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

September 2015
Table of Contents
Part No. 218700 ZX-135/70 xi
Checklist C Procedures .....................................................................................58
C-1 Perform Engine Maintenance - Deutz Models...............................................58
C-2 Perform Engine Maintenance - Deutz Models...............................................58
C-3 Perform Engine Maintenance - Perkins Models ............................................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) .........................................61
C-7 Check and Adjust the Engine RPM ...............................................................63
C-8 Inspect for Turntable Bearing Wear ..............................................................66
Checklist D Procedures .....................................................................................68
D-1 Check the Boom Wear Pads .........................................................................68
D-2 Check the Free-wheel Configuration.............................................................69
D-3 Replace the Drive Hub Oil .............................................................................70
D-4 Adjust the Turntable Rotatation Gear Backlash ............................................72
D-5 Replace the Hydraulic Filter Elements ..........................................................73
D-6 Perform Engine Maintenance - Deutz Models...............................................74
D-7 Perform Engine Maintenance - Perkins Models ............................................75
D-8 Check the Turntable Rotation Bearing Bolts .................................................75
Checklist E Procedures .....................................................................................77
E-1 Test or Replace the Hydraulic Oil ..................................................................77
E-2 Perform Engine Maintenance - Perkins Models ............................................79
E-3 Perform Engine Maintenance - Deutz Models...............................................79
E-4 Perform Engine Maintenance - Perkins Models ............................................80
E-5 Perform Engine Maintenance - Perkins Models ............................................80
E-6 Perform Engine Maintenance - Deutz Models...............................................81
E-7 Perform Engine Maintenance - Perkins Models ............................................81
E-8 Perform Engine Maintenance - Deutz Models...............................................82

September 2015
Table of Contents
xii ZX-135/70 Part No. 218700
Section 4 Repair Procedures ............................................................................................. 83
Introduction .......................................................................................................... 83
Platform Controls............................................................................................... 85
Platform Controls ................................................................................................. 85
1-1 Platform Circuit Board.................................................................................... 85
How to Remove the LED Circuit Board .......................................................... 87
1-2 Joysticks - How to Calibrate a Joystick ......................................................... 87
How to Reset a Proportional Valve Coil Default ............................................. 91
How to Set the Function Thresholds and Default Functions Speeds ............. 92
How to Adjust the Function Speeds ............................................................... 94
How to Adjust the Function Ramp Rate Setting ............................................. 94
Platform Components ....................................................................................... 95
2-1 Platform.......................................................................................................... 95
2-2 Platform Leveling Cylinder............................................................................. 96
2-3 Platform Rotator............................................................................................. 97
How to Bleed the Platform Rotator ................................................................. 98
2-4 Platform Level Sensor - How to Calibrate the Platform Level Sensor........... 99
2-5 Platform Overload System (if equipped)...................................................... 100
2-6 Platform Overload Recovery Message ........................................................ 101
Jib Boom Components.................................................................................... 103
3-1 Jib Boom Cable Track ................................................................................. 104
How to Repair the Cable Track..................................................................... 105
3-2 Jib Boom ...................................................................................................... 106
3-3 Jib Boom Lift Cylinder .................................................................................. 108
3-4 Jib Boom Level Cylinder .............................................................................. 109
3-5 Jib Boom Extension Cylinder....................................................................... 110
3-6 Jib Boom Bellcrank Angle Sensor - How to Calibrate the Jib Boom Bellcrank
Angle Sensor.............................................................................................. 111

September 2015
Table of Contents
Part No. 218700 ZX-135/70 xiii
Boom Components ..........................................................................................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...............................................................................................123
4-4 Primary Boom Lift Cylinder ..........................................................................125
4-5 Secondary Boom Lift Cylinder......................................................................126
4-6 Primary Boom Extension Cylinder ...............................................................129
4-7 Secondary Boom Extension Cylinders.........................................................130
4-8 Primary Boom Angle Sensor - How to Calibrate the Primary Boom Angle
Sensor ........................................................................................................131
4-9 Secondary Boom Angle Sensor - How to Calibrate the Secondary Boom Angle
Sensor ........................................................................................................136
(i) 6 Point Calibration procedure...................................................................137
Engines..............................................................................................................141
5-1 RPM Adjustment ..........................................................................................141
5-2 Flex Plate .....................................................................................................141
How to Install the Flex Plate..........................................................................142
Ground Controls...............................................................................................143
6-1 Bypass/Recovery Key Switch ......................................................................143
How to Use the Recovery Mode ...................................................................145
6-2 Circuit Boards...............................................................................................146
6-3 Membrane Decal..........................................................................................148
6-4 Full Machine Calibration...............................................................................149
Display Module .................................................................................................150
Hydraulic Pumps ..............................................................................................159
7-1 Function Pump .............................................................................................159
How to Prime the Function Pump .................................................................160
How to Adjust the Function Pump Standby Pressure ...................................160
How to Adjust the Function Pump Pressure Compensator ..........................160
7-2 Drive Pump...................................................................................................162
How to Prime the Drive Pump.......................................................................163

September 2015
Table of Contents
xiv ZX-135/70 Part No. 218700
Manifolds .......................................................................................................... 164
8-1 Function Manifold Components ................................................................... 164
8-2 Valve Adjustments - Function Manifold ....................................................... 168
8-3 Platform Manifold ......................................................................................... 170
8-4 Jib Boom Manifold ....................................................................................... 172
8-5 Flow Control Mainfold .................................................................................. 174
8-6 Function Enable Valve................................................................................. 175
8-7 Turntable Rotation Manifold......................................................................... 176
8-8 Steer and Axle Manifold............................................................................... 177
8-9 Valve Adjustments - Steer and Axle Manifold ............................................. 181
8-10 Traction Manifold Components.................................................................. 182
8-11 Valve Adjustments - Traction Manifold ...................................................... 186
8-12 Drive Oil Diverter Manifold Components (welder option) .......................... 187
8-13 Valve Coils ................................................................................................. 188
How to Test a Coil Diode .............................................................................. 189
Turntable Rotation Components .................................................................... 190
9-1 Turntable Rotation Assembly....................................................................... 190
How to Adjust the Turntable Rotation Gear Backlash .................................. 191
9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor ..... 192
Axle Components............................................................................................. 195
10-1 Steer Sensors ............................................................................................ 195
How to Calibrate a Replacement Steer Sensor............................................ 197
How to Calibrate All Steer Sensors .............................................................. 197
10-2 Steer Cylinders .......................................................................................... 199
10-3 Axle Extension Cylinders ........................................................................... 200
10-4 Axle Angle Sensors - How to Calibrate the Axle Angle Sensors............... 201

September 2015
Table of Contents
Part No. 218700 ZX-135/70 xv
Section 5 Fault Codes .......................................................................................................203
Introduction.........................................................................................................203
Control System Fault Codes ..............................................................................204
Fault Matrix.........................................................................................................221
Deutz TD 2.9 L4 Engine Fault Codes..............................................................222
Perkins 854F-34T Engine Fault Code .............................................................237
Section 6 Schematics........................................................................................................245
Introduction.........................................................................................................245
Wire Circuit Legend ............................................................................................246
Wire Color Legend .............................................................................................250
Limit Switches and Angle Sensors .....................................................................255
Circuit Connector Legend...................................................................................259
Drive Chassis and Platform Controller Pin Legend............................................262
Safety Controller Pin Legend .............................................................................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 1104D-44T ............................268
Engine Relay and Fuse Panel Legend- Perkins 854F Models ..........................269
Electrical Symbols Legend .................................................................................270
Hydraulic Symbols Legend.................................................................................271
Perkins 1104D Engine Electrical Schematic ......................................................274
Perkins 854F-34T Engine Electrical Schematic .................................................276
Perkins 854F-34T Engine Harness ....................................................................277
Deutz TD2.9 Engine Electrical Schematic .........................................................280
Deutz TD2.9 Engine Harness.............................................................................281
Generator Wiring Schematic ..............................................................................283
Hydraulic Generator (Welder Option).................................................................286
Hydraulic Schematic...........................................................................................287
Electrical Schematic (Includes Deutz Engine) ...................................................289

Service Manual September 2015
16 ZX-135/70 Part No. 218700
This page intentionally left blank.

September 2015 Service Manual
Specifications
Part No. 218700 ZX-135/70 1
Section 2 Speci fi c 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
420 ft-
lbs
569.4 Nm
Lug nut torque,
lubricated 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 Manual September 2015
Specifications
2 ZX-135/70 Part No. 218700
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, an
d 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 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.
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
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

September 2015 Service Manual
Specifications
Part No. 218700 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: An 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
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
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

Service Manual September 2015
Specifications
4 ZX-135/70 Part No. 218700
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 @ 235
0 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 @
2350 rpm 0 to 28 g
pm
0 t
o 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 cu 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 micron
with 25 p
si /
1.7 b
ar
bypass
Drive motor case drain return filter
Beta 10 ≥
2