Terex Genie ZX-135/70 Installation and operating manual

Service and Repair Manual
Serial Number Range
ZX®-135/70
from ZX13514-2533 to
ZX13516H-
3199
Includes:
ZX13514-
2463
ZX13514-
2469
ZX13514-
2631
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
ZX135H-3200 to
ZX135H-
4000
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your
machine.
Part No. 1268558GT
Rev A5
March 2018

Service and Repair Manual March 2018
Introduction
ii ZX®-135/70 Part No. 1268558GT
Intr od ucti o n Intr od ucti o n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2015 by Terex Corporation
1268558GT Rev A, September 2015
First Edition, First Printing
Genie and “ZX” are registered trademark of Terex South Dakota,
Inc. in the U.S.A. and many other countries.

March 2018 Service and Repair Manual
Introduction
Part No. 1268558GT ZX®-135/70 iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 11/2015 Schematics Limit Switch Legend
A2 5/2016 Repair Procedure 4-9
A3 9/2016 Introduction Serial Number Legend
A4 10/2016 Schematics Electrical / Hydraulic Schematics
A5 3/2018 Repair Display Module
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual March 2018
Introduction
iv ZX®-135/70 Part No. 1268558GT
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
1 Sequence number
2 Serial label (located under cover)
3 Serial number (stamped on chassis)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
1 Serial label (located under cover)
2 Serial number (stamped on chassis)

March 2018 Service and Repair Manual
Safety Rules
Part No. 1268558GT ZX®-135/70 v
Section 1 Safet y R ul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual March 2018
Safety Rules
vi ZX®-135/70 Part No. 1268558GT
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could res
ult in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to
wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are
in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

March 2018
Table of Contents
Part No. 1268558GT ZX®-135/70 vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules ..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................1
Hydraulic Oil Specifications....................................................................................2
Hydraulic Component Specifications......................................................................5
Deutz TD 2.9 Engine Specifications.......................................................................7
Deutz TD2011L04i Engine Specifications ..............................................................8
Perkins 854F-34T Engine Specifications .............................................................10
Perkins 1104D-44T Engine Specifications ...........................................................12
Machine Torque Specifications ............................................................................14
Hydraulic Hose and Fitting Torque Specifications ...............................................15
Torque Procedure ................................................................................................16

March 2018
Table of Contents
viii ZX®-135/70 Part No. 1268558GT
Section 3 Repair Procedures..............................................................................................19
Introduction ...........................................................................................................19
Platform Controls ...............................................................................................21
Platform Controls ..................................................................................................21
1-1 Platform Circuit Board ....................................................................................21
How to Remove the LED Circuit Board ...........................................................23
1-2 Joysticks - How to Calibrate a Joystick ..........................................................23
How to Reset a Proportional Valve Coil Default..............................................27
How to Set the Function Thresholds and Default Functions Speeds..............28
How to Adjust the Function Speeds ................................................................30
How to Adjust the Function Ramp Rate Setting..............................................31
Platform Components ........................................................................................32
2-1 Platform ..........................................................................................................32
2-2 Platform Leveling Cylinder .............................................................................33
2-3 Platform Rotator .............................................................................................34
How to Bleed the Platform Rotator..................................................................35
2-4 Platform Level Sensor - How to Calibrate the Platform Level Sensor ...........36
2-5 Platform Overload System (if equipped) ........................................................37
2-6 Platform Overload Recovery Message ..........................................................39

March 2018
Table of Contents
Part No. 1268558GT ZX®-135/70 ix
Jib Boom Components ......................................................................................40
3-1 Jib Boom Cable Track....................................................................................41
How to Repair the Cable Track .......................................................................43
3-2 Jib Boom ........................................................................................................44
3-3 Jib Boom Lift Cylinder ....................................................................................46
3-4 Jib Boom Level Cylinder ................................................................................47
3-5 Jib Boom Extension Cylinder .........................................................................48
3-6 Jib Boom Bellcrank Angle Sensor - How to Calibrate the Jib Boom Bellcrank
Angle Sensor ................................................................................................50
Boom Components ............................................................................................56
4-1 Primary Boom Cable Track ............................................................................57
How to Repair the Primary Boom Cable Track ...............................................59
4-2 Secondary Boom Cable Track .......................................................................60
How to Repair the Secondary Boom Cable Track ..........................................62
4-3 Primary Boom.................................................................................................63
4-4 Primary Boom Lift Cylinder ............................................................................65
4-5 Secondary Boom Lift Cylinder........................................................................66
4-6 Primary Boom Extension Cylinder .................................................................70
4-7 Secondary Boom Extension Cylinders...........................................................71
4-8 Primary Boom Angle Sensor - How to Calibrate the Primary Boom Angle
Sensor ..........................................................................................................73
4-9 Secondary Boom Angle Sensor - How to Calibrate the Secondary Boom Angle
Sensor ..........................................................................................................78
Engines................................................................................................................83
5-1 RPM Adjustment ............................................................................................83
5-2 Flex Plate .......................................................................................................83
How to Install the Flex Plate............................................................................84

March 2018
Table of Contents
x ZX®-135/70 Part No. 1268558GT
Ground Controls.................................................................................................85
6-1 Bypass/Recovery Key Switch.........................................................................85
How to Use the Recovery Mode......................................................................87
6-2 Circuit Boards .................................................................................................88
6-3 Membrane Decal ............................................................................................90
6-4 Full Machine Calibration.................................................................................91
Display Module ...................................................................................................92
Hydraulic Pumps ..............................................................................................101
7-1 Function Pump .............................................................................................101
How to Prime the Function Pump .................................................................102
How to Adjust the Function Pump Standby Pressure ...................................102
How to Adjust the Function Pump Pressure Compensator...........................103
7-2 Drive Pump...................................................................................................104
How to Prime the Drive Pump .......................................................................105
Manifolds ...........................................................................................................106
8-1 Function Manifold Components....................................................................106
8-2 Valve Adjustments - Function Manifold........................................................110
8-3 Platform Manifold .........................................................................................112
8-4 Jib Boom Manifold........................................................................................114
8-5 Flow Control Mainfold...................................................................................116
8-6 Function Enable Valve .................................................................................117
8-7 Turntable Rotation Manifold .........................................................................118
8-8 Steer and Axle Manifold ...............................................................................120
8-9 Valve Adjustments - Steer and Axle Manifold ..............................................124
8-10 Traction Manifold Components ..................................................................126
8-11 Valve Adjustments - Traction Manifold.......................................................130
8-12 Drive Oil Diverter Manifold Components (welder option)...........................131
8-13 Valve Coils .................................................................................................132