Genie Z-45 Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-45/25
from Z452513A
to Z452516N-
57199
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
Z®-45/25J
from Z4525N-57200
Bi-Energy Power
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268546
GT
Rev A3
November 2017

Service and Repair Manual September 2016
Introduction
ii Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Intr od ucti o n Intr od ucti o 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 http://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
1268546GT Rev A, September 2016
First Edition, First Printing
Genie and “Z” are registered trademarks of Terex South Dakota,
Inc. in the U.S.A. and many other countries.

September 2016 Service and Repair Manual
Introduction
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
A2 9/2016 Repair 12-1
A3 11-2017 Specifications Machine Specifications
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 September 2016
Introduction
iv Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label (located under cover)
6 Serial number (stamped on chassis)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy v
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.

Service and Repair Manual September 2016
Safety Rules
vi Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
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 i
t.
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. Alwa
ys 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 intended for on
e
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 2016
Table of Contents
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
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
Machine Torque Specifications ..............................................................................6
Generator Specifications ........................................................................................6
Kubota Z482-E2B/E3B Engine Specifications .......................................................7
Hydraulic Hose and Fitting Torque Specifications .................................................8
Torque Procedure ..................................................................................................9
SAE and Metric Fasteners Torque Charts ...........................................................11

September 2016
Table of Contents
viii Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Section 3 Repair Procedures..............................................................................................12
Introduction ...........................................................................................................12
Platform Controls ...............................................................................................14
1-1 Controllers ......................................................................................................14
Platform Components ........................................................................................16
2-1 Platform Leveling Slave Cylinder ...................................................................16
How to Bleed the Slave Cylinder.....................................................................17
2-2 Platform Rotator .............................................................................................18
Jib Boom Components ......................................................................................20
3-1 Jib Boom.........................................................................................................20
3-2 Jib Boom Lift Cylinder ....................................................................................21
Primary Boom Components ..............................................................................23
4-1 Cable Track ....................................................................................................23
How to Remove the Cable Track, Z-45/25......................................................23
How to Remove the Cable Track, Z-45/25J ....................................................25
How to Repair the Primary Boom Cable Track ...............................................27
4-2 Primary Boom.................................................................................................27
How to Disassemble the Primary Boom..........................................................29
4-3 Primary Boom Lift Cylinder.............................................................................30
4-4 Primary Boom Extension Cylinder .................................................................31
4-5 Platform Leveling Master Cylinder .................................................................32
Secondary Boom Components .........................................................................33
5-1 Secondary Boom............................................................................................34
5-2 Secondary Boom Lift Cylinders ......................................................................39
Engines................................................................................................................40
6-1 Timing Adjustment..........................................................................................40
6-2 RPM Adjustment ............................................................................................40
6-3 Engine Drive Pulley ........................................................................................40
How to Remove the Engine Drive Pulley ........................................................40
How to Install the Engine Drive Pulley ............................................................41

September 2016
Table of Contents
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy ix
Generator ............................................................................................................43
7-1 Generator Pulley ............................................................................................43
How to Remove the Generator Pulley ............................................................43
How to Install the Generator Pulley ................................................................43
7-2 Generator Belts ..............................................................................................44
7-3 Generator Voltage Regulator .........................................................................44
How to Adjust the Generator Voltage Regulator.............................................44
How to Replace the Voltage Regulator...........................................................45
Hydraulic Pumps ................................................................................................47
8-1 Auxiliary Pump ...............................................................................................47
8-2 Function Pump ...............................................................................................48
Manifolds.............................................................................................................49
9-1 Function Manifold Components .....................................................................49
9-2 Valve Adjustments - Function Manifold..........................................................51
How to Adjust the System Relief Valve...........................................................51
How to Adjust the Secondary Boom Down Relief Valve.................................51
9-3 Jib Boom / Platform Rotate Manifold Components ........................................52
9-4 Turntable Rotation Manifold Components .....................................................53
9-5 Valve Coils .....................................................................................................54
How to Test a Coil Diode ................................................................................54
Turntable Rotation Components ......................................................................56
10-1 Turntable Rotation Assembly .......................................................................56
Motor Controllers ...............................................................................................57
11-1 Motor Controller ...........................................................................................57
Steer Axle Components.....................................................................................58
12-1 Hub and Bearings ........................................................................................58
How to Remove the Hub and Bearings...........................................................58
How to Install the Hub and Bearings...............................................................58

September 2016
Table of Contents
x Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Section 4 Fault Codes .........................................................................................................60
Introduction ...........................................................................................................60
Fault Code Charts ...........................................................................................62
Section 5 Schematics..........................................................................................................66
Introduction ...........................................................................................................66
Electrical Symbol Legend .....................................................................................67
Hydraulic Symbols Legend...................................................................................68
Electrical Schematics – Options.......................................................................69
Platform Options Wiring Diagram .........................................................................70
Engine Panel Wiring Diagram ..............................................................................71
Power Panel Wiring Diagram ...............................................................................74
CTE Option Wiring Diagram, (CE)........................................................................75
Charger Interlock Option ......................................................................................78
Hydraulic Schematics ........................................................................................79
Hydraulic Schematic.............................................................................................80
Electrical Schematics – ANSI and CSA Models ..............................................81
Electrical Schematic, (ANSI / CSA) ......................................................................82
Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA) .....................86
Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA).......................87
Platform Control Box Wiring Diagram, (ANSI / CSA) ...........................................90
Electrical Schematics – CE Models ..................................................................91
Electrical Schematic, (CE)....................................................................................92
Ground Control Box Terminal Strip Wiring Diagram, (CE)...................................96
Ground Control Box Switch Panel Wiring Diagram, (CE) ....................................97
Platform Control Box Wiring Diagram, (CE) .......................................................100
Electrical Schematics – AS Models ................................................................101
Electrical Schematic, (AS) ..................................................................................102
Ground Control Box Terminal Strip Wiring Diagram, (AS) .................................106
Ground Control Box Switch Panel Wiring Diagram, (AS)...................................107
Platform Control Box Wiring Diagram, (AS) .......................................................110

September 2016 Service and Repair Manual
Specifications
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 1
Section 2 Speci fi c ati ons
Machine Specifications
Tires and wheels
Tire size
9-
14.5 LT
Tire ply rating
Tread 8
Sidewall 6
Overall tire diameter
28 in
71 cm
Wheel diameter
14.5 in
37 cm
Wheel width
7 in
18 cm
Wheel lugs
9 @ 5/8 -
18
Lug nut torque, lubricated
83 ft-
lbs
112.5 Nm
Lug
nut torque, dry 110 ft-
lbs
149 Nm
Tire contact area
43.5 sq in
280 sq cm
Fluid capacities
Fuel tank
9 gallons
34.1 liters
Hydraulic tank
8 gallons
30.3 liters
Hydraulic system (including
tank)
11 gallons
41.6 liters
Drive hubs (refer to tag on drive
hub to determine type)
EW1 type
17 fl oz
503 cc
W1 type
23 fl oz
680 cc
Turntable rotation drive hub
25.5 fl oz
750 cc
Drive hub oil type: SAE 90 multipurpose hypoid gear oil
API service classification GL5
Batteries
Type
6V DC
Group
L-
16
Quantity
8
Capacity
350 AH
Reserve capacity @ 25A rate
750 minutes
Performance Specifications
Drive speed, maximum
Stowed position
3 mph
4.8 km/h
40 ft / 9 sec
12.2 m / 9 sec
Raised or extended
0.6 mph
0.98 km/h
40 ft / 45 sec
12.2 m / 45 sec
Gradeability
See Operator's Manual
Braking distance, maximum
High range on paved surface
5 to 7 ft
1.5 to 2 m
Joystick function speeds, maximum from platform
controls
Jib boom up, Z
-45/25J
33 to 39 seconds
Jib boom down, Z
-45/25J
22 to 28 seconds
Primary boom up
32 to 40 seconds
Primary boom down
26 to 30 seconds
Primary boom extend
14 to 18 seconds
Primary boom retract
17 to 21 seconds
Secondary boom up
38 to 46 seconds
Secondary boom down
38 to 46 seconds
Turntable rotate, 355ø
primary boom
retracted
95 to 125 seconds
Platform rotate, 180°, Z
-45/25
6 to 10 seconds
Platform rotate, 160°, Z
-45/25J
6 to 10 seconds
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual September 2016
Specifications
2 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
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, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 ppm
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 2016 Service and Repair Manual
Specifications
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 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
Viscosi
ty 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 September 2016
Specifications
4 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
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

September 2016 Service and Repair Manual
Specifications
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 5
Hydraulic Component
Specifications
Function pump
Type
Fixed displacement
gear pump
Displacement per
revolution
0.183 cu in
3 cc
Flow rate
2.1 gpm
7.9 L/min
Hydraulic tank return filter
10 micron with
25 psi / 1.7 bar bypass
Function manifold
System relief valve pressure,
maximum
3200 psi
220.6 bar
Secondary boom down
relief
valve pressure
2100 psi
145 bar
Platform level flow regulator
0.6 gpm
2.27 L/min
Jib boom / platform rotate flow
regulator
0.4 gpm
1.5 L/min
Auxiliary pump
Type: fixed displacement gear pump
Displacement per revolution
0.5 gpm
1.9 L/min
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 Specification
Description
Specification
Solenoid valve, 3 position 4 way, 20V DC
(schematic items B, C, D, E, F and H)
25 to 29
Ω
Solenoid valve, 2 position 3 way, 20V DC
(schematic items A, K, S and AA)
25 to 29
Ω
Proportional solenoid valve, 24V DC
(schematic item I)
17 to 21
Ω

Service and Repair Manual September 2016
Specifications
6 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Machine Torque Specifications
Platform Rotator
3/4
-10 center bolt, GR 8 380 ft-
lbs
515 Nm
3/8
-16 bolts, GR 8 44 ft-
lbs
60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts,
lubricated 180 ft-
lbs
244 Nm
Drive motor/brake mounting bolts, dry
110 ft-
lbs
149 Nm
Drive motor/brake mounting bolts,
lubricated
80 ft-
lbs
108 Nm
Drive motors and hubs
Drive hub mounting bolts, lubricated
180 ft-
lbs
244 Nm
Drive motor mounting
bolts, lubricated 55 ft-
lbs
75 Nm
Generator
Generator output with engine @ 3000 rpm
54V DC,
100A
Generator pulley to engine pulley offset,
maximum
1/16 inch
1.6 mm
Belt deflection, maximum
1/4 inch
6.5 mm
Generator Torque
Specifications
Generator pulley retaining nut torque
80-90 ft-
lbs
108-
122 Nm
Engine pulley retaining bolts
108 in-
lbs
12.2 Nm
#10 screw
25 in-
lbs
2.8 Nm
#10 nut
25 in-
lbs
2.8 Nm
#4 nut
8-10 in-
lbs
0.9-
1.1 Nm
Voltage regulator mounting fasteners
25 in-
lbs
2.8 Nm

September 2016 Service and Repair Manual
Specifications
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 7
Kubota Z482-E2B Engine
Kubota Z482-E3B Engine
Displacement
29.23 cu in
0.48 liters
Number of cylinders
2
Bore and Stroke
2.64 x 2.68 inches
67 x 68 mm
Horsepower
13.3 @ 3600 rpm
9.9 kW
Firing
order 1 -
2
Low idle
2000 rpm
High idle
3000 rpm
Governor
centrifugal mechanical
Valve clearance, cold
0.0057 to 0.0072 in
0.145 to 0.185 mm
Compression ratio
23:1
Compression pressure
412 to 469 psi
28.4 to 32.3 bar
Lubrication system
Oil
pressure
36 to 64 psi
2.48 to 4.41 bar
Oil capacity (including filter)
Z482
-E2B
Z482
-E3B
2.2 quarts
2.1 liters
2.6 quarts
2.5 liters
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Injection system
Injection pump make
Bosch MD
Injection timing
21° BTDC
Injection pump pressure
1991 psi
137
bar
Starter motor
Brush length, new
0.5188 in
13 mm
Brush length, minimum
0.3346 in
8.5 mm
Alternator
Alternator output
12V DC, 150 watts
Fan belt deflection
1/4 to 3/8 inch
7 to 9 mm
Battery
Type
12V DC, Group 70
Quantity
1
Cold cranking
ampere
450A
Reserve capacity @ 25A rate
125 minutes

Service and Repair Manual September 2016
Specifications
8 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be
torqued to specification when they are removed
and installed or when new hoses or fittings are
installed.
Seal-Lok™ Fittings
(hose end - ORFS)
SAE Dash Size Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 ¼
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash Size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
Adjustable Fitting Non-adjustable fitting
1 jam nut
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash Size Torque
-4 ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)
15 ft-lbs / 20.3 Nm
26 ft-lbs / 35.3 Nm
22 ft-lbs / 30 Nm
-6 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
35 ft-lbs / 47.5 Nm
29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
60 ft-lbs / 81.3 Nm
52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
100 ft-lbs / 135.6 Nm
85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm

September 2016 Service and Repair Manual
Specifications
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 9
Torque Procedure
Seal-Lok™ fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight.
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in
this section.
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
approximately 30 in-lbs / 3.4 Nm.
2 Using a permanent ink marker, make a
reference mark on one the flats of the hex nut
and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
Illustration 1
1 hex nut
2 reference mark
3 body hex fitting

Service and Repair Manual September 2016
Specifications
10 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
3 Working clockwise on the body hex fitting,
make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section to
determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.