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Genie ZX-135/70 Service Manual 218700 – PDF DOWNLOAD
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Description
Genie ZX-135/70 Service Manual 218700 – PDF DOWNLOAD
Language : English
Pages : 307
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie ZX-135/70 Service Manual 218700 – PDF DOWNLOAD
Front Cover........................................................................................... 1 Introduction Introduction............................................................................. 2 Important Information............................................................................. 2 Find a Manual for this Model...................................................................... 2 Revision History.................................................................................. 3 Serial Number Legend.............................................................................. 5 Section 1 Safety Rules................................................................................ 6 General Safety Rules.............................................................................. 6 Section 2 Specifications.............................................................................. 17 Machine Specifications............................................................................ 17 Performance Specifications........................................................................ 17 Hydraulic Specification........................................................................... 18 Hydraulic Component Specifications................................................................ 20 Deutz TD2011L04i Engine Specifications............................................................ 22 Deutz TD 2.9 Engine Specifications................................................................ 23 Perkins 1104D-44T Engine Specifications........................................................... 24 Perkins 854F-34T Engine Specifications............................................................ 26 Machine Torque Specifications..................................................................... 27 Hydraulic Hose and Fitting Torque Specifications.................................................. 28 Torque Procedure.................................................................................. 29 SAE and Metric Fasteners Torque Charts............................................................ 30 Section 3 Scheduled Maintenance Procedures............................................................ 31 Introduction...................................................................................... 31 Pre-Delivery Preparation Report................................................................... 35 Maintenance Inspection Report..................................................................... 37 Checklist A Procedures............................................................................ 39 A-1 Inspect the Manuals and Decals............................................................ 39 A-2 Perform Pre-operation Inspection.......................................................... 40 A-3 Perform Function Tests.................................................................... 40 A-4 Perform Engine Maintenance – Perkins Models............................................... 41 A-5 Perform Engine Maintenance – Deutz Models................................................. 41 A-6 Check the Hydraulic Return Filter Condition Indicator..................................... 42 A-7 Perform 30-Day Service.................................................................... 43 A-8 Grease the Turntable Rotation Bearing and Rotate Gear..................................... 43 A-9 Replace the Drive Hub Oil................................................................. 44 Checklist B Procedures............................................................................ 45 B-1 Inspect the Batteries..................................................................... 45 B-2 Inspect the Electrical Wiring............................................................. 46 B-3 Test the Key Switches..................................................................... 48 B-4 Inspect the Engine Air Filter............................................................. 50 B-5 Check the Oil Cooler and Cooling Fins - Deutz Models...................................... 51 B-6 Check the Exhaust System.................................................................. 52 B-7 Confirm the Proper Brake Configuration.................................................... 53 B-8 Inspect the Tires, Wheels and Lug Nut Torque.............................................. 54 B-9 Check the Drive Hub Oil Level and Fastener Torque......................................... 54 B-10 Test the Platform Self-leveling.......................................................... 55 B-11 Test the Engine Idle Select Operation.................................................... 56 B-12 Test the Ground Control Override......................................................... 57 B-13 Test the Drive Brakes.................................................................... 58 B-14 Test the Drive Speed – Stowed Position................................................... 58 B-15 Test the Drive Speed – Raised or Extended................................................ 59 B-16 Test the Drive Speed – Raised and Extended............................................... 60 B-17 Test the Alarm and Optional Flashing Beacon.............................................. 60 B-18 Perform Hydraulic Oil Analysis........................................................... 61 B-19 Test the Turntable Level Sensor.......................................................... 61 B-20 Test the Secondary Boom Angle Sensor..................................................... 63 B-21 Test the Primary Boom Angle Sensor....................................................... 65 B-22 Test the Safety Envelope Limit Switches.................................................. 67 B-23 Test the Recovery Mode System............................................................ 71 B-24 Inspect the Calibration Decal............................................................ 72 B-25 Inspect for Turntable Bearing Wear....................................................... 73 Checklist C Procedures............................................................................ 74 C-1 Perform Engine Maintenance - Deutz Models................................................. 74 C-2 Perform Engine Maintenance - Deutz Models................................................. 74 C-3 Perform Engine Maintenance - Perkins Models............................................... 75 C-4 Replace the Engine Air Filter Element..................................................... 75 C-5 Grease the Platform Overload Mechanism (if equipped)...................................... 76 C-6 Test the Platform Overload System (if equipped)........................................... 77 C-7 Check and Adjust the Engine RPM........................................................... 79 C-8 Inspect for Turntable Bearing Wear........................................................ 82 Checklist D Procedures............................................................................ 84 D-1 Check the Boom Wear Pads.................................................................. 84 D-2 Check the Free-wheel Configuration........................................................ 85 D-3 Replace the Drive Hub Oil................................................................. 86 D-4 Adjust the Turntable Rotatation Gear Backlash............................................. 88 D-5 Replace the Hydraulic Filter Elements..................................................... 89 D-6 Perform Engine Maintenance - Deutz Models................................................. 90 D-7 Perform Engine Maintenance - Perkins Models............................................... 91 D-8 Check the Turntable Rotation Bearing Bolts................................................ 91 Checklist E Procedures............................................................................ 93 E-1 Test or Replace the Hydraulic Oil......................................................... 93 E-2 Perform Engine Maintenance - Perkins Models............................................... 95 E-3 Perform Engine Maintenance - Deutz Models................................................. 95 E-4 Perform Engine Maintenance - Perkins Models............................................... 96 E-5 Perform Engine Maintenance - Perkins Models............................................... 96 E-6 Perform Engine Maintenance - Deutz Models................................................. 97 E-7 Perform Engine Maintenance - Perkins Models............................................... 97 E-8 Perform Engine Maintenance - Deutz Models................................................. 98 Section 4 Repair Procedures........................................................................... 99 Introduction...................................................................................... 99 Platform Controls.................................................................................101 Platform Controls.............................................................................101 1-1 Platform Circuit Board....................................................................101 How to Remove the LED Circuit Board.......................................................103 1-2 Joysticks - How to Calibrate a Joystick...................................................103 How to Reset a Proportional Valve Coil Default............................................107 How to Set the Function Thresholds and Default Functions Speeds...........................108 How to Adjust the Function Speeds.........................................................110 How to Adjust the Function Ramp Rate Setting..............................................110 Platform Components...............................................................................111 2-1 Platform..................................................................................111 2-2 Platform Leveling Cylinder................................................................112 2-3 Platform Rotator..........................................................................113 How to Bleed the Platform Rotator.........................................................114 2-4 Platform Level Sensor - How to Calibrate the Platform Level Sensor........................115 2-5 Platform Overload System (if equipped)....................................................116 2-6 Platform Overload Recovery Message........................................................117 Jib Boom Components...............................................................................119 3-1 Jib Boom Cable Track......................................................................120 How to Repair the Cable Track.............................................................121 3-2 Jib Boom..................................................................................122 3-3 Jib Boom Lift Cylinder....................................................................124 3-4 Jib Boom Level Cylinder...................................................................125 3-5 Jib Boom Extension Cylinder...............................................................126 3-6 Jib Boom Bellcrank Angle Sensor - How to Calibrate the Jib Boom Bellcrank Angle Sensor....127 Boom Components...................................................................................133 4-1 Primary Boom Cable Track..................................................................134 How to Repair the Primary Boom Cable Track................................................136 4-2 Secondary Boom Cable Track................................................................136 How to Repair the Secondary Boom Cable Track..............................................138 4-3 Primary Boom..............................................................................139 4-4 Primary Boom Lift Cylinder................................................................141 4-5 Secondary Boom Lift Cylinder..............................................................142 4-6 Primary Boom Extension Cylinder...........................................................145 4-7 Secondary Boom Extension Cylinders........................................................146 4-8 Primary Boom Angle Sensor - How to Calibrate the Primary Boom Angle Sensor................147 4-9 Secondary Boom Angle Sensor - How to Calibrate the Secondary Boom Angle Sensor............152 Engines...........................................................................................157 5-1 RPM Adjustment............................................................................157 5-2 Flex Plate................................................................................157 How to Install the Flex Plate.............................................................158 Ground Controls...................................................................................159 6-1 Bypass/Recovery Key Switch................................................................159 How to Use the Recovery Mode..............................................................161 6-2 Circuit Boards............................................................................162 6-3 Membrane Decal............................................................................164 6-4 Full Machine Calibration..................................................................165 Display Module....................................................................................166 Hydraulic Pumps...................................................................................175 7-1 Function Pump.............................................................................175 How to Prime the Function Pump............................................................176 How to Adjust the Function Pump Standby Pressure..........................................176 How to Adjust the Function Pump Pressure Compensator......................................176 7-2 Drive Pump................................................................................178 How to Prime the Drive Pump...............................................................179 Manifolds.........................................................................................180 8-1 Function Manifold Components..............................................................180 8-2 Valve Adjustments - Function Manifold.....................................................184 8-3 Platform Manifold.........................................................................186 8-4 Jib Boom Manifold.........................................................................188 8-5 Flow Control Mainfold.....................................................................190 8-6 Function Enable Valve.....................................................................191 8-7 Turntable Rotation Manifold...............................................................192 8-8 Steer and Axle Manifold...................................................................193 8-9 Valve Adjustments - Steer and Axle Manifold...............................................197 8-10 Traction Manifold Components.............................................................198 8-11 Valve Adjustments - Traction Manifold....................................................202 8-12 Drive Oil Diverter Manifold Components (welder option)...................................203 8-13 Valve Coils..............................................................................204 How to Test a Coil Diode..................................................................205 Turntable Rotation Components.....................................................................206 9-1 Turntable Rotation Assembly...............................................................206 How to Adjust the Turntable Rotation Gear Backlash........................................207 9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor......................208 Axle Components...................................................................................211 10-1 Steer Sensors............................................................................211 How to Calibrate a Replacement Steer Sensor...............................................213 How to Calibrate All Steer Sensors........................................................213 10-2 Steer Cylinders..........................................................................215 10-3 Axle Extension Cylinders.................................................................216 10-4 Axle Angle Sensors - How to Calibrate the Axle Angle Sensors.............................217 Section 5 Fault Codes.................................................................................219 Introduction......................................................................................219 Control System Fault Codes........................................................................220 Fault Matrix......................................................................................237 Deutz TD 2.9 L4 Engine Fault Codes................................................................238 Perkins 854F-34T Engine Fault Code................................................................253 Section 6 Schematics..................................................................................261 Introduction......................................................................................261 Wire Circuit Legend...............................................................................262 Wire Color Legend.................................................................................266 Limit Switches and Angle Sensors..................................................................271 Circuit Connector Legend..........................................................................275 Drive Chassis and Platform Controller Pin Legend..................................................278 Safety Controller Pin Legend......................................................................279 Turntable Controller Pin Legend...................................................................280 Telematics Connector Pin Legend...................................................................281 Engine Relay and Fuse Panel Legend - Deutz TD2011L04i.............................................282 Engine Relay and Fuse Panel Legend- Deutz TD2.9 Models............................................283 Engine Relay and Fuse Panel Legend - Perkins 1104D-44T............................................284 Engine Relay and Fuse Panel Legend- Perkins 854F Models...........................................285 Electrical Symbols Legend.........................................................................286 Hydraulic Symbols Legend..........................................................................287 Perkins 1104D Engine Electrical Schematic.........................................................290 Perkins 854F-34T Engine Electrical Schematic......................................................292 Perkins 854F-34T Engine Harness...................................................................293 Deutz TD2.9 Engine Electrical Schematic...........................................................296 Deutz TD2.9 Engine Harness........................................................................297 Generator Wiring Schematic........................................................................299 Hydraulic Generator (Welder Option)...............................................................302 Hydraulic Schematic...............................................................................303 Electrical Schematic (Includes Deutz Engine)......................................................306 Back Cover............................................................................................307
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