AWARNING Crushing hazard The boom lift cylinder may become 1 Remove the hose and cable clamps from the unbalanced and fall if it is not primary boom lift cylinder properly supported when it is 2 Remove the cable track retainin
161. ailure Oxygen Level Test 3217 13 After treatment 1 Intake 02 Out of Calibration Oxygen Level Test 3217 15 After treatment 1 Intake 02 High least Oxygen Level Test severe 1 Genie 242 ZX 135 70 Part No 218700 September 2015 A Tea ee Perkins 854F 34T Engine Fault Code SPN Suspect Parameter Number FMI Failure Mode Identifier Service Manual SPN FMI Description Refer to Engine Manual 3219 15 After treatment 1 Intake Gas Sensor at Oxygen Level Test Temperature High least severe 1 3219 17 After treatment 1 Intake Gas Sensor at Oxygen Level Test Temperature Low least severe 1 3222 3 After treatment 1 Intake Gas Sensor Heater Oxygen Level Test Voltage Above Normal 3222 4 After treatment 1 Intake Gas Sensor Oxygen Level Test Heater Voltage Below Normal 3222 5 After treatment 1 Intake Gas Sensor Oxygen Level Test Heater Current Below Normal 3242 3 Particulate Trap Intake Gas Engine Temperature Sensor Open or Short Circuit Temperature Voltage Above Normal Test 3242 4 Particulate Trap Intake Gas Engine Temperature Sensor Open or Short Circuit Temperature Voltage Below Normal Test 3251 0 Particulate Trap Differential Pressure High Diesel Particulate Filter Collects Excessive Soot most severe 3 3251 3 Particulate Trap Differential Pressure Voltage Engine Pressure Sensor Open or Short Circuit Test Above Normal 3251 4 Particulate Trap Dif
162. al H 8 E z E SE 9 8 z y S Ww 2 or 5 FE z 2 JENE Su E 53 HI zz Fr DD E 8 EEN ES GHuO 3 Y A ren Y74 FUNCTION ENABLE VALVE 1166 Lu e SM Q 40 30d99 14 H T u E b y z E ie 9 z Ex 3 ae 9Szu z Goer 8 Y e tr s gps ES a Ze a B m vlg 555 z 20 E Sue HYDRAULIC A PER 8 E MO GAH9LIM E OIL COOLER FAN SE E mia E HOQ 5 aN MONTANES TEMP SWITCH Lu 3 273 ES a A 5 BE a T g zz E E 53g 3 H 3 YSZIIVMA E 8 E HM NHHOPH E x HORN ENLA SAWA 87614 lt S HOLVYANTO ov zz amp id S 3 SEV A Du LU 124 lt i E e 3 Sv X Lir LU 0e eld lt g Bpm 94 LOHLLOL23MOd BE d St iLd L CRUHMAULSEIS amp 8 9 Wai uova Bela lt Y E FX2 8 920 Inge j HaONa OL YMd SE A ZEIA Z HAVCH TIZELS 8 UMd0ZA tax pa RE AROS ete E M SEL C E A 3 uia OS HAGEN Gu MA dO UM Mee DUU SEL A Rn 2 usted Ousted ONO USNS DU OI F td 5 A 38 P00NO 5 ANAL s31vMn
163. al load 140 200A Oil pressure hot 2000 rpm 40 to 60 psi 2 8t04 1bar Cranking speed 250 350 rpm Oil capacity including filter 9 4 quarts Battery Engine starting and control system 8 9 liters Type 12V DC Group 31 Oil viscosity requirements Quantity 1 22 F to 86 F 30 C to 30 C 5W 30 Battery capacity maximum 1000A synthetic Reserve capacity 25A rate 200 Minutes A F10 REMO e 10W40 Engine coolant Ethylene Glycol Above 5 F 15 C 15W 40 Engine coolant capacity 11 1 quarts Unit ships with 15W 40 10 5 liters Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Alternator output 95A 14V DC Engine Operator Manual for your engine Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Genie Part No 218700 ZX 135 70 7 Service Manual September 2015 Specifications Perkins 1104D 44T Displacement Number of cylinders Bore and Stroke Horsepower net intermittent 2200 rpm 268 5 Cu in 4 4 liters 4 4 13 x 5 inches 105 x 127 mm 68 hp 50 7 kW 74 hp 55 2 kW Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 8 3 quarts 7 9 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Induction system turbocharged Unit ships with 15W 40 Extreme op
164. al sensing valve P Primary boom extend retract 30 35 ft Ibs 41 47 Nm 150 psi 10 3 bar circuit regulates pressure drop across primary boom extend retract proportional valve 24 Relief valve 2600 psi X Primary boom extend 20 25 ft lbs 27 34 Nm 179 bar 25 Proportional solenoid S Primary boom up down circuit 50 55 ft Ibs 68 75 Nm valve 26 Differential sensing valve O Primary boom up down circuit 30 35 ft lbs 41 47 Nm 150 psi 10 3 bar regulates pressure drop across primary boom up down proportional valve Genie 166 ATEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Manifolds AN SS Se Das c 3 fj x Q CC o ON Hie T 2 m Genie ATEREX BRAND Part No 218700 ZX 135 70 167 Service Manual September 2015 ee aa U a 2 Manifolds 8 2 4 Simultaneously push and hold the auxiliary Valve Adjustments Function power button and the primary boom retract button with the primary boom fully retracted Manifold Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic s Component Specification How to Adjust the Function 5 Hold the relief valve stem with a hex wrench Manifold Relief Valve and loosen the lock nut Note Perform this procedure with the boom in the 6 Adjust the valve stem Turn it clockwise to stowed position increase the pressure Tighten the lock nut No
165. all be cleared by a person trained and qualified on the troubleshooting and repair of this machine Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 ad Previous Plus Minus Enter 1 Turn the key switch to the off position 2 Pressand hold the enter button on the ground control panel while turning the key switch to ground controls Hold the enter button for approximately 5 seconds Service Manual September 2015 Ties EA Platform Components 3 Press the buttons on the ground controls in the following sequence plus minus minus plus 4 Press the enter or previous button on the LCD screen until CLEAR OVERLOAD RECOVERY is displayed 5 Press the plus button or the minus button to select YES Then press the buttons in the following sequence plus plus plus minus and press the enter button to accept Note The passcode buttons plus plus plus minus must be entered in the proper sequence before the enter button is pressed 6 Press the enter or previous button on the LCD screen until EXIT is displayed 7 Press the plus button or minus button to select YES and then press the enter button 8 Turn the key switch to the off position Genie ATEREX BRAND 102 ZX 135 70 Part No 218700 September 2015 Service Manual Jib Boom Components
166. allow operation at default speed Perform auto calibrate procedure Primary Boom Extend Valve Primary Boom Retract Valve Primary Boom Up Valve Primary Boom Down Valve Primary Lock Out Valve 1 Primary Lock Out Valve 2 Fault Check Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Secondary Boom Up Down Extend Retract Flow Valve Not calibrated Normal function except threshold for one or the other direction is zero Display message on LCD Perform calibration procedure Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Value Too Low Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Part No 218700 enie ATEREX BRAND ZX 135 70 205 Service Manual September 2015 Fault Codes SAFETY SWITCH FAULT Error Source Error Type Effects Recovery Actions Safety Switch P3 Fault Check Display message on LCD P3 SAFETY Internal fault not on 2135 SWITCH FAULT Safety Switch P6R1 Fault Check
167. allow the platform to be manually adjusted to within the normal operating envelope 34 5 Only auxiliary power can be used to correct an out of level platform fault 1 Turn the engine off 2 Turn the main key switch to ground controls Remove the key from the main key switch and insert the key into the bypass recovery key switch Note The main key switch must remain in the ground control position Genie A TEREX BRAND 144 ZX 135 70 3 Turn the bypass recovery key switch to the bypass position 4 Using auxiliary power operate the ground control buttons to level the platform Note Only the auxiliary power unit can be used to correct an out of level platform fault 5 Turn the bypass recovery key switch to the run position 6 Remove the key from the bypass recovery key switch and insert the key into the main key switch Note If the Bypass function has been used there may be faults with the machine Check the LCD screen on the ground control box for machine faults then contact trained service personnel Part No 218700 September 2015 Service Manual How to Use the Recovery Mode Recovery is only to be used as a last attempt to lower the platform when the operator in the platform is unable to do so system failure or in emergency situations AWARNING Bodily injury hazard When using recovery mode the platform may not fully lower to the ground when the recovery mode is completed Failure to
168. and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition D Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Part No 218700 Genie ATEREX BRAND ZX 135 70 23 Checklist A Procedures 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition D Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Service Manual September 2015 Checklist A Procedures A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is design
169. anifold 2 Locate the axle relief valve on the steer and axle manifold Hold the relief valve with a wrench and remove the cap 3 Startthe engine from the platform controls and press down the foot switch Press and hold the axle extend button at the platform controls Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specifications Part No 218700 Genie ATEREX BRAND ZX 135 70 Manifolds Turn the engine off Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Component damage hazard Do not adjust the relief valve pressures higher than specifications Repeat steps 3 through 5 to confirm relief valve pressure Remove the pressure gauge 181 Service Manual September 2015 ee aa U a 2 Manifolds 8 10 Traction Manifold Components The traction manifold is mounted inside the manifold box at the blue triangle side of the machine jd Description nn Function Torque 1 Check valve 5 psi 0 3 bar K Anti cavitation dh 2 Solenoid Valve 2 position 3 way P Two speed drive motor shift A prodi 3 Solenoid Valve 2 position 3 way Q Brake release ydp A 4 Check valve 5 psi 0 3 bar R Brake circuit mc She van Spostonsway Do D RE dE 6 Relief valve 250 psi 17 23 bar E Charge pressure circuit ee 7 Orifice Plug 0
170. annot return the boom to the stowed position 1 Push in the platform red Emergency Stop button to the off position 2 Turn the key switch to ground controls Pull out the red Emergency Stop button to the on position at the ground controls 4 Startthe engine and operate each boom function through a partial cycle Result All boom functions should operate 5 From the platform activate the foot switch and operate each boom function Result No boom functions operate 6 Pull out the red Emergency stop button to the on position at the platform controls 7 Activate the foot switch and operate each boom function Result No boom functions operate Genie ATEREX BRAND ZX 135 70 41 Part No 218700 Service Manual September 2015 Checklist B Procedures B 13 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational 4 WARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration Refer to maintenance procedure Confirm the Proper Brake Configuration Note Select a test area that i
171. apacity Specifications Repeat steps 3 through 7 for the other turntable rotate drive hub assembly Adjust turntable rotation gear backlash Refer to Repair Procedure How to Adjust the Turntable Rotation Gear Backlash 71 Service Manual September 2015 Checklist D Procedures D 4 Adjust the Turntable Rotation Gear Backlash Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Properly adjusted turntable rotation gear backlash is essential for good machine performance and service life Improperly adjusted turntable rotation gear backlash will cause the machine to perform poorly and continued use will cause component damage The turntable rotation drive hubs are mounted on an adjustable plate on the swing Oo chassis behind the fixed side cover at the ground controls side of the machine Note Perform this procedure with the machine fully stowed and the counterweight at the square end of the machine Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Secure the turntable from rotating with the turntable rotation lock pin 2 Remove the fixed turntable cover at the ground controls side of the machine 3 Loosen the backlash pivot plate mounting bolts 4 Push the backlash pivot plate towards the turntable as far as possible this will push the rotation pinion gears into the turntable beari
172. arts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Part No 218700 Repair Procedures Machine Configuration V Unless otherwise specified perform each repair procedure with the machine in the following configuration Genie ATEREX BRAND ZX 135 70 Machine parked on a firm level surface Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock 83 Service Manual September 2015 Ps 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 Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert A personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Indicates a imminently hazardous situation whic
173. ary boom fully retracted Secondary boom fully retracted safety Jib boom length fully retracted Drive enable left direction Drive enable right direction Drive enable safety retracted axles Front axle fully retracted Rear axle fully retracted Switches which sense the extended length and LSP1RO WE B the booms and rotational position of the LSP1EO urntable LSS1RO For example when the secondary boom is fully LSS1RS raised and the operational sensor is activated it LSJ4RO tells the ECM at the ground controls to start extending the secondary boom pi LST20 Another example is the drive enable limit switch LSTIS which disables the drive function anytime the boom is rotated past the rear tires indicated by the circle LSFATES end of the drive chassis In some cases the engine LSRA1ES will be stopped if safety parameters are exceeded Genie 256 ZX 135 70 Part No 218700 September 2015 Service Manual Limit Switches and Angle Sensors Rotary Sensor Numbering RSP1AO Primary boom angle sensor RSP1AS Primary boom angle sensor safety RSJ1AO Jib boom angle sensor RSS1AO Secondary boom angle sensor RSS1AS Secondary boom angle sensor safety RSFA10 Front axle postioning sensor RSRA10 Rear axle positioning sensor RSLF1SO Left front wheel positioning sensor RSRF1SO Right front wheel positioning sensor RSLR1SO Left rear wheel positioning sensor RSRR1SO Right rear wheel positioning sensor Limit Switch Functions
174. ary extension boom 6 Tag disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to the platform manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the retaining fasteners from the hose and cable guide at the platform end of the primary boom Remove the hose and cable guide 8 Tagand disconnect the electrical connector from the limit switch on the side of the primary boom Do not remove the limit switch 9 Remove the cotter pin from the upper cable track tube at the platform end of the primary extension boom Note Always replace the cotter pin with a new one 10 Remove the retaining fasteners from the cable track guide at the platform end of the boom Remove the cable track guide from the machine 11 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together A WARNING Crushing hazard If the upper Component damage hazard and lower cable tracks are not Cables can be damaged if they properly secured together the are kinked or pinched cable track could become unbalanced and fall when removed from the machine Genie A TEREX BRAND 118 ZX 135 70 Part No 218700 September 2015 Service Manual Boom Components 1
175. bearing is good D Result The measurement is more than 0 118 inch 3 0 mm The bearing is worn and needs to be replaced 8 Move the boom sections to the positions indicated in step 3 Visually inspect the dial indicator to be sure the needle returns to the zero position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the boom to the stowed position and turn the machine off Remove the dial indicator from the machine Service Manual September 2015 Checklist C Procedures C 1 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 500 hours All Models e Engine oil and filter replace TD 2 9 Models e Primary fuel filter replace e V belts inspect adjust replace e Air intake pipe check e Cooling system check TD 2011L04i Models e Valve clearance check at first oil change Required maintenance procedures and additional engine information is available in the Deutz TD2011 Operation Manual Deutz 2011 Series Operation Manual C 2 Perform Engine Maintenance Deutz Models Engine specifications require that this one time procedure be performed at 500 hours e Engine valve lash inspect adjust Required maintenance procedures and additional engine information is available in the Deutz
176. before installing Install the new filter element Install the end cap on the canister and secure Note Be sure the discharge slot is pointing down A TEREX BRAND 34 ZX 135 70 Part No 218700 September 2015 Service Manual B 5 Check the Oil Cooler and Cooling Fins Deutz Models Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns 1 Open the engine side turntable cover Oil cooler 2 Remove the retaining fasteners from the engine side cover Remove the cover 3 Inspect the oil cooler for leaks and physical damage 4 Clean the oil cooler of debris and foreign material Part No 218700 Genie ATEREX BRAND ZX 135 70 35 Checklist B Procedures Cooling and blower fins 5 Inspect the fan blower fins for physical damage 6 Clean the fan blower fins of debris and foreign material 7 Using a flashlight inspect the head cooling passages an
177. booms in the fully stowed position and the axles fully extended 12 1 Open the ground controls side turntable side cover 2 Pull out the red Emergency Stop button to the 13 on position at both the ground and platform controls 14 3 Atthe ground controls turn the bypass recovery key switch to the run position 15 4 Turn the main key switch to ground control start the engine and then turn the key switch to platform control 5 Check any machine function from the ground controls 16 Result The machine functions should not operate 17 6 Turn the main key switch to ground control 7 Check any machine function from the platform 18 controls Result The machine functions should not operate 8 Turn the main key switch to the off position Result The engine should stop and no functions should operate 9 Turn the main key switch to ground control and start the engine 10 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The main key switch must remain in the ground control position Genie Part No 218700 ZX 135 70 Service Manual Checklist B Procedures Raise the primary boom 3 ft 1 m Result The primary boom should raise Remove the key from the bypass recovery key Switch and insert the key into the main key Switch Turn the main key switch to the off position Remove the key from the main key switch and insert the key into t
178. cifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the secondary boom to the point where Genie part number 123702 it begins to extend Turn the machine off 2 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine f E AE e e Es jae SE j m 1 al 1 engine pivot plate anchor hole 2 engine pivot plate retaining fastener 3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Genie Part No 218700 ZX 135 70 75 Service Manual September 2015 Checklist D Procedures 5 Confirm that each turntable mounting bolt is Dodd 7 Remove the engine pivot plate retaining torqued Pee qMEneS to specification Refer to fastener from the engine pivot plate anchor Specifications Machine Torque hole at the pivot end of the engine pivot plate Specifications 8 Swing the engine pivot plate in towards the machine 20 O o 9 Ins
179. comes first Maintaining the safety decal in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls 2 Open the turntable cover on the ground controls side of the machine Open the ground control box 4 Verify the ground control panel is equipped with the required calibration decal Result The control box is equipped with the required decal and is legible and in good condition D Result The control box is not equipped with the required decal or is illegible or in poor condition Remove the machine from service until the decal is replaced Genie A TEREX BRAND 56 ZX 135 70 Note Contact your authorized Genie distributor or Genie if a replacement is required 1 calibration decal Only technicians that have Genie factory service training shall perform calibration Tip Over Hazard Improper calibration can result in death or serious injury ANSI and CSA CE and AUS Part No 218700 September 2015 Service Manual B 25 I
180. condary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Value at 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Out of Tolerance Primary up Secondary up down and Extend disabled Alarm sounds Recalibrate sensor Not calibrated Primary up only active from TCON activate alarm Perform calibration procedure per service manual Just calibrated Initiate one second beep of audible warning device Self clearing transient Secondary Boom Joystick Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Value Too High Value Too Low Value at 0 V Not calibrated Joystick Speed and Direction frozen at zero and neutral Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Just calibrated Initiate one second beep of audible warning device Self clea
181. cts Recovery Actions Primary Ext Ret Joystick Primary Up Down Joystick Value at 5 0 V Value Too High Value Too Low Value at 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Not calibrated Just calibrated Value at 5 0 V Value Too High Value Too Low Value at 0 V Joystick Speed and Direction frozen at zero and neutral Initiate one second beep of audible warning device Limited Speed and Direction frozen at zero and neutral Alarm sounds Calibrate Joystick Self clearing transient Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Joystick Just calibrated Initiate one second beep of audible warning device Self clearing transient Steer Joystick Value at 5 0 V Value Too High Value Too Low Value at 0 V Not calibrated Just calibrated Limited Speed and Direction frozen at zero and neutral Alarm sounds Joystick Speed and Direction frozen at zero and neutral Initia
182. ctuator exhaust gas mass flow CRT system defective plausibility error 3699 2 1617 Temperature sensor us and ds 2659 12 1526 Exhaust gas recirculation AGS DOC simultaneously defect Sensor 0a DU once 3699 14 1615 Maximum stand still duration performed reached oil exchange required 2797 4 1337 Injector diagnostics timeout error 4765 0 1039 Physical range check high for of short circuit to ground exhaust gas temperature measurement cyl Bank O upstream DOC 4765 1 1042 Physical range check low for exhaust gas temperature upstream DOC Genie 228 ZX 135 70 Part No 218700 September 2015 A AA ZZ Deutz TD 2 9 L4 Engine Fault Codes Service Manual SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier 523008 2 649 Timeout error in Manipulation KWP Keyword Protocol control SPN FMI KWP Description 523009 9 825 Pressure Relief Valve PRV 4766 0 1029 Physical range check high for reached maximun allowed exhaust gas temperature opening count downstream DOC 523009 10 833 Pressure relief valve PRV 4766 1 1032 Physical range check low for reached maximun allowed open exhaust gas temperature time downstream DOC 523212 9 171 Timeout Error of 4768 2 1036 Sensor exhaust gas temperature CAN Receive Frame f upstream DOC plausibility ComEngPrt Engine Protection error 523216 9 198 Timeout Error of 4768 3 1044 Sensor error exhaust gas CAN
183. culate Filter Active Regeneration Indicator Lamp Circuit Test Inhibited Status Current Above Normal 4765 3 After treatment 1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit Intake Gas Temperature Voltage Above Test Normal 4765 4 After treatment 1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit Intake Gas Temperature Voltage Below Test Normal 5055 17 Engine Oil Viscosity Low least severe 1 Oil Contains Fuel 5055 18 Engine Oil Viscosity Low moderate severity Oil Contains Fuel 2 5099 6 Engine Oil Pressure Low Lamp Data Current Indicator Lamp Circuit Test Above Normal 5319 31 After treatment Diesel Particulate Filter Diesel Particulate Filter Active Regeneration Was Incomplete Regeneration Interrupted 5324 7 Engine Glow Plug 1 Not Responding Properly Glow Plug Starting Aid Test 5325 7 Engine Glow Plug 2 Not Responding Properly Glow Plug Starting Aid Test 5326 7 Engine Glow Plug 3 Not Responding Properly Glow Plug Starting Aid Test 5327 7 Engine Glow Plug 4 Not Responding Properly Glow Plug Starting Aid Test 5419 5 Engine Throttle Actuator 1 Current Below Motorized Valve Test Normal 5419 6 Engine Throttle Actuator 1 Current Above Motorized Valve Test Normal 5419 7 Engine Throttle Actuator 1 Not Responding Motorized Valve Test Properly 5571 2 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem Relief Valve Erratic Intermittent or Incorrect 5
184. d YE INOTL amod sas Hired lt Olga zg L E E ae a Si gt Ed Ban gis E 2 3 e28 Bars ON m LO N eo Part No 218700 ZX 135 70 276 September 2015 Service Manual Perkins 854F 34T Engine Harness A B C D E F G H I J K L M 8 ogg 2 a 9 3 E S Ss g 3 S E DETAIL C PERKINS 854T TIER IV ENGINE 1 amp 292 9 3 227 5 25 c a o RS 2147 S e 2 S GLOW PLUG CONTROLLER 2 S S 4K pasa T T acPsle GCPOND X GPCDIAG lt R34SA1 K R3ASA2 RE RASAS 2 R34SA4 E 58 3 82 2 5 b a or 2 22222225 ee E 3 5 S EK Im EEN E EE 5 3 un i EIC 57 _R345A4 m m 2 gt E gt GPCDIAG RD BK ElC 58 R34SA3 bau e EN YY e EIC 60 R345A2 ban 2 i la E 3 ElC 61 7 R34SA1 AVI kd EC Rike R E lt TSTEMPRETK81 8 JE PR SA END 3 e R20PWR RD Kt 1 ECU PWR ENGINE ECU INJECTOR 2 HIGH D A 1 INJ2HE 1200 GND BR Ki2 lt ECUGND INJECTOR 4 HIGH A2 INJ4HE dal R20PWR RD Ki3 lt l ECU PWR ELECT WAST GATE VALVE ACTUATOR DA4 EWGVA Best EWGV
185. d A flat level surface of 0 allows the primary boom maximum operational angle to reach 68 On a 5 downhill slope the primary boom maximum operational angle is reduced to 43 0 slope 68 boom angle 5 slope 43 boom angle Genie ATEREX BRAND ZX 135 70 131 Part No 218700 Service Manual September 2015 Boom Components How to Calibrate the Primary Boom Angle Sensor Note If the axle sensor or secondary boom angle sensor have been removed or replaced or the turntable level sensor has been replaced they must be calibrated first Refer to Repair Procedures How to Calibrate the Axle Angle Sensors or How to Calibrate the Secondary Boom Angle Sensor or How to Calibrate the Turntable Level Sensor AWARNING Tip over hazard Failure to properly calibrate the machine could cause the machine to tip over resulting in death or serious injury Note For software versions 4 01 and higher use the 2 Point Calibration procedure For software versions before 4 01 use the 6 Point Calibration procedure The software version is displayed on the LCD screen when the red Emergency Stop button is pulled out to the on position Note Perform this procedure with the machine on a firm level surface Note A digital level will only be required to perform the 6 Point Calibration procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital
186. d Air Pressure Is Low moderate severity 2 1188 5 Engine Turbocharger Wastegate Actuator 1 Solenoid Valve Test Position Current Below Normal 1188 6 Engine Turbocharger Wastegate Actuator 1 Solenoid Valve Test Position Current Above Normal 1209 3 Engine Exhaust Gas Pressure Voltage Above Engine Pressure Sensor Open or Short Circuit Test Normal 1209 4 Engine Exhaust Gas Pressure Voltage Below Engine Pressure Sensor Open or Short Circuit Test Normal 1221 2 Continuously Monitored Systems ECM Memory Test Support Status Erratic Intermittent or Incorrect 1221 14 Continuously Monitored Systems Another diagnostic code has requested engine speed Support Status Special Instruction limitation The warning lamp will flash The engine speed is limited to 1200rpm Troubleshoot all other diagnostic codes No troubleshooting is required for this diagnostic code 1239 Engine Fuel Leakage 1 High most severe 3 Fuel Rail Pressure Problem 1485 ECM Main Relay Not Responding Properly Electrical Power Supply Test 1485 14 ECM Main Relay Special Instruction Electrical Power Supply Test Part No 218700 ATEREX BRAND ZX 135 70 241 Service Manual September 2015 AAA AA AAA AAA gt ar Perkins 854F 34T Engine Fault Code SPN Suspect Parameter Number FMI Failure Mode Identifier SPN FMI Description Refer to Engine Manual 2791 5 Engine Exhaust Gas Recirculation EGR Va
187. d Platform Controller Pin Legend J21 o o so a WN N 0 13 14 15 16 17 18 19 20 21 22 23 ml GL Ce 0 yoooococo qe X wer e men En Co En Pin Numbering 23 pin connector Plat Controller GNDPCON BR P52PCON WH UNUSED S56PRV RD UNUSED UNUSED P56PRV RD WH UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED C470UT WH BK C46HN WH D81CAN GR D82CAN YL UNUSED UNUSED UNUSED UNUSED P23PCON BK J22 o o nN o Oc Ek WN N o0 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Plat Controller VLVRET1 BR V153JBE BK V18PRR GR BK V17PRL GR V43JU GR V44JD GR BK V14PLU OR V15PLD OR BK V154JBR BK WH UNUSED C90PXS RD BK GR YL OR BK C88PTS RD BK C64LS OR BK C56FTS RD C154JBR BK WH P85RET BR C84TAY GR BK P85PTS GR P87RET BR P87PTS RD UNUSED UNUSED UNUSED UNUSED V146JBU BL V147JBD BL BK P109JBS GR WH P110JBS BK C148JBS BLIWH UNUSED VLVRET2 BR UNUSED 262 J32 oA 4 o Om E ON N M M IO a a ch a a a daa n W N gt O O o O0 FF wann O Genie ZX 135 70 Co E KEEN L OONOOOOOOOO CEET EECH Pin Numbering
188. d fins for physical damage or foreign material 8 If needed clean the cylinder head cooling passages and fins of debris and foreign material 9 Install the engine side cover and tighten the retaining fasteners Service Manual September 2015 Checklist B Procedures B 6 Check the Exhaust System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Operating the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions A WARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation CAUTION Bodily injury hazard Beware of hot engine components Contact with hot engine components may cause severe 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving A WARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Besure that all nuts and bolts are tight Inspect all welds for cracks 6 Inspect for exhaust leaks i e carbon buildup around seams and joints 7 Remove the engine pivot plate retaini
189. d fully retracts when activating high idle 7 Check for excessive movement in the linkage bar pins Result If there is excessive wear in the linkage the linkage bar should be replaced Genie A TEREX BRAND 64 ZX 135 70 Perkins models 1 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine H Ip Gm 77mm o o ate es Y C i _ gt SE A E CF L m NM Luna M S a 1 engine pivot plate anchor hole 2 engine pivot plate retaining fastener 2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving A WARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 4 Startthe engine from the ground controls Component damage hazard Be sure the hydraulic supply hoses to the function and drive pumps are not kinked before starting the engine Part No 218700 September 2015 Service Manual 5 Press the enter or previous button on the LCD screen until engine rpm is displayed Result Low idle should be 1300 rpm Skip to step 7 if the low idle rpm is correct 6 Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm
190. d or extended 0 7 mph Overall tire diameter 45 47 in 1 1 km h 115 5 cm 40 ft 40 sec Wheel diameter 28 in 12 2 m 40 sec 71 1cm Primary and Secondary booms 0 4 mph Wheel width 15 in raised and Primary and Jib 0 6 km h 38 1 cm extended 40 ft 68 sec 12 2 m 68 sec Wheel lugs 10 Q 3 4 16 Braking distance maximum Lug nut torque dry 420 ft lbs 569 4 Nm High range on paved surface 3 to 6 ft 1to2m Lug nut torque lubricated 320 ft lbs 433 9 Nm Gradeability See Operator s Manual Fluid capacities Boom function speeds maximum from platform Fuel tank 40 gallons controls 151 4 liters r Jib boom up down 38 to 43 seconds Hydraulic tank 65 gallons 246 liters Jib boom extend retract 28 to 38 seconds Hydraulic system including tank 123 gallons Primary boom up down 110 to 125 seconds 466 liters 60 to 70 Drive hubs 47 fl oz Primary boom extend retract 35 to 48 seconds 1390cc Secondary boom up down 80 to 95 seconds Turntable rotation drive hub i OZ _ Secondary boom extend retract 88 to 98 seconds cc Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 218700 Genie ATEREX BRAND Turntable rotate 360 fully stowed 88 to 92 seconds Turntable rotate 360 jib or primary booms extended 160 to 180 seconds Turntable rotate 360 jib and primary booms extended 280 to 350 seconds For operational specifications refer to the Operator s Manual e
191. d select button and the platform level down button until the digital level displays approximately 44 2 degrees Genie A TEREX BRAND 114 ZX 135 70 24 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note Be sure the number entered at the ground controls is a negative number Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 25 Press and hold a function enable speed select button and the platform level down button until the digital level displays approximately 70 2 degrees The jib boom level cylinder should be fully retracted at this point 26 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note Be sure the number entered at the ground controls is a negative number Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value Note With the jib boom
192. death or serious injury Refer to Repair Procedure How to Calibrate the Level Sensor y Plus Minus Previous Enter 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls Genie ATEREX BRAND Part No 218700 ZX 135 70 47 Service Manual September 2015 AO ss Checklist B Procedures Start the engine from the ground controls 7 Lower the secondary boom to 65 Press the plus and minus buttons at the O Result The reading at the display and digital same time on the LCD screen to enter the level is within 2 of each other and of 65 MACHINE STATUS screen Press the enter or previous button until SECONDARY BOOM amp Result The reading at the display and digital ANGLE is displayed level is greater than 2 of each other and of 65 The secondary boom angle sensor must Fully raise the secondary boom The boom is be calibrated Refer to Repair Procedure How fully raised when the cylinder is fully extended to Calibrate the Secondary Boom Angle and the boom stops moving Sensor Zero a digital level to the Y axis of the 8 Lower the secondary boom to 50 turntable Refer to Maintenance Procedure f a Test the Turntable Level Sensor Result The reading at the display and digital level is within 2 of each other and of 50 PI the digital level on top ofthe
193. detection reported error home mode exceeded PRV 523612 12 615 Internal ECU monitoring 523470 11 831 The PRV can not be opened at detection reported error this pals a with a 523612 12 616 Internal ECU monitoring Pieper S109 detection reported error 523470 11 832 Rail pressure out of tolerance 523612 12 617 Internal ECU monitoring Seet EE e detection reported error 9234 0 12 828 rte Ge 523612 12 618 Internal ECU monitoring shut off condition detection reported error ze 523612 12 619 Internal ECU monitoring warning condition detection reported error 523470 14 830 Pressure Relief Valve PRV is 523612 12 620 Internal ECU monitoring open detection reported error 523550 12 980 en start switch active for too 523612 12 621 Internal ECU monitoring ong detection reported error 523601 13 948 Seier SE voltage monitor 523612 12 623 Internal ECU monitoring error detection reported error gen O een 523612 12 624 Internal ECU monitoring Side i detection reported error Ambient Temperature Sensor 523605 9 300 Timeout Error of an nn CAN Receive Frame TSC1AE Traction Control 523612 12 627 Internal ECU monitoring 523606 9 301 Timeout Error of ee AO CAN Receive Frame TSC1AR 523612 12 628 Internal ECU monitoring Retarder detection reported error 523612 12 387 Internal software error ECU injection cut off 523612 12 612 Internal ECU monitoring detection reported error Genie A TEREX BRAND 230 ZX 135 70 Part No 218700 Sep
194. e Always replace the cotter pin with a new one 6 Remove the cable track guide fasteners from the cable track guide at the platform end of the jib boom and remove the cable track guide from the jib boom 7 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together AWARNING Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 8 Attach a lifting strap from an overhead crane to the cable track 9 Remove the mounting fasteners that attach the lower cable track to the jib boom ellen 10 Remove the cable track from the machine and AWARNING Bodily injury hazard Spraying lay to the side hydraulic oil can penetrate and WARNIN Crushing hazard The cable burn skin Loosen hydraulic A G track could become connections very slowly to allow unbalanced and fall it sot m Don E Ge properly attached to the EEN OO overhead crane squirt or spray Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Genie A TEREX BRAND 106 ZX 135 70 Part No 218700 September 2015 A a ht AA E AAA Service Manual Jib Boom Components 11 Disconnect the electrical connector from the 19 Secure the jib boom lift cylinder to the jib boom jib boom angle sensor located at the jib boom with a strap or other suitable device pivot pin on the engin
195. e Voltage Engine Pressure Sensor Open or Short Circuit Test Below Normal 102 20 Engine Intake Manifold 1 Pressure Data Engine Pressure Sensor Open or Short Circuit Test Drifted High 102 21 Engine Intake Manifold 1Pressure Data Engine Pressure Sensor Open or Short Circuit Test Drifted Low 105 3 Engine Intake Manifold 1 Engine Temperature Sensor Open or Short Circuit Temperature Voltage Above Normal Test 105 4 Engine Intake Manifold 1 Engine Temperature Sensor Open or Short Circuit Temperature Voltage Below Normal Test 107 2 Engine Air Filter 1Differential Pressure Switch Circuits Test Erratic Intermittent or Incorrect 107 15 Engine Air Filter 1Differential Pressure High Inlet Air Is Restricted least severe 1 107 16 Engine Air Filter 1Differential Pressure High Inlet Air Is Restricted moderate severity 2 e Part No 218700 ATEREX BRAND Genie ZX 135 70 237 Service Manual AAA A AAA gt Perkins 854F 34T Engine Fault Code SPN Suspect Parameter Number FMI Failure Mode Identifier September 2015 SPN FMI Description Refer to Engine Manual 108 3 Barometric Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 108 4 Barometric Pressure Voltage Below Normal Engine Pressure Sensor Open or Short Circuit Test 110 3 Engine Coolant Temperature Voltage Above Engine Temperature Sensor Open or Short Circuit
196. e Manual E 2 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 2000 hours e Aftercooler core inspect e Alternator inspect e Engine mounts inspect e Starting Motor inspect e Turbocharger inspect Checklist E Procedures E 3 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every two years e Alternator belt replace e Glow plugs replace Required maintenance procedures and additional engine information is available in the Deutz TD2011 Operation Manual Deutz TD2011 Operation Manual e Water pump inspect Genie part number 139320 Required maintenance procedures and additional engine information is available in the Perkins 1100D Operation and Maintenance Manual Perkins 1100D Operation and Maintenance Manual Genie part number 123702 Genie Part No 218700 ZX 135 70 79 Service Manual September 2015 Checklist E Procedures E 4 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 3000 hours e Alternator belt inspect adjust replace e Fuel Injector test change Required maintenance procedures and additional engine information is available in the Perkins 1100D Operation and Maintenance Manual Perkins 1100D Operation and Maintenance Manual Genie part number 123702 E 5 Perfor
197. e Turntable Rotation Gear Backlash Part No 218700 September 2015 Service Manual Turntable Rotation Components How to Adjust the Turntable d Rotation Gear Backlash 1 Secure the turntable from rotating with the 8 turntable rotation lock pin 2 Remove the fixed turntable cover at the ground controls side of the machine 3 Loosen the backlash pivot plate mounting bolts 4 Push the backlash pivot plate towards the turntable as far as possible this will push the rotation pinion gears into the turntable bearing ring gear 5 Loosen the lock nut on the adjustment bolt Turn the adjustment bolt clockwise until it contacts the backlash pivot plate 020 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts Genie Turn the adjustment bolt 1 2 to 3 4 turn counterclockwise Tighten the lock nut on the adjustment bolt Pull the backlash pivot plate away from the turntable until it contacts the adjustment bolt Then lubricate the mounting fasteners on the backlash pivot plate and torque to specification Refer to Specifications Machine Torque Specifications Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary ATEREX BRAND Part No 218700 ZX 135 70 191 Service Manual September 2015 Turntable Rotation Components 9 2 Turntable Level Sensor How to Calibrate the Tu
198. e axle extension cylinder may become unbalanced and fall if not properly supported by the lifting device Part No 218700 September 2015 Service Manual 10 4 Axle Angle Sensors The axle angle sensors measure the axle angle and communicates that information to the ground controls ECM There are two axle angle sensors They are located on opposite axle pivot pins at each end of the chassis How to Calibrate the Axle Angle Sensors Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 a Plus Minus Previous Enter Note If an axle angle sensor has been removed or replaced the axle angle sensors will need to be calibrated Note Perform this procedure with the axles fully retracted and the boom in the stowed position Note Two people will be required to perform this procedure 1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Open the ground control box 3 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction Axle Components 4 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machi
199. e display If calibration faults exist repeat procedure for that joystick controlled function Note Perform this procedure with the engine off Note Use the following chart to identify the description of each LCD screen control button used in this procedure el Enter Plus y Minus Previous Service Manual i se Platform Controls Drive functions 1 2 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 platform controls Hold the enter button for approximately 5 seconds Press the minus button twice then press the enter button twice Use the scroll button to scroll through the menu until DELETE DRIVE JOYSTICK DEFAULTS is displayed Press the plus button to select YES then press the enter button Do not start the engine Locate the drive steer joystick Move the drive steer joystick full stroke in the forward direction and hold for 5 seconds then return to the center or neutral position Move the drive steer joystick full stroke in the reverse direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration 88 Genie A TEREX BRAND September 2015 Steer functions 1 Turn the key switch to the off position 2 Pressand hold the enter button on the
200. e joystick Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Thresholds Just calibrated Initiate one second beep of audible warning device Self clearing transient Propel Valves Forward Reverse Propel EDC Forward Reverse Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Thresholds Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Value Too Low Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Check for shorts to ground in the wiring Replace coil if necessary Motor Valve Speed Brake Valve Fault Check Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Part No 218700 enie ATEREX BRAND ZX 135 70 217 Service Manual September 2015 Fault Codes Error Source Error Type Effects Recovery Actions Left Front Steer Angle Sensor Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds
201. e oil filter Tank breather filter 26 Locate the breather filter on top of the hydraulic tank 27 Remove the filter and install the new hydraulic tank breather filter Tighten securely by hand 28 Start the engine from the ground controls 29 Inspect the all of the filter housings and related components to be sure that there are no leaks Genie A TEREX BRAND 74 ZX 135 70 D 6 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first e Fuel system primary filter water separator element replace e Engine valve lash inspect adjust e Hoses and clamps inspect replace e Glow plugs check e V belts re tension renew Required maintenance procedures and additional engine information is available in the Deutz TD2011 Operation Manual Deutz TD2011 Operation Manual Genie part number 139320 Part No 218700 September 2015 Service Manual D 7 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 1000 hours e Engine valve lash inspect adjust Required maintenance procedures and additional engine information is available in the Perkins 1100D Operation and Maintenance Manual Perkins 1100D Operation and Maintenance Manual Checklist D Procedures D 8 Check the Turntable Rotation Bearing Bolts Genie spe
202. e side of the machine 20 Raise the jib boom to a horizontal position 12 Remove the cover retaining fasteners from the using the overhead crane jib boom angle sensor Remove the cover 21 Attach a second lifting strap from the overhead 13 Remove the jib boom angle sensor mounting crane to the pivot end of the jib boom bracket fasteners from the side of the primary extension boom 22 Remove the pin retaining fastener from the jib boom pivot pin Do not remove the pin 14 Carefully remove the bracket and sensor assembly Note the location of the springs Do 23 Place a block under the jib boom level cylinder not lose the springs for support Protect the cylinder rod from Note There is one spring inside the jib boom pivot damage pin and one inside the angle sensor 24 Use a soft metal drift to tap the pin halfway out in one direction and lower one side of the jib Note When the jib boom is installed the jib boom boom bellcrank Tap the pin in the other angle sensor will need to be calibrated Refer to direction and lower the other side of the jib repair procedure Jib Boom Bellcrank Angle boom bellcrank Sensor for the calibration procedure 25 Use a soft metal drift to remove the jib boom 15 Attach a lifting strap from an overhead crane pivot pin Remove the jib boom from the to the platform end of the jib boom machine and place it on a structure capable of 16 Support the barrel end of the jib boom lift supporting it cylinder with another sui
203. e the ground control box lid fasteners Open the ground control box Tag and disconnect the harnesses from the ground control box Remove the control cable receptacle retaining fasteners from the side of the control box Attach a grounded wrist strap to the ground screw inside the control box Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap Part No 218700 Genie ATEREX BRAND ZX 135 70 10 11 Service Manual Ground Controls Tag and carefully disconnect the wire connectors from the circuit board Carefully disconnect the LCD circuit board ribbon cable from the ECM circuit board Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit board Remove the circuit board mounting fasteners Carefully remove the circuit board from the control box 147 Service Manual September 2015 Ground Controls 6 3 Membrane Decal The membrane decal is a special decal that consists of a decal with an electronic membrane on the backside The membrane contains touch sensitive areas that when pushed activate the
204. eater than 2 of each other and of 58 The primary boom angle sensor must be calibrated Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor DANGER Tip over hazard If the boom is not within 2 of 58 immediately lower the primary boom Failure to lower the boom could cause the machine to tip over resulting in death or serious injury Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor 50 A TEREX BRAND ZX 135 70 September 2015 Fully raise the secondary boom The boom is fully raised when the cylinder is fully extended and the boom stops moving Fully lower the primary boom until it stops at approximately 50 Result The reading at the display and digital level is within 2 of each other and of 50 Result The reading at the display and digital level is greater than 2 of each other and of 50 The primary boom angle sensor must be calibrated Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor Genie Part No 218700 September 2015 A A OA EA A AA 10 12 Raise the primary boom to 20 Result The reading at the display and digital level is within 2 of each other and of 20 Result The reading at the display and digital level is greater than 2 of each other and of 20 The primary boom angle sensor must be calibrated Refer to Repair Procedure How
205. ecifications Hydraulic Hose and Fitting Torque Specifications 7 Remove the cover from the lower jib boom cable track 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 8 Tagand disconnect the electrical connectors inside the lower cable track 2 Remove the jib boom lift cylinder Refer to u Repair Procedure How to Remove the Jib 9 Remove the hose and cable clamp retaining Boom Lift Cylinder fasteners from lower cable track at the pivot end of the jib boom Remove the clamps 3 Attach a lifting strap from an overhead crane to the platform end of the jib boom for support 10 Pull the electrical cables out of the lower cable Raise the jib boom to a horizontal position track that lead to the primary boom using the overhead crane 11 Attach a lifting strap from a second overhead 4 Extend the jib boom until the jib boom crane to the pivot end of the jib boom for extension cylinder rod end pivot pin is support Do not apply any lifting pressure accessible 12 Place a block under the jib boom level cylinder for support Protect the cylinder rod from damage Genie 110 ZX 135 70 Part No 218700 September 2015 Service Manual 13 Remove the pin retaining fastener from the jib boom pivot pin Do not remove the pin 14 Use a soft metal drift to tap the pin halfway out in one direction and lower one side of the jib boom bellcrank Tap the pin in the other direction and lower the other side of the jib boom bellc
206. ect the other end of the resistor to a 3 Seta multimeter to read DC current terminal on the coil Note The multimeter when set to read DC current Resistor 100 should be capable of reading up to 800 mA EE 4 Connect the negative lead to the other Note The battery should read 9V DC or more when terminal on the coil measured across the terminals 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Genie ATEREX BRAND Part No 218700 ZX 135 70 189 Service Manual September 2015 Turntable Rotation Components 9 1 Turntable Rotation Assembly How to Remove a Turntable Rotation Assembly Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the primary
207. ed and Direction frozen at zero and neutral Alarm sounds Calibrate Thresholds Self clearing transient Check for opens in the wiring or a bad ground Replace coil if necessary Operational Primary Boom Angle Sensor Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Value at 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Out of Tolerance Primary up Secondary up down and Extend disabled Alarm sounds Recalibrate sensor Not calibrated Primary up only active from TCON activate alarm Perform calibration procedure per service manual Just calibrated Initiate one second beep of audible warning device Self clearing transient Part No 218700 enie ATEREX BRAND ZX 135 70 209 Service Manual BEE Fault Codes September 2015 Error Source Error Type Effects Recovery Actions Safety Primary Boom Angle Sensor Value at 5 0 V Primary up Se
208. ed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie ATEREX BRAND 24 ZX 135 70 A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 218700 September 2015 Service Manual A 4 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first e Engine oil level check e Coolant level check add e Fuel system filter water separator drain e Engine tightness check for leaks e Exhaust system check for leaks Required maintenance procedures and additional engine inf
209. ed to reduce turntable rotate speed when secondary boom is extended and to disable secondary boom down unitl fully retracted LSS1RS Limit switch Secondary Boom 1 Retract Safety Switch Backup switch for LSS1RO Used to cut circuits P9B P_11 and P_30 LSJ1RO Limit Switch Jib Boom 1 Retract Operational Switch is held closed when the jib boom fully retracted Used to limit turntable rotate speed and drive speed when jib boom is extended LSP1EO Limit Switch Primary Boom 1 Extend Operational Switch closes when the primary boom is fully extended NOHC when fully extended LSP1RO Limit Switch Primary Boom 1 Retract Operational Switch closes when the primary boom is extended NCHO when fully retracted 257 Service Manual September 2015 Limit Switches and Angle Sensors Rotary Sensor Functions RSP1A0 Rotary Sensor Primary 1 Angle Operational Provides operational primary boom angle positioning relative to secondary boom angle RSP1AS Rotary Sensor Primary 1 Angle Safety Provides safety primary boom angle positioning relative to secondary boom angle RSJ1AO Rotary Sensor Jib 1 Angle Operational Used to level jib bell crank relative to the primary secondary and turntable angles RSS1AO Rotary Sensor Secondary 1 Angle Operational Used to measure the angle of the secondary boom Lowers drive speed when elevated sequences secondary boom up extend and down retract RSS1AS Rotary Sensor
210. efer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Extend the primary boom until the jib boom level cylinder barrel end pivot pin is accessible 2 Raise the jib boom above horizontal Jib Boom Components 6 Remove the external snap rings from the jib boom level cylinder barrel end pivot pin Use a soft metal drift to remove the pin 7 Tag disconnect and plug the jib boom level cylinder hydraulic hoses from the jib boom manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Attach an overhead crane or other suitable device to the jib boom level cylinder for support 9 Carefully remove the jib boom level cylinder from the machine Attach an overhead crane to the jib boom AWARNING EE d c assembly for Supponi unbalanced and fall when 4 Place a block under the jib boom level cylinder removed from the machine if not for support Protect the cylinder rod from properly supported damage 5 Remove the pin retaining fasteners from the jib boom level cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The jib boom could fall if not properly supported when the jib boom level cylinder rod end pivot pin is removed Genie Part No 218700 ZX 135 70
211. eplaced or the turntable level sensor has been replaced they must be calibrated first Refer to Repair Procedure How to Calibrate the Axle Angle Senors or How to Calibrate the Turntable Level Sensor AWARNING Tip over hazard Failure to properly calibrate the machine could cause the machine to tip over resulting in death or serious injury Note For software versions 4 01 and higher use the 2 Point Calibration procedure For software versions before 4 01 use the 6 Point Calibration procedure The software version is displayed on the LCD screen when the red Emergency Stop button is pulled out to the on position Note Perform this procedure with the machine on a firm level surface Note A digital level will only be required to perform the 6 Point Calibration procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 Plus Minus Previous Enter Part No 218700 September 2015 Service Manual 6 Point Calibration procedure Note Use this procedure for software versions before 4 01 Note For the 2 Point Calibration procedure proceed to step 32 1 Push in the ground controls red Emergency Stop button to the off position Do not tu
212. eptember 2015 SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier 2798 4 1338 Injector diagnostics timeout error KWP Keyword Protocol of short circuit to ground SPN FMI KWP Description measurement cyl Bank 1 1237 2 747 Override switch plausibility error 2798 4 1339 Injector diagnostics short circuit to ground monitoring Test in Cyl 1322 12 610 Too many recognized misfires in Bank 0 more than one cylinder 2798 4 1340 Injector diagnostics short circuit 1323 12 604 Too many recognized misfires in to ground monitoring Test in Cyl cylinder 1 in firing order Bank 1 1324 12 605 Too many recognized misfires in 3224 2 127 DLC Error of cylinder 2 in firing order CAN Receive Frame AT1IG1 1325 12 606 Too many recognized misfires in NOX Sensor SCR system cylinder 3 in firing order upstream cat DPF system downstream cat length of frame 1326 12 607 Too many recognized misfires in incorrect cylinder 4 in firing order TE m T E i t 2659 0 1524 Physical range check high for CAN ever ame EE EGR exhaust gas mass flow NOX sensor upstream 2659 1 1925 Physical range check low for 3248 4 1047 Sensor error particle filter EGR exhaust gas mass flow downstream temperature signal 2659 2 1523 Exhaust gas recirculation AGS range check low sensor plausibility error 3699 2 1616 DPF differential pressure sensor 2659 2 1527 AGS sensor temperature and a further sensor or a
213. er to ground 653 5 570 Injector 3 in firing order 703 5 424 Engine running lamp open load interruption of electric connection 703 42 425 Engine running lamp 654 3 583 Injector 4 in firing order short powerstage over temperature circuit 729 5 545 Cold start aid relay open load 654 4 589 High side to low side short circuit in the injector 4 in firing order 729 12 547 Cold start aid relay over temperature error 654 5 571 Injector 4 in firing order i 898 9 305 Timeout Error of interruption of electric connection CAN Receive Frame TSC1TE 676 11 543 Cold start aid relay error Setpoint 676 11 544 Cold start aid relay open load 1079 13 946 Sensor supply voltage monitor 1 error ECU 1080 13 947 Sensor supply voltage monitor 2 error ECU Genie 226 ZX 135 70 Part No 218700 September 2015 A AA ZZ Deutz TD 2 9 L4 Engine Fault Codes Service Manual SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier 1180 1 1463 Exhaust gas temperature KWP Keyword Protocol upstream turbine shut off SPN FMI KWP Description threshold exceeded 1109 2 121 Engine shut off demand ignored TAB Ge BE S Sor error exhaust gas temperature upstream turbine 1136 0 1398 Physikal range check high for signal range check high ECU temperature 1180 11 1066 Sensor exhaust gas temperature 1136 1 1399 Physikal range check low for upstream
214. er 2015 Choose an axle extend safety limit switch to test Locate and disconnect the Deutsch connector to the axle extend limit switch Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the Deutsch connector of the limit switch cable Result The limit switch should have continuity Result The limit switch does not have continuity The limit switch is faulty and needs to be replaced Remove the multimeter leads and connect the Deutsch connector to the limit switch Repeat steps 11 through 13 for the other axle extend safety limit switch Part No 218700 September 2015 Service Manual B 23 Test the Recovery System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning recovery system is essential to safe machine operation The Recovery mode allows the platform to be lowered in the event the operator in the platform is unable to lower the platform using the platform controls system failure or emergency situations Note Perform this procedure with the machine on a firm level surface with the axles extended Note Perform this procedure with all weight tools equipment and personnel removed from the platform De D 1 Run 2 Bypass 3 Recovery Part No 218700 Gen A TEREX BRAND ZX 135 70 55 Checklist B Procedures 1 Turn the key switch to the
215. erating Firing order 1 3 4 2 temperatures may require the use of alternative engine mng oils For oil requirements refer to the Engine Operator Low idle 1300 rpm Manual for your engine plete Oil Pressure switch High idle N Installation torque 8 18 ft Ibs E 11 24 Nm Compression ratio 18 251 Pressure switch point 8 psi Compression pressure pressure psi or bar of the 0 55 bar lowest cylinder must be at least 75 of the highest Oil Sensor Settings cylinder E rer 0 psi 10 ohms overnor centrifuga mechanical 50 psi 120 ohms Valve Clearance cold Fuel injection system Intake 0 008 in Injector opening pressure 43 psi 0 2 mm 3 bar Exhaust 0 018 in Fuel requirement 0 45 mm For fuel requirements refer to the engine Operator Manual for your engine Genie 8 ZX 135 70 Part No 218700 September 2015 Service Manual AE ee 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 2 Battery capacity maximum 285 AH Reserve capacity 25A rate 745 minutes Battery Engine starting and control system Type 12V DC Group 31 Quantity 1 Battery capacity maximum 1000A Reserve capacity 25A rate 200 Minutes Engine coolant Capacity 9 5 quarts engine only 9 liters Coolant temperature switch Installation torque 8 18 ft Ibs 11 24 Nm Temperature switch point 230 F 110 C Temperature Sensor Settings
216. es 5 Manually rotate each wheel at the square end of the machine Result Each wheel at the square end of the machine should rotate with minimum effort 6 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks Lower the machine AWARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage 7 Chock both of the wheels at the square end of the machine to prevent the machine from rolling Place a lifting jack of ample capacity 35 000 Ibs 16000 kg under each of the steer yokes at the circle end of the machine 9 Lt the wheels off the ground and place blocks under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the circle end of the machine nr UL 1 brake disengaged position 2 brake engaged position Service Manual September 2015 Checklist D Procedures 11 Manually rotate each wheel at the circle end of the machine Result Each wheel at the circle end of the machine should rotate with minimum effort 12 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks Lower the machine AWARNING Collision hazard Failure to re engage the drive hubs could re
217. es a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION 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 Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Genie A TEREX BRAND 16 ZX 135 70 Part No 218700 September 2015 Service Manual Scheduled Maintenance Procedures Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure E Indicates that a cold engine will be required to perform this procedure ES Indicates that a warm engine will be required to perform this procedure ES Part No 218700 Genie ATEREX BRAND ZX 135 70 17 Pre delivery P
218. eutral Alarm sounds Check for an open or shorted valve coil Repair or replace as necessary Secondary Boom Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring Extend Sequence Valve zero and neutral Alarm sounds Check for an open or shorted valve coil Repair or replace as necessary Secondary Boom Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring Down Sequence Valve zero and neutral Alarm sounds Check for an open or shorted valve coil Repair or replace as necessary Operational Secondary Value at 5 0 V Primary up Secondary up down and Check for an open ground circuit going to the sensor Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds Value at 0 V Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Out of Tolerance Primary up Secondary up down and Extend disabled Alarm sounds Recalibrate sensor Not calibrated Secondary up only active from TCON activate alarm Perform calibration procedure per service manual Just calibrated Initiate one second beep of audible warn
219. every 500 hours or six months whichever comes first Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rom is incorrect and continued use may cause component damage Note Use the following chart to identify the description of each LCD screen control button used in this procedure el Enter 4 Plus Deutz models Minus Previous 1 Start the engine from the ground controls 2 Press the enter or previous button on the LCD screen until engine rpm is displayed Result Low idle should be 1500 rpm Service Manual September 2015 Checklist C Procedures Skip to step 5 if the low idle rpm is correct 1 low idle adjustment screw 2 yoke 3 high idle adjustment nut 3 Loosen the lock nut on the low idle adjustment Screw 4 Adjustthe low idle adjustment screw until low idle is 1500 rpm Tighten the locknut 5 Press and hold the function enable high speed button Note the engine rpm on the display Result High idle should be 2350 rpm If the high idle is correct disregard adjustment step 6 6 Loosen the yoke lock nut Turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Note Be sure the solenoi
220. ferential Pressure Voltage Engine Pressure Sensor Open or Short Circuit Test Below Normal 3251 7 Particulate Trap Differential Pressure Not Diesel Particulate Filter Has Differential Pressure Responding Properly Problem 3251 10 Particulate Trap Differential Diesel Particulate Filter Has Differential Pressure Pressure Abnormal Rate of Change Problem 3251 16 Particulate Trap Differential Diesel Particulate Filter Collects Excessive Soot Pressure High moderate severity 2 3251 17 Particulate Trap Differential Pressure Low Diesel Particulate Filter Has Differential Pressure least severe 1 Problem 3509 2 Sensor Supply Voltage 1 Erratic Intermittent or 5 Volt Sensor Supply Circuit Test Incorrect 3510 2 Sensor Supply Voltage 2 Erratic Intermittent 5 Volt Sensor Supply Circuit Test or Incorrect 3511 2 Sensor Supply Voltage 3 Erratic Intermittent or 5 Volt Sensor Supply Circuit Test Incorrect 3697 6 Particulate Trap Lamp Command Current Indicator Lamp Circuit Test Above Normal 3698 6 Exhaust System High Temperature Lamp Indicator Lamp Circuit Test Command Current Below Normal e Part No 218700 ATEREX BRAND Genie ZX 135 70 243 Service Manual AAA A AAA gt Perkins 854F 34T Engine Fault Code SPN Suspect Parameter Number FMI Failure Mode Identifier September 2015 SPN FMI Description Refer to Engine Manual 3702 6 Diesel Parti
221. fety limit switches is critical to safe machine operation If the boom is allowed to operate when a safety switch is not functioning correctly the machine stability could be compromised and may tip over Note Perform this procedure with the boom in the stowed position Note Perform this procedure with the axles extended Note Two people will be required to perform this procedure Note Use the following chart to identify the description of each LCD screen control button used in this procedure el Enter Plus Secondary Boom 1 Retracted Safety Limit Switch LSS1RS y Minus Previous 1 Working at the platform end of the turntable support and secure the lower turntable riser end cover to a suitable lifting device Service Manual oe Checklist B Procedures 2 Remove the lower cover retaining fasteners and remove the lower cover from turntable AWARNING Crushing hazard The turntable riser lower cover could become unbalanced and fall when removed from the turntable if not properly supported and secured to the lifting device 3 Support and secure the upper turntable riser end cover to a suitable lifting device 4 Remove the upper cover retaining fasteners and remove the upper cover from turntable A WARNING Crushing hazard The turntable riser upper cover could become unbalanced and fall when removed from the turntable if not properly supported and secured t
222. filter head and tighten it securely 12 Remove the high pressure filter housing by using a wrench on the nut provided on the bottom of the housing 13 Remove the filter element from the housing 14 Inspect the housing seal and replace it if necessary Service Manual September 2015 Checklist D Procedures 15 Install the new high pressure filter element into the housing Install the filter housing onto the filter head and tighten it securely 16 Clean up any oil that may have spilled during the installation procedure 17 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter Medium pressure filter Note The medium pressure filter is for the charge pump 18 Open the engine side turntable cover and locate the medium pressure filter mounted to the engine tray near the hydraulic pumps 19 Place a suitable container under the filter s 20 Remove the medium pressure filter housing by using a wrench on the nut provided on the bottom of the housing 21 Remove the filter element from the housing 22 Inspect the housing seal and replace it if necessary 23 Install the new medium pressure filter element into the housing Install the filter housing onto the filter head and tighten it securely 24 Clean up any oil that may have spilled during the installation procedure 25 Use a permanent ink marker to write the date and number of hours from the hour meter on th
223. full stroke in the retract direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration 89 Service Manual September 2015 Platform Controls Primary boom up down functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then press the enter button twice 4 Use the scroll button to scroll through the menu until DELETE PRIMARY BOOM UP DOWN JOYSTICK DEFAULTS is displayed 5 Press the plus button to select YES then press the enter button 6 Do not start the engine Locate the primary boom turntable rotate joystick 8 Move the boom turntable rotate joystick full stroke in the up direction and hold for 5 seconds then return to the center or neutral position 9 Move the boom turntable rotate joystick full stroke in the down direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration A TEREX BRAND Genie Jib boom up down functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the ente
224. g if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the axles extended 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Support the steer cylinder with a suitable lifting device Protect the cylinder rod from damage 3 Remove the pin retaining fasteners from both steer cylinder pivot pins 4 Use a soft metal drift to remove the pins 5 Remove the steering cylinder from the machine A CAUTION Crushing hazard The steer cylinder may become unbalanced and fall if not properly supported by the lifting device when removed from the machine Service Manual September 2015 Axle Components 10 3 Axle Extension Cylinders How to Remove an Axle Extension Cylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedu
225. g fasteners at eee Ite s the primary boom lift cylinder A WARNING Crushing hazard The primary 3 Place blocks under both ends of the primary boom lift cylinder linkage arms boom lift cylinder Place another block under may fall if not properly the cylinder linkage arms under the primary supported when the barrel end boom lift cylinder barrel end pivot pin pivot pin is removed Genie Part No 218700 ZX 135 70 125 Service Manual September 2015 Boom Components 4 5 Secondary Boom Lift Cylinder How to Remove the Secondary Boom Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the machine on a firm level surface and in the stowed position with the axles extended 1 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder The hoses can be accessed from under the turntable AWARNING Bodily injury hazard Spraying hydraulic oil can penetra
226. ge arm down A CAUTION Crushing hazard The upper 19 20 21 primary boom lift cylinder linkage arms could fall if not properly supported when the pivot pins are removed Attach a 5 ton 5000 kg overhead crane to both ends of the primary boom Do not apply any lifting pressure Remove the pin retaining fasteners from the primary boom pivot pins Use a soft metal drift to remove the primary boom pivot pins Carefully remove the primary boom from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The primary Genie boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Part No 218700 September 2015 Service Manual 4 4 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be repl
227. ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then press the enter button twice 4 Usethe scroll button to scroll through the menu until DELETE STEER JOYSTICK DEFAULTS is displayed 5 Pressthe plus button to select YES then press the enter button 6 Do not start the engine 7 Locate the drive steer joystick 8 Move the drive steer joystick or thumb rocker switch if equipped full stroke in the left direction and hold for 5 seconds then return to the center or neutral position 9 Move the drive steer joystick or thumb rocker switch if equipped full stroke in the right direction and hold for 5 seconds then return to the center or neutral position O Result The alarm at the ground controls should sound for a successful calibration ZX 135 70 Part No 218700 September 2015 A m AN E Secondary boom up down and extend retract functions 1 2 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 platform controls Hold the enter button for approximately 5 seconds Press the minus button twice then press the enter button twice Use the scroll button to scroll through the menu until DELETE SECONDARY BOOM JOYSTICK DEFAULTS is displayed Press the plus button to select YES then press the enter button Do not start
228. h if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION 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 Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Genie A TEREX BRAND 84 ZX 135 70 Part No 218700 September 2015 Service Manual 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 The circuit board PCON sends the data to the turntable control box TCON for processing The platform controls ECM circuit board communicates with the turntable controls The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment The operating parameters of the joysticks are stored in memory at the turntable controls If a joystick controller error occurs or if a joystick is replaced it will need to be calibrated before that particular machine function w
229. h is faulty and needs to be replaced OR the mounting position of the limit switch needs to be adjusted until it activates when the turntable is rotated more than 15 Remove the multimeter leads and connect the Deutsch connector to LST1S 53 Service Manual AR AAAAAAAAAAAAAAA A A A A A lt A lt A lt A22A2A2A2 lt 2 lt 2 lt lt RR Checklist B Procedures Axle Extended Safety Limit Switches LSFA1ES and LSRA1ES 1 Start the engine from the ground controls and lower the boom to the stowed position Turn the key switch to platform controls From the platform controls drive the machine in either direction and fully retract the axles Turn the machine off Choose an axle extend safety limit switch to test Locate and disconnect the deutsch connector to the axle extend limit switch Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the Deutsch connector of the limit switch cable Result The limit switch should not have continuity Result The limit switch does have continuity The limit switch is faulty and needs to be replaced Remove the multimeter leads and connect the Deutsch connector to the limit switch Repeat steps 5 through 7 for the other axle extend safety limit switch Start the engine from the platform controls and fully extend the axles Turn the machine off 54 10 11 12 13 14 Genie A TEREX BRAND ZX 135 70 Septemb
230. h the digital level to the surface of the jib boom bellcrank as shown 1 jib boom angle sensor 2 jib boom bellcrank 3 place level on this surface 15 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value Part No 218700 Genie ATEREX BRAND ZX 135 70 113 Jib Boom Components 16 Press and hold a function enable speed select button and the platform level down button until the digital level displays approximately 34 2 degrees 17 At the ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 18 Press and hold a function enable speed select button and the platform level down button until the digital level displays approximately 8 2 degrees 19 At
231. he bypass recovery key Switch Turn and hold the bypass recovery key switch to the recovery position The switch must be held in the recovery position Result The primary boom lowers to the stowed position Turn the bypass recovery key switch to the run position Remove the key from the bypass recovery key switch and insert the key into the main key switch Close the turntable side cover 33 Service Manual September 2015 Checklist B Procedures B 4 2 Inspect the Engine Air Filter E Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the engine air filter in good condition is 5 essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage 6 Note Perform this procedure with the engine off 7 1 Open the engine side cover Empty the dust discharge valve by pressing together the sides of the discharge slot Clean the discharge slot as needed 1 clamp 2 cannister end cap 3 dust discharge valve Genie Release the latches on the air cleaner cap Remove the end cap from the air cleaner canister Remove the filter element Use a damp cloth to wipe the filter sealing surface and the inside of the outlet tube Make sure that all contaminant is removed before the filter is inserted Check new filter element gasket for damage
232. he control system to maintain a level platform through boom range of motion If a platform level sensor is replaced it must be calibrated prior to machine operation How to Calibrate the Platform Level Sensor Note Perform this procedure with the machine on a firm level surface Note Perform this procedure with the boom in the stowed position Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 a Plus Minus Previous Enter 1 Secure a digital level to one of the side railings of the platform 2 Start the machine and level the platform to gravity Turn the machine off 3 Open the ground control box Platform Components 4 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 5 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 6 Insert the key into the bypass recovery key Switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 7 Press and hold the enter button on the ground control panel while turning the key switch to ground
233. head crane lift the extension cylinder to clear the saddle blocks 8 Supportand slide the primary boom extension cylinder out of the primary boom and place it on a structure capable of supporting it A WARNING Crushing hazard The extension cylinder could become unbalanced and fall when removed from primary boom extension tube if not properly supported Note During removal the overhead crane strap will need to be adjusted for proper balancing Note Note the length of the cylinder after removal The cylinder must be at the same length for installation Genie ATEREX BRAND ZX 135 70 129 Part No 218700 Service Manual September 2015 Boom Components 4 7 Secondary Boom Extension Cylinders The secondary boom extension cylinders extend and retract the secondary boom The secondary boom extension system consists of 3 hydraulic cylinders and each are equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Secondary Boom Extension Cylinders AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must
234. heck low 97 4 465 Sensor error water in fuel signal 51 5 1223 Actuator EGR Valve open load range check low 51 6 1014 Actuator error EGR Valve signal 97 12 1157 Water in fuel level prefilter range check high maximum value exceeded Genie A TEREX BRAND 222 ZX 135 70 Part No 218700 September 2015 Service Manual Deutz TD 2 9 L4 Engine Fault Codes SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier 108 3 412 Sensor error ambient air press KWP Keyword Protocol signal range check high SPN FMI KWP Description 108 4 413 Sensor error ambient air press 100 0 734 High oil pressure warning signal range check low threshold exceeded 110 0 98 High coolant temperature 100 0 735 High oil pressure shut off warning threshold exceeded threshold exceeded 110 0 99 High coolant temperature shut 100 1 736 Low oil pressure warning off threshold exceeded threshold exceeded 110 3 96 Sensor error coolant temp 100 1 737 Low oil pressure shut off signal range check high threshold exceeded 110 4 97 Sensor error coolant temp 100 3 732 Sensor error oil pressure signal signal range check low range check high 111 1 101 Coolant level too low 100 4 733 Sensor error oil pressure sensor 132 11 1 Air flow sensor load correction signal range check low factor exceeding the maximum 102 2 88 Charged air pressure above drift l
235. hen removed from the 13 Remove the turntable cover using a suitable machine if not properly lifting device supported Crushing hazard The turntable IE A WARNING cover may become unbalanced AWARNING Bodily injury hazard Batteries and fall if not properly supported contain acid Avoid spilling or and secured to a suitable lifting contacting battery acid device Neutralize battery acid spills with baking soda and water 14 Remove the ground control box mounting the way Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate lifting device Genie Part No 218700 ZX 135 70 127 Service Manual _ AA AAA Boom Components 22 4 WARNING 23 24 25 26 27 28 Note Protect the hoses and cables underneath the Remove the hydraulic tank from the machine Crushing hazard The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine Place a block under the secondary boom lift cylinder for support Remove the secondary boom lift cylinder rod end pivot pin retaining fasteners Use a soft metal drift to remove the pin through the access holes in the turntable bulkheads Attach an overhead crane with a minimum capacity of 7 tons 7000 kg to the counterweight end of the secondary boom Raise the boom assembly with the overhead crane approximately 20 feet 6 m DANGER Crushing hazard The boom assembly can fall if not
236. hile Driving NO YES Holding button will cause display to scroll through options or increment number settings automatically at 0 2 min increase decrease Genie A TEREX BRAND 158 ZX 135 70 Part No 218700 September 2015 Service Manual a AA EA A Hydraulic Pumps 7 1 2 Tag disconnect and plug the function pump Function Pump hydraulic hoses Cap the fittings on the pump AWARNING Bodily injury hazard Spraying The function pump is a pressure compensated hydraulic oil can penetrate and variable displacement piston pump Any internal burn skin Loosen hydraulic service to the pump should be performed at an connections very slowly to allow authorized Sauer Danfoss service center Contact the oil pressure to dissipate Genie Product Support to locate your local gradually Do not allow oil to authorized service center squirt or spray How to Remove the Function 3 Support the pump with a suitable lifting device Pump 4 Remove the two pump mounting fasteners Carefully remove the pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump 1 Locate the two hydraulic ta
237. hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump Genie A TEREX BRAND 162 ZX 135 70 2 Locate the two hydraulic tank valves at the hydraulic tank Close the valves open closed Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key Switch and tag the machine to inform personnel of the condition 3 Tag disconnect and plug the hydraulic hoses from the drive and function pumps Cap the fittings on the pumps AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners Part No 218700 September 2015 Service Manual a AA EA A Hydraulic Pumps 5 Carefully pull the drive pump out until the How to Prime
238. ibrated Refer to Repair Procedure How to Calibrate the Secondary Boom Angle Sensor Genie ZX 135 70 Part No 218700 September 2015 Service Manual 11 Fully lower the secondary boom until it stops at approximately 3 5 Result The reading at the display and digital level is within 2 of each other and of 3 5 Result The reading at the display and digital level is greater than 2 of each other and of 3 5 The secondary boom angle sensor must be calibrated Refer to Repair Procedure How to Calibrate the Secondary Boom Angle Sensor Part No 218700 Genie ATEREX BRAND ZX 135 70 49 Checklist B Procedures B 21 Test the Primary Boom Angle Sensor Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning primary boom angle sensor is essential to safe machine operation The ECM at the ground controls TCON monitors the position and angle of the primary boom using the signal from the primary boom angle sensor The primary boom angle sensor signal is used to control the ramping of the primary boom limiting the speed of the primary boom to 2 3 feet 0 7 meters per second Note The turntable level sensor and secondary boom angle sensor must be tested before starting this procedure Refer to Maintenance Procedures Test the Turntable Level Sensor and Test the Secondary Boom Angle Sensor Note A digital level
239. ification 3 position 4 way solenoid valve 7 20 schematic item A B C D W 2 position 3 way solenoid valve 5 60 schematic items D E F G I Z 2 position 3 way solenoid valve 7 20 schematic items P Q 2 position 3 way solenoid valve 8 80 schematic items AE 3 position 4 way proportional solenoid valve 8 80 schematic items Y and AF 2 position 2 way solenoid valve 3 5 to schematic item A 5 50 Genie A TEREX BRAND 188 ZX 135 70 Part No 218700 September 2015 Service Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes a E D Voltage spikes naturally occur within a function A circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit 8 3 breaker or component damage Electrocution burn hazard A WARNING Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry RER Is E rd ir A i I I AA Iti id f s PAN fM e i i p al VV Y oe E DA be 1 I I 1 multimeter 2 9v DC battery 3 100 resistor 1 Test the coil for resistance Refer to Repair Procedure How to Test a Coil 2 Connect a 10W resistor to the negative 4 coil terminal of a known good 9V DC battery Conn
240. iftup the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 8 Connectthe ends of the replacement cable track section to the existing cable track using the pins and snap rings 9 Install the rollers onto the new section of cable track 10 Operate the primary boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track Genie A TEREX BRAND 120 ZX 135 70 4 2 Secondary Boom Cable Track The secondary boom cable track guides the cables and hoses running up through the inside of the secondary boom It can be repaired link by link without removing the cables and hoses that run through it Removal of the secondary boom cable track is required to repair it How to Remove the Secondary Boom Cable Track Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Working at the counterweight end of the secondary boom support and secure the secondary boom end cover to a suitable lifting device 2 Remove the cover retaining fasteners and remove the cover from the secondary boom AWARNING Crushing hazard The secondary boom end cover could become
241. igital level that has been calibrated to gravity on the X axis of the turntable Note Illustrations are shown from the platform end e of the machine negative degree side slope Genie Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls Press the enter or previous button on the LCD screen until TURNTABLE LEVEL SENSOR X DIRECTION is displayed Result The reading at the display and digital level is within 1 of each other Result The reading at the display and digital level is greater than 1 of each other The level sensor must be calibrated Refer to Repair Procedure How to Calibrate the Level Sensor DANGER Tip over hazard If the X axis is not within 1 failure to properly calibrate the level sensor could cause the machine to tip over resulting in death or serious injury Refer to Repair Procedure How to Calibrate the Level Sensor Place the machine on a firm surface that has an uphill or downhill slope greater than 2 6 5 inches 16 5 cm but less than 5 16 inches 40 6 cm Press the enter or previous button on the LCD screen until TURNTABLE LEVEL SENSOR Y DIRECTION is displayed A TEREX BRAND 46 ZX 135 70 Part No 218700 September 2015 Service Manual EEE EEE ET Checklist B Procedures 7 Place a digital level that has been calibrated to B 20 gravity on the Y axis of the t
242. ill operate Refer to Repair Procedure How to Calibrate a Joystick Controller Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion For further information or assistance consult Genie Product Support Genie mE Part No 218700 ZX 135 70 Platform Controls 1 2 Co as platform controls ALC 1000 circuit board jib boom up down jib boom extend retract and platform rotate left right joystick secondary boom up extend and down retract joystick drive steer joystick controller LED circuit board primary boom up down primary boom extend retract and turntable rotate left right joystick 85 Service Manual A a Platform Controls September 2015 1 1 7 Attach a grounded wrist strap to the ground Platform Circuit Board screw inside the control box Electrocution burn hazard AWARNING Electrocution burn hazard AWARNING Contact with electrically charged Contact with electrically charged circuits could result in death or circuits could result in death or serious injury Remove all rings serious injury Remove all rings watches and other jewelry watches and other jewelry Note When the platform circuit board is replaced Component damage hazard Electrostatic discharge ES
243. imit plausibility error warning threshold 132 11 2 Air flow sensor load correction 102 2 89 Charged air pressure above shut factor exceeding drift limit off threshold plausibility error 102 4 777 Sensor error charged air press 132 11 3 Air flow sensor low idle correction signal range check low factor exceeding the maximum drift limit 105 0 996 High charged air cooler temperature warning threshold 132 11 4 Air flow sensor load correction exceeded factor exceeding the maximum drift limit 105 0 997 High charged air cooler E e temperature shut off threshold 157 3 877 Sesnor error rail pressure signal exceeded range check high 105 3 994 Sensor error charged air 157 4 878 Sensor error rail pressure signal temperature signal range check range check low high 105 4 995 Sensor error charged air temperature signal range check low Genie Part No 218700 ZX 135 70 223 Service Manual AAA AAA AAA a Deutz TD 2 9 L4 Engine Fault Codes September 2015 SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier 174 0 481 High low fuel temperature KWP Keyword Protocol warning threshold exceeded SPN FMI KWP Description 174 0 482 High Low fuel temperature shut 168 0 1180 Physical range check high for off threshold exceeded battery voltage 175 0 740 Physical range check high for oil 168 1 1181 Physical range check low for tem
244. imum platform capacity Refer to the machine serial plate 3 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor Genie ATEREX BRAND 100 ZX 135 70 Determine the limit switch trigger point 4 Gently move the platform up and down by hand so it bounces approximately 1 to 2 inches 2 5 to 5 cm Allow the platform to settle Result The overload indicator light and the alarm is on Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off Note The platform will need to be moved up and down and allowed to settle in between adjustments Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Result The overload indicator light and alarm is off Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Note The platform will need to be moved up and down and allowed to settle in between adjustments Part No 218700 September 2015 Service Manual Confirm the setting 5 Startthe engine from the platform controls 6 Lt the test weight off the platform floor using a suitable lifting device 7 Place the
245. in Loosen hydraulic ached connections very slowly to allow H the oil pressure to dissipate gradually Do not allow oil to squirt or spray 17 Disconnect the electrical connectors for the electrical cables that lead to the cable track at the end of the secondary boom 18 Pullall hydraulic hoses and electrical cables that lead to the cable track out of the secondary boom riser Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Genie Part No 218700 ZX 135 70 119 Service Manual September 2015 Boom Components How to Repair the Primary Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Service Parts Department 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Support the cable track assembly above the section to be replaced 3 Carefully remove the snap rings and pins from each end of the damaged section of cable track 4 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced Remove the rollers 5 Liftup the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 6 Remove the upper rollers from the replacement section of cable track 7 L
246. ing device Self clearing transient Part No 218700 enie ATEREX BRAND ZX 135 70 211 Service Manual September 2015 Fault Codes Error Source Error Type Effects Recovery Actions Safety Secondary Boom Angle Sensor Value at 5 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Value Too High Value Too Low Value at 0 V Primary up Secondary up down and Extend disabled Alarm sounds Primary up Secondary up down and Extend disabled Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Out of Tolerance Primary up Secondary up down and Extend disabled Alarm sounds Recalibrate sensor Not calibrated Secondary up only active from TCON activate alarm Perform calibration procedure per service manual Just calibrated Initiate one second beep of audible warning device Self clearing transient Operational Turntable Level Sensor X Direction Value at 5 0 V Value Too High Value Too Low Value at 0 V Out of Tolerance Flash unit out of level icon and LED and activate alarm Check that SCON is grounded
247. installed to alert operators and ground personnel of machine proximity and motion There are four alarm option modes that can be activated based on user preference or requirement Refer to Display Module in the Repair Section for information 1 Turnthe key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls Result The alarm should sound twice The flashing beacon should be on and flashing Part No 218700 September 2015 Service Manual B 18 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications Refer to Specifications Hydraulic Specifications Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Refer to Maintenance Procedure Test or Replace the Hydraulic Oil Part N
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249. ion should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Start the engine from the platform controls 3 Press the engine rpm select button until the foot switch activated high idle rabbit and foot switch symbols is selected 4 Press down the foot switch and raise the primary boom greater than 10 degrees and the secondary boom greater than 20 degrees 5 Extend the primary boom 12 inches 0 3 m and the jib boom 12 inches 0 3 m 6 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 7 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 8 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications Genie A TEREX BRAND 44 ZX 135 70 B 17 Test the Alarm and Flashing Beacon Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first An alarm and or flashing beacon are
250. ion tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Service Manual September 2015 Ss This page intentionally left blank Genie ATEREX BRAND 20 ZX 135 70 Part No 218700 September 2015 Model Maintenance Inspection Report Service Manual NEE Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions e Make copies of this report to use for each inspection e Select the appropriate checklist s for the type of inspection s to perform Daily or every 8 hours 250 hours every 500 hours Annually or every 1000 hours every 2000 hours e Place a check in the appropriate box after each inspection procedure is completed e Use the step by step procedures in this section to learn how to perform these inspections e If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Quarterly or every A B Semi annually or A B C A B C D Two yearor A B C D E Part No 218700
251. ions require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions There are 3 batteries on the machine One is used for starting the engine and powering the control system The other two batteries are 6V DC deep cycle batteries which are wired in series to provide power for the auxiliary power units The batteries are charged by the alternator through a battery separator A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water A WARNING Note Fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize Checklist B Procedures 1 Remove the cover from the auxiliary power unit batteries located at the ground controls side of the machine Note Perform the remaining steps on the auxiliary power unit batteries and the engine starting battery 2 Besure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corr
252. ires that this procedure be performed every 500 hours or six months whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the boom fully retracted and in the stowed position and with the machine on a firm level surface 1 Grease the turntable bearing Refer to Maintenance Procedure Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification Refer to Maintenance Procedure Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and fully raise but do not extend the primary boom and jib The secondary riser should remain in its stowed position 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Genie A TEREX BRAND 66 ZX 135 70 Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing 0 1 turntable 2 dial indicator 3 drive chassis 4 turntable rotation bearing 5 Adjust the dial indicator needle to
253. is selected 4 Press down the foot switch and raise the boom greater than 10 degrees 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications Genie Checklist B Procedures Lower the boom to the stowed position Extend the primary boom 12 inches 0 3 m Choose a point on the machine e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications ATEREX BRAND Part No 218700 ZX 135 70 43 Service Manual September 2015 Checklist B Procedures B 16 Test the Drive Speed Raised and Extended Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function is essential to safe machine operation The drive funct
254. it Frame SPN FMI KWP Description EEC3VOL2 Engine send 523922 7 1262 Burner Shut Off Valve blocked messages closed 523946 0 1158 Zerofuel calibration injector 1 in 523922 7 1264 Burner Shut Off Valve blocked firing order maximum value closed exceeded 523929 0 109 Fuel Balance Control integrator 523946 1 1184 nn det in injector 1 in firing order iring a Ge SC maximum value exceeded eee 523929 1 115 Fuel Balance Control integrator u 1159 See ere seg 2 in injector 1 in firing order mng ei S MENTIR minimum value exceeded ii 523930 0 110 Fuel Balance Control integrator 523947 1 1165 pi ae NEA Oe 2 in injector 2 in firing order mng x EU DIN SR maximum value exceeded Re 523930 1 116 Fuel Balance Control integrator 923948 0 1160 ae ka a eer deed SR injector 2 in firing order iring vi S NAO minimum value exceeded ps 523931 0 111 Fuel Balance Control integrator 523948 1 1166 cier bles deer 3 in injector 3 in firing order iring si Be maximum value exceeded mr 523931 1 117 Fuel Balance Control integrator 523949 0 1161 RE E 4 in injector 3 in firing order Ing vi eu maximum yate minimum value exceeded Kee 523932 0 112 Fuel Balance Control integrator 523949 1 167 a in injector 4 in firing order iring ei s t Gate maximum value exceeded er 523932 1 118 Fuel Balance Control integrator 523960 0 n s nca SE i for injector 4 in firing order COO er CownSitTeam 1mp minimum value exceeded 523935 12 168 Timeout Error
255. itch P39 Fault Check Display message on LCD P39 Recycle power and check wiring on circuit S139TRF white red between SCON and TCON Check SCON chart for possible faults Part No 218700 enie ATEREX BRAND ZX 135 70 207 Service Manual September 2015 Fault Codes at TCON to AUX Power FUEL POWER P9B FAULT 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 Footswitch Timeout Calibration check Display message on LCD Recycle power Engine Speed Range Check underspeed Display message on LCD Engine is running below 50 RPM Check fuel system Oil Pressure Range Check low oil pressure Display message on LCD Oil pressure is low Check sender and oil level Water Oil Temperature Range Check Display message on LCD Engine is overheating Check sender Water Oil Temp Sender Axle Extend Retract Buttons Fault Check both buttons pressed Axle extend retract disabled Display message on LCD high temp water or oil level or radiator heat exchanger Oil Pressure Sender Fault Check Display message on LCD Check wiring to senders for opens or shorts Repair or replace senders Check ribbon and connector from membrane switch If necessary
256. ium MV Chevron 5606A Hydraulic Oil Specifications Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C 8 0 cSt 104 F 40 C 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating 180 F 82 C temperature UCON Hydrolube HP 5046 Fluid Properties Fluid Properties ISO Grade 46 ISO Grade 15 Viscosity index 192 Tm Kinematic Viscosity Viscosity index 300 cSt 149 F 65 C 22 Kinematic Viscosity cSt 104 F 40 C 46 cSt 200 F 100 C 5 5 cSt 0 F 18 C 1300 cSt 104 F 40 C 15 0 cSt 40 F 40 C sig Fash point None Flash point 180 F 82 G Four point EO RE Pour point 81 F 63 C Maximum continuous operating 189 F 87 C temperature Maximum continuous operating 124 F 51 C temperature Note Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Genie Part No 218700 ZX 135 70 3 Service Manual Specifications Hydraulic Component September 2015 _ _ A X A A ss
257. ive constant power Supply power to device 5 Amp Max allowed draw System Ground 0 VDC Battery Negative Device Ground Digital Output 1 12 VDC Engine Run Hour Meter Monitor Engine Hours 12V engine run OV engine off 4 Digital Output 2 12 VDC Key Switch Activation Monitor machine utilization 12V key switch on OV key switch off 5 Digital Output 3 12 VDC Foot switch Monitor machine utilization 12V active OV inactive 6 Digital Input 1 12 VDC Remote Disable Engine Start Remotely Prevent Engine Start 7 Databus H CAN HIGH Genie Databus J1939 Engine Messages Receive Proprietary Genie Telematics Message 8 Databus L CAN LOW Genie Databus J1939 Engine Messages Receive Proprietary Genie Telematics Message Tier IV engine models only J1939 engine message available Genie proprietary databus support Wireless Certifications Telematic device s should comply with specific wireless carrier certifications where applicable and comply with the following North America PTCRB FCC IC Europe CE R amp TTE e Genie ATEREX BRAND Part No 218700 ZX 135 70 265 Service Manual September 2015 Engine Relay and Fuse Panel Legend Deutz TD2011L04i Deutz TD2011L04i Models
258. lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft lbs 54 Nm 3 Apply a high viscosity coupling grease Genie part number 128025 to the splines of the pump shaft and flex plate 4 Install the pump plate and pump assembly onto the engine Grease Specification Shell Alvania Grease CG NLGI 0 1 or equivalent Deutz and Perkins models How to Install the Pump Plate 1 Using a suitable lifting device install the pump plate and pump assembly onto the engine 2 Deutz engines Torque the pump plate mounting bolts in sequence to 23 ft lbs 31 Nm Then torque the pump plate mounting bolts in sequence to 47 ft lbs 63 Nm A TEREX BRAND 142 ZX 135 70 Genie Perkins engines Torque the pump plate mounting bolts in sequence to 23 ft lbs 31 Nm Then torque the pump plate mounting bolts in sequence to 47 ft lbs 63 Nm Perkins 1104D pump plate Perkins 854F pump plate Deutz TD2011L04i pump plate Deutz TD2 9 pump plate Part No 218700 September 2015 Service Manual Ground Controls 6 1 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 The key switch at the bottom of the control box is the Bypass Recovery key switch Bypass and Recovery mode
259. level with a magnetic base and cable harnesses Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 Enter 4 Plus Minus Previous Genie A TEREX BRAND 132 ZX 135 70 6 Point Calibration procedure Note Use this procedure for software versions before 4 01 Note For the 2 Point Calibration procedure proceed to step 33 1 Pushin the ground controls red Emergency Stop button to the off position Do not turn the key switch to the off position 2 Turnthe key switch to ground controls Open the ground control box 4 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 5 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 6 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated Part No 218700 September 2015 Service Manual 7 Press and hold the enter button on the ground control panel while pulling out the ground controls red
260. ll necessary tools and test equipment are available and ready for use Genie Part No 218700 Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray ATEREX BRAND ZX 135 70 245 Service Manual September 2015 Wire Circuit Legend Circuit numbering 1 Circuit numbers consist of three parts the circuit prefix circuit number and circuit suffix The circuit prefix indicates the type of circuit The circuit number describes the function of the circuit The circuit suffix provides an abbreviation for the number or may be used to further define the function of this portion of the circuit It also may be used to indicate the final end of the circuit Le LS or limit sw 2 The circuit number may be used more than once in a circuit For Example C 74 PL This is the circuit for the lockout valve 1 C stands for control 74 is the number of the circuit for the primary 1 lock out valve PL stands for Primary Lockout S 62 BST This is the circuit that communicates to the onboard computers of the machine that the boom is fully stowed S stands for safety 62 is the number of the circuit for boom stowed and BST stands for Boom Stowed P 48 LP P stands for power 48 is the circuit number for work lamps and LP stands for Lamp R 48 LP R stands for relay
261. llowing sequence plus enter enter plus Press the enter or previous button on the LCD screen until DELETE JIB LEVEL ANGLE SENSOR CALIBRATION is displayed Press the plus button to select YES then press the enter button to accept Press and hold the platform level up button to fully extend the jib level cylinder until it stops at the end of the cylinder stroke Press the enter or previous button on the LCD screen until JIB LEVEL CYLINDER FULLY EXTENDED is displayed Press the plus button to select YES then press the enter button to accept Press and hold the platform level down button to fully retract the jib level cylinder until it stops at the end of the cylinder stroke Note The jib will need to be raised to prevent the platform from hitting the ground while fully retracting the jib level cylinder 48 49 Press the enter or previous button on the LCD screen until JIB LEVEL CYLINDER FULLY RETRACTED is displayed Press the plus button to select YES then press the enter button to accept 116 Genie A TEREX BRAND September 2015 50 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 51 Press the enter or previous button on the LCD screen until EXIT is displayed Press the plus button
262. lls is less than 1 177 Replace the battery 11 Check the battery acid level If needed oo replenish with distilled water to 1 8 inch 3 mm 1 enging pivot plate anchor hole below the bottom of the battery fill tube Do not 2 engine pivot plate retaining fastener overfill 2 Locate the engine pivot plate anchor hole at 12 Install the vent caps and neutralize any the pivot end of the engine pivot plate electrolyte that may have spilled 13 Install the cover for the auxiliary power unit batteries Genie 30 ZX 135 70 Part No 218700 September 2015 Service Manual A A O AAA EA ZZ Checklist B Procedures 3 Install the bolt that was just removed into the 11 Start the engine from the ground controls and anchor hole to secure the engine pivot plate raise the secondary boom above the turntable from moving covers AWARNING Crushing hazard Failure to Component damage hazard Be install the bolt into the engine sure the hydraulic supply hoses pivot plate to secure it from to the function and drive pumps moving could result in death or are not kinked before starting the serious injury engine 4 Inspect the following areas for burnt chafed 12 Inspect the turntable area for burnt chafed corroded pinched and loose wires and pinched cables e Engine wiring harness 13 Lower the secondary boom to the stowed s Ballo asaming position and turn the engine off 14 t the followi f t chaf Open the ground controls side turntable cover Miti an SES
263. lt BKIWH gt Y73 JIB DWN J79 are 6 AS JSGND2 BR 21 JIB UP P22 05 V43JU GR V43JU GR KEBK 5 Y72 JIB UP J78 E de LEE GND BR J29 Ki PLAT ROT CCW P22 04 V17PRL GR lobo vri PLAT ROT Cow urn 8 agS 5 CctesPES BUWH PLAT ROT CWP22 03 V18PRR GR BK ans A Y70 PLAT ROT CW J76 5 es 28 4 C165TRS WH RD JIB EXTEND a V153JBE BK V153JBE BK FOR gt Y84 JIB EXTEND J140 gt 9 8 5 5 375 CIe4PLS RDWH VLV RTN P22 01 VLVRET1 BR 538 2 P162IPW OR P57PBD RD WH Gu T JSGND4 BR ZHE P63LS OR RD SCH 7 a EX9 r C60AXEX GR WH a I 8 FTg 62 z g Ir meng TEL olo Lerares ad O 3 2 e P3LS OR RD 95 BK x REAR AXLE SAFETY wr J1 OR BK SS WH sw ESTOP PWR RD BK 9 20 PWR PCN ES 500 Ea 138 N OES gt S9 a a VES ALARM RD BK 3 19 ALARM e 23895 5 gt 18 PLAT ROTR 5 5 2 amp 5 J2 GR BK DH R o o gt 17 PLAT ROTL E ull RK IR SS EMISIT ESTOP PWR RD gt 16 GND J156 J1 OR BK e BK E ad FRONT AXLE GND BR gt L_ PS7PBD RD WI H LES SAFETY SW o gt 15 J18 DN 3156 Jiss FUSE 5 P20BAT RD amp P20BAT RD He EN e J137 35 4 JBUP 3155 NA St t KS udi nun p GND1 BR gt 13 _ GND l ESTOP RET BK GND12 BR 12 GND GR gt 11 soor S 2d NOT USED ESTOP RET BK 3_10__ OUT PWR ENBL GND2B8R 3 9 GND AXLE NOT EXT PWR P31 2 P61LSA GR P61LSA GR NL RSRA10 P312 lt BK d REAR AXLE SENSOR PLAT LVL DN
264. lve Motorized Valve Test Control Current Below Normal 2791 6 Engine Exhaust Gas Recirculation EGR Valve Motorized Valve Test Control Current Above Normal 2791 7 Engine Exhaust Gas Recirculation EGR Valve Motorized Valve Test Control Not Responding Properly 2797 6 Engine Injector Group 1 Current Above Normal Injector Solenoid Circuit Test 2797 7 Engine Injector Group 1 Not Responding Injector Solenoid Circuit Test Property 2798 6 Engine Injector Group 2 Current Above Normal Injector Solenoid Circuit Test 2840 12 ECU Instance Failure ECM Memory Test 2840 14 ECU Instance Special Instruction Electrical Power Supply Test 2880 2 Engine Operator Primary Intermediate Speed Throttle Switch Circuit Test Select Erratic Intermittent or Incorrect 2880 3 Engine Operator Primary Intermediate Speed Throttle Switch Circuit Test Select Voltage Above Normal 2880 4 Engine Operator Primary Intermediate Speed Throttle Switch Circuit Test Select Voltage Below Normal 2970 2 Accelerator Pedal 2 Low Idle Switch Erratic Idle Validation Switch Circuit Test Intermittent or Incorrect 3217 3 After treatment 1 Intake 02 Voltage Above Oxygen Level Test Normal 3217 4 After treatment 1 Intake 02 Voltage Below Oxygen Level Test Normal 3217 5 After treatment 41 Intake 02 Current Below Oxygen Level Test Normal 3217 6 After treatment 1 Intake 02 Current Above Oxygen Level Test Normal 3217 12 After treatment 1 Intake 02 F
265. ly charged solvent als ul EE dea a 19 Install the suction strainers using pipe thread serious injury Remove all rings sealant on the threads watches and other jewelry 20 Install the drain plug using pipe thread sealant 12 Attach an overhead crane or similar lifting on the threads device to the battery box for the auxiliary A power unit batteries 21 Install the hydraulic tank onto the machine 13 Remove the battery box retaining fasteners a ground San ral box andimaunling and carefully remove the battery box from the machine 23 Install the two suction hoses return filter hose hind h The b drive motor case drain filter hose and the AWARNING Crushing hazard The battery supply hoses for the auxiliary power units box could become unbalanced and fall when removed from the 24 Install the turntable cover d DEER 25 Fill the tank with hydraulic oil until the level is PP within the top 2 inches 5 cm of the sight T gauge Do not overfill Refer to Specifications AWARNING Bodily injury hazard Batteries Machine Specifications contain acid Avoid spilling or contacting battery acid 26 Open the two hydraulic tank shut off valves at Neutralize battery acid spills with the hydraulic tank paking soda ane Water 27 Clean up any oil that may have spilled during 14 Remove the hydraulic tank retaining fasteners the installation procedure 28 Start the engine and check for leaks Genie 78 ZX 135 70 Part No 218700 September 2015 Servic
266. ly worn wear pads may result in component damage and unsafe operating conditions 1 Measure each wear pad Replace the wear pad once it reaches the minimum allowable thickness If the wear pad is still within specification shim as necessary to obtain minimum clearance with zero binding Note The minimum shim clearance for the secondary boom wear pads is 0 070 inch 1 8 mm and the maximum allowable shim clearance is 0 25 inch 6 4 mm Note The minimum shim clearance for the jib boom and primary boom wear pads is 0 070 inch 1 8 mm and the maximum allowable shim clearance is 0 188 inch 4 8 mm 2 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Note Always maintain squareness between the outer and inner boom tubes Primary boom wear pad specifications Minimum Top bottom and side wear pads 5 8 inch platform end of boom 15 9 mm Top and bottom wear pads 1 2 inch pivot end of boom 12 7 mm Side wear pads 3 8 inch pivot end of boom 9 5 mm Secondary boom wear Minimum pad specifications Top wear pads 3 8 inch extension end of boom 9 5 mm Side wear pads 1 2 inch extension end of boom 12 7 mm Bottom wear pads 7 8 inch extension end of boom 22 mm Top and bottom wear pads 5 8 inch pivot end of boom 15 9 mm Side wear pads 1 2 inch pivot end of boom 12 7 mm Jib boom wear pad specificatio
267. m Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 3000 hours e Cooling system coolant Heavy Duty change Required maintenance procedures and additional engine information is available in the Perkins 1100D Operation and Maintenance Manual Perkins 1100D Operation and Maintenance Manual Genie part number 123702 Genie ATEREX BRAND 80 ZX 135 70 Part No 218700 September 2015 Service Manual E 5 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 3000 hours TD 2011L04i Models e Injection valve replace e Aftercooler core clean test e Charge air cooler entry drain lube oil condensate e Turbocharger compressor outlet clean TD 2 9 Models Checklist E Procedures E 6 Perform Engine Maintenance Perkins Models Engine specifications require that this procedure be performed every 4000 hours All Models e Aftercooler core clean test Required maintenance procedures and additional engine information is available in the Perkins 1100D Operation and Maintenance Manual OR the Perkins 854F Operation and Maintenance Manual Perkins 1100D Operation and Maintenance Manual Genie part number 123702 e V belt and tensioning pulley replace Perkins 854F Operation and Maintenance Manual Required maintenance procedures and additional Genie part nu
268. m this procedure with the engine off Hydraulic return filter 1 Open the ground controls side turntable cover and locate the hydraulic return filter mounted on the hydraulic tank 2 Place a suitable container under the filter s Remove the filter with an oil filter wrench 4 Apply a thin layer of fresh oil to the gasket of the new oil filter 5 Install the new hydraulic return filter element and tighten it securely by hand 6 Clean up any oil that may have spilled during the installation procedure 7 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter Part No 218700 Genie ATEREX BRAND ZX 135 70 73 Checklist D Procedures Hi pressure filter and drive motor case drain filter Note The high pressure filter is for all machine functions except the drive functions The drive motor case drain filter is used to filter oil returning to the hydraulic tank from the drive motors LL 19 Sh d ENS 8 1 drive motor case drain filter 2 high pressure filter 8 Locate the high pressure filter and the drive motor case drain filter near the auxillary power units 9 Place a suitable container under the filter s 10 Use a filter wrench to remove the drive motor case drain filter element 11 Install the new drive motor case drain filter element onto the
269. mber ES0366 Machine unladen weight Rated work load including occupants 600 Ib 273 kg Maximum number of platfrm occupants 2 Maximum allowable side force 150 Ib 670 N Maximum allowable inclination of the chassis 0 deg ZX135 113 12345 Maximum wind speed 28 mph 12 5 m s n Maximum platform height 135 ft 41 15 m Maximum platform reach 69 ft 9 in 21 26 m Gradeability 4595 Country of manufacture USA This machine complies with ANSI A92 5 CAN B 354 4 Terex South Dakota Inc 500 Oakwood Road PO Box 1150 Watertown SD 57201 USA 1 Model 2 Model year 3 Sequence number 4 Serial label located under cover 5 Serial number stamped on chassis PN 77055 e Genie ATEREX BRAND Part No 218700 ZX 135 70 V Service Manual September 2015 Safety Rules 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 VI You are trained and qualified to perform maintenance on this machine VI You read understand and obey e manufacturer s instructions and safety rules e employer s safety rules and worksite regulations e applicable governmental regulations MI Yo
270. mber FMI Failure Mode Identifier September 2015 SPN FMI Description Refer to Engine Manual 652 5 Engine Injector Cylinder 02 Current Below Normal Injector Solenoid Circuit Test 652 6 Engine Injector Cylinder 02 Current Above Normal Injector Solenoid Circuit Test 652 20 Engine Injector Cylinder 02 Data Drifted High Injector Data Incorrect Test 652 21 Engine Injector Cylinder 02 Data Drifted Low Injector Data Incorrect Test 653 5 Engine Injector Cylinder 03 Current Below Normal Injector Solenoid Circuit Test 653 Engine Injector Cylinder 403 Current Above Normal Injector Solenoid Circuit Test 653 20 Engine Injector Cylinder 03 Data Drifted High Injector Data Incorrect Test 653 21 Engine Injector Cylinder 03 Data Drifted Low Injector Data Incorrect Test 654 5 Engine Injector Cylinder 04 Current Below Normal Injector Solenoid Circuit Test 654 6 Engine Injector Cylinder 04 Current Above Normal Injector Solenoid Circuit Test 654 20 Engine Injector Cylinder 04 Data Drifted High Injector Data Incorrect Test 654 21 Engine Injector Cylinder 04 Data Drifted Low Injector Data Incorrect Test 676 5 Engine GloW Plug Relay Current Below Normal Glow Plug Starting Aid Test 676 6 Engine Glow Plug Relay Current Above Normal Glow Plug Starting Aid Test 676 19 Engine Glow Plug Relay Data Error Glow Plug Starting Aid Test 677 3 Engine Starter Motor Relay Vol
271. mber 1299971 engine information are available in the Deutz 2011 Series Operation Manual OR the Deutz D 2 9 L4 Series Operation Manual Deutz 2011 Series Operation Manual Genie part number 139320 Deutz D 2 9 L4 Series Operation Manual Genie part number 1251561 Genie Part No 218700 ZX 135 70 81 Service Manual September 2015 Checklist E Procedures E 7 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 6 000 hours TD 2011L04i Models e Toothed belt replace Required maintenance procedures and additional engine information are available in the Deutz 2011 Series Operation Manual OR the Deutz D 2 9 L4 Series Operation Manual Deutz 2011 Series Operation Manual Genie part number 139320 Deutz D 2 9 L4 Series Operation Manual Genie part number 1251561 Genie ATEREX BRAND 82 ZX 135 70 Part No 218700 September 2015 Service Manual Observe and Obey EN v Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start v v NN 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 p
272. mber Leger tnde red lid V Section 1 CIA fte vi General Safety Rules cid vi Section 2 SPOCITICATIONS coi ri 1 Machine Specifications iint ette ettet nani nad ined tna didis 1 Performance Specifications sss 1 Hydraulic Specification oeiras eid eruditos eda te edd gested de dde SES 2 Hydraulic Component Specifications ooooonooccccnnnnnconacococcconcnonannnononncnnnnnnnnnnrncnncnnn 4 Deutz TD2011L04i Engine Specifications seeen 6 Deutz TD 2 9 Engine Specifications sssse eee 7 Perkins 1104D 44T Engine Specifications oooocnninnnnnnnnocccnnncoccnnnnnarnnonnnarnnrnnno 8 Perkins 854F 34T Engine Specifications 0 0 0 2 cccceeeeeeeeeeeeeneeeeeeneeeeeenaeeeeeeaas 10 Machine Torque Specifications cecececceccececeeeeecneceeeeeeeesesecaeeeeeeeeeseesnseeeeees 11 Hydraulic Hose and Fitting Torque Specifications oocoonnnnicninnnnncnnnnnnnnnnocccnnnons 12 Torque ProcedVlre o itii tien th ero and REN HR SERERE e EX EA NEAR nennen 13 SAE and Metric Fasteners Torque Charts 14 Genie A TEREX BRAND viii ZX 135 70 Part No 218700 September 2015 ee Table of Contents Introduction dilatada adicta 15 Pre Delivery Preparation Report 19 Maintenance Inspection Report 21 Checklist A Procedures uusuu2uununanunannnennnnnnnnnnnnnnnnunnnunnnnnnnnnnnnannnnnnnnnnnnnnnnnn 23 A 1 Inspect the Manuals a
273. ment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustment value programming IMA injector 2 in firing order SPN FMI KWP Description 523897 13 561 check of missing injector adjustment value programming IMA injector 3 in firing order 523898 13 562 check of missing injector adjustment value programming IMA injector 4 in firing order 523910 6 1261 Air Pump over current 523913 3 74 Sensor error glow plug control diagnostic line voltage signal range check high 523913 4 75 Sensor error glow plug control diagnostic line voltage signal range check low 523914 3 78 Glow plug control short circuit to battery 523914 4 79 Glow plug control short circuit to ground 523914 76 Glow plug control open load 523914 1216 Glow plug control release line short circuit error 523914 11 1217 Glow plug control internal error 523914 12 77 Glow plug control powerstage over temperature 523919 2 1378 Sensor air pump airpressure plausibility error 523920 2 1379 Sensor exhaust gas back pressure burner plausibility error Genie A TEREX BRAND 232 ZX 135 70 Part No 218700 September 2015 Service Manual DEENEN ZZ Deutz TD 2 9 L4 Engine Fault Codes SPN Suspect Parameter Number SPN FMI KWP Description CECR gg om 523936 12 169 Timeout Error of RA dd ee CAN Transm
274. mit Frame A1DOC ComDPFHisDat 524115 9 1660 Timeout error of 524101 9 1667 Timeout error of CAN Transmit Frame AT1S nn 524116 9 1661 Timeout error of om SEM CAN Transmit Frame SCR2 924102 9 1674 m O 524117 9 1662 Timeout error of ComRxDPFBrnAirPmpCtl CAN Transmit Frame SCR3 EPUPU RES 524118 9 1672 Timeout error of 524103 9 1675 Timeout error of CAN Receive Frame CAN Receive Frame ComRxCM1 ComRxDPFBrnAirPmp 524119 9 1673 Timeout error of ELE M CAN Receive Frame ComRxDPFCII ComRxCustSCR3 524105 9 1668 Timeout error of CAN Transmit Frame ComEGRMsFlw 524106 9 1677 Timeout error of CAN Receive Frame ComRxEGRMsFIw1 524107 9 1678 Timeout error of CAN Receive Frame ComRxEGRMsFlw2 Genie ATEREX BRAND Part No 218700 ZX 135 70 235 Service Manual September 2015 H ___ AA Deutz TD 2 9 L4 Engine Fault Codes SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description 524120 9 1682 Timeout error of CAN Receive Frame ComRxSCRHtDiag 524121 9 1683 Timeout error of CAN Receive Frame ComRxTrbChActr 524122 9 1684 Timeout error of CAN Receive Frame ComRxUQSens 524123 9 1685 Timeout error of CAN Receive Frame ComSCRHtCtl 524124 9 1686 Timeout error of CAN Receive Frame ComTxAT1IMG 524125 9 1687 Timeout error of CAN Receive Frame ComTxTrbChActr Genie ATEREX BRAND 236 ZX 135 7
275. mode 31 Pull out the red Emergency Stop button Start the engine and lower the boom to the stowed position Be sure there are no calibration faults shown on the display 32 Perform a primary boom angle test Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual Test the Primary Boom Angle Sensor Part No 218700 September 2015 Service Manual 2 Point Calibration procedure Note Use this procedure for software versions 4 01 and higher 33 Push in the ground controls red Emergency Stop button to the off position Do not turn the key switch to the off position 34 Turn the key switch to ground controls 35 Open the ground control box 36 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 37 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 38 Remove the key from the main key switch Insert the key into the bypass recovery key Switch and turn it to the bypass position 39 Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 40 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button
276. mp Standby Pressure een 160 How to Adjust the Function Pump Pressure Compensator 160 7 2 Drive Pump ener eren nn enhn tente tn stre nnne nnmnnn ennen 162 How to Prime the Drive Pump enn 163 Genie ATEREX BRAND Part No 218700 ZX 135 70 xiii September 2015 namK EEE AA AAA AA Table of Contents ET 1 DE 164 8 1 Function Manifold Components oooocccccococococcconocononononccnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 164 8 2 Valve Adjustments Function Manifold A 168 8 3 Platform Manifold ios is 170 8 4 Jib Boom Manifold ssssseseeneeeen m nem enemies 172 8 5 Flow Control Mainfold A 174 8 6 Function Enable Valesca aaa anne 175 8 7 Turntable Rotation Manifold seen 176 8 8 Steer and Axle Manttold een 177 8 9 Valve Adjustments Steer and Axle Manifold esssesssss 181 8 10 Traction Manifold Components enne 182 8 11 Valve Adjustments Traction Manifold eeeee 186 8 12 Drive Oil Diverter Manifold Components welder option 187 8 13 Valve EE 188 Flow to Testa Coll DiOd Gis seats sasncietescceed nennen 189 Turntable Rotation Components cccceceeseeeeeeceeeeeeeeeeaneeeeeeeeeeeesneneeeeeeeeeees 190 9 1 Turntable Rotation Assembly sss eene 190 How to Adjust the Turntable Rotation Gear Backlash 191 9 2 Turntable Level Sensor How to Calibrate the Turntable Le
277. nd Decals nnns nent 23 A 2 Perform Pre operation Inspechon nnen 24 A 3 Perform FUNCION Tests u deterret e toe Rete pa t Renta cid 24 A 4 Perform Engine Maintenance Perkins Models seseesssss 25 A 5 Perform Engine Maintenance Deutz Model 25 A 6 Check the Hydraulic Return Filter Condition Indicator 26 A 7 Perform 30 Day Service cima aa deed EEN EEN 27 A 8 Grease the Turntable Rotation Bearing and Rotate Gear 27 A 9 Replace the Drive Hub OU 28 Genie ATEREX BRAND Part No 218700 ZX 135 70 ix September 2015 namK EEE AA AAA AA Table of Contents Checklist B Procedures nennen arrancan rra 29 B 1 Inspect the Battertes eene 29 B 2 Inspect the Electrical Wiring sennm nn 30 B 3 Test the Key Switches nennen nn 32 B 4 Inspect the Engine Air Elter 34 B 5 Check the Oil Cooler and Cooling Fins Deutz Models 35 B 6 Check the Exhaust System ssssssssssseeeeeneeeneenenns 36 B 7 Confirm the Proper Brake Configuration oconicnccninncnccnnnocncccononnncnnnannnnnnnons 37 B 8 Inspect the Tires Wheels and Lug Nut Torgoue 38 B 9 Check the Drive Hub Oil Level and Fastener Torque nenne 38 B 10 Test the Platform Self leveling ssssee enm 39 B 11 Test the Engine Idle Select Operation ssssseeene 40 B 12 Te
278. nder from the machine A CAUTION Crushing hazard The platform leveling cylinder may fall if not properly supported when removed from the machine Part No 218700 September 2015 Service Manual 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator Component damage hazard Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Tag and disconnect the electrical connector from the platform angle sensor Part No 218700 Genie ATEREX BRAND ZX 135 70 97 Platform Components 3 Remove the platform angle sensor retaining fasteners Remove the platf
279. ne 5 Remove the key from the main key switch Insert the key into the bypass recovery key Switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated a NE 6 20 1 Run 2 Bypass 3 Recovery 6 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it Genie ATEREX BRAND ZX 135 70 201 Part No 218700 Service Manual September 2015 Axle Components 7 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 8 Pressthe enter or previous button on the LCD screen until DELETE AXLE ANGLE SENSORS CALIBRATION is displayed Press the plus button to select YES then press the enter button to accept 9 Atthe AXLE ANGLES FULLY RETRACTED screen press the plus button to select YES then press the enter button to accept 10 When the AXLE ANGLES FULLY EXTENDED screen is displayed start the engine and fully extend the axles Note If the system exits out of calibration mode when the engine is started repeat step 10 11 Press the plus button to select YES then press the enter button to accept 12 Press the enter
280. ng fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate 8 Swing the engine pivot plate in towards the machine 9 Install the bolt that was just removed into the burns original hole to secure the engine pivot plate 1 Remove the engine pivot plate retaining A WARNING Crushing hazard Failure to fastener Swing the engine pivot plate out install the bolt into the engine away from the machine pivot plate to secure it from moving could result in death or f serious injury E GR vy c 0 7 gars AF ME Lun d ES a 1 engine pivot plate anchor hole 2 engine pivot plate retaining fastener Genie A TEREX BRAND 36 ZX 135 70 Part No 218700 September 2015 Service Manual B 7 Confirm the Proper Brake Configuration Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes and hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each drive hub disconnect cap to be sure it is in the engaged position iz YES 1 brake disengaged position 2 brake engaged position Part No 218700 Genie ATEREX BRAND ZX 135 70 37 Checklist B Procedures 2 Besure the free wheel valve on the drive pump is closed cl
281. ng ring gear 5 Loosen the lock nut on the adjustment bolt 72 A TEREX BRAND ZX 135 70 Genie Turn the adjustment bolt clockwise until it contacts the backlash pivot plate 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts Turn the adjustment bolt 1 2 to 3 4 turn counterclockwise Tighten the lock nut on the adjustment bolt Pull the backlash pivot plate away from the turntable until it contacts the adjustment bolt Then lubricate the mounting fasteners on the backlash pivot plate and torque to specification Refer to Specifications Machine Torque Specifications Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary Part No 218700 September 2015 Service Manual D 5 Replace the Hydraulic Filter Elements Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic filters is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often ACAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns Note Perfor
282. nk valves at the hydraulic tank Close the valves Component damage hazard The engine must not be started Ki with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed Genie ATEREX BRAND Part No 218700 ZX 135 70 159 Service Manual September 2015 Hydraulic Pumps How to Prime the Function Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the case drain hydraulic hose from the top of the function pump Note The case drain hose is the smaller of the two hoses on top of the function pump and closest to the drive pump 2 Locate and open the hydraulic tank shut off valve at the hydraulic tank that supplies hydraulic oil to the function pump Do not open the valve for the drive pump 3 When hydraulic fluid begins to come out of the case drain port of the function pump install the function pump case drain hose 4 Clean up any oil that may have spilled Properly discard the used oil Start the engine from the ground controls 6 Check for hydraulic leaks Genie A TEREX BRAND 160 ZX 135 70
283. nly 523613 0 862 Maximum rail pressure exceeded Cv56B RailMeUn4 523718 12 1487 SCR mainrelay powerstage over 523613 1 861 Minimum rail pressure exceeded temperature only CV56B RailMeUn3 523766 9 281 Timeout Error of 523613 2 864 Setpoint of metering unit in ae Active overrun mode not plausible 523767 9 282 Timeout Error of 523615 3 594 Metering unit Fuel System i Hon SE CAN Receive Frame Passive short circuit to battery highside TSC1AE Genie Part No 218700 ZX 135 70 231 Service Manual September 2015 Deutz TD 2 9 L4 Engine Fault Codes SPN Suspect Parameter Number FMI Failure Mode Identifier KWP Keyword Protocol SPN FMI KWP Description 523768 9 283 Timeout Error of CAN Receive Frame Active TSC1AR 523769 9 284 Timeout Error of CAN Receive Frame Passive TSC1AR 523770 9 285 Timeout Error of CAN Receive Frame Passive TSC1DE 523776 9 291 Timeout Error of CAN Receive Frame TSC1TE active 523777 9 292 Passive Timeout Error of CAN Receive Frame TSC1TE Setpoint 523778 9 293 Active Timeout Errorof CAN Receive Frame TSC1TR 523779 9 294 Passive Timeout Error of CAN Receive Frame TSC1TR 523788 12 299 Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 523793 9 202 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 203 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523895 13 559 Check of missing injector adjust
284. nnne nnn trn nnne tenen 85 Platform Controls ne 85 1 1 Platform Circuit Board a ae ete ine in 85 How to Remove the LED Circuit Board 87 1 2 Joysticks How to Calibrate a Joystick AA 87 How to Reset a Proportional Valve Coil Default en 91 How to Set the Function Thresholds and Default Functions Speeds 92 How to Adjust the Function Speeds sssseee ee 94 How to Adjust the Function Ramp Rate Setting sssssesss 94 Platform Components esses nnne nre nennen nnn 95 2 PATON DEET 95 2 2 Platform Leveling Cylinder seem 96 2 3 Platform Rotator cocaina ici nds 97 How to Bleed the Platform Rotator seem 98 2 4 Platform Level Sensor How to Calibrate the Platform Level Sensor 99 2 5 Platform Overload System if equipped uunnsnnnnnennnnnnennnnnnennnn 100 2 6 Platform Overload Recovery Message ee 101 Jib Boom Gomponenis 3 44 rhon ner REIR eR XRRRR nenn anne 103 3 1 Jib Boom Cable Track Henne 104 How to Repair the Cable Track 105 3 2 JID BOOM EE 106 3 9 Jib Boom Lift EE 108 3 4 Jib Boom Level Cylinder esee 109 3 5 Jib Boom Extension Cylinder esee 110 3 6 Jib Boom Bellcrank Angle Sensor How to Calibrate the Jib Boom Bellcrank Angle Sensor E 111 Genie A TER
285. ns Minimum Bottom and side wear pads 5 8 inch platform end of boom 15 9 mm Top wear pads 1 2 inch platform end of boom 12 7 mm Top and side wear pads 3 8 inch pivot end of boom 9 5 mm Bottom wear pads 5 8 inch pivot end of boom 15 9 mm Genie A TEREX BRAND 68 ZX 135 70 Part No 218700 September 2015 Service Manual D 2 Check the Free wheel Configuration Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage AWARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h 1 Chock both of the wheels at the circle end of the machine to prevent the machine from rolling 2 Place a lifting jack of ample capacity 35 000 Ibs 16000 kg under each of the steer yokes at the square end of the machine 3 Lt the wheels off the ground and place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each wheel hub at the square end of the machine Part No 218700 Genie ATEREX BRAND ZX 135 70 69 Checklist D Procedur
286. ns require that this procedure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over The platform overload system is designed to detect an overloaded platform and prevent machine operation anytime the machine is turned on When activated the system halts all normal boom operation giving visual and audible warning to the operator Models equipped with the platform overload option are provided with additional machine components an adjustable spring loaded platform support subassembly a limit switch an electronic module which receives the overload signal and interrupts power and an audio visual warning indication to alert the operator of the overload The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into a shear or vertical state which translates into a compressive load A spring in the parallelogram link supports this purely compressive load regardless of where the load is placed in the platform Part No 218700 Genie ATEREX BRAND ZX 135 70 61 Checklist C P
287. nspect for Turntable Bearing Wear Genie requires that this one time procedure be performed after the first 3 months of usage After this interval refer to the maintenance checklist for continued scheduled maintenance 1 Grease the turntable bearing Refer to Maintenance Procedure Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification Refer to Maintenance Procedure Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and fully raise but do not extend the primary boom and jib The secondary riser should remain in its stowed position 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing Part No 218700 Genie ATEREX BRAND ZX 135 70 57 Checklist B Procedures 1 turntable 2 dial indicator 3 drive chassis 4 turntable rotation bearing 5 Adjust the dial indicator needle to the zero position 6 Raise the secondary riser but do not extend it Move the primary boom and jib to horizontal and fully extend 7 Note the reading on the dial indicator O Result The measurement is less than 0 118 inch 3 0 mm The
288. o 218700 Gen ATEREX BRAND ZX 135 70 45 le Checklist B Procedures B 19 Test the Turntable Level Sensor Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning level sensor SCON is essential to safe machine operation The ECM at the ground controls TCON monitors the position and angle of the machine using the signal from the level sensor The level sensor signal is used to control the maximum working height of the primary and secondary booms Note A digital level will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Note Use the following chart to identify the description of each LCD screen control button used in this procedure y a Previous Enter an D SS Service Manual September 2015 Checklist B Procedures Note Perform this procedure with the booms in the 3 fully stowed position and the axles fully extended 1 Place the machine on a firm surface that has a side slope greater than 2 6 5 inches 4 16 5 cm but less than 5 16 inches 40 6 cm 2 Place a d
289. o secondary boom angle Primary boom length Secondary boom angle Secondary boom length Jib bellcrank angle DPF Regeneration Mode Auto Force Inhibit 0 4500 PSI 0 31000 kPa 22 to 136 0 gt 0 gt 22 3 5 to 76 0FT 0 FT 10 to 10 referenced to chassis tilt angle Unit of Measure and Language With key switch OFF press and hold the enter button and turn key switch to on position Release the enter button and press plus minus minus plus Overload Recovery software V3 07 and later Metric English measurement units Set engine Clear Overload Recovery English German French Spanish Portuguese Italian Dutch and Swedish Deutz TD2011L04i DLO4i Perkins 1104D 44T P1104 YES NO A passcode is required to clear the message Default Reset With key switch OFF press and hold the enter button and turn key switch to on position Release the enter button and press minus minus previous pre vious Delete drive functions Delete boom function speed Delete lift function ramps Delete all Contact Genie Product Support before using this option Delete Faults Delete faults will reset active latching faults Delete faults will not clear fault history e Genie Part No 218700 ATEREX BRAND ZX 135 70 151 Service Manual Display Module September 2015 gees Screen or Menu Procedure De
290. o the lifting device 5 Locate the secondary boom 1 retracted safety limit switch LSS1RS inside the secondary boom tube Note The secondary boom 1 retracted safety limit switch LSS1RS is attached to the number 1 boom tube and can easily be identified by the blue and red tie wraps attached to the limit switch cable 6 7 Start the engine from the ground controls Fully raise the secondary boom Do not extend the boom Turn the machine off Locate and disconnect the Deutsch connector to LSS1RS Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the Deutsch connector of the limit switch cable Result The limit switch should not have continuity Result The limit switch does have continuity The limit switch is faulty and needs to be replaced 52 10 11 12 September 2015 Remove the multimeter leads and connect the Deutsch connector to the limit switch Start the engine from the ground controls Extend the secondary boom while visually inspecting the roller arm of the limit switch Continue to extend the boom until the limit switch arm is released by the limit switch ramp bracket Result The roller arm of the limit switch remains centered with the limit switch ramp bracket through the entire length of travel Result The roller arm of the limit switch does not remain centered with the limit switch ramp bracket through the entire length of travel Adjust
291. oard mounted to the inside of the platform control box A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 4 Tagand carefully disconnect the ribbon cables from the membrane circuit board 5 Remove the circuit board mounting fasteners Carefully remove the LED circuit board from the platform control box lid Do not lose the plastic spacers Note When installing the LED circuit board be sure the plastic spacers are installed between the circuit board and the control box lid Part No 218700 Genie ATEREX BRAND ZX 135 70 87 Platform Controls 1 2 Joysticks How to Calibrate a Joystick The joystick controllers on this machine utilize digital Hall Effect technology for proportional control H a joystick controller is disconnected or replaced it must be calibrated before that particular machine function will operate Note The joystick must be calibrated before the threshold max out or ramping can be set Note After each joystick is calibrated check the display at the ground control box There should be no calibration faults shown on th
292. ocedure How to Calibrate the Turntable Level Sensor Platform level sensor Refer to Repair Procedure How to Calibrate the Platform Level Sensor Axle angle sensors Refer to Repair Procedure How to Calibrate the Axle Angle Sensors Steer sensors Refer to Repair Procedure How to Calibrate All Steer Sensors Secondary boom angle sensor Refer to Repair Procedure How to Calibrate the Secondary Boom Angle Sensor Primary boom angle sensor Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor Jib boom bellcrank angle sensor Refer to Repair Procedure How to Calibrate the Jib Boom Bellcrank Sensor Select option configuration Refer to Repair Section Display Module Options 149 Service Manual September 2015 Display Module This table lists the various screens and menu options of the operating software Some display menus are for informational purpose only while others can be used to change the machine operating parameters AWARNING Tip over hazard Calibration and parameter settings must be completed by a person trained and qualified on the repair of this machine Failure to properly calibrate or set parameters could cause the machine to tip over resulting in death or serious injury Note The key switch must be in the off position before entering the programming mode Note Use the following chart to identify the description of each LCD screen control button used in this procedure
293. ocedure with the boom in the stowed position 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the platform mounting weldment and the platform rotator Refer to Repair Procedure How to Remove the Platform Rotator 3 Remove the jib boom Refer to Repair Procedure How to Remove the Jib Boom Note When the jib boom is installed the jib boom angle sensor will need to be calibrated Refer to Repair Procedure How to Calibrate the Jib Boom Bellcrank Angle Sensor 123 Service Manual September 2015 Boom Components 4 Remove the primary boom cable track Refer to repair procedure How to Remove the Cable Track 5 Remove the end cover from the pivot end of the primary boom 6 Remove the limit switch mounting fasteners from the limit switch on the ground controls side of the primary boom Do not disconnect the wiring Remove the limit switch 7 Disconnect the electrical connector from the primary boom angle sensor Note The primary boom angle sensor is located inside the primary boom at the pivot end 8 Remove the primary boom angle sensor bracket mounting fasteners and remove the primary boom angle sensor from the primary boom Do not remove the angle sensor from the bracket Note the location of the springs Do not lose the springs Note There is one spring inside the primary boom pivot pin and one inside the angle sensor Note When the primary boom is installed the
294. ocedures 6 Press and hold a function enable speed select button and fully lower the primary boom O Result The platform should remain level at all times to within 2 degrees Note If the platform becomes out of level the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls The platform level up down buttons will only work in the direction that will level the platform Level the platform until the indicator light turns off Note If the platform does not level properly refer to Repair Procedure How to Calibrate the Platform Level Sensor Genie A TEREX BRAND 40 ZX 135 70 B 11 Test the Engine Idle Select Operation Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly operating engine idle select function is essential to good engine performance and safe machine operation There are two settings Low idle turtle symbol allows the operator to control multiple boom and or drive functions simultaneously though at reduced speed This setting maintains a consistent low idle Foot switch activated high idle rabbit symbol should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Turn the key switch to ground controls 2 Pullout the red Emergency Stop button to the on position at both the ground and platform controls 3 Startthe
295. ockwise Note The free wheel valve should always remain closed 1 drive pump 2 screwdriver 3 lift pump 4 free wheel valve Service Manual September 2015 Checklist B Procedures B 8 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Note The tires on this machine are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Specifications Machine Specifications Genie A TEREX BRAND 38 ZX 135 70 B 9 Check the Drive Hub Oil Level and Fastener Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive hubs 1 Drive the machine to rotate the hub until the plugs are located one at the side and the other at the other
296. of CAN Transmit Frame EEC3VOL1 Engine send messages Ganie Part No 218700 ZX 135 70 233 Service Manual AAA AAA AAA a Deutz TD 2 9 L4 Engine Fault Codes September 2015 SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier um F KWP Keyword Protocol 524016 2 1259 BE is not plausible to SEN FMI KWP Descripti n 524016 2 1260 Calculated amount of air is not 523960 0 1458 High exhaust gas temperature plausible to HFM reading EE 524016 11 1258 HFM sensor electrical fault warning threshold exceeded 523960 1 1012 Physical range check low for SEL T ieee an Pipe Teck behind EGR cooler downstream temp 523960 1 1459 High exhaust gas temperature SS e EE EGR cooler downstream shut off ihshold exceeded downstream DOC too high 523980 14 1187 Bad quality of reduction agent 924920 eo SM LEON aF POESIE detected 523981 11 918 Urea tank without heating u 22 nn function heating phase ComEGRActr exhaust gas 523982 0 360 Powerstage diagnosis disabled recirculation positioner high battery voltage 524030 7 1440 EGR actuator internal error 523982 1 361 Powerstage diagnosis disabled 524031 13 1441 EGR actuator calibration error low battery voltage 523988 3 1245 Charging lamp short circuit to 324092 le AE EE messags battery 523988 4 1246 Charging lamp short circuit to SES uf 1443 E iet ue to
297. oke pivot pin retaining plate is fully engaged into the pivot pin and that the fasteners are securely tightened Genie ATEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual How to Calibrate a Replacement Steer Sensor Note If a steer angle sensor has been removed or replaced the steer angle sensors will need to be calibrated Note Perform this procedure with the axles retracted and the tires straightened Note Two people will be required to perform this procedure Note Be sure the yoke pivot pin retaining plate is fully engaged into the pivot pin and that the fasteners are securely tightened 1 Start the engine from the platform controls 2 Selectthe proper steer mode If a front square end steer angle sensor has been replaced select rear steer mode If a rear circle end steer angle sensor has been replaced select front steer mode 3 Have another person press down the foot Switch 4 Atthe new steer angle sensor loosen the steer angle sensor cover retaining fasteners Do not remove the fasteners or the sensor cover 5 Rotate the sensor cover clockwise or counterclockwise until the tire is straight in relation with the other tires Tighten the sensor cover fasteners Note If available WebGPI can also be used for this procedure Axle Components How to Calibrate All Steer Sensors Note This procedure will only need to be performed if the ground controls circ
298. on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value Genie ATEREX BRAND 134 ZX 135 70 25 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do nat turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 26 Press the enter or previous button on the LCD screen until EXIT is displayed 27 Press the plus button to select YES then press the enter button to accept 28 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine 29 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 30 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration
299. on the pressure gauge Result The gauge should show 2900 psi 200 bar Result If the gauge does not show 2900 psi 200 bar proceed to step 6 to adjust the function pump pressure compensator Loosen the set screw for the pressure compensator adjustment screw 1 pressure compensator set screw 2 pressure compensator adjustment screw Genie Part No 218700 Service Manual Hydraulic Pumps Adjust the pressure compensator pressure Turn the adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure Tighten the set screw Component damage hazard Do not adjust the pressure compensator higher than specified Turn the engine off and remove the pressure gauge ATEREX BRAND ZX 135 70 161 Service Manual September 2015 Hydraulic Pumps 7 2 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 The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should be performed at an authorized Sauer Danfoss service center Contact Genie Product Support to locate your local authorized service center How to Remove the Drive Pump Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the
300. ons Secondary Boom Switch Too much time Inhibit Secondary Boom Extend if the If the fault occurs on extend retract Timeout has elapsed from fault occurs boom until LSS1RO is engaged and try when LSS1RO is again Check LSS1RS and LSS1RO released and for physical damage and proper LSS1RS is operation released on extend and LSS1RS is engged and LSS1RO is engaged Or the joystick was engaged three times in the interval Secondary Boom Switches Either LSS1RS or Inhibit Secondary Boom Down until the Check switch for proper operation or Intermittence Fault LSS1RS LSS1RO have fault is cleared damage Use TCON display menu or Fault changed state laptop with WebGPI to clear faults without a secondary boom extend retract command or they have changed state when the secondary boom is not fully raised Jib Angle Sensor Value at 5 0 V Limited Speed and Direction frozen at Power up controller with problem Operational RSJ1AO a zero and neutral Alarm sounds corrected Value Too High Value Too Low Value at 0 V SCON Tilt Sensor Calibration check Display X direction and Y direction not Re power after entering tilt x axis and y calibrated axis matrix information LSS1RO Fault LSS1RO did not Inhibit secondary boom extend and Check switch for proper operation or Switch within a sound an audible warning damage Use TCON display menu or specified time laptop with WebGPI to clear faults
301. ontrols September 2015 Index S Schematic No Description item Function Torque 1 Check valve 5 psi 0 34 bar A Prevents hydraulic pressure from 60 ft lbs 81 Nm flowing back into auxiliary pump 1 2 Check valve 5 psi 0 34 bar B Prevents hydraulic pressure from 60 ft lbs 81 Nm flowing back into auxiliary pump 2 3 Check valve 5 psi 0 34 bar C Pressure Circuit 30 35 ft Ibs 41 47 Nm 4 Solenoid Valve 2 position 3 way D Primary boom down 33 37 ft Ibs 45 50 Nm 5 Solenoid Valve 2 position 3 way E Primary boom up 33 37 ft Ibs 45 50 Nm 6 Solenoid Valve 2 position 3 way F Primary boom extend 33 37 ft Ibs 45 50 Nm 7 Solenoid Valve 2 position 3 way G Primary boom retract 33 37 ft Ibs 45 50 Nm 8 Solenoid Valve 2 position 3 way Z Secondary boom retract 33 37 ft lbs 45 50 Nm 9 Solenoid Valve 2 position 3 way Y Secondary boom extend 50 55 ft lbs 68 75 Nm 10 Differential sensing valve 150 psi FF Secondary boom extend retract 50 55 ft lbs 68 75 Nm 10 3 bar circuit regulates pressure drop across secondary boom extend retract proportional valve 11 Solenoid Valve 2 position 3 way H Secondary boom up 50 55 ft lbs 68 75 Nm 12 Solenoid Valve 2 position 3 way l Secondary boom down 33 37 ft lbs 45 50 Nm 13 Check valve 100 psi 6 9 bar HH Prevents the draining of 90 100 ft lbs 122 136 hydraulic oil from the jib manifold Nm and platform manifold 14 Solenoid valve
302. or previous button on the LCD screen until EXIT is displayed 13 Press the plus button to select YES then press the enter button to accept 14 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved A TEREX BRAND Genie 15 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 16 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 17 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine 202 ZX 135 70 Part No 218700 September 2015 Service Manual Observe and Obey v v Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before
303. orm Daily or every 8 hours A Quarterly or every A B 250 hours Semi annually or A B C every 500 hours Annually or A B C D every 1000 hours Two yearor A B C D E every 2000 hours Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist C C 1 Engine maintenance Deutz models September 2015 AAA AAA ON AY Checklist E E 1 Hydraulic oil E 2 Engine maintenance Perkins models E 3 Engine maintenance Deutz models Perform every 3000 hours E 4 Engine maintenance Perkins models E 5 Engine maintenance Perkins models E 6 Engine maintenance Deutz models Perform every 4000 hours E 7 Engine maintenance Perkins models Perform every 5000 hours E 8 Engine maintenance Deutz models C 2 Engine maintenance Deutz models C 3 Engine maintenance Perkins models C 4 Engine air filter C 5 Grease platform overload if equipped C 6 Test platform overload if equipped C 7 Engine RPM C 8 Turntable bearing wear Checklist D D 1 Boom wear pads D 2
304. orm angle sensor from the platform rotator Component damage hazard The platform angle sensor is a very sensitive instrument It can be damaged internally if is dropped or sustains any physical shock even if the damage is not visible 4 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Tag disconnect and plug the hydraulic hoses from the platform manifold Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the power to platform electrical outlet box bracket mounting fasteners Do not disconnect the wiring 7 Remove the hose and cable guide retaining fasteners and remove the guide from the platform support Service Manual September 2015 Platform Components 8 Remove the weld cable from the platform if equipped WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 9 Support the platform mounting weldment but do
305. ormation is available in the Perkins 1100D Operation and Maintenance Manual Perkins 1100D Operation and Maintenance Manual Genie part number 123702 Part No 218700 Checklist A Procedures A 5 Perform Engine Maintenance Deutz Models Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first e Engine oil level check e Fuel system filter water separator drain e Engine tightness check for leaks e Exhaust system check for leaks Required maintenance procedures and additional engine information is available in the Deutz TD2011 Operation Manual Deutz TD2011 Operation Manual Genie part number 139320 Genie ATEREX BRAND ZX 135 70 25 Service Manual September 2015 Checklist A Procedures A 6 3 Open the ground control side turntable cover e and inspect the filter condition indicator gauge Check the Hydraulic Return Filter on the in tank return filter Condition Indicator Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the hydraulic filters in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic System and cause component damage
306. osion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Besure that the battery retainers and cable connections are tight 4 Besure that the battery separator wire connections are tight if equipped Models without maintenance free or sealed batteries 5 Puton protective clothing and eye wear 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 7 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 F 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 F 5 5 C below 80 F 26 7 C O Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 D Result One or more battery cells display a specific gravity of 1 276 or below Proceed to step 8 Genie ATEREX BRAND ZX 135 70 29 Part No 218700 Service Manual September 2015 Checklist B Procedures 8 Perform an equalizing charge OR fully charge B 2 the battery s and allow the battery s to rest at Inspect the Electrical Wiring least 6 hours 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Genie specifications require that this procedure be
307. ove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold Genie 186 ZX 135 70 September 2015 Hold the hot oil relief valve and remove the cap Start the engine from the ground controls Press and hold the function enable high rpm select button rabbit symbol position Adjust the internal hex socket until the pressure reading on the gauge is 40 psi 2 8 bar less than the pressure reading on the pump Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Turn the engine off Remove the pressure gauge Part No 218700 September 2015 Service Manual Manifolds 8 12 Drive Oil Diverter Manifold welder option The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment Index Schematic No Description Item Function Torque 1 Directional valve BV Diverter valve 80 90 ft Ibs 108 122 Nm 2 Orifice 0 030 inch 0 080 cm BW Delays shift to drive 3 Solenoid Valve BX Pilot valve to diverter 35 40 ft Ibs 47 54 Nm 4 Relief valve 270 psi 18 6 bar BZ Charge pressure circuit 35 40 ft Ibs 47 54 Nm 5 Check valve BY Prevents oil to generator 35 40 ft Ibs 47 54 Nm BY Genie ATEREX BRAND Part No 218700 ZX 135 70 187 Service Manual September 2015 Manifolds 8 13 Valve Coils How to Test a Coil A prope
308. ow divider combinsFvalva A Controls flow to circle end drive motors in 90 100 ft lbs forward and reverse 122 135 6 Nm d 90 100 ft Ibs 17 Flow divider combiner valve B Controls flow to divider combiner valves 122 135 6 Nm Pee 20 25 ft lbs 18 Check valve 5 psi 0 3 bar O Drive motor anti cavitation 27 1 33 9 Nm Genie A TEREX BRAND 184 ZX 135 70 Part No 218700 Service Manual Manifolds September 2015 o OZA CoN Y d a e o Ma A p LARA E ura NA Fi ED Le 3 EE iA Nt AN c ip OE gt NV NU Y A v Genie ZX 135 70 185 Part No 218700 Service Manual SS TS ees Manifolds 8 11 8 Valve Adjustments Traction Manifold 10 How to Adjust the Hot Oil Relief Valve Note The hydraulic oil temperature must be 100 F to 150 F 38 C to 65 5 C before performing this procedure 1 Connect a 0 to 600 psi O to 50 bar pressure gauge to either the A or B test port on the 12 drive pump 13 2 Locate the hot oil relief valve on the traction manifold Hold the relief valve and remove the cap 3 Turn the internal hex socket clockwise fully until it stops Install the cap 4 Startthe engine from the ground controls Press and hold the function enable high rpm select button rabbit symbol position Note the reading on the pressure gauge 6 Turn the engine off 7 Rem
309. ower limit switch harness engine harness 1 way Deutsch connector for platform power jib primary Number Description J87 2 pin Deutsch connector for two speed motor J121 stroke valve J122 J91 2 pin Deutsch connector for right rear steer J124 right valve J92 2 pin Deutsch connector for right rear steer J125 left valve J93 2 pin Deutsch connector for left rear steer J126 right valve J94 2 pin Deutsch connector for left rear steer left J127 valve J95 2 pin Deutsch connector for right front steer J128 right valve J96 2 pin Deutsch connector for right front steer J129 left valve J97 2 pin Deutsch connector for left front steer J135 right valve J98 2 pin Deutsch connector for left front steer left J136 valve J99 2 pin Deutsch connector for axle extend valve J137 J100 2 pin Deutsch connector for axle retract valve J106 2 pin Deutsch connector for brake release J138 valve J107 3 pin Deutsch connector for right rear steer J140 sensor J141 J108 3 pin Deutsch connector for left rear steer J146 sensor J109 3 pin Deutsch connector for right front steer J147 sensor J110 3 pin Deutsch connector for left front steer sensor J114 6 pin Deutsch connector for primary boom angle sensor PBAS J119 2 pin Deutsch connector for jib not retracted J120 4 pin Weatherpack EDC connection Ganie 260 ZX 135 70 Part No 218700 September 2015 A TFT A A A Circuit Connector Legend Number J148 J149 J150 J151 J152 J153 J15
310. own ramp 120 max and 50 min acceleration 100 default 5 incr Jib boom up down ramp deceleration Genie ATEREX BRAND 154 ZX 135 70 Part No 218700 September 2015 Service Manual AA AA A A A A Display Module Screen or Menu Procedure Description Range or Selection Valve Calibration With key switch OFF press and Delete drive valve calibration hold the enter button and turn key switch to on position Release the enter button and press Delete primary boom minus minus enter enter extend retract valve calibration Delete primary boom up down valve calibration Delete secondary boom up down and extend retract valve calibration Delete turntable rotate valve YES NO calibration Allow primary boom up down speed calibration Allow primary boom extend retract speed calibration Allow secondary boom up down speed calibration Allow turntable rotate speed calibration Delete drive joystick calibration Delete primary boom up down joystick calibration Delete primary boom extend retract joystick calibration Delete secondary boom joystick calibration Delete turntable rotate joystick calibration Delete steer joystick calibration Delete jib up down joystick calibration e Genie ATEREX BRAND Part No 218700 ZX 135 70 155 Service Manual September 2015 gees Display Module Screen or Menu Procedure Description Range or
311. pens in the wiring or a bad ground Replace coil if necessary 214 Genie A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Fault Codes Error Source Error Type Effects Recovery Actions Jib Level Bellcrank Up Down Flow Valve s Platform Level Up Platform Level Down Flow Valve Not calibrated Normal function except threshold for one or the other direction is zero Display message on LCD Perform calibration procedure Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Value Too Low Not calibrated Limited Speed and Direction frozen at zero and neutral Alarm sounds Normal function except threshold for one or the other direction is zero Display message on LCD Check for opens in the wiring or a bad ground Replace coil if necessary Perform calibration procedure Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Value Too Low Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for shorts to ground in the wiring Replace coil if necessary Platform Rotate Switches Fault Check both closed Affected functions disabled Display
312. perature battery voltage 175 0 745 High oil temperature warning 168 2 47 High battery voltage warning threshold exceeded threshold exceeded 175 0 746 High oil temperature shut off 168 2 48 Low battery voltage warning threshold exceeded threshold exceeded 175 1 741 Physical range check low for oil 168 3 45 Sensor error battery voltage temperature signal range check high 175 2 738 Sensor oil temperature 168 4 46 Sensor error battery voltage plausibility error signal range check low 175 2 739 Sensor oil temperature 171 3 417 Sensor error environment plausibility error oil temperature temperature signal range check too high high 175 3 743 Sensor error oil temperature 171 4 418 Sensor error environment signal range check high temperature signal range check 175 4 744 Sensor error oil temperature low signal range check low 172 0 1182 Physical range check high for 190 0 389 Engine speed above warning intake air temperature threshold FOC Level 1 172 1 1183 Physical range check low for 190 2 421 Offset angle between crank and intake air temperature camshaft sensor is too large 172 2 9 Sensor ambient air temperature 190 8 419 Sensor camshaft speed plausibility error disturbed signal 172 2 983 Intake air sensor plausibility error 172 3 981 Sensor error intake air signal range check high 172 4 982 Sensor error intake air sensor signal range check low Genie 224 ZX 135 70 Part No 218700 September 2015 A AA ZZ Deutz TD 2 9 L4 Engine Fa
313. platform BL RD WH 23 Power to platform WH BK RD 24 Power to warning senders WH BK 25 Power to oil pressure sender BRAVA Genie Part No 218700 ZX 135 70 251 Service Manual September 2015 Circuit 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 Primary Function Hydraulic Filter restricted Platform Level Safety Power Platform Level Safety Output Platform Level Safety Ground Proximity Kill Gate Interlock Motor Speed LO HI Motor Bypass Load Sensor Tether ESTOP return Tether Power Tether ESTOP Power J1708 high J1708 low Outrigger lowered Outrigger raised Pothole protector up Pothole protector down Proprietary Data buss l e ITT or AP Proprietary Data buss l e ITT or AP Spare Alternator Field Engine Status Sensor Power Sensor Return Steer Signal Steer Signal to Solenoid Valve Multi function Valve Load Moment Overweight Load Moment Underweight Hydraulic Oil Cooler Wire Color Legend Color Circuit Primary Function Color GR BK 55 Axle oscillation OR RD 56 Foot switch TCON estop power RD RD WH 57 Boom down safety interlock RD BK RD BK 58 Safety interlock to engine BR GR WH 59 Chain break circuit RD BK GR WH 60 Axle extend RD WH GR 61 Axle retract WH BK OR 62 Boom stowed safety WH RD OR RD 63 Power to boom envelope safety WH switch OR OR BK 64 Power for operational
314. position 4 way up down Genie 172 ZX 135 70 Part No 218700 Service Manual September 2015 OS Genie ZX 135 70 173 Part No 218700 Service Manual September 2015 ee aa Zst IG r 2 Manifolds 8 5 Flow Control Manifold The flow control manifold is located at the platform next to the jib manifold Index Schematic No Description Item Function Torque 1 Flow regulator valve 0 5 gpm 1 9 L min AC Controls flow in the jib and platform 20 ft lbs 27 Nm manifold recirculation circuit O Genie A TEREX BRAND 174 ZX 135 70 Part No 218700 September 2015 Service Manual Manifolds 8 6 Function Enable Valve The function enable valve is mounted behind the medium pressure filter Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 2 way A Enables lift pump to provide 20 25 ft lbs hydraulic pressure for all boom and 27 34 Nm steer axle functions Genie ATEREX BRAND Part No 218700 ZX 135 70 175 Service Manual Manifolds 8 7 September 2015 ee aa U a 2 Turntable Rotation Manifold The turntable rotation manifolds are mounted to the turntable rotation drive hub motors Index WT Schematic 5 No Description itam Function Torque 1 Counterbalance valve Turntable rotate right 25 30 ft lbs CA 34 41 Nm 2 Counterbalance valve Turntable rotate left 25
315. positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks e le Service Manual September 2015 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Grade 5 Grade 8 E LUBED LUBED LUBED indbs Nm in bs__ Nm in ibs Nm in ibs Nm imibs_ Nm 44 Po 80 9 100 113 f 110 124 140 158 130 147 I 28 90 101 120 135 120 135 160 18 140 158 El DRY LUBED DRY LUBED ft lbs Nm ftibs Nm fttbs Nm ftibs Nm telbs Nm sae 18 13 176 17 28 18 24 25 339 21 284 24 14 19 19 257 20 271 27 366 24 325 16 23 312 31 42 33 447 44 596 38 515 24 35 2 50 1 49 664 50 678 70 947 e 827 55 745 eo 813 80 1084 68 921 773 75 1016 80 1084 110 149 93 126 867 85 115 90 122 120 162 105 142 108 4 122 162 130 176 170 230 140 189
316. primary boom angle sensor will need to be calibrated Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor 9 Remove the hose and cable guide fasteners at the primary boom pivot pin Remove the hose and cable guide 10 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray A TEREX BRAND 124 ZX 135 70 11 12 13 14 15 16 17 Place blocks under both ends of the primary boom lift cylinder for support Attach a lifting strap from an overhead crane to the rod end of the primary boom lift cylinder Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the rod end pivot pin Rest the rod end of the primary boom lift cylinder on the blocks Support both upper primary boom lift cylinder linkage arms with a suitable lifting device Do not apply any lifting pressure Remove the pin retaining fasteners from the upper primary boom lift cylinder linkage arm pivot pin where it connects to the primary boom Use a soft metal drift to tap the pin halfway out and lower one of the linkage arms down Tap the pin in the other direction and lower the other linka
317. properly supported by the overhead crane Remove the secondary boom lift cylinder barrel end pivot pin retaining fasteners Do not remove the pin Attach a lifting strap from a second overhead crane to each end of the secondary boom lift cylinder cylinder from damage 128 Genie A TEREX BRAND September 2015 29 Use aslide hammer to remove the barrel end pivot pin Component damage hazard Hoses and cables can become damaged if the barrel end of the secondary boom lift cylinder is allowed to fall when the barrel end pivot pin is removed 30 Carefully remove the secondary boom lift cylinder from the machine A WARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Component damage hazard Hoses and cables can be damaged if the secondary boom lift cylinder is pulled across them ZX 135 70 Part No 218700 September 2015 Service Manual 4 6 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Extension Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop A
318. r Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease fitting for the turntable rotate bearing 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Service Manual September 2015 Checklist A Procedures A 9 Replace the Drive Hub Oil Drive hub specifications require that this one time procedure be performed after the first 100 hours of usage After this interval refer to the maintenance checklist for continued scheduled maintenance Failure to replace the drive hub oil may cause the machine to perform poorly and continued use may result in component damage 1 Refer to Maintenance Procedure Replace the Drive Hub Oil Genie ATEREX BRAND 28 ZX 135 70 Part No 218700 September 2015 Service Manual B 1 Inspect the Batteries Genie specificat
319. r Turntable Bearing Wear sss 66 Checklist D Procedures nurssunsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnunnnunnnnnnnnnnnnnnnnnnnnnnnnn nnn 68 D 1 Check the Boom Wear Pads sse 68 D 2 Check the Free wheel Configuration cccceeccccceeeeeteeeeeeeieeeeetneeeeeeneeeeees 69 D 3 Replace the Drive Hub OH 70 D 4 Adjust the Turntable Rotatation Gear Backlash 4 72 D 5 Replace the Hydraulic Filter Elements 73 D 6 Perform Engine Maintenance Deutz Modele 440 74 D 7 Perform Engine Maintenance Perkins Models A 75 D 8 Check the Turntable Rotation Bearing Boite 75 Checklist E Procedures uunnsssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnsnnnnn nn nennen 77 E 1 Test or Replace the Hydraulic OU 77 E 2 Perform Engine Maintenance Perkins Models 24404 nenn 79 E 3 Perform Engine Maintenance Deutz Model 79 E 4 Perform Engine Maintenance Perkins Models u02 4404 80 E 5 Perform Engine Maintenance Perkins Models 24404 nenn 80 E 6 Perform Engine Maintenance Deutz Model 81 E 7 Perform Engine Maintenance Perkins Models A 81 E 8 Perform Engine Maintenance Deutz Model 82 Genie ATEREX BRAND Part No 218700 ZX 135 70 xi September 2015 Se AAA A Table of Contents Section 4 Repair Procedures eroe rine e EEN 83 Introduction ST 83 Platform Controls esses nennen
320. r button for approximately 5 seconds 3 Press the minus button twice then press the enter button twice 4 Use the scroll button to scroll through the menu until RESET JIB BOOM UP DOWN JOYSTICK DEFAULTS is displayed 5 Press the plus button to select YES then press the enter button 6 Do not start the engine 7 Locate the jib boom joystick 8 Move the jib boom joystick full stroke in the up direction and hold for 5 seconds then return to the center or neutral position 9 Move the jib boom joystick full stroke in the down direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration 90 ZX 135 70 Part No 218700 September 2015 Service Manual Turntable rotate functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then press the enter button twice 4 Use the scroll button to scroll through the menu until DELETE TURNTABLE ROTATE JOYSTICK DEFAULTS is displayed 5 Press the plus button to select YES then press the enter button 6 Donotstart the engine 7 Locate the primary boom turntable rotate joystick 8 Move the boom turntable joystick full stroke in the left direction and hold for 5 seconds then ret
321. raised YES NO Delete primary boom angle sensor calibration YES NO Primary boom fully lowered YES NO Primary boom fully raised YES NO Delete jib level angle sensor calibration YES NO Jib level cylinder fully extended YES NO Jib level cylinder fully retracted YES NO e Genie ATEREX BRAND Part No 218700 ZX 135 70 157 Service Manual September 2015 gees Display Module Screen or Menu Procedure Description Range or Selection Options With key switch OFF press and Boom Function Limit No LT No limit EXT LT hold the enter button and turn NO LT EXT LT secondary boom extend key switch to on position AC Generator inhibited Release the enter button and NONE BELT HILO HYDRL GHG press 10 PA amino NO AL Motion MO AL Travel TR AL Descent DE AL V Travel and Descent TD AL Lift Drive No NO CO Drive cut out while not stored DCONS Lifting or driving LORDR Proximity Kill Switch NONE PROX Platform Overload NONE WARN CUTPT CUTAL PL FTS Work Li ghts YES NO Flashing Beacon NO YES Drive Lights NO YES Disable Steer Mode Change while Driving NO YES Rocker Switch NO YES Chassis Tilt Cutout NONE Chassis Tilt Cutout COALL Cutout All Drive Tilt Cutout CODRV Cutout Drive Foot Switch Lockout 30 0 max and 0 0 min 0 30 minutes 10 0 default Platform Always Level to Gravity NO YES Axle Motion Only W
322. rank 15 Use a soft metal drift to remove the jib boom pivot pin Remove the jib boom from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane 16 Remove the pin retaining fasteners from the jib boom extension cylinder rod end pivot pin Use a soft metal drift to remove the pin 17 Attach a lifting strap from an overhead crane to the barrel end of the jib boom extension cylinder 18 Remove the pin retaining fasteners from the jib boom extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 19 Carefully slide the jib boom extension cylinder out of the jib boom and place it on a structure capable of supporting it AWARNING Crushing hazard The jib boom extension cylinder could become unbalanced and fall when removed from the jib boom if not properly supported Note During removal the overhead crane strap will need to be adjusted for proper balancing Part No 218700 Genie ATEREX BRAND ZX 135 70 111 Jib Boom Components 3 6 Jib Boom Bellcrank Angle Sensor The jib boom bellcrank angle sensor is monitored by the control system to keep the jib boom bellcrank vertical and to help maintain a level platform through boom range of motion If a jib boom bellcrank angle sensor is replaced it must be calibrated
323. rcle end blue side angle sensors Rotate the sensor cover clockwise or counterclockwise until the voltage reading is between 3 4 to 3 6V DC Tighten the sensor cover fasteners Note If available WebGPI can also be used for this procedure 7 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 8 Push in the red Emergency Stop button to the off position Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 6 O e 1 Run 2 Bypass 3 Recovery 10 Enter sensor calibration mode by pressing the A TEREX BRAND 198 ZX 135 70 Genie buttons at the ground controls in the following sequence plus enter enter plus Part No 218700 September 2015 Service Manual Delete all Steer Sensor Calibrations 11 Press the enter or previous button on the LCD screen until DELETE ALL STEER SENSORS CALIBRATION is displayed Press the plus button to select YES then press the enter button to accept 12 Press the enter or previous button on the LCD screen until EXIT is displayed 13 Press the
324. re with the machine on a firm level surface and in the stowed position with the axles extended Note This procedure will require the use of a portable hydraulic power unit 1 Tag disconnect and plug the hydraulic hoses from the axle extension cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the axle extension limit switch cover fasteners Remove the cover 3 Remove the limit switch mounting fasteners and remove the limit switch Do not disconnect the wiring Genie A TEREX BRAND 200 ZX 135 70 4 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension cylinder Note Connect the pressure hose from the power unit to the R port of the cylinder and the return hose from the power unit to the E port on the cylinder 5 Support the axle extension cylinder with a suitable lifting device Protect the cylinder rod from damage 6 Remove the pin retaining fasteners from both axle extension cylinder pivot pins 7 Use a soft metal drift to remove the pins 8 Using the portable hydraulic power unit retract the axle extension cylinder until the ends of the cylinder clear the axles 9 Remove the axle extension cylinder from the machine A CAUTION Crushing hazard Th
325. reparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Service Manual September 2015 c NON MA U A I This page intentionally left blank Genie ATEREX BRAND 18 ZX 135 70 Part No 218700 September 2015 Service Manual Pre Delivery Preparation Report Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong
326. replace membrane switch Axle Valve Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring zero and neutral Alarm sounds Check for an open or shorted valve coil Repair or replace as necessary DCON CAN Bus Fault Check Display message on LCD Disable Check CAN bus wiring from TCON to propel DCON through rotator Repair or replace wiring or DCON CAN Bus Fault Check Display message on LCD Check CAN bus wiring from TCON to SCON PCON Repair or replace wiring or SCON PCON 208 Genie A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up Down Flow Valve Not calibrated Normal function except threshold for one or the other direction is zero Display message on LCD Calibrate Thresholds Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Value Too Low Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Primary Boom Extend Retract Flow Valve Not calibrated Just calibrated Value Too High Value Too Low Normal function except threshold for one or the other direction is zero Display message on LCD Initiate one second beep of audible warning device Limited Spe
327. ring transient Secondary Boom Up Extend Down Retract Switches on TCON Fault Check both buttons pressed Secondary boom Up Ext Down Retract disabled Display message on LCD Check ribbon and connector from membrane switch If necessary replace membrane switch Secondary Boom Up Down Not calibrated Display message on LCD and allow See service manual on how to perform Speed operation at default speed this procedure Genie 210 ZX 135 70 Part No 218700 September 2015 Service Manual Fault Codes Boom Angle Sensor Extend disabled Alarm sounds 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 Repair or replace as necessary Secondary Boom Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring Retract Valve zero and neutral Alarm sounds Check for an open or shorted valve coil Repair or replace as necessary Secondary Boom Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring Up Valve zero and neutral Alarm sounds Check for an open or shorted valve coil Repair or replace as necessary Secondary Boom Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring Down Valve zero and n
328. rly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested N Test the coil resistance O Result The resistance should be within specification plus or minus 30 W Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 10 C that your air temperature increases or decreases from 68 F 20 C Valve Coil Resistance Spec
329. rm end of the primary extension boom Genie 104 ZX 135 70 Part No 218700 September 2015 a A AA E MN 15 16 Pull the two hydraulic hoses just removed and all of the cables through the hose and cable guide at the platform support Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Remove the cotter pin from the upper cable track tube at the platform end of the jib boom Do not discard the washer Note Always replace the cotter pin with a new one 17 18 Remove the fasteners from the cable track tube guide at the platform end of the jib boom Remove the cable track tube guide from the jib boom Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together AWARNING Crushing hazard If the upper 19 20 21 and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine Attach a lifting strap from an overhead crane to the cable track Remove the mounting fasteners that attach the lower cable track to the jib boom Carefully remove the cable track from the machine and lay it on a structure capable of supporting it AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overhead crane Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Part No 21870
330. rn hazard the tank valves are closed A WARNING Contact with electrically charged remove the key from the key circuits could result in death or switch and tag the machine to serious injury Remove all rings inform personnel of the watches and other jewelry condition 18 Tag and disconnect the cables from the 8 Remove the drain plug from the hydraulic tank engine starting controls battery located on the and completely drain the tank into a container engine side of the machine of suitable capacity Refer to Specifications Fluid Capacity Specifications AWARNING Electrocution burn hazard Contact with electrically charged 9 Tag disconnect and plug the two suction circuits could result in death or hoses from the hydraulic tank serious injury Remove all rings 10 Tag disconnect and plug the two supply watches and other jewelry hoses for the auxiliary power units Cap the fittings on the hydraulic tank 19 Attach an overhead crane or similar lifting device to the battery box for the auxiliary 11 Tag disconnect and plug the hydraulic hose power unit batteries from the drive motor case drain filter at the hydraulic tank Cap the fitting on the hydraulic 20 Remove the battery box retaining fasteners tank and carefully remove the battery box from the machine 12 Tag disconnect and plug the hydraulic hose at the return filter Cap the fitting on the return A WARNING Crushing hazard The battery filer housing box could become unbalanced and fall w
331. rn the key switch to the off position 2 Turn the key switch to ground controls Open the ground control box 4 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 5 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 6 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 7 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 8 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 9 Press the enter or previous button on the LCD screen until DELETE SECONDARY BOOM ANGLE SENSOR CALIBRATION is displayed Part No 218700 Genie ATEREX BRAND ZX 135 70 Boom Components 10 Press the plus button to select YES then press the enter button to accept 11 Place a digital level that has been calibrated to the Y axis of the
332. rntable Level Sensor Note If the Safety Controller SCON has been replaced the entire machine must be calibrated in a specific order Refer to Repair Procedure Full Machine Calibration 4 WARNING Tip over hazard Failure to properly calibrate the machine could cause the machine to tip over resulting in death or serious injury Note A digital level will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 a Plus Minus Previous Enter Note Perform this procedure with the machine on a firm level surface with the booms in the fully stowed position and the axles fully extended 1 Pushin the ground controls red Emergency Stop button to the off position 2 Open the ground control box Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction Genie ATEREX BRAND 192 ZX 135 70 4 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 5 Turn the key switch to ground controls
333. rocedures As weight is added to the platform the spring will compress until when the platform is overloaded the lower arm contacts a limit switch and thereby activating the overload signal When adjusted correctly the platform overload system will deactivate normal boom operation at platform capacity Note Perform this procedure with the boom fully retracted and in the stowed position and with the machine on a firm level surface 1 Remove all weight tools accessories and equipment from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine from the ground controls and level the platform Do not turn the engine off 3 Determine the maximum platform capacity Refer to the machine serial plate Service Manual September 2015 Checklist C Procedures Using a suitable lifting device place a test weight equal to that of the available capacity in one of the locations shown Refer to Illustration 1 Result The platform overload indicator light should be off at both the ground and platform controls illustration 1 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The platform overload indicator light should be off at both
334. ry 75 ft lbs Alternator output 120A 12V DC 102 Nm Fan belt deflection 3 8 to 1 2 inch Drive motor mounting bolts lubricated 56 ft lbs 9 to 12 mm 76 Nm Backlash plate mounting bolts lubricated 320 ft lbs 434 Nm Drive motors and hubs Drive hub mounting bolts lubricated 180 ft lbs 217 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm Drive motor mounting bolts lubricated 56 ft lbs 76 Nm Engine vibration isolators Mounting bolts dry 60 ft lbs 81 Nm Mounting bolts lubricated 45 ft lbs 61 Nm Genie Part No 218700 ZX 135 70 11 Service Manual September 2015 Specifications Hydraulic Hose and Fitting Torque Specifications SAE O ring Boss Port 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 specifications require that fittings and hose ends be 4 14 ft lbs 19 Nm torqued to specification when they are removed 6 23 ft lbs 31 2 Nm and installed or when new hoses or fittings are 8 36 ft lbs 54 2 Nm Installed 40 62 ft lbs 84 Nm E 12 84 ft lbs 114 Nm Seal Lok Fittings 16 125 ft lbs 169 5 Nm More IKE S SIR 20 151 ft lbs 204 7 Nm SAB Dash Size Torque 24 184 ft lbs 2
335. s are only intended for certain circumstances and are not part of normal machine operation If either the Bypass or the Recovery function is required this indicates there may be faults with the machine Contact trained personnel immediately Bypass is used for a platform out of level condition and calibrating certain machine parameters Recovery is only to be used as a last attempt to lower the platform when the operator in the platform is unable to do so system failure or in emergency situations 1 R c n 2 Bypass 3 Recovery Genie ATEREX BRAND Part No 218700 ZX 135 70 143 Service Manual September 2015 Ground Controls How to Use the Bypass Mode INNEJ Tip over hazard Operating the machine outside of the operating envelope while in Bypass mode will result in death or serious injury if proper operating procedures and safety precautions are not followed Do not use this mode if you are not trained and familiar with the operating envelope of the machine Note Before using the Bypass mode make sure you understand the fault code or issue affecting the operation of the machine to be sure the use of bypass is required The Bypass mode will allow the platform to be manually leveled when an out of level condition exists In the event that the platform angle is greater than 10 from level the boom angle and platform level functions are disabled Use of the Bypass mode will
336. s firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls Press the engine rpm select button until the foot switch activated high idle rabbit symbol is selected then lower the boom into the stowed position 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Specifications Performance Specifications Genie A TEREX BRAND 42 ZX 135 70 B 14 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Perform this procedure with the machine on a firm level surface that is free of obstructions Note Perform this procedure with the boom in the stowed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2
337. scription Range or Selection Drive Functions With key switch OFF press and hold the enter button and turn key switch to on position Release the enter button and press plus plus enter enter Forward extended drive speed Forward not stowed drive speed Forward low drive speed Forward high drive speed Reverse extended drive speed Reverse not stowed drive speed Reverse low drive speed Reverse high drive speed Drive acceleration Drive deceleration Speed limit on steer angle 120 max 100 default 50 min 120 max 100 default 50 min 120 max 100 default 50 min 120 max 100 default 50 min 120 max 100 default 50 min 120 max 100 default 50 min 120 max 100 default 50 min 120 max 100 default 50 min 125 max 100 default 25 min 125 max 100 default 25 min 100 max 50 default 0 152 Genie ATEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Tee ZZ a m nP mmim n S o 5 Display Module Screen or Menu Procedure Description Range or Selection Boom Function With key switch OFF press and Primary boom up speed stowed Speeds hold the enter button and turn key switch to on position Primary boom up speed not Release the enter button and stowed press plus plus minus minus Primary boom down speed stowed Primar
338. se the jib boom to a slightly less than horizontal position co 10 11 12 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus Press the enter or previous button on the LCD screen until DELETE JIB LEVEL ANGLE SENSOR CALIBRATION is displayed Press the plus button to select YES then press the enter button to accept At the jib level calibration deg 60 0deg screen start the engine Note If the system exits out of calibration mode when the engine is started repeat step 8 and continue to step 12 3 Push in the ground controls red Emergency Stop button to the off position Do not turn the key switch to the off position Open the ground control box Genie 112 A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual 13 Press and hold a function enable speed select button and the platform level up button Fully extend the jib boom level cylinder Note When in bypass mode the platform level buttons are used to adjust the jib boom level cylinder Note With the jib boom level cylinder is fully extended the jib boom bellcrank angle should be at approximately 60 2 degrees 14 Attac
339. secondar iets GC P T Result The reading at the display and digital level is greater than 2 of each other and of Result The reading at the display and digital 50 The secondary boom angle sensor must level is within 2 of each other and of 76 be calibrated Refer to Repair Procedure How Result The reading at the display and digital e Calibrate the Secondary Boom Angle level is greater than 2 of each other and of STE 76 The secondary boom angle sensor must 9 Lower the secondary boom to 35 be calibrated Refer to Repair Procedure How 2 to Calibrate the Secondary Boom Angle Result The reading at the display and digital Sensor level is within 2 of each other and of 35 DG Result The reading at the display and digital ADANGER rietser d PER level is greater than 2 of each other and of immediately lower the secondary 35 The secondary boom angle sensor must be calibrated Refer to Repair Procedure How boom Failure to lower the boom to Calibrate the Secondary Boom Angle could cause the machine to tip Sensor over resulting in death or serious injury Refer to Repair 10 Lower the secondary boom to 20 Procedure How to Calibrate the Result The reading at the display and digital dary B Angl f EE SENSO level is within 2 of each other and of 20 Result The reading at the display and digital level is greater than 2 of each other and of 20 The secondary boom angle sensor must be cal
340. section of cable track Part No 218700 September 2015 Service Manual 6 Remove the upper rollers from the replacement section of cable track 7 Lt up the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 8 Connect the ends of the replacement cable track section to the existing cable track using the pins and snap rings 9 Install the rollers onto the new section of cable track 10 Install the secondary boom cable track into the secondary boom 11 Operate the secondary boom up extend and down retract functions through a full cycle to ensure smooth operation of the new section of cable track Part No 218700 Genie ATEREX BRAND ZX 135 70 Boom Components 4 3 Primary Boom How to Remove the Primary Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this pr
341. splayed 5 Press the plus button to increase the speed or press the minus button to decrease the speed 6 Press the enter button to save the setting in memory 7 Press the enter or previous button on the LCD screen until EXIT is displayed 8 Press the plus button or minus button to select YES and then press the enter button 9 Continue to perform this procedure until the machine function speed meets specification Refer to Specifications Performance Specifications Genie A TEREX BRAND 94 ZX 135 70 How to Adjust the Function Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure with the boom in the stowed position Note Use the following chart to identify the description of each LCD screen control button used in this procedure P Enter 4 Plus Minus Previous 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the plus button twice then press the
342. ss connectors to DCON module Genie ATEREX BRAND Part No 218700 ZX 135 70 31 Service Manual September 2015 Checklist B Procedures B 3 Test the Main Key Switch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation Failure of either key switch to function properly could cause a hazardous operating situation There are two key switches on the machine the Main key switch and the Bypass Recovery key switch The Main key switch controls machine operation from the ground or platform controls Note When the axles are retracted the boom cannot be rotated past either circle end wheel Genie A TEREX BRAND 32 ZX 135 70 When the Bypass Recovery key switch is turned and held to the recovery position the auxiliary power units will turn on and fully retract the secondary boom then the primary boom and then lower the primary boom This feature of the machine is especially helpful if the operator in the platform cannot lower the boom if the platform controls become inoperative or for returning the machine to a safe position when the safety switches have been tripped 1 Run 2 Bypass 3 Recovery Part No 218700 September 2015 A A O AAA EA ZZ Note Perform this procedure with the machine on 11 a firm level surface with the
343. ss the enter button B 19 Press the previous button until EXIT appears 20 Select YES then press the enter button 4 21 Install the secondary boom end covers 5 6 7 D 8 Genie Part No 218700 ZX 135 70 Service Manual Checklist B Procedures Turntable Rotate Safety Limit Switch LST1S Locate the turntable rotate safety limit switch LST1S at the center of the turntable Note The turntable rotate safety limit switch LST1S is located between the two operational turntable rotate limit switches It can easily be identified by the orange and red tie wraps attached to the limit switch cable Locate and disconnect the deutsch connector to LST1S Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the Deutsch connector of the limit switch cable Result The limit switch should have continuity Result The limit switch does not have continuity The limit switch is faulty and needs to be replaced Remove the multimeter leads and connect the Deutsch connector to the limit switch Start the engine and rotate the turntable more than 15 Turn the engine off Locate and disconnect the Deutsch connector to LST1S Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the Deutsch connector of the limit switch cable Result The limit switch should not have continuity Result The limit switch does have continuity The limit switc
344. st the Ground Control Override ooooccoonoccccconocicccononcncnononcnccnnancnr nano nenn 41 GERGZ aHel VH 42 B 14 Test the Drive Speed Stowed Poetion 42 B 15 Test the Drive Speed Raised or Extended sn 43 B 16 Test the Drive Speed Raised and Extended msn 44 B 17 Test the Alarm and Optional Flashing Beacon nennen 44 B 18 Perform Hydraulic Oil Analysis non narann nano nc 45 B 19 Test the Turntable Level Sensor nnn 45 B 20 Test the Secondary Boom Angle Sensor sse 47 B 21 Test the Primary Boom Angle Gensor nenn 49 B 22 Test the Safety Envelope Limit Switches 440 nn nennen 51 B 23 Test the Recovery Mode System sssssssssee eee 55 B 24 Inspect the Calibration Decal ne 56 B 25 Inspect for Turntable Bearing Wear A 57 Genie A TEREX BRAND D ZX 135 70 Part No 218700 September 2015 Bee Table of Contents Checklist C Procedures aunssunssnnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnunnnunnnsnnnnnnnnnnnnnnnnnnnnnnnnnnn 58 C 1 Perform Engine Maintenance Deutz Modelen 58 C 2 Perform Engine Maintenance Deutz Modelen 58 C 3 Perform Engine Maintenance Perkins Modelen 59 C 4 Replace the Engine Air Filter Element 59 C 5 Grease the Platform Overload Mechanism if equipped 60 C 6 Test the Platform Overload System if equipped ssesssss 61 C 7 Check and Adjust the Engine RM 63 C 8 Inspect fo
345. sult in death or serious injury and property damage All models 13 Be sure the free wheel valve on the drive pump is closed clockwise Note The free wheel valve should always remain closed 1 drive pump 2 screwdriver 3 lift pump 4 free wheel valve Genie A TEREX BRAND 70 ZX 135 70 D 3 Replace the Drive Hub Oil Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may result in component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove the plugs and drain the oil into a suitable container 3 Drive the machine to rotate the hub until the plugs are located one at the side and the other at the other side 1 drive hub plugs 4 Fillthe hub with oil from upper plug hole until the oil level is even with the bottom of the middle plug hole Install the plugs Refer to Specifications Fluid Capacity Specifications 5 Repeat steps 1 through 4 for all the other drive hubs Part No 218700 September 2015 Service Manual Turntable Rotate Drive Hub 1 A WARNING A WARNING Secure the turntable from rotating with the turntable ro
346. switch is in the run position before attempting to operate the machine 18 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 19 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 20 Start the engine Be sure there are no calibration faults shown on the display 21 Perform level sensor test Refer to Maintenance Procedure Test the Level Sensor Genie A TEREX BRAND 194 ZX 135 70 Part No 218700 September 2015 Service Manual 10 1 Steer Sensors The steer sensors measure steer angle and communicates that information to the ground controls ECM The steer sensor on the ground controls side of the machine at the square end acts as the lead sensor when in front wheel steer mode In rear wheel steer mode the steer sensor on the ground controls side of the machine at the circle end acts as the lead sensor The other three sensors follow the position or steer angle of the lead sensor There is a steer sensor mounted to the top of each steer yoke upper pivot pin How to Replace a Steer Sensor Note When the steer sensor is replaced both the sensor and magnet must be replaced as a set Note Perform this procedure with the axles fully retracted and the boom
347. t No 218700 Wire Circuit Legend Definition Engine Speed Select Axle Front Position Flashing Beacon Function Enable Fuel Select gas LP Filter Restricted Filter Switch Fuel Pump Float Switch Fuel Solenoid Foot switch Signal Forward AC Generator Ground Hydraulic Generator Horn High RPM Ignition Jib Bellcrank Down Jib Extend Jib Retract Jib Sensor Jib Bellcrank Up Jib Down Jib Extend Retract Control Jib Up Down Flow Control Propel Signal Joystick 5V DC Power Jib Rotate Left CCW Jib Rotate Right CW ATEREX BRAND ZX 135 70 247 Service Manual September 2015 Wire Circuit Legend Definition Platform Level Flow Control Propel Lockout Primary Boom Extend Retract Signal Platform Level Up Platform Rotate Control Platform Rotate Flow Control Platform Rotate Left CCW Platform Rotate Right CW Proportional Valve Pressure Switches Program Setup Enable Power to Length Sensor Pressure Sender Platform Tilt Alarm Platform Tilt Sensor Primary Boom Up Down Flow Control Power Proximity Sensor Axle Rear Position Recovery Receptacle Return Reverse Right Front Right Front Steer Sensor Retract Lockout RPM Right Rear Suffix Definition Suffix JSV Jib Select Valve PLF JU Jib Up PLL JUD Jib Up Down Control PLS LDS Load Sensor PLU LF Left Front PRC LFS Left Front Steer Sensor PRF LO Lockout PRL LOF Low fuel PRR LPS Lamps PRV LR Left Rear PS LRS Left Rear S
348. table lifting device AWARNING Crushing hazard The jib boom 17 Remove the pin retaining fasteners from the may become unbalanced and fall jib boom lift cylinder barrel end pivot pin when it is removed from the machine if it is not properly 18 Use a soft metal drift to remove the jib boom supported by the overhead lift cylinder barrel end pivot pin crane Crushing hazard The jib boom A WARNING could fall when the barrel end pivot pin is removed if not properly supported by the overhead crane A WARNING Crushing hazard The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane Genie Part No 218700 ZX 135 70 107 Service Manual September 2015 Jib Boom Components 3 3 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 2 Tag disconnect and plug
349. tage Above Normal Start Relay Circuit Test 677 5 Engine Starter Motor Relay Current Below Normal Start Relay Circuit Test 677 6 Engine Starter Motor Relay Current Above Normal Start Relay Cricuit Test 723 8 Engine Speed Sensor 2 Abnormal Engine Speed liming Sensor Circuit Test Frequency Pulse Width or Period 976 2 PTO Governor State Erratic Intermittent or PTO Switch Circuit Test Incorrect 1041 2 Start Signal Indicator Erratic Intermittent or Start Relay Circuit Test Incorrect Genie 240 A TEREX BRAND ZX 135 70 Part No 218700 September 2015 A Tea ee Perkins 854F 34T Engine Fault Code SPN Suspect Parameter Number FMI Failure Mode Identifier Service Manual SPN FMI Description Refer to Engine Manual 1076 2 Engine Fuel Injection Pump Fuel Control Solenoid Valve Test Valve Erratic Intermittent or Incorrect 1076 5 Engine Fuel Injection Pump Fuel Control Solenoid Valve Test Valve Current Below Normal 1076 6 Engine Fuel Injection Pump Fuel Control Solenoid Valve Test Valve Current Above Normal 1081 5 Engine Wait to Start Lamp Current Below Indicator Lamp Circuit Test Normal 1081 6 Engine Wait to Start Lamp Current Above Indicator Lamp Circuit Test Normal 1127 16 Engine Turbocharger 1 Boost Pressure High Intake Manifold Air Pressure Is High moderate severity 2 1127 18 Engine Turbocharger 1 Boost Pressure Low Intake Manifol
350. tall the bolt that was just removed into the SE original hole to secure the engine pivot plate O 24 AWARNING Crushing hazard Failure to Bolt torque sequence from above turntable 6 Lower the secondary boom to the stowed position A TEREX BRAND 76 ZX 135 70 Genie install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Confirm that each bearing mounting bolt under the drive chassis is torqued in sequence to specification Refer to Specifications Machine Torque Specifications 23 1 9 36 13 ef HO o 15 29 O O 33 186 8 316 20 270 11 120 3 40 O 26 21 9 O 34 35 Hu o 9 14 24 40 2 19 Bolt torque sequence from below turntable Part No 218700 September 2015 Service Manual E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer or hydraulic filters may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Note Before replacing the hydraulic oil the oil may be tested by an oil dis
351. tation lock pin Tag disconnect and plug the hydraulic hoses to the drive hub drive motor and brake for each drive hub assembly Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Attach a suitable lifting device to the lifting eye of one turntable rotate drive hub assembly Remove the drive hub mounting bolts from one drive hub assembly Carefully remove the turntable rotate drive hub assembly from the machine Do not remove both turntable rotate drive hub assemblies at the same time Crushing hazard The turntable rotate drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported by the lifting device Part No 218700 ATEREX BRAND ZX 135 70 Gen Checklist D Procedures 1 drive hub mounting bolts 2 drive hub fill plug 3 drive hub drain plug Remove the plug from the side of the drive hub Drain the oil from the hub into a suitable container Install the drive hub assembly onto the machine Lubricate and torque the drive hub mounting bolts to specification Refer to Specifications Machine Torque Specifications Fill the drive hub with oil from the top hole until the oil level is even with the bottom of the threads Apply pipe thread sealant to the plug Install the plug Refer to Specifications Fluid C
352. te Auxiliary power will be used to perform this Tip over hazard Do not adjust procedure Do not start the engine AWARNING the relief valve higher than specified Note Refer to Function Manifold Component list to locate th t lief valve nn 7 Repeat step 4 to confirm relief valve pressure 1 Hold the relief valve stem with a hex wrench 8 a a loosen the lock nut Remove the pressure gauge 2 Turm the valve stem counterclockwise several turns Do not allow the relief valve to come apart Tighten the lock nut 3 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold Genie ATEREX BRAND 168 ZX 135 70 Part No 218700 September 2015 A A 1 How to Adjust the Primary Boom Extend Relief Valve Note Perform this procedure with the axles extended 1 Remove the primary boom end cover from the pivot end of the boom 2 Locate the primary boom extend limit switch on the side of the primary boom 3 Follow the wiring from the switch to the pivot end of the primary boom Locate and disconnect the wire connector for the primary boom extend limit switch Note The correct wire connector will be a 2 pin connector with a yellow marker on the cable 4 Start the engine and fully extend the primary 4 boom Turn the engine off 0 5 Connect a 0 to 5000 psi 0 to 350 bar 11 pressure gauge to the ptest port on the function manifold 6 Start the engine from the gro
353. te Joystick Value at 5 0 V Value Too High Value Too Low Value at 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Power up controller with problem corrected Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Joystick Just calibrated Initiate one second beep of audible warning device Self clearing transient Front Axle Angle Sensor Value at 5 0 V Value Too High Value Too Low Primary up Secondary up down and Extend disabled Alarm sounds Primary up Secondary up down and Extend disabled Alarm sounds Check for an open ground circuit going to the sensor Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Value at 0 V Primary up Secondary up down and Extend disabled Alarm sounds Check for 5 0 VDC at the sensor Check for damaged wiring going to the sensor Check that the 0 VDC LED is lit on the TCON board Repair or replace as necessary Out of Tolerance Primary up Secondary up down and Extend disabled Alarm sounds Recalibrate sensor Not calibrated Primary up only active from TCON activate alarm Perform calibration procedure per service manual Just calibrated Initiate one second beep of audible warning device Genie A TEREX BRAND ZX 135 70 Self clearing transient Part No 218700
354. te and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie A TEREX BRAND 126 ZX 135 70 2 Remove the engine pivot plate retaining fastener Swing the engine pivot plate out away from the machine a 1 engine pivot plate anchor hole 2 engine pivot plate retaining fastener 3 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate 4 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving AWARNING Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury Remove the retaining fasteners from the fixed turntable cover at the ground controls side of the machine Remove the fixed turntable cover from the machine 6 Tag disconnect and plug the fuel hoses from the fuel tank Clean up any fuel that may have spilled Part No 218700 September 2015 a eee Service Manual Boom Components 7 Close the two hydraulic tank shut off valves at 15 Remove the hydraulic tank retaining fasteners he nyaran ganik 16 Remove the cover from the auxiliary power Component damage hazard unit batteries The engine must not be started wth ine hydraulic oer De he catis fom the valves in the closed position or component damage will occur If Electrocution bu
355. te one second beep of audible warning device Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Calibrate Joystick Self clearing transient 204 Genie A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up Down buttons on TCON Fault Check both buttons pressed Primary Boom Up Down disabled display message on LCD Check ribbon and connector from membrane switch If necessary replace membrane switch Primary Boom Ext Ret buttons on TCON Fault Check both buttons pressed Primary Boom Ext Retract disabled display message on LCD Check ribbon and connector from membrane switch If necessary replace membrane switch Primary Boom Length Fault Check unknown length Stop all boom functions allow only boom retract once fully retracted allow boom down Display message on LCD Check primary boom retracted and extended switches for proper contact with the boom Readjust or shim switch as necessary Primary Up Down Speed Not calibrated Display message on LCD and allow operation at default speed Perform auto calibrate procedure Primary Extend Retract Speed Not calibrated Display message on LCD and
356. teer Sensor PSE LS Limit Switch PSL LS Low RPM PSR LSR Lift Speed Reduction PTA MFV Multi Function Valve PTS MS Motor Shift Speed PUD PBD Primary Boom Down PWR PBE Primary Boom Extend PXS PBL Primary Boom Extend Retract Lockout RAP Valve RCV PBR Primary Boom Retract REC PBS Primary Boom Angle Sensor RET PBU Primary Boom Up REV PCE Pressure Comp Enable RF PCN Platform Control RFS PEL Primary Ext Ret Lockout RL PER Primary Boom Extend Retract Flow Control RPM PES Primary Boom Up Down Signal RR PL Primary Lockout PLD Platform Level Down Genie 248 ZX 135 70 Part No 218700 September 2015 Service Manual Wire Circuit Legend Suffix Definition Suffix Definition RRS Right Rear Steer Sensor STR Starter RS Rotary Sensor SUD Sec Boom Up Down Flow Control SA Start Aid Glow Plug or choke TAX Tilt Alarm X axis SB Secondary Boom TAY Tilt Alarm Y axis SBD Sec Boom Down TCN Ground Control SBE Sec Boom Extend TCN Ground Control Panel SBL Sec Boom Elevated TET Tether SBR Sec Boom Retract TRF Turntable Rotate Flow Control SBS Sec Boom Angle Sensor TRR Turntable Rotate Right CW SBU Sec Boom Up TS Temp Switches SCC Steering Valve CCW TSR Temp Sender SCW Steering Valve CW TSW Test Switch SEN Sensor TTA Turntable Tilt Alarm SER Sec Boom Extend Retract Flow Control TTS Turntable Tilt Sensor SHD CAN Shield SLD Secondary Boom Lockout Valve riser down SLE Secondary Boom Lockout Valve extend SP Spare SS Speed Sensor STC Steer Con
357. tember 2015 DEENEN ZZ Deutz TD 2 9 L4 Engine Fault Codes Service Manual SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier 5 523615 3 596 Metering unit Fuel System EE short circuit to battery low side SEN FMI KWP Description 523615 4 595 Metering unit Fuel System 523612 12 637 Internal ECU monitoring short circuit to ground high side detection reported ermar 523615 4 597 Metering Unit Fuel System 523612 12 1170 Internal software error ECU short circuit to ground low side 523612 14 973 Softwarereset CPU SWReset_0 523615 5 592 Metering unit Fuel System 523612 14 974 Softwarereset CPU SWReset 1 open load 523612 14 975 Softwarereset CPU SWReset 2 523615 12 593 Metering unit Fuel System powerstage over temperature man ene o SE a 523619 2 488 Physical range check high for RailMeUn0 exhaust gas temperature upstrem SCR CAT N Dr oo o 523698 11 122 Shut off request from supervisory exceeded RailMeUn1 monitoring function 523717 12 125 Timeout Error of 523613 0 858 eg detected CAN Transmit Frame AmbCon Weather environments Ze a S 523718 3 1488 SCH mainrelay short circuit to exceeded RailMeUn2 battery only CV56B 523613 0 860 Negative deviation of rail 523718 4 1489 SCR mainrelay short circuit to pressure second stage ground only CV56B RailMeUn22 523718 5 1486 SCR mainrelay open load o
358. the Drive Pump pump coupler separates from the flex plate Remove the drive pump from the machine Component damage hazard The pump s may become unbalanced and fall if not Component damage hazard Be sure to open the two hydraulic tank valves before performing this procedure 1 Connect a 0 to 600 psi O to 50 bar pressure ted BEEERCSEESRSE gauge to either the A or B test port on the Component damage hazard Ste pumps The engine must not be started 2 Perkins models Disconnect the engine with the hydraulic tank shut off wiring harness from the fuel shutoff solenoid at valves in the closed position or the injector pump component damage will occur If the tank valves are closed pie dee SEH dein ds shutoff remove the key from the key valve clockwise to the closed position switch and tag the machine to 3 Have another person crank the engine with inform personnel of the the starter motor for 15 seconds wait condition 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches approximately 250 psi 17 bar 4 Perkins models Connect the engine wiring harness to the fuel solenoid Deutz models Release the manual fuel shutoff valve 5 Startthe engine from the ground controls 6 Check for hydraulic leaks Genie Part No 218700 ZX 135 70 163 Service Manual SS a ts Manifolds 8 1 Function Manifold Components The function manifold is mounted to the turntable next to the ground c
359. tick very slowly towards the neutral or center position just before the machine function stops Do not let go of the joystick 7 While holding the joystick in position press the engine start button at the platform controls to set the joystick controller threshold 8 Repeatsteps for each joystick controlled machine function e Primary boom up down e Turntable rotate left right e Primary boom extend retract e Secondary up down and extend retract e Drive forward reverse 9 Once the threshold has been set press and hold the engine start button until the engine shuts off Do not press the red Emergency Stop button Note Approximately 3 seconds after the engine shuts off the alarm at the ground controls will sound to indicate the settings are being saved in memory 10 Atthe ground controls turn the key switch to the off position wait a moment and then turn the key switch to platform controls 11 Check the display at the ground controls to be sure there are no calibration faults Note There should be no calibration faults shown on the display If calibration faults exist repeat this procedure Part No 218700 September 2015 Service Manual Function speeds Note Be sure the machine is in the stowed position and the boom is rotated between the circle end tires Note Perform this procedure with the machine on a firm level surface that is free of obstructions Note Unless the LCD screen displays NOT
360. til EXIT is displayed Press the plus button to select YES then press the enter button to accept 135 Service Manual September 2015 Boom Components 54 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine 55 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 56 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 57 Pull out the red Emergency Stop button Start the engine and lower the boom to the stowed position Be sure there are no calibration faults shown on the display 58 Perform a primary boom angle test Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual Test the Primary Boom Angle Sensor Genie ATEREX BRAND 136 ZX 135 70 4 9 Secondary Boom Angle Sensor The secondary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity How to Calibrate the Secondary Boom Angle Sensor Note If the axle sensor has been removed or r
361. tion Switch Circuit Test Intermittent or Incorrect 593 31 Engine Idle Shutdown has Shutdown Engine This code indicates that an engine idle shutdown is about to occur This code does not represent a fault If equipped the warning lamp will come on 594 31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shut down has occurred This code does not represent a fault If equipped the warning lamp will flash and the shutdown lamp will come on 623 6 Red Stop Lamp Current Above Normal Indicator Lamp Circuit Test 624 6 Amber Warning Lamp Current Above Normal Indicator Lamp Circuit Test 630 Calibration Memory Erratic Intermittent or Injector Data Incorrect Test Incorrect 637 11 Engine Timing Sensor Other Failure Mode Engine Speed Timing Sensor Circuit Test 639 9 J1939 Network 1 Abnormal Update Rate CAN Data Link Circuit Test 639 14 J1939 Network 1 Special Instruction CAN Data Link Circuit Test 651 5 Engine Injector Cylinder 01 Current Below Injector Solenoid Circuit Test Normal 651 6 Engine Injector Cylinder 01 Current Above Injector Solenoid Circuit Test Normal 651 20 Engine Injector Cylinder 01 Data Drifted High Injector Data Incorrect Test 651 21 Engine Injector Cylinder 01 Data Drifted Low Injector Data Incorrect Test e Part No 218700 ATEREX BRAND Genie ZX 135 70 239 Service Manual AAA A AAA o Perkins 854F 34T Engine Fault Code SPN Suspect Parameter Nu
362. to Calibrate the Primary Boom Angle Sensor Raise the primary boom to 10 Result The reading at the display and digital level is within 2 of each other and of 10 Result The reading at the display and digital level is greater than 2 of each other and of 10 The primary boom angle sensor must be calibrated Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor Raise the primary boom to 40 Result The reading at the display and digital level is within 2 of each other and of 40 Result The reading at the display and digital level is greater than 2 of each other and of 40 The primary boom angle sensor must be calibrated Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor Fully raise the primary boom until it stops at approximately 58 Result The reading at the display and digital level is within 2 of each other and of 58 Result The reading at the display and digital level is greater than 2 of each other and of 58 The primary boom angle sensor must be calibrated Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor Part No 218700 Genie ATEREX BRAND ZX 135 70 51 Service Manual Checklist B Procedures B 22 Test the Safety Envelope Limit Switches Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Testing the machine envelope sa
363. to select YES then press the enter button to accept 27 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls Note Be sure that the bypass recovery key switch is in the run position before attempting to operate the machine 28 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 29 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 30 Pull out the red Emergency Stop button Start the engine and lower the boom to the stowed position Be sure there are no calibration faults shown on the display 31 Perform secondary boom angle test Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual Test the Secondary Boom Angle Sensor 2 Point Calibration procedure Note Use this procedure for software versions 4 01 and higher 32 Push in the ground controls red Emergency Stop button to the off position Do not turn the key switch to the off position 33 Turn the key switch to ground controls 34 Open the ground control box Part No 218700 Gen ATEREX BRAND ZX 135 70 139 Boom Components 35 Locate the calibration toggle switch at
364. to the on position Hold the enter button for approximately 5 seconds and then release it 41 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence plus enter enter plus 42 Press the enter or previous button on the LCD screen until DELETE PRIMARY BOOM ANGLE SENSOR CALIBRATION is displayed 43 45 46 47 48 49 50 51 Boom Components Press the plus button to select YES then press the enter button to accept Lower the primary boom to the stowed position Press the enter or previous button on the LCD SCREEN UNTIL PRIMARY BOOM FULLY LOWERED is displayed Press the plus button to select YES then press the enter button to accept Fully raise the secondary boom until it stops at the end of the cylinder stroke Fully raise the primary boom until it stops at the end of the cylinder stroke Press the enter or previous button on the LCD screen until PRIMARY BOOM FULLY RAISED is displayed Press the plus button to select YES then press the enter button to accept Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 52 53 Genie ATEREX BRAND Part No 218700 ZX 135 70 Press the enter or previous button on the LCD screen un
365. to the stowed position Be sure there are no calibration faults shown on the display 53 Perform secondary boom angle test Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual Test the Secondary Boom Angle Sensor Genie A TEREX BRAND 140 ZX 135 70 Part No 218700 September 2015 Service Manual A AAA Engines 5 1 5 2 RPM Adjustment Flex Plate Refer to Maintenance Procedure in the appropriate The flex plate acts as a coupler between the engine Service or Maintenance Manual for your machine and the pump It is bolted to the engine flywheel Check and Adjust the Engine RPM and has a splined center to drive the pump How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine flywheel Genie ATEREX BRAND Part No 218700 ZX 135 70 141 Service Manual September 2015 Engines How to Install a Flex Plate 1 Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the pump 2 Use blue thread locking compound and torque the flex plate mounting bolts in sequence to 28 ft
366. tor on TCON White 35 pin AMP connector on TCON Black 4 pin DTP connector on PCON 16 pin Molex mini fit circuit board to key switch 12 pin Deutsch connector lower upper limit switch harness Black 23 pin AMP connector on PCON White 35 pin AMP connector on PCON 10 pin ribbon connector PCON to LED driver board 20 pin Molex connector LED driver board 6 pin Deutsch connector on drive steer joystick 6 pin Deutsch connector on secondary boom up extend and down retract joystick 16 pin Molex conn on PCON PCB Black 23 pin AMP connector on DCON White 23 pin AMP connector on DCON 4 pin Deutsch connector on LSS1RS 4 pin Deutsch connector on sec boom retract LSS1RO 6 pin Deutsch connector on platform tilt sensor 3 pin Deutsch connector on RPM solenoid 2 pin Deutsch connector for pri boom up down flow control Part No 218700 Genie ATEREX BRAND ZX 135 70 Service Manual Circuit Connector Legend Number Description J59 J60 J61 J62 J63 J65 J66 J67 J68 J69 J70 J71 J76 J78 J79 J82 J84 e 2 pin Deutsch connector for primary boom up valve 2 pin Deutsch connector for primary boom down valve 2 pin Deutsch connector for primary boom ext ret flow control valve 2 pin Deutsch DT pri boom extend valve 2 pin Deutsch DT pri boom retract valve 2 pin Deutsch connector for secondary boom extend valve 2 pin Deutsch connector for secondary boom retract valve 2 pin
367. tributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom in the stowed position Checklist E Procedures Close the two hydraulic tank shut off valves at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 2 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Specifications Machine Specifications 3 Tag disconnect and plug the two suction hoses from the hydraulic tank 4 Tag disconnect and plug the two supply hoses for the auxiliary power units Cap the fittings on the hydraulic tank 5 Tag disconnect and plug the hydraulic hose from the drive motor case drain filter at the hydraulic tank Cap the fitting on the hydraulic tank 6 Tag
368. trol Signal Genie Part No 218700 ZX 135 70 249 Service Manual September 2015 Wire Color Legend Wire Coloring Power Circuits 1 All cylinder extension colors are solid and all P9A retract functions are striped black When using POB black wire the stripe shall be white 2 Allrotations that are LEFT or CW are solid P10 P11 RIGHT or CCW are striped and black When P30 the wire is black the stripe is white 3 All proportional valve wiring is striped Wire Color Legend BL Blue BL BK Blue Black BL RD Blue Red BL WH Blue White BK Black BK RD Black Red BK WH Black White BK YL Black Yellow BR Brown GR Green GR BK Green Black GR WH Green White RD Red RD BK Red Black RD WH Red White OR Orange OR BK Orange Black OR RD Orange Red WH White WH BK White Black WH RD White Red YL Yellow P38 P39 Genie 250 Primary boom down valve Engine ignition Fuel Primary boom extend valve Primary boom up valve Secondary boom down and extend valves Propel drive valves Turntable rotate flow control valve A TEREX BRAND ZX 135 70 Part No 218700 September 2015 Service Manual Circuit 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Wire Color Legend Primary Function Power to temp sender Auxiliary Power Platform level alarm Drive Motor shift speed Forward EDC A Reverse EDC B Brake Start Start
369. ttempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the machine on a firm level surface and in the stowed position with the axles extended 1 Extend the primary boom until the primary boom extension cylinder rod end pivot pin is accessible in the primary boom extension tube Boom Components 2 Remove the access cover from the pivot end of the primary boom 3 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Atthe platform end remove the external snap rings from the extension cylinder rod end pivot pin Use a soft metal drift to remove the pin 5 Remove the extension cylinder retainers from the saddle blocks 6 Attach a lifting strap from an overhead crane to the barrel end of the primary boom extension cylinder 7 Using the over
370. turbine plausibility ECU temperature error 1136 3 1400 Sensor error ECU temperature 1188 2 1414 Wastegate status message from signal range check high ECU missing 1136 4 1401 Sensor error ECU temperature 1188 7 1415 Wastegate actuator blocked signal range check low 1188 11 1411 Wastegate actuator internal 1176 3 849 Sensor error pressure sensor error upstream turbine signal range check high 1188 11 1412 Wastegate actuator EOL calibration not performed 1176 4 850 Sensor error pressure sensor correctly downstream turbine signal range check high 1188 11 1416 Wastegate actuator over 1180 0 1193 Physical heck high f BO 2 ysical range check high for exhaust gas temperature 1188 11 1417 Wastegate actuator over upstream turbine temperature gt 1359C 1180 0 1460 Turbocharger Wastegate CAN 1188 11 1418 Wastegate actuator operating feedback warning threshold voltage error exceeded 1188 13 1413 Wastegate actuator calibration 1180 0 1462 Exhaust gas temperature deviation too large recalibration upstream turbine warning required threshold exceeded 1231 14 85 CAN Bus 1 BusOff Status 1180 1 1194 Physical range check low for 1235 14 86 CAN Bus 2 BusOff Status exhaust gas temperature upstream turbine 1180 1 1461 Turbocharger Wastegate CAN feedback shut off threshold exceeded Genie Part No 218700 ZX 135 70 227 Service Manual AAA AAA a ss Deutz TD 2 9 L4 Engine Fault Codes S
371. turntable on top of the secondary boom and note the angle displayed on the digital level 12 Atthe SECONDARY BOOM ANGLE TO GRAVITY 3 5DEG screen press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note Be sure the number entered at the ground controls is a negative number Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 13 Start the engine from the ground controls Note If the system exits out of calibration mode when the engine is started repeat step 8 and then continue with step 14 14 Press and hold a function enable speed select button and the secondary boom up button until the digital level displays 20 degrees 137 Service Manual September 2015 Boom Components 15 Atthe ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated val
372. u have the appropriate tools lifting equipment and a suitable workshop Genie A TEREX BRAND vi ZX 135 70 Part No 218700 September 2015 Service Manual 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 A ADANGER 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 AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION 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 e 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 Part No 218700 Genie ATEREX BRAND ZX 135 70 vii
373. ual 6 4 Full Machine Calibration Full machine calibration must be completed in the proper sequence when the ALC 1000 circuit board TCON in the ground control box has been replaced or the turntable level sensor SCON has been replaced How to Fully Calibrate the Machine Calibration procedures shall only be completed by qualified technicians that have Genie factory service training 44 WARNING Tip over hazard Failure to calibrate the machine in the proper sequence could cause the machine to tip over resulting in death or serious injury Note A digital level will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Note Use the following chart to identify the description of each LCD screen control button used in this procedure m Enter ch Plus Note Start this procedure with the booms in the fully stowed position and the axle retracted y Minus Previous Part No 218700 Genie ATEREX BRAND ZX 135 70 Ground Controls Full machine calibration must be completed in the following sequence Select engine configuration Refer to Repair Section Display Module Unit of Measure and Language Joysticks Refer to Repair Procedure How to Calibrate a Joystick Turntable level sensor Refer to Repair Pr
374. ue 16 Press and hold a function enable speed select button and the secondary boom up button until the digital level displays 35 degrees 17 At the ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 18 Press and hold a function enable speed select button and the secondary boom up button until the digital level displays 50 degrees 19 At the ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 20 Press and hold a function enable speed select button and the secondary boom up button until the digital level displays 65 degrees Genie A TEREX BRAND 138 ZX 135 70 21 Atthe ground controls press the plus button or minus button to adjust the display to the exact value sho
375. ughout the full cycle of primary boom raising and lowering is essential for safe machine operation The platform is maintained level by the communication between the platform level sensor and the turntable level sensor If the platform becomes out of level the computer at the platform controls will open the appropriate solenoid valve s at the platform manifold to maintain a level platform A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Startthe engine from the ground controls 2 Pressand hold a function enable speed select button and fully retract the primary boom 3 Press the enter or previous button on the LCD screen until PLATFORM ANGLE is displayed 4 Press and hold a function enable speed select button and adjust the platform to zero degrees using the platform level up down buttons 5 Press and hold a function enable speed select button and fully raise the primary boom while observing the platform angle shown on the LCD display Result The platform should remain level at all times to within 2 degrees Note If the platform becomes out of level the tilt alarm will sound and the Platform Not Level Indicator will flash at the ground controls The platform level up down buttons will only work in the direction that will level the platform Level the platform until the indicator light turns off e le Service Manual September 2015 Checklist B Pr
376. uit board TCON has been replaced Note Perform this procedure with the axles retracted and the tires straightened Note Use the following chart to identify the description of each LCD screen control button used in this procedure el Enter ch Plus y Minus Previous 1 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 2 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 3 Turnthe key switch to ground controls and pull out the ground controls red Emergency Stop button to the on position 4 Loosen the steer angle sensor cover retaining fasteners Do not remove the fasteners or the sensor cover 5 Using a voltmeter set to DC voltage probe the back of the electrical connector at pins B and 6 Push in the red Emergency Stop button to the C off position Genie Part No 218700 ZX 135 70 197 Service Manual September 2015 Axle Components 6 Left front square end blue side and right 9 rear circle end yellow side angle sensors Rotate the sensor cover clockwise or counterclockwise until the voltage reading is between 1 4 to 1 6V DC Tighten the sensor cover fasteners Right front square end yellow side and left rear ci
377. ult Codes Service Manual SPN Suspect Parameter Number SPN FMI KWP Description FMI Failure Mode Identifier 412 3 1007 Sensor error EGR cooler KWP Keyword Protocol downstream temperature signal SPN FMI KWP Description range check high 190 8 422 Sensor crankshaft speed 412 4 1008 Sensor error EGR cooler disturbed signal downstream temperature signal range check low 190 11 390 Engine speed above warning threshold FOC Level 2 520 9 306 Timeout Error of CAN Receive Frame TSC1TR 190 12 420 Sensor camshaft speed no Setpoint signal 597 2 49 Break lever mainswitch and 190 12 423 Sensor crankshaft speed no break lever redundancy switch signal status not plausible 190 14 391 Engine speed above warning 624 3 971 SVS lamp short circuit to batt threshold Overrun Mode m 624 4 972 SVS lamp short circuit to grd 190 14 1222 Camshaft and Crankshaft speed sensor signal not available on 624 5 969 SVS lamp open load CAN 624 12 970 SVS lamp powerstage over 411 0 791 Physical range check high for temperature differential pressure Venturiunit 630 12 376 Access error EEPROM memory EGR delete 411 1 792 Physical range check low for 630 12 377 Access error EEPROM memory differential pressure Venturiunit read E25 630 12 378 Access error EEPROM memory 411 3 795 Sensor error differential pressure write Venturiunit EGR signal range check high 63
378. und controls and 12 press and release the rpm select button until 13 the engine changes to high idle da Genie Part No 218700 ZX 135 70 Service Manual Manifolds Simultaneously push and hold the function enable high speed button and the primary boom extend button with the primary boom fully extended Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specifications Turn the engine off Use a wrench to hold the relief valve and remove the cap Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified Repeat step 7 to confirm relief valve pressure At the pivot end of the primary boom connect the primary boom extend limit switch connector that was disconnected in step 3 Install the primary boom end cover Remove the pressure gauge Start the engine and fully retract the primary boom Turn the engine off 169 Service Manual September 2015 Manifolds 8 3 Platform Manifold The platform manifold is mounted to the platform mounting weldment Index Schematic No Description item Function Torque 1 Solenoid valve 3 position 4 way AH Platform rotate left right 20 25 ft lbs 27 34 Nm 2 Proportional solenoid valve 3 position 4 way Al Platform level up down 20 25 ft lbs 27 3
379. urn to the center or neutral position 9 Move the boom turntable joystick full stroke in the right direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Part No 218700 Genie ATEREX BRAND ZX 135 70 91 Platform Controls How to Reset a Proportional Valve Coil Default Note Use the following chart to identify the description of each LCD screen control button used in this procedure el Enter y ch Plus Previous Note This procedure only needs to be performed if a proportional valve has been replaced Minus Note After the valve coil defaults have been set each machine function threshold and default function speed must be set Refer to Repair Procedure How to Set the Function Thresholds and Default Function Speeds 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then press the enter button twice 4 Use the previous button to scroll through the menu until the function valve that needs to be reset is displayed Press the plus button to select yes then press the enter button to save the setting 5 Press the enter or previous button on the LCD screen
380. urntable Ss Test the Secondary Boom Angle Result The reading at the display and digital level is within 1 of each other Sensor Result The reading at the display and digital Genie specifications require that this procedure be level is greater than 1 of each other The performed every 250 hours or quarterly whichever level sensor must be calibrated Refer to comes first Repair Procedure How to Calibrate the Level m Sensor A properly functioning secondary boom angle sensor is essential to safe machine operation The ECM at the ground controls TCON monitors the position and angle of the secondary boom using the signal from the secondary boom angle sensor The secondary boom angle sensor signal is used to control the ramping of the secondary boom Note The turntable level sensor must be tested before starting this procedure Refer to Maintenance Procedure Test the Turntable Level Sensor Note A digital level will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit negative degree uphill slope includes a digital level with a magnetic base and si a deal cable harnesses ip over hazard e Y axis is A DANGER not within 1 failure to Note Use the following chart to identify the calibrate the level sensor could description of each LCD screen control button used cause the machine to tip over in this procedure resulting in
381. use only suitable equipment and or practices to allow the operator to safely exit the platform could result in death or serious injury Bodily injury hazard Platform leveling is not active when using recovery mode The platform could reach high out of level conditions when using this mode The operator will need to secure themself to the platform to prevent falling injury AWARNING The Recovery mode allows the platform to be lowered in the event the operator in the platform is unable to lower the platform using the platform controls system failure or emergency situations The recovery sequence will automatically retract the primary boom retract the secondary boom and then lower the primary boom using the auxiliary power unit to allow the operator at the platform controls to exit the platform Ground Controls 1 Turn the main key switch to ground controls Remove the key from the main key switch and insert the key into the bypass recovery key switch Note If this procedure is performed with the main key switch in the off position an active latched safety fault will be set and will have to be cleared 2 Turn and hold the bypass recovery key switch to the recovery position The switch must be held in the recovery position Result The auxiliary power unit will turn on and the boom will begin the following recovery sequence e The primary boom will retract e The secondary boom will retract e The primary boom will lo
382. vel Sensor 192 e Ne ET 195 UE DT CT 195 How to Calibrate a Replacement Steer Gensor nennen 197 How to Calibrate All Steer Sensors oncccoonncccccnnocccconnoncccnnnancccnnnanccc cnn nenn 197 10 2 Steer en TT 199 10 3 Axle Extension Cylinders A 200 10 4 Axle Angle Sensors How to Calibrate the Axle Angle Sensors 201 Genie A TEREX BRAND xiv ZX 135 70 Part No 218700 September 2015 ee Table of Contents Introduction litis lala dida 203 Control System Fault Codes esse eene nennen 204 Fault Mali 221 Deutz TD 2 9 L4 Engine Fault Codes eene 222 Perkins 854F 34T Engine Fault Code eene 237 Section 6 UE c s 245 introducti EL 245 Wire Circuit Legend icono dir tico 246 Wire Color Legend cm 250 Limit Switches and Angle Sensors sss 255 Circuit Connector Legend sssini oisin eE E EEEE ine denote dna dins 259 Drive Chassis and Platform Controller Pin Legend 262 Safety Controller Pin Legend ccccecceceseesceceeneneeceeneeeeeeeneeaecesneeeeeeeneeaeenensaee 263 Turntable Controller Pin Legend 264 Telematics Connector Pin Legend 265 Engine Relay and Fuse Panel Legend Deutz TD2011L04i 266 Engine Relay and Fuse Panel Legend Deutz TD2 9 Models 267 Engine Relay and Fuse Panel Legend Perkins
383. wer Note The key switch must be held in the recovery position until the recovery sequence is complete or until the operator in the platform can safely exit the platform Note If any boom safety limit switches are faulty the boom will only retract and not lower and the operator will need to be recovered from that point Note If the event the platform becomes out of level 15 all functions using auxiliary power will be disabled PLATFORM LEVEL gt 15 DEGREES will be displayed on the ground control LCD screen and the operator will have to be recovered using the Recovery Mode Note If the Recovery function has been used this may indicate there may be faults with the machine Tag and remove the machine from service until the fault has been corrected by trained personnel Genie ATEREX BRAND ZX 135 70 145 Part No 218700 Service Manual September 2015 Ground Controls 6 2 How to Remove the LCD Display Circuit Boards Screen Circuit Board The ground control box contains a replaceable 1 membrane decal with touch sensitive buttons for various machine functions The ground control box also contains two printed circuit boards 2 The LCD Liquid Crystal Display circuit board 3 is mounted to the inside of the control box lid which Push in the red Emergency Stop button to the off position at both the ground and platform controls Remove the ground control box lid fasteners Open the ground control bo
384. will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 Enter Plus Note Perform this procedure with the machine on a firm level surface with the booms in the fully stowed position and the axles fully extended y Minus Previous 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls Service Manual AR AAAAAAAAAAAAAAA A A A A A lt A lt A lt A22A2A2A2 lt 2 lt 2 lt lt RR Checklist B Procedures Start the engine from the ground controls Press the enter or previous button on the LCD screen until PRIMARY BOOM ANGLE TO GRAVITY DEGREES is displayed Place a digital level that has been calibrated to gravity on top of the primary boom 58 Le er gt ZA o t Gasta 0 5 Raise the primary boom while watching the display screen 6 Continue to raise the primary boom until it stops at approximately 58 Result The reading at the display and digital level is within 2 of each other and of 58 D Result The reading at the display and digital level is gr
385. witch Turntable Rotate Speed Not calibrated Display message on LCD and allow operation at default speed Perform auto calibrate procedure Turntable Rotate Flow Valve Not calibrated Normal function except threshold for one or the other direction is zero Display message on LCD Perform calibration procedure Just calibrated Value Too High Value Too Low Initiate one second beep of audible warning device Limited Speed and Direction frozen at zero and neutral Alarm sounds Self clearing transient Check for opens in the wiring or a bad ground Replace coil if necessary Check for shorts to ground in the wiring Replace coil if necessary Sensor Y Direction Value Too High Value Too Low Value at 0 V Out of Tolerance sounds Turntable Rotate Clockwise Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring Valve zero and neutral Alarm sounds Check for an open or shorted valve Turntable Rotate coil Repair or replace as necessary Counterclockwise Valve Operational Turntable Level Value at 5 0 V Primary up and extend disabled Alarm Check that SCON is grounded Replace SCON Just calibrated Initiate one second beep of audible warning device Self clearing transient Part No 218700 enie ATEREX BRAND ZX 135 70 213 Service Manual September 2015 Fault Codes Error Source Error T
386. with alternate zero function Note Prepare the digital level by placing it vertically on a known surface that is perpendicular to gravity Zero out the level with the alternate zero function Note When the level is calibrated correctly it should read 0 on a vertical surface Digital levels without alternate zero function Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 8 Note If your digital level does not have an alternate zero function it will read 90 on a vertical surface During calibration the measured value will need to be subtracted from 90 degrees to get the correct number to enter into the system 6 Point Calibration procedure Note Use this procedure for software versions before 4 01 Note For the 2 Point Calibration procedure proceed to step 33 1 Fully extend the axles with the booms in the stowed positions 2 Rai
387. wn on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 22 Press and hold a function enable speed select button and the secondary boom up button Fully raise the secondary boom The boom is fully raised when the cylinder is fully extended and the boom stops moving The angle will be 76 degrees 23 At the ground controls press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 24 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved Part No 218700 September 2015 Service Manual 25 Press the enter or previous button on the LCD screen until EXIT is displayed 26 Press the plus button
388. x controls the LCD display screen AWARNING Electrocution burn hazard The ECM circuit board is the main circuit board for the machine All operating parameters and configuration of options for the machine are stored in the ECM memory Note When the ECM circuit board is replaced the machine will need to be fully calibrated Refer to Repair Procedure How to Fully Calibrate the Machine Genie Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap Carefully disconnect the LCD circuit board ribbon cable from the ECM circuit board Remove the LCD display circuit board retaining fasteners Carefully remove the LCD display circuit board from the ground control box lid A TEREX BRAND 146 ZX 135 70 Part No 218700 September 2015 A How to Remove the ALC 1000 Circuit Board Note If the ALC 1000 circuit board TCON has been replaced the entire machine must be calibrated in a specific order Refer to Repair Procedure Full Machine Calibration 1 WARNING Push in the red Emergency Stop button to the off position at both the ground and platform controls Remov
389. x 125 mm Horsepower net intermittent 74 hp 2400 rpm 55 kW Induction system turbocharged Firing order 1 3 4 2 Low idle 1500 rpm 383 Hz High idle 2350 rpm 599 Hz Compression ratio 17 5 1 Compression pressure pressure psi or bar of the lowest cylinder must be at least 75 of the highest cylinder Governor centrifugal mechanical Valve Clearance cold Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 12 8 quarts 12 1 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24Nm Temperature switch point 275 F 135 C Oil Pressure switch Installation torque 8 18 ft lbs 11 24Nm Pressure switch point 22 psi 1 5 bar 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 Cranking speed 250 350 rpm Battery
390. x com Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Genie A TEREX BRAND ii ZX 135 70 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 Copyright 2014 by Terex Corporation 218700 Rev F September 2015 First Edition 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 Part No 218700 September 2015 Service Manual Introduction Revision History Revision Date Section Procedure Page Description A 12 2012 Initial Release A1 9 2013 Schematics Electrical Schematic B 9 2013 Maintenance B 18 D 1 Schematics Electrical Schematic B1 12 2013 Repair 4 8 C 4 2014 Specifications Perkins 1104D 44T Repair 4 8 4 9 D 4 2014 Fault Codes Fault Codes Specifications Performance Specifications D1 6 2014 Maintenance B 19 D2 8 2014 Maintenance Added B 20 Moved D 9 to C 8 C 1 C 3 Repair 1 2 D3 10 2014 Specifications Deutz TD2011L04i Repair 6 1 D4 11 2014 Specifications Machine Specifications Repair 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
391. y boom down speed not stowed Primary boom extend speed Primary boom retract speed Secondary boom up speed stowed Secondary boom up speed not stowed Secondary boom down speed 120 max 50 min stowed Secondary boom down speed not 100 default stowed Secondary boom extend speed Secondary boom retract speed Turntable rotate speed retracted Turntable rotate speed not retracted Turntable rotate speed extended Jib up speed retracted Jib up speed not retracted Jib down speed retracted Jib down speed not retracted e Genie ATEREX BRAND Part No 218700 ZX 135 70 153 Service Manual September 2015 gees Display Module Screen or Menu Procedure Description Range or Selection Lift Functions With key switch OFF press and Primary boom up down ramp Ramps hold the enter button and turn acceleration key switch to on position Primary boom up down ramp Release the enter button and deceleration press 8 plus plus previous previou Primary boom extend retract ramp s acceleration Primary boom extend retract ramp 150 max and 50 min deceleration 100 default Secondary boom up down ramp 5 increment acceleration Secondary boom up down ramp deceleration Secondary boom extend retract ramp acceleration Secondary boom extend retract ramp deceleration Turntable rotate ramp acceleration Turntable rotate ramp deceleration Jib boom up d
392. ype Effects Recovery Actions Safety Turntable Level Sensor Y Direction Platform Level Sensor Y Direction Value at 5 0 V Value Too High Value Too Low Value at 0 V Out of Tolerance Just calibrated Value at 5 0 V Value Too High Value Too Low Value at 0 V Primary up and extend disabled Alarm sounds Initiate one second beep of audible warning device Primary up and extend disabled Alarm sounds Check that SCON is grounded Replace SCON Self clearing transient Check that SCON is grounded Just calibrated Initiate one second beep of audible warning device Self clearing transient Platform Rotate Clockwise Fault Check Fault Check Check for defective or damaged wiring Valve Check for an open or shorted valve Platform Rotate coil Repair or replace as necessary Counterclockwise Valve Jib Extend Retract Valve Fault Check Fault Check Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Jib Up Down Flow Valve s Not calibrated Normal function except threshold for one or the other direction is zero Display message on LCD Perform calibration procedure Just calibrated Value Too High Value Too Low Initiate one second beep of audible warning device Limited Speed and Direction frozen at zero and neutral Alarm sounds Self clearing transient Check for o
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