Terex Genie ZX-135/70 User manual

Service Manual
Serial Number Range
ZX-135/70
From ZX13513-2001
to ZX13514-
2532
(does not include
ZX13514-
2463,
ZX13514-2469
and
ZX13514-2531)
Part No.
218700
Rev F
September 2015

Service Manual September 2015
Introduction
ii ZX-135/70Part No. 218700
Intr od ucti on Intr od ucti on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
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 Operator's, Parts,
Maintenance, and Service and Repair manuals.
Copyright © 2014 by Terex Corporation
218700 Rev F, September 2015
First Edition, 6L[WK Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“ZX” is a trademark of Terex South Dakota, Inc..

September 2015 Service Manual
Introduction
Part No. 218700 ZX-135/70 iii
Revision History
Revision Date Section Procedure / Page / Description
A 12/2012 Initial Release
A1 9/2013 Schematics Electrical Schematic
B 9/2013 Maintenance
Schematics
B-18, D-1
Electrical Schematic
B1 12/2013 Repair 4-8
C 4/2014 Specifications
Repair
Perkins 1104D-44T
4-8, 4-9
D 4/2014 Fault Codes
Specifications
Fault Codes
Performance Specifications
D1 6/2014 Maintenance B-19
D2 8/2014 Maintenance
Repair
Added B-20, Moved D-9 to C-8, C-1, C-3
1-2
D3 10/2014 Specifications
Repair
Deutz TD2011L04i
6-1
D4 11/2014 Specifications
Repair
Machine Specifications
Display Module, 4-8, 4-9
D5 11/2014 Specifications Performance Specifications
E 2/2015 Maintenance Checklist B, B-3, B-19, B-20, B-21, B-22, B-23, B-24
Repair 1-1, 3-6, 4-8, 4-9, 6-1, 6-2, 6-4, 8-5, 9-2
Display Module
Fault Codes Fault Matrix
Schematics Hydraulic Schematic
E1 5/2015 Maintenance B-23
Repair 6-1 (Recovery mode)
Reference Examples:
Section – Maintenance, B-3
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service Manual September 2015
Introduction
iv ZX-135/70 Part No. 218700
Revision History
Revision Date Section Procedure / Page / Description
F 9/2015 Repair 3-6, 4-8, 4-9, 6-1
Fault Codes Added Deutz TD2.9 L4, Perkins 854F-34T
Schematics Updated Perkins 1104D-44T
Added Perkins 854F-34T
Added Deutz TD2.9 L4
Electrical schematic
Reference Examples:
Section – Maintenance, B-3
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

September 2015 Service Manual
Introduction
Part No. 218700 ZX-135/70 v
Serial Number Legend
1 Model
2 Model year
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)

Service Manual September 2015
Safety Rules
vi ZX-135/70 Part No. 218700
Section 1 Safet y R ul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

September 2015 Service Manual
Safety Rules
Part No. 218700 ZX-135/70 vii
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
ma
y cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of
potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approve
d fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, over
head crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e.,
cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop
or work area
is properly ventilated and well lit.

September 2015
Table of Contents
viii ZX-135/70 Part No. 218700
Introduction Introduction .......................................................................................................... ii
Important Information ..............................................................................................ii
Find a Manual for this Model...................................................................................ii
Revision History .....................................................................................................iii
Serial Number Legend ........................................................................................... v
Section 1Safety Rules......................................................................................................... vi
General Safety Rules .............................................................................................vi
Section 2 Specifications....................................................................................................... 1
Machine Specifications .......................................................................................... 1
Performance Specifications ................................................................................... 1
Hydraulic Specification........................................................................................... 2
Hydraulic Component Specifications ..................................................................... 4
Deutz TD2011L04i Engine Specifications ............................................................. 6
Deutz TD 2.9 Engine Specifications ...................................................................... 7
Perkins 1104D-44T Engine Specifications ............................................................ 8
Perkins 854F-34T Engine Specifications ............................................................. 10
Machine Torque Specifications............................................................................ 11
Hydraulic Hose and Fitting Torque Specifications ............................................... 12
Torque Procedure ................................................................................................ 13
SAE and Metric Fasteners Torque Charts........................................................... 14

September 2015
Table of Contents
Part No. 218700 ZX-135/70 ix
Section 3 Scheduled Maintenance Procedures ...............................................................15
Introduction...........................................................................................................15
Pre-Delivery Preparation Report ..........................................................................19
Maintenance Inspection Report............................................................................21
Checklist A Procedures .....................................................................................23
A-1 Inspect the Manuals and Decals....................................................................23
A-2 Perform Pre-operation Inspection..................................................................24
A-3 Perform Function Tests .................................................................................24
A-4 Perform Engine Maintenance – Perkins Models ...........................................25
A-5 Perform Engine Maintenance – Deutz Models ..............................................25
A-6 Check the Hydraulic Return Filter Condition Indicator ..................................26
A-7 Perform 30-Day Service ................................................................................27
A-8 Grease the Turntable Rotation Bearing and Rotate Gear .............................27
A-9 Replace the Drive Hub Oil .............................................................................28

September 2015
Table of Contents
x ZX-135/70 Part No. 218700
Checklist B Procedures..................................................................................... 29
B-1 Inspect the Batteries...................................................................................... 29
B-2 Inspect the Electrical Wiring .......................................................................... 30
B-3 Test the Key Switches ................................................................................... 32
B-4 Inspect the Engine Air Filter .......................................................................... 34
B-5 Check the Oil Cooler and Cooling Fins - Deutz Models................................ 35
B-6 Check the Exhaust System ........................................................................... 36
B-7 Confirm the Proper Brake Configuration ....................................................... 37
B-8 Inspect the Tires, Wheels and Lug Nut Torque............................................. 38
B-9 Check the Drive Hub Oil Level and Fastener Torque ................................... 38
B-10 Test the Platform Self-leveling .................................................................... 39
B-11 Test the Engine Idle Select Operation ........................................................ 40
B-12 Test the Ground Control Override ............................................................... 41
B-13 Test the Drive Brakes.................................................................................. 42
B-14 Test the Drive Speed – Stowed Position..................................................... 42
B-15 Test the Drive Speed – Raised or Extended............................................... 43
B-16 Test the Drive Speed – Raised and Extended ............................................ 44
B-17 Test the Alarm and Optional Flashing Beacon............................................ 44
B-18 Perform Hydraulic Oil Analysis.................................................................... 45
B-19 Test the Turntable Level Sensor ................................................................. 45
B-20 Test the Secondary Boom Angle Sensor .................................................... 47
B-21 Test the Primary Boom Angle Sensor ......................................................... 49
B-22 Test the Safety Envelope Limit Switches .................................................... 51
B-23 Test the Recovery Mode System ................................................................ 55
B-24 Inspect the Calibration Decal ...................................................................... 56
B-25 Inspect for Turntable Bearing Wear ............................................................ 57