Genie ZX-135/70 with Jib-Extend Installation and operating manual

Service and Repair Manual
Serial Number Range
ZX-135/70
From ZX13514-
2533 to
ZX13516H-3
199
Includes:
ZX13514-
2463
ZX13514-
2469
ZX13514-
2631
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
From ZX135H-3200
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268558
Rev A4
October 2016

Service and Repair Manual October 2016
Introduction
ii ZX-135/70 Part No. 1268558
Intr oduct io n Intr oduct io 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 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
1268558 Rev A4, October 2016
First Edition, First 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..

October 2016 Service and Repair Manual
Introduction
Part No. 1268558 ZX-135/70 iii
Revision History
Revision
Date
Section
Procedure / Page / Description
A 9/2015 Initial Release
A1 11/2015 Schematics Page 201
A2 5/2016 Repair Procedure 4-9
A3 9/2016 Introduction Serial Number Legend
A4
10/2016
Schematics
Hydraulic Schematic; Electrical Schematic
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 October 2016
Introduction
iv ZX-135/70 Part No. 1268558
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)

October 2016 Service and Repair Manual
Safety Rules
Part No. 1268558 ZX-135/70 v
Section 1 Safet y Rul 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 October 2016
Safety Rules
vi ZX-135/70 Part No. 1268558
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,
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 int
ended 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.

October 2016
Table of Contents
Part No. 1268558 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
Section 3 Repair Procedures .............................................................................................19
Introduction...........................................................................................................19
Platform Controls...............................................................................................21
Platform Controls..................................................................................................21
1-1 Platform Circuit Board....................................................................................22
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

October 2016
Table of Contents
viii ZX-135/70 Part No. 1268558
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
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................................................................................................................84
5-1 RPM Adjustment ............................................................................................84
5-2 Flex Plate........................................................................................................84
How to Install the Flex Plate............................................................................85
Ground Controls.................................................................................................86
6-1 Bypass/Recovery Key Switch.........................................................................86

October 2016
Table of Contents
Part No. 1268558 ZX-135/70 ix
How to Use the Recovery Mode .....................................................................88
6-2 Circuit Boards.................................................................................................89
6-3 Membrane Decal............................................................................................91
6-4 Full Machine Calibration.................................................................................92
Display Module...................................................................................................93
Hydraulic Pumps..............................................................................................102
7-1 Function Pump.............................................................................................102
How to Prime the Function Pump .................................................................103
How to Adjust the Function Pump Standby Pressure...................................103
How to Adjust the Function Pump Pressure Compensator ..........................104
7-2 Drive Pump...................................................................................................105
How to Prime the Drive Pump.......................................................................106
Manifolds...........................................................................................................108
8-1 Function Manifold Components ...................................................................108
8-2 Valve Adjustments - Function Manifold........................................................112
8-3 Platform Manifold .........................................................................................114
8-4 Jib Boom Manifold........................................................................................116
8-5 Flow Control Mainfold ..................................................................................118
8-6 Function Enable Valve .................................................................................119
8-7 Turntable Rotation Manifold.........................................................................120
8-8 Steer and Axle Manifold...............................................................................122
8-9 Valve Adjustments - Steer and Axle Manifold..............................................126
8-10 Traction Manifold Components..................................................................128
8-11 Valve Adjustments - Traction Manifold ......................................................132
8-12 Drive Oil Diverter Manifold Components (welder option)...........................133
8-13 Valve Coils .................................................................................................134
Turntable Rotation Components ....................................................................136
9-1 Turntable Rotation Assembly.......................................................................136
How to Adjust the Turntable Rotation Gear Backlash ..................................137
9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor .....138
Axle Components.............................................................................................141
10-1 Steer Sensors ............................................................................................141
How to Calibrate a Replacement Steer Sensor ............................................143

October 2016
Table of Contents
x ZX-135/70 Part No. 1268558
How to Calibrate All Steer Sensors...............................................................144
10-2 Steer Cylinders...........................................................................................146
10-3 Axle Extension Cylinders............................................................................147
10-4 Axle Angle Sensors - How to Calibrate the Axle Angle Sensors ...............148
Section 4 Fault Codes.......................................................................................................151
Introduction.........................................................................................................151
Control System Fault Codes...............................................................................152
Fault Matrix.........................................................................................................169
Deutz TD 2.9 L4 Engine Fault Codes..............................................................170
Perkins 854F-34T Engine Fault Code .............................................................185
Section 5 Schematics........................................................................................................193
Introduction.........................................................................................................193
Wire Circuit Legend............................................................................................194
Wire Color Legend..............................................................................................198
Limit Switches and Angle Sensors.....................................................................203
Circuit Connector Legend...................................................................................207
Drive Chassis and Platform Controller Pin Legend............................................210
Safety Controller Pin Legend..............................................................................211
Turntable Controller Pin Legend.........................................................................212
Telematics Connector Pin Legend .....................................................................213
Engine Relay and Fuse Panel Legend - Deutz TD2011L04i .............................214
Engine Relay and Fuse Panel Legend - Deutz TD2.9 .......................................215
Engine Relay and Fuse Panel Legend - Perkins 1104D-44T ............................216
Engine Relay and Fuse Panel Legend - Perkins 854F-34T...............................217
Electrical Symbols Legend.................................................................................218
Hydraulic Symbols Legend.................................................................................219
Perkins 1104D Engine Electrical Schematic......................................................222
Perkins 854F-34T Engine Electrical Schematic.................................................224
Perkins 854F-34T Engine Harness ....................................................................225
Deutz TD2.9 Engine Electrical Schematic..........................................................228
Deutz TD2.9 Engine Harness.............................................................................229
Hydraulic Generator (Welder Option).................................................................232

October 2016
Table of Contents
Part No. 1268558 ZX-135/70 xi
Generator Wiring Schematic..............................................................................233
Hydraulic Schematic (to SN ZX13516H-2804)...................................................236
Hydraulic Schematic (from SN ZX13516H-2805) ..............................................237
Electrical Schematic...........................................................................................239
Electrical Schematic...........................................................................................240

October 2016 Service and Repair Manual
Specifications
Part No. 1268558 ZX-135/70 1
Section 2 Speci fic ati ons
Machine Specifications
Tires and wheels
Tire size
445D50/710, 18PR
Tire ply rating
18
Tire weight, new foam
-filled
(minimum)
800 l
bs
363 k
g
Overall tire diameter
45.47 i
n
115.5 c
m
Wheel diameter
28 i
n
71.1 c
m
Wheel width
15 i
n
38.1 c
m
Wheel lugs
10 @ 3/4 -
16
Lug nut torque, dry
(before sn 15
-2585) 420 ft-
lbs
569.4 Nm
Lug nut torque, lubricated
(before sn 15
-2585) 320 ft-
lbs
433.9 Nm
Lug nut torque, dry, dull gray
(from sn 15
-2585 320 ft-
lbs
433.9 Nm
Fluid capacities
Fuel tank
40 g
allons
151.4 l
iters
Hydraulic tank
65 g
allons
246 l
iters
Hydraulic system (including tank)
123 g
allons
466 l
iters
Drive hubs
47 f
l oz
1390 c
c
Turntable rotation drive hub
40 f
l oz
1183 c
c
Drive hub oil type: SAE 9
0 multipurpose hypoid gear oil
API service classification GL5
Performance Specifications
Drive speed, maximum
Stowed position, high speed
3.0 m
ph
4.8 k
m/h
40 ft / 9.1 s
ec
12.2 m / 9.1 s
ec
Raised or extended
0.7 m
ph
1.1 k
m/h
40 ft / 40 s
ec
12.2 m / 40 s
ec
Primary and Secondary booms
raised, and Primary and Jib
extended
0.4 m
ph
0.6 k
m/h
40 ft / 68 s
ec
12.2 m / 68 s
ec
Braking distance, maximum
High
range on paved surface 3 to 6 f
t
1 to 2
m
Gradeability
See Operator's
Manual
Boom function speeds, maximum from platform
controls
Jib boom up/down
38 to 43 s
econds
Jib boom extend/retract
28 to 38 s
econds
Primary boom up/down
-
60° to +70° 110 to 125 s
econds
Primary boom extend/retract
35 to 48 s
econds
Secondary boom up/down
80 to 95 s
econds
Secondary boom extend/retract
88 to 98 s
econds
Turntable rotate, 360°
fully stowed
88 to 92 s
econds
Turntable rotate, 360°jib or
primary booms extended
160 to 180 s
econds
Turntable rotate, 360°jib and
primary booms extended
280 to 350 s
econds
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual October 2016
Specifications
2 ZX-135/70 Part No. 1268558
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,
oxidatio
n prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity
grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
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.
Optional fluids may not have the
same hydraulic lifespan and
may result i
n 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.
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 hydra
ulic 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
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

October 2016 Service and Repair Manual
Specifications
Part No. 1268558 ZX-135/70 3
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic
Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
124°F / 51°C
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.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage

Service and Repair Manual October 2016
Specifications
4 ZX-135/70 Part No. 1268558
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash
point
>100
Pour point
-76°F / -
60°C
Maximum continuous operating
temperature
103°F / 75°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C

October 2016 Service and Repair Manual
Specifications
Part No. 1268558 ZX-135/70 5
Hydraulic Component
Specifications
Drive Pump
Type: bi
-directional variable displacement piston pump
Displacement per revolution
2.8 c
u in
46 c
c
Flow rate @ 235
0 rpm 28.5 g
pm
108 L/min
Drive pressure, maximum
3625 p
si
250 b
ar
Charge Pump
Type
gerotor
Displacement per revolution
0.85 c
u in
13.9 c
c
Flow rate @ 235
0 rpm 9 g
pm
34 L/min
Charge pressure
@ 2350 rpm
Neutral position
315 p
s
21.7 b
ar
Function pump
Type: variable displacement piston pump
Displacement per revolution
0 to 2.75 c
u in
0 to 45 c
c
Flow rate @ 235
0 rpm 0 to 28 g
pm
0 to 106 L/min
Pressure, maximum
2900 p
si
200 b
ar
Pressure
compensator 2900 p
si
200 b
ar
Standby pressure
250 p
si
17 b
ar
Auxiliary Pump
Type: fixed displacement gear pump
Displacement per revolution
0.15 c
u in
2.47 c
c
Function manifold
System relief valve pressure, maximum
(measured at test port)
3100 p
si
213.7 b
ar
Primary boom extend relief pressure
(measured at ptest port)
2600 p
si
179 b
ar
Jib and platform manifolds
Platform rotate and platform level flow
regulator
0.2 g
pm
0.76 L/min
Jib manifold flow regulator
2 g
pm
7.6 L/min
Steer/Axle Manifold
Axle extend relief pressure
2400 p
si
165 b
ar
Traction Manifold
Hot oil relief pressure
250 p
si
17.2 b
ar
Hydraulic Filters
High pressure filter:
Beta 3 ≥ 200
High pressure filter bypass pressure
102 p
si
7 b
ar
Medium pressure filter
Beta 3 ≥ 200
Medium pressure filter bypass pressure
51 p
si
3.5 b
ar
Hydraulic tank return filter
10 m
icron
with 25 p
si /
1.7 b
ar
bypass
Drive motor case drain return filter
Beta 10 ≥ 2

Service and Repair Manual October 2016
Specifications
6 ZX-135/70 Part No. 1268558
Brakes
Brake relief pressure
190 p
si
13 b
ar
Drive Motors
Displacement
per revolution, high
speed
0.8 c
u in
13.3 c
c
Displacement per revolution, low
speed (square end)
2.7 c
u in
45 c
c
Displacement per revolution, low
speed (circle end)
1.5 c
u in
25 c
c
Manifold Component Specifications
Plug torque
SAE No. 2
36 in-lbs /
4 Nm
SAE No. 4
10 ft-
lbs / 13 Nm
SAE No. 6
14 ft-
lbs / 19 Nm
SAE No. 8
38 ft-
lbs / 51 Nm
SAE No. 10
41 ft-
lbs / 55 Nm
SAE No. 12
56 ft-
lbs / 76 Nm
Valve coil resistance specifications
Solenoid valve,
3 position 4 way
(schematic item A, B, C, D, W)
7.2Ω
Solenoid Valve,
2 position 3 way
(schematic items D, E, F, G, I, Z )
5.6Ω
Solenoid Valve,
2 position 3 way
(schematic items P,Q )
7.2Ω
Solenoid Valve,
2 position 3 way
(schematic items AE )
8.8Ω
Proportional solenoid valve,
3 position 4 way
(schematic items Y and AF)
8.8Ω
Solenoid Valve,
2 position 3 way
(schematic items AD)
7.1Ω
Solenoid valve,
2 position 2 way
(schematic item A)
3.5 t
o
5.5Ω

October 2016 Service and Repair Manual
Specifications
Part No. 1268558 ZX-135/70 7
Deutz TD 2.9 Engine
Displacement
177 c
u. in
2.9 l
iters
Number of cylinders
4
Bore and Stroke
3.6 x 4.3 i
nches
92 x 110 m
m
Horsepower net intermittent @
260
0 rpm 74.2 h
p
55 k
W
Induction system
turbocharged
Firing order
1 - 3 - 4 -
2
Low idle
1000 r
pm
High idle
2500 r
pm
Compression ratio
17.4:1
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 (@ 200
0 rpm) 40 to 60 p
si
2.8 to 4.1 b
ar
Oil capacity (including filter)
9.4 q
uarts
8.9 l
iters
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 -
24 Nm
Temperature switch point
275°F
135°C
Oil Pressure switch
Installation torque
8 - 18 ft-
lbs
11 -
24 Nm
Pressure switch point
22 p
si
1.5 b
ar
Fuel injection system
Motorpal
Injection pump pressure, maximum
15,000 p
si
1034 b
ar
Injector opening pressure
3046 p
si
210 b
ar
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 r
pm
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
95A @ 14V DC
Fan belt deflection
3/8 to 1/2 i
nch
9 to 12 m
m

Service and Repair Manual October 2016
Specifications
8 ZX-135/70 Part No. 1268558
Deutz TD2011L04i Engine
Displacement
220.9 c
u. in
3.62 liters
Number of cylinders
4
Bore and Stroke
3.78 x 4.92 i
nches
96 x 125 m
m
Horsepower net intermittent @
240
0 rpm 74 h
p
55 k
W
Induction system
turbocharged
Firing order
1 - 3 - 4 -
2
Low idle
1500 r
pm
383 Hz
High idle
2350 r
pm
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 i
n
0.3 m
m
Exhaust
0.020 i
n
0.5 m
m
Lubrication system
Oil pressure, hot (@ 200
0 rpm) 40 to 60 p
si
2.8 to 4.1 b
ar
Oil capacity
(including filter) 12.8 q
uarts
12.1 l
iters
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 -
24 Nm
Temperature switch point
275°F
135°C
Oil Pressure switch
Installation
torque 8 - 18 ft-
lbs
11 -
24 Nm
Pressure switch point
22 p
si
1.5 b
ar