Rev 4, April 2018
Serial Number Range
ZX135H-4001
Content for Service Manual:
INTRODUCTION
Important Information
Find a Manual for this Model
Revision History
Serial Number Legend
Section 1. SAFETY RULES
General Safety Rules
Section 2. SPECIFICATIONS
Machine Specifications
Hydraulic Oil Specifications
Hydraulic Component Specifications
Deutz TD 2.9 Engine Specifications
Deutz TD2011L04i Engine Specifications
Perkins 854F-34T Engine Specifications
Perkins 1104D-44T Engine Specifications
Machine Torque Specifications
Performance Specifications
Hydraulic Hose and Fitting Torque Specifications
Section 3. REPAIR PROCEDURES
Introduction
Platform Controls
Platform Controls
1-1 Platform Circuit Board
How to Remove the LED Circuit Board
1-2 Joysticks - How to Calibrate a Joystick
How to Reset a Proportional Valve Coil Default
How to Set the Function Thresholds and Default Functions Speeds
How to Adjust the Function Speeds
How to Adjust the Function Ramp Rate Setting
Platform Components
2-1 Platform
2-2 Platform Leveling Cylinder
2-3 Platform Rotator
How to Bleed the Platform Rotator
2-4 Platform Level Sensor - How to Calibrate the Platform Level Sensor
2-5 Platform Overload System
How to Calibrate the Platform Overload System
How to Perform a Zero Load Cell Calibration
How to Replace the Platform Overload Load Cell
2-6 Platform Overload Recovery Message
Jib Boom Components
3-1 Jib Boom Cable Track
How to Repair the Cable Track
3-2 Jib Boom
3-3 Jib Boom Lift Cylinder
3-4 Jib Boom Level Cylinder
3-5 Jib Boom Extension Cylinder
3-6 Jib Boom Bellcrank Angle Sensor - How to Calibrate the Jib Boom Bellcrank Angle Sensor
Boom Components
4-1 Primary Boom Cable Track
How to Repair the Primary Boom Cable Track
4-2 Secondary Boom Cable Track
How to Repair the Secondary Boom Cable Track
4-3 Primary Boom
4-4 Primary Boom Lift Cylinder
4-5 Secondary Boom Lift Cylinder
4-6 Primary Boom Extension Cylinder
4-7 Secondary Boom Extension Cylinders
4-8 Primary Boom Angle Sensor - How to Calibrate the Primary Boom Angle Sensor
4-9 Secondary Boom Angle Sensor - How to Calibrate the Secondary Boom Angle Sensor
Engines
5-1 RPM Adjustment
5-2 Flex Plate
How to Install the Flex Plate
Ground Controls
6-1 Bypass/Recovery Key Switch
How to Use the Recovery Mode
6-2 Circuit Boards
6-3 Membrane Decal
6-4 Full Machine Calibration
Display Module
Hydraulic Pumps
7-1 Function Pump
How to Prime the Function Pump
How to Adjust the Function Pump Standby Pressure
How to Adjust the Function Pump Pressure Compensator
7-2 Drive Pump
How to Prime the Drive Pump
Manifolds
8-1 Function Manifold Components
8-2 Valve Adjustments - Function Manifold
8-3 Jib Boom Manifold
8-4 Platform Manifold
8-5 Flow Control Mainfold
8-6 Function Enable Valve
8-7 Turntable Rotation Manifold
8-8 Steer and Axle Manifold
8-9 Valve Adjustments - Steer and Axle Manifold
8-10 Traction Manifold Components
8-11 Valve Adjustments - Traction Manifold
8-12 Generator Manifold Component
8-13 Valve Coils
Turntable Rotation Components
9-1 Turntable Rotation Assembly
How to Adjust the Turntable Rotation Gear Backlash
9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor
Axle Components
10-1 Steer Sensors
How to Calibrate a Replacement Steer Sensor
How to Calibrate All Steer Sensors
10-2 Steer Cylinders
10-3 Axle Extension Cylinders
10-4 Axle Angle Sensors - How to Calibrate the Axle Angle Sensors
Section 4. FAULT CODES
Introduction
Control System Fault Codes
Fault Code Source
Fault Matrix
Deutz TD 2.9 L4 Engine Fault Codes
Perkins 854F-34T Engine Fault Code
Section 5. SCHEMATICS
Introduction
Wire Circuit Legend
Wire Color Legend
Limit Switches and Angle Sensors
Circuit Connector Legend
Drive Chassis and Platform Controller Pin Legend
Safety Controller Pin Legend
Turntable Controller Pin Legend
Telematics Connector Pin Legend
VEC Module - Deutz TD2011L04i and Perkins 1104D-44T Models
VEC Module - Deutz TD2.9 Models
VEC Module - Perkins 854F Models
Electrical Symbols Legend
Hydraulic Symbols Legend
Perkins 1104D-44T Engine Electrical Schematic- View 1
Perkins 1104D-44T Engine Electrical Schematic- View 2
Perkins 854F-34T Engine Electrical Schematic- View 1
Perkins 854F-34T Engine Electrical Schematic- View 2
Perkins 854F-34T Engine Harness
Deutz TD2.9 Engine Electrical Schematic- View 1
Deutz TD2.9 Engine Electrical Schematic- View 2
Deutz TD2.9 Engine Harness
Contact Alarm Schematic
Generator Wiring Diagram- ANSI
Generator Wiring Diagram- AUS
Hydraulic Schematic
Electrical Schematic
---------------------------
Content for Parts List Manual:
How to Read Your Serial Number
Parts Stocking List
How to Order Parts
Service Parts Fax Order Form
001 Parts Stocking List
001.1 Parts Stocking List
100 Decals
101.1 Decals with Words, Hydraulic Tank Side
102.1 Decals with Words, Hydraulic Tank Side (chassis)
103.1 Decals with Words, Engine Side
104.1 Decals with Words, Engine Side (chassis)
105.1 Decals with Words, Boom
106.1 Decals with Words, Platform
107.1 Decals with Symbols, Hydraulic Tank Side
108.1 Decals with Symbols, Hydraulic Tank Side (chassis)
109.1 Decals with Symbols, Engine Side
110.1 Decals with Symbols, Engine Side (chassis)
111.1 Decals with Symbols, Boom
112.1 Decals with Symbols, Platform
200 Chassis Components
201.1 Chassis Components, Top View
202.1 Chassis Components, Bottom View
203.1 Chassis Components, Tank Side
204.1 Chassis Components, Engine Side
205.1 Steer Yoke, Wheel Drive and Motor
300 Turntable Components
301.1 Tank Side Covers - View 1
302.1 Tank Side Covers - View 2
303.1 Engine Side Covers - View 1
304.1 Engine Side Covers - View 2
305.1 Hydraulic Tank Side Components - View 1
306.1 Hydraulic Tank Side Components - View 2
307.1 Ground Control Box
308.1 Turntable Center Components
309.1 Secondary Boom Lift Cylinder
310.1 Wire Harness Diagram
400 Engine Components
401.1 Deutz TD2011L04i Engine, View 1
402.1 Deutz TD2011L04i Engine, View 2
403.1 Deutz TD 2.9L4 Engine - View 1
404.1 Deutz TD 2.9L4 Engine - View 2
405.1 Deutz TD 2.9L4 Engine - View 3
406.1 Deutz TD 2.9L4 Engine - View 4
407.1 Perkins 1104D-44T Engine - View 1
408.1 Perkins 1104D-44T Engine - View 2
409.1 Perkins 1104D-44T Engine - View 3
410.1 Perkins 854F-E34T Engine - View 1
411.1 Perkins 854F-E34T Engine - View 2
412.1 Perkins 854F-E34T Engine - View 3
413.1 Perkins 854F-E34T Engine - View 4
500 Boom Components
501.1 Secondary Boom Tube Reference
502.1 Secondary Boom Tube 1
503.1 Secondary Boom Tube 2
504.1 Secondary Boom Tube 3
505.1 Secondary Boom Tube 4
506.1 Secondary Boom Extension Cylinders
507.1 Secondary Boom Cable Track and Pull Tube
508.1 Secondary Boom Cable and Hose Clamps, Front View
509.1 Secondary Boom Cable and Hose Clamps, Rear View
510.1 Primary Boom Link, Lever and Lift Cylinder
511.1 5 Primary Boom Angle Sensor and Retract Limit Switch
512.1 Primary Boom Cable Track
513.1 Primary Boom Bearings and Wear Pads
514.1 Primary Extension Boom
515.1 Bellcrank, Bellcrank Level Cylinder and Jib Boom Lift Cylinder
516.1 Jib Boom Cable Track
517.1 Jib Boom Extension and Platform Level Cylinders
518.1 Jib Boom Tubes and Wear Pads
519.1 Platform Rotator
600 Platform Components
601.1 Platform Mount
602.1 Platform Configurations
603.1 Platform Controls
604.1 Joystick
700 Hydraulic Components
701.1 Traction Manifold
702.1 Steer/Axle Manifold
703.1 Jib Manifold
704.1 Function Manifold
705.1 Function Enable Valve and Platform Rotator Manifold
706.1 Platform Manifold
707.1 Hydraulic Hoses and Fittings, Drive System
708.1 Hydraulic Hoses and Fittings, Steering System
709.1 Hydraulic Hoses and Fittings, Turntable Components
710.1 Hydraulic Hoses and Fittings, Boom Components
711.1 Hydraulic Hoses and Fittings, Platform Components
712.1 Pumps
800 Accessories
801.1 Platform Accesories
802.1 Half-Mesh and Pipe Cradle Options
803.1 Hostile Enviroment Option - Secondary Boom Wipers
804.1 Hostile Enviroment Option - Primary and Jib Boom Wipers, Cable Track Covers
805.1 Hostile Enviroment Option - Bellows Installation
806.1 Hostile Environment Option - Air Cleaners - Deutz
TD2011L04I and Perkins 1104D-44T
807.1 Hostile Environment Option - Air Cleaners - Deutz TD 2.9L4 and Perkins 854F-E34T
808.1 Hostile Environment DLX Option - Slew Ring Guard
809.1 Cold Start Package
810.1 Welder Option - Platform Components
811.1 Welder Option - Hydraulic Hoses and Fittings
812.1 Hydraulic Generator Option, Hydraulic Hoses and Fittings
813.1 Hydraulic Generator Option, J Box, Circuit Breaker
814.1 Hydraulic Generator Option, Platform J Box, Australian Models
815.1 Boom Latch Kit
816.1 Operator Protection Structure
817.1 Airline to Platform
818.1 Drive Light and Flashing Beacon
819.1 Fall Arrest Bar
820.1 Lift Guard Contact Alarm Option
821.1 Platform Recirculating Hydraulic Oil Option
Indices
Part Number Index
Part Description Index
Cross References
Fittings Cross Reference
Rev 4, April 2018
Serial Number Range
ZX135H-4001
Content for Service Manual:
INTRODUCTION
Important Information
Find a Manual for this Model
Revision History
Serial Number Legend
Section 1. SAFETY RULES
General Safety Rules
Section 2. SPECIFICATIONS
Machine Specifications
Hydraulic Oil Specifications
Hydraulic Component Specifications
Deutz TD 2.9 Engine Specifications
Deutz TD2011L04i Engine Specifications
Perkins 854F-34T Engine Specifications
Perkins 1104D-44T Engine Specifications
Machine Torque Specifications
Performance Specifications
Hydraulic Hose and Fitting Torque Specifications
Section 3. REPAIR PROCEDURES
Introduction
Platform Controls
Platform Controls
1-1 Platform Circuit Board
How to Remove the LED Circuit Board
1-2 Joysticks - How to Calibrate a Joystick
How to Reset a Proportional Valve Coil Default
How to Set the Function Thresholds and Default Functions Speeds
How to Adjust the Function Speeds
How to Adjust the Function Ramp Rate Setting
Platform Components
2-1 Platform
2-2 Platform Leveling Cylinder
2-3 Platform Rotator
How to Bleed the Platform Rotator
2-4 Platform Level Sensor - How to Calibrate the Platform Level Sensor
2-5 Platform Overload System
How to Calibrate the Platform Overload System
How to Perform a Zero Load Cell Calibration
How to Replace the Platform Overload Load Cell
2-6 Platform Overload Recovery Message
Jib Boom Components
3-1 Jib Boom Cable Track
How to Repair the Cable Track
3-2 Jib Boom
3-3 Jib Boom Lift Cylinder
3-4 Jib Boom Level Cylinder
3-5 Jib Boom Extension Cylinder
3-6 Jib Boom Bellcrank Angle Sensor - How to Calibrate the Jib Boom Bellcrank Angle Sensor
Boom Components
4-1 Primary Boom Cable Track
How to Repair the Primary Boom Cable Track
4-2 Secondary Boom Cable Track
How to Repair the Secondary Boom Cable Track
4-3 Primary Boom
4-4 Primary Boom Lift Cylinder
4-5 Secondary Boom Lift Cylinder
4-6 Primary Boom Extension Cylinder
4-7 Secondary Boom Extension Cylinders
4-8 Primary Boom Angle Sensor - How to Calibrate the Primary Boom Angle Sensor
4-9 Secondary Boom Angle Sensor - How to Calibrate the Secondary Boom Angle Sensor
Engines
5-1 RPM Adjustment
5-2 Flex Plate
How to Install the Flex Plate
Ground Controls
6-1 Bypass/Recovery Key Switch
How to Use the Recovery Mode
6-2 Circuit Boards
6-3 Membrane Decal
6-4 Full Machine Calibration
Display Module
Hydraulic Pumps
7-1 Function Pump
How to Prime the Function Pump
How to Adjust the Function Pump Standby Pressure
How to Adjust the Function Pump Pressure Compensator
7-2 Drive Pump
How to Prime the Drive Pump
Manifolds
8-1 Function Manifold Components
8-2 Valve Adjustments - Function Manifold
8-3 Jib Boom Manifold
8-4 Platform Manifold
8-5 Flow Control Mainfold
8-6 Function Enable Valve
8-7 Turntable Rotation Manifold
8-8 Steer and Axle Manifold
8-9 Valve Adjustments - Steer and Axle Manifold
8-10 Traction Manifold Components
8-11 Valve Adjustments - Traction Manifold
8-12 Generator Manifold Component
8-13 Valve Coils
Turntable Rotation Components
9-1 Turntable Rotation Assembly
How to Adjust the Turntable Rotation Gear Backlash
9-2 Turntable Level Sensor - How to Calibrate the Turntable Level Sensor
Axle Components
10-1 Steer Sensors
How to Calibrate a Replacement Steer Sensor
How to Calibrate All Steer Sensors
10-2 Steer Cylinders
10-3 Axle Extension Cylinders
10-4 Axle Angle Sensors - How to Calibrate the Axle Angle Sensors
Section 4. FAULT CODES
Introduction
Control System Fault Codes
Fault Code Source
Fault Matrix
Deutz TD 2.9 L4 Engine Fault Codes
Perkins 854F-34T Engine Fault Code
Section 5. SCHEMATICS
Introduction
Wire Circuit Legend
Wire Color Legend
Limit Switches and Angle Sensors
Circuit Connector Legend
Drive Chassis and Platform Controller Pin Legend
Safety Controller Pin Legend
Turntable Controller Pin Legend
Telematics Connector Pin Legend
VEC Module - Deutz TD2011L04i and Perkins 1104D-44T Models
VEC Module - Deutz TD2.9 Models
VEC Module - Perkins 854F Models
Electrical Symbols Legend
Hydraulic Symbols Legend
Perkins 1104D-44T Engine Electrical Schematic- View 1
Perkins 1104D-44T Engine Electrical Schematic- View 2
Perkins 854F-34T Engine Electrical Schematic- View 1
Perkins 854F-34T Engine Electrical Schematic- View 2
Perkins 854F-34T Engine Harness
Deutz TD2.9 Engine Electrical Schematic- View 1
Deutz TD2.9 Engine Electrical Schematic- View 2
Deutz TD2.9 Engine Harness
Contact Alarm Schematic
Generator Wiring Diagram- ANSI
Generator Wiring Diagram- AUS
Hydraulic Schematic
Electrical Schematic
---------------------------
Content for Parts List Manual:
How to Read Your Serial Number
Parts Stocking List
How to Order Parts
Service Parts Fax Order Form
001 Parts Stocking List
001.1 Parts Stocking List
100 Decals
101.1 Decals with Words, Hydraulic Tank Side
102.1 Decals with Words, Hydraulic Tank Side (chassis)
103.1 Decals with Words, Engine Side
104.1 Decals with Words, Engine Side (chassis)
105.1 Decals with Words, Boom
106.1 Decals with Words, Platform
107.1 Decals with Symbols, Hydraulic Tank Side
108.1 Decals with Symbols, Hydraulic Tank Side (chassis)
109.1 Decals with Symbols, Engine Side
110.1 Decals with Symbols, Engine Side (chassis)
111.1 Decals with Symbols, Boom
112.1 Decals with Symbols, Platform
200 Chassis Components
201.1 Chassis Components, Top View
202.1 Chassis Components, Bottom View
203.1 Chassis Components, Tank Side
204.1 Chassis Components, Engine Side
205.1 Steer Yoke, Wheel Drive and Motor
300 Turntable Components
301.1 Tank Side Covers - View 1
302.1 Tank Side Covers - View 2
303.1 Engine Side Covers - View 1
304.1 Engine Side Covers - View 2
305.1 Hydraulic Tank Side Components - View 1
306.1 Hydraulic Tank Side Components - View 2
307.1 Ground Control Box
308.1 Turntable Center Components
309.1 Secondary Boom Lift Cylinder
310.1 Wire Harness Diagram
400 Engine Components
401.1 Deutz TD2011L04i Engine, View 1
402.1 Deutz TD2011L04i Engine, View 2
403.1 Deutz TD 2.9L4 Engine - View 1
404.1 Deutz TD 2.9L4 Engine - View 2
405.1 Deutz TD 2.9L4 Engine - View 3
406.1 Deutz TD 2.9L4 Engine - View 4
407.1 Perkins 1104D-44T Engine - View 1
408.1 Perkins 1104D-44T Engine - View 2
409.1 Perkins 1104D-44T Engine - View 3
410.1 Perkins 854F-E34T Engine - View 1
411.1 Perkins 854F-E34T Engine - View 2
412.1 Perkins 854F-E34T Engine - View 3
413.1 Perkins 854F-E34T Engine - View 4
500 Boom Components
501.1 Secondary Boom Tube Reference
502.1 Secondary Boom Tube 1
503.1 Secondary Boom Tube 2
504.1 Secondary Boom Tube 3
505.1 Secondary Boom Tube 4
506.1 Secondary Boom Extension Cylinders
507.1 Secondary Boom Cable Track and Pull Tube
508.1 Secondary Boom Cable and Hose Clamps, Front View
509.1 Secondary Boom Cable and Hose Clamps, Rear View
510.1 Primary Boom Link, Lever and Lift Cylinder
511.1 5 Primary Boom Angle Sensor and Retract Limit Switch
512.1 Primary Boom Cable Track
513.1 Primary Boom Bearings and Wear Pads
514.1 Primary Extension Boom
515.1 Bellcrank, Bellcrank Level Cylinder and Jib Boom Lift Cylinder
516.1 Jib Boom Cable Track
517.1 Jib Boom Extension and Platform Level Cylinders
518.1 Jib Boom Tubes and Wear Pads
519.1 Platform Rotator
600 Platform Components
601.1 Platform Mount
602.1 Platform Configurations
603.1 Platform Controls
604.1 Joystick
700 Hydraulic Components
701.1 Traction Manifold
702.1 Steer/Axle Manifold
703.1 Jib Manifold
704.1 Function Manifold
705.1 Function Enable Valve and Platform Rotator Manifold
706.1 Platform Manifold
707.1 Hydraulic Hoses and Fittings, Drive System
708.1 Hydraulic Hoses and Fittings, Steering System
709.1 Hydraulic Hoses and Fittings, Turntable Components
710.1 Hydraulic Hoses and Fittings, Boom Components
711.1 Hydraulic Hoses and Fittings, Platform Components
712.1 Pumps
800 Accessories
801.1 Platform Accesories
802.1 Half-Mesh and Pipe Cradle Options
803.1 Hostile Enviroment Option - Secondary Boom Wipers
804.1 Hostile Enviroment Option - Primary and Jib Boom Wipers, Cable Track Covers
805.1 Hostile Enviroment Option - Bellows Installation
806.1 Hostile Environment Option - Air Cleaners - Deutz
TD2011L04I and Perkins 1104D-44T
807.1 Hostile Environment Option - Air Cleaners - Deutz TD 2.9L4 and Perkins 854F-E34T
808.1 Hostile Environment DLX Option - Slew Ring Guard
809.1 Cold Start Package
810.1 Welder Option - Platform Components
811.1 Welder Option - Hydraulic Hoses and Fittings
812.1 Hydraulic Generator Option, Hydraulic Hoses and Fittings
813.1 Hydraulic Generator Option, J Box, Circuit Breaker
814.1 Hydraulic Generator Option, Platform J Box, Australian Models
815.1 Boom Latch Kit
816.1 Operator Protection Structure
817.1 Airline to Platform
818.1 Drive Light and Flashing Beacon
819.1 Fall Arrest Bar
820.1 Lift Guard Contact Alarm Option
821.1 Platform Recirculating Hydraulic Oil Option
Indices
Part Number Index
Part Description Index
Cross References
Fittings Cross Reference
