Genie Z-45/25 Installation and operating manual

Service and Repair Manual
Serial Number Range
Z-45/25
from Z452513A-47001 to
Z452516N-57199
This manual includes:
Repair
procedures
Fault Codes
Electrical and
Hydraulic Schematics
Z-45/25J
from Z452514B-3301 to
Z452516M-6699
IC Power
from Z452513D-101 to
Z452516D-
939
from Z4525D-940
from Z4525M-6700
For detailed maintenance
procedures, refer to
the
appropriate Maintenance
Manual for your machine.
from Z4525N-57200
Part No. 1268548
Rev A1
September 2016

Service and Repair Manual September 2016
Introduction
ii Z-45/25 • Z-45/25J Part No. 1268548
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 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
1268548 Rev A, September 2015
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“Z” is a trademark of Terex South Dakota, Inc.

September 2016 Service and Repair Manual
Introduction
Part No. 1268548 Z-45/25 • Z-45/25J iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
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 • Z-45/25J Part No. 1268548
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label (located under cover)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1268548 Z-45/25 • Z-45/25J 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 September 2016
Safety Rules
vi Z-45/25 • Z-45/25J Part No. 1268548
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 res
ult 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 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 2016
Table of Contents
Part No. 1268548 Z-45/25 • Z-45/25J 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....................................................................................2
Hydraulic Specification...........................................................................................3
Hydraulic Component Specifications......................................................................5
Ford MSG-425 EFI Engine Specifications .............................................................7
Deutz D2011 L03i Engine Specifications...............................................................9
Deutz D 2.9 L4 Engine Specifications..................................................................11
Perkins 404D-22 Engine Specifications...............................................................13
Perkins 404F-22 Engine Specifications ...............................................................15
Machine Torque Specifications............................................................................16
Hydraulic Hose and Fitting Torque Specifications ...............................................17
Torque Procedure ................................................................................................18
SAE and Metric Fasteners Torque Charts ...........................................................20

September 2016
Table of Contents
viii Z-45/25 • Z-45/25J Part No. 1268548
Section 3 Repair Procedures..............................................................................................21
Introduction...........................................................................................................21
Platform Controls ...............................................................................................23
1-1 ALC-500 Circuit Board ...................................................................................23
1-2 Joysticks.........................................................................................................24
How to Adjust the Joystick Max-out Setting....................................................25
How to Adjust the Joystick Ramp Rate Setting...............................................26
How to Adjust the Joystick Threshold Setting.................................................27
Platform Components........................................................................................29
2-1 Platform Leveling Slave Cylinder ...................................................................29
How to Bleed the Slave Cylinder.....................................................................30
2-2 Platform Rotator .............................................................................................31
2-3 Platform Overload System .............................................................................32
Jib Boom Components ......................................................................................34
3-1 Jib Boom.........................................................................................................34
3-2 Jib Boom Lift Cylinder ....................................................................................35
Primary Boom Components..............................................................................37
4-1 Cable Track....................................................................................................37
How to Remove the Cable Track, Z-45/25......................................................37
How to Remove the Cable Track, Z-45/25J....................................................39
How to Repair the Primary Boom Cable Track...............................................41
4-2 Primary Boom.................................................................................................41
How to Disassemble the Primary Boom..........................................................43
4-3 Primary Boom Lift Cylinder.............................................................................44
4-4 Primary Boom Extension Cylinder .................................................................45
4-5 Platform Leveling Master Cylinder .................................................................46

September 2016
Table of Contents
Part No. 1268548 Z-45/25 • Z-45/25J ix
Secondary Boom Components.........................................................................47
5-1 Secondary Boom............................................................................................48
5-2 Secondary Boom Lift Cylinders......................................................................53
Engines................................................................................................................55
6-1 RPM Adjustment - Deutz D2011L03i Models ................................................55
6-2 RPM Adjustment - Perkins 404D-22 Models .................................................55
6-3 Flex Plate .......................................................................................................55
How to Install the Flex Plate............................................................................57
How to install the Pump and Bell Housing Assembly .....................................58
6-4 Ford MSG-425 Engine Fault Codes...............................................................59
6-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models.............59
Hydraulic Pumps................................................................................................60
7-1 Lift/Steer Pump ..............................................................................................60
7-2 Drive Pump.....................................................................................................61
How to Prime the Pump ..................................................................................62
Manifolds.............................................................................................................64
8-1 Function Manifold Components .....................................................................64
8-2 Valve Adjustments - Function Manifold..........................................................68
How to Adjust the System Relief Valve...........................................................68
How to Adjust the Secondary Boom Down Relief Valve.................................69
8-3 Jib Boom / Platform Rotate Manifold Components........................................70
8-4 Turntable Rotation Manifold Components .....................................................71
8-5 Directional Valve Manifold Components........................................................72
How to Set Up the Directional Valve Linkage.................................................73
8-6 Traction Manifold Components, 2WD............................................................74
8-7 Valve Adjustments, 2WD Traction Manifold...................................................76
8-8 Traction Manifold Components, 4WD............................................................77
8-9 Valve Adjustments, 4WD Traction Manifold...................................................79
8-10 Hydraulic Generator Manifold Components, 2.2kW ....................................80
8-11 Valve Coils ...................................................................................................81
How to Test a Coil Diode ................................................................................81

September 2016
Table of Contents
x Z-45/25 • Z-45/25J Part No. 1268548
Turntable Rotation Components.......................................................................83
9-1 Turntable Rotation Assembly.........................................................................83
Axle Components...............................................................................................85
10-1 Hub and Bearings, 2WD Models..................................................................85
How to Remove the Hub and Bearings...........................................................85
How to Install the Hub and Bearings...............................................................85
10-2 Oscillating Axle Cylinders.............................................................................86
Section 4 Fault Codes.........................................................................................................87
Introduction...........................................................................................................87
Control System Fault Codes .............................................................................88
How to Retrieve Control System Fault Codes.................................................88
Control System Fault Codes ...........................................................................89
Fault Code Display - Deutz and Perkins Models.............................................93
How to Retrieve Active Engine Fault Codes
Deutz D 2.9 L4 and Perkins 404F-22 Models .........................................93
Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 and
Perkins 404F-22 Models..........................................................................94
Soft Key Functions and Icons -
Deutz D 2.9 L4 and Perkins 404F-22 Models .........................................95
Main Menu Structure - Deutz D 2.9 L4 Models...............................................96
Main Menu Structure - Perkins 404F-22 Models.............................................97
Deutz D 2.9 L4 Engine Fault Codes ..................................................................98
Perkins 404F-22 Engine Fault Codes .............................................................109
Ford MSG-425 Engine Fault Codes ................................................................111
How to Retrieve Ford MSG-425 Engine Fault Codes...................................111
Ford MSG-425 Engine Fault Codes..............................................................112

September 2016
Table of Contents
Part No. 1268548 Z-45/25 • Z-45/25J xi
Section 5 Schematics........................................................................................................117
Introduction.........................................................................................................117
Electrical Symbol Legend...................................................................................118
Hydraulic Symbols Legend.................................................................................119
Electrical Component and Wire Color Legends .................................................120
Ford Engine Relay Layout..................................................................................123
Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22............................124
Electrical Schematics – Options.....................................................................125
Ford MSG-425 EFI Engine Wire Harness..........................................................126
Deutz D 2.9 L4 Engine Wire Harness ................................................................127
Perkins 404F-22 Engine Wire Harness..............................................................130
Electrical Schematic, Options (All Models) ........................................................131
Ground Control Box Terminal Strip Wiring Diagram, Options............................134
Platform Control Box Wiring Diagram, Options..................................................135
Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options ...........138
Wiring Diagram, 2.2kW Hydraulic Generator.....................................................139
Hydraulic Schematics......................................................................................141
Hydraulic Schematic, 2WD Models....................................................................142
Hydraulic Schematic, 4WD Models....................................................................143

September 2016
Table of Contents
xii Z-45/25 • Z-45/25J Part No. 1268548
Electrical Schematics – ANSI and CSA Models ............................................145
Electrical Schematic, Ford MSG-425 EFI Models (ANSI/CSA)..........................146
Ground Control Box Terminal Strip Wiring Diagram -
Ford MSG-425 EFI Models (ANSI/CSA) ....................................................150
Ground Control Box Switch Panel Wiring Diagram -
Ford MSG-425 EFI Models (ANSI/CSA) ....................................................151
Platform Control Box Wiring Diagram -
Ford MSG-425 EFI Models (ANSI/CSA) ....................................................154
Platform Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models
(ANSI/CSA).................................................................................................155
Electrical Schematic, Deutz D2011 L03i / Perkins 404D-22 Models
(ANSI/CSA).................................................................................................158
Ground Control Box Terminal Strip Wiring Diagram - Deutz D2011 L03i /
Perkins 404D-22 Models (ANSI/CSA)........................................................162
Ground Control Box Switch Panel Wiring Diagram - Deutz D2011 L03i /
Perkins 404D-22 Models (ANSI/CSA)........................................................163
Platform Control Box Wiring Diagram - Deutz D2011 L03i /
Perkins 404D-22 Models (ANSI/CSA)........................................................166
Platform Control Box Switch Panel Wiring Diagram - Deutz D2011 L03i /
Perkins 404D-22 Models (ANSI/CSA)........................................................167

September 2016
Table of Contents
Part No. 1268548 Z-45/25 • Z-45/25Jxiii
Electrical Schematics – ANSI Models ............................................................169
Electrical Schematic, Deutz D 2.9 L4 Models
(ANSI).........................................................................................................170
Ground Control Box Terminal Strip Wiring Diagram -
Deutz D 2.9 L4 Models (ANSI)..................................................................174
Ground Control Box Switch Panel Wiring Diagram - Deutz D 2.9 L4 Models
(ANSI).........................................................................................................175
Platform Control Box Wiring Diagram - Deutz D 2.9 L4 Models (ANSI) ............178
Platform Control Box Switch Panel Wiring Diagram -
Deutz D 2.9 L4 Models
(ANSI).........................................................................................................179
Electrical Schematic, Perkins 404F-22 Models (ANSI).....................................182
Ground Control Box Terminal Strip Wiring Diagram -
Perkins 404F-22 Models (ANSI).................................................................186
Ground Control Box Switch Panel Wiring Diagram -
Perkins 404F-22 Models (ANSI).................................................................187
Platform Control Box Wiring Diagram Perkins 404F-22 Models (ANSI)............190
Platform Control Box Switch Panel Wiring Diagram -
Perkins 404F-22 Models (ANSI).................................................................191
Electrical Schematics – AS Models................................................................193
Electrical Schematic, Ford MSG-425 EFI Models (AS)......................................194
Ground Control Box Terminal Strip Wiring Diagram - Ford MSG-425 EFI Models
(AS).............................................................................................................198
Ground Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models
(AS).............................................................................................................199
Platform Control Box Wiring Diagram - Ford MSG-425 EFI Models (AS)..........202
Platform Control Box Switch Panel Wiring Diagram -
Ford MSG-425 EFI Models (AS) ................................................................203
Electrical Schematic, Deutz 2011 L03i / Perkins 404D-22 Models (AS)............206
Ground Control Box Terminal Strip Wiring Diagram -
Deutz 2011 L03i / Perkins 404D-22 Models (AS).......................................210
Ground Control Box Switch Panel Wiring Diagram -
Deutz 2011 L03i / Perkins 404D-22 Models (AS).......................................211
Platform Control Box Wiring Diagram - Deutz 2011 L03i /
Perkins 404D-22 Models (AS)....................................................................214
Platform Control Box Switch Panel Wiring Diagram - Deutz 2011 L03i /
Perkins 404D-22 Models (AS)....................................................................215

September 2016
Table of Contents
xiv Z-45/25 • Z-45/25J Part No. 1268548
Electrical Schematics – CE Models................................................................217
Electrical Schematic, Ford MSG-425 EFI Models (CE) .....................................218
Ground Control Box Terminal Strip Wiring Diagram - Ford MSG-425 EFI Models
(CE).............................................................................................................222
Ground Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models
(CE).............................................................................................................223
Platform Control Box Wiring Diagram - Ford MSG-425 EFI Models (CE) .........226
Platform Control Box Switch Panel Wiring Diagram - Ford MSG-425 EFI Models
(CE).............................................................................................................227
Electrical Schematic, Deutz 2011 L03i / Perkins 404D-22 Models (CE)............230
Ground Control Box Terminal Strip Wiring Diagram - Deutz 2011 L03i / Perkins
404D-22 Models (CE).................................................................................234
Ground Control Box Switch Panel Wiring Diagram - Deutz 2011 L03i / Perkins
404D-22 Models (CE).................................................................................235
Platform Control Box Wiring Diagram - Deutz 2011 L03i / Perkins 404D-22 Models
(CE).............................................................................................................238
Platform Control Box Switch Panel Wiring Diagram - Deutz 2011 L03i / Perkins
404D-22 Models (CE).................................................................................239

September 2016 Service and Repair Manual
Specifications
Part No. 1268548 Z-45/25 • Z-45/25J 1
Section 2 Speci fic ati ons
Machine Specifications
Tires and wheels
rough terrain
Tire size
315/55 D20
Tire ply rating
12
Tire and wheel weight, air filled
140 l
bs
63.5 k
g
foam filled (minimum)
290 l
bs
131.5 k
g
Overall tire diameter
32.5 i
n
82.5 c
m
Wheel diameter
20 i
n
50.8 c
m
Wheel width
11 i
n
27.9 c
m
Wheel lugs
9 @ 5/8 -
18
Lug nut
torque, lubricated 94 ft-
lbs
127.4 Nm
Lug nut torque, dry
125 ft-
lbs
169.5 Nm
Tire pressure
60 p
si
4.1 b
ar
Tires and wheels
Hi-flotation (option)
Tire size
33/16LL500
Tire ply rating
10
Overall tire diameter
33 i
n
84 c
m
Wheel diameter
19.5 i
n
49.5 c
m
Wheel width
14 i
n
35.6 c
m
Wheel lugs
9 @ 5/8 -
18
Lug nut torque, lubricated
94 ft-
lbs
127.4 Nm
Lug nut torque, dry
125 ft-
lbs
169.5 Nm
Tire pressure
38 p
si
2.6 b
ar
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

Service and Repair Manual September 2016
Specifications
2 Z-45/25 • Z-45/25J Part No. 1268548
Fuel capacities
LPG tank
33.5 p
ounds
15.2 k
g
Fuel tank
17 g
allons
64.4 liters
Hydraulic tank
22 g
allons
83 l
iters
Hydraulic
system
(including tank)
30 g
allons
113.6 l
iters
Drive hubs
24 f
l oz
710 c
c
Drive hub oil type: SAE 9
0 multipurpose hypoid gear oil
API service classification GL5
Performance Specifications
Drive speed, maximum
Stowed
position 4.5 m
ph
7.2 k
m/h
40 ft / 6.1 s
ec
12.2 m / 6.1 s
ec
Raised or extended
0.6 m
ph
0.98 k
m/h
40 ft / 45 s
ec
12.2 m / 45 s
ec
Gradeability
See Operator's Manual
Braking distance, maximum
High range on paved surface
3 to 6 f
t
0.9 to 1.8
m
Joystick
function speeds, maximum from platform
controls
Primary boom up
24 to 28 s
econds
Primary boom down
24 to 28 s
econds
Primary boom extend
18 to 22 s
econds
Primary boom retract
18 to 22 s
econds
Secondary boom up
24 to 28 s
econds
Secondary boom down
24 to 28 s
econds
Turntable rotate, 355ø
62 to 68 s
econds
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

September 2016 Service and Repair Manual
Specifications
Part No. 1268548 Z-45/25 • Z-45/25J 3
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 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

Service and Repair Manual September 2016
Specifications
4 Z-45/25 • Z-45/25J Part No. 1268548
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
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. 1268548 Z-45/25 • Z-45/25J 5
Hydraulic Component
Specifications
Drive Pump
Type: bi
-directional variable displacement piston pump
Flow rate @ 250
0 psi /
17
2 bar 32 g
pm
121 L/min
Drive pressure, maximum
3500 p
si
241 b
ar
Charge Pump
Type
gear
Displacement per
revolution
0.84 c
u in
13.76 c
c
Flow rate @ 250
0 psi /
17
2 bar 9.1 g
pm
34.4 L/min
Charge pressure @
250
0 rpm 315 p
si
21.7 b
ar
Function pump
Type
gear
Displacement per
revolution
0.67 c
u in
11 c
c
Flow rate @ 250
0 psi /
17
2 bar 7.25 g
pm
27.4 L/min
Auxiliary Pump
Type
gear,
fixed
displacement
Displacement per revolution
0.067 c
u in
1.1 c
c
Auxiliary pump relief pressure
3200 p
si
220.6 b
ar
Function manifold
System relief valve pressure,
maximum
3200 p
si
220.6 b
ar
Secondary boom down relief
valve pressure
2100 p
si
145 b
ar
Platform level relief valve
pressure
2500 p
si
172 b
ar
Steer flow regulator
2.0 g
pm
7.6 L/min
Boom extend flow regulator
2 g
pm
7.6 L/min
Jib boom / platform rotate flow
regulator
0.4 g
pm
1.5 L/min
Traction Manifold
Hot oil relief pressure
250 p
si
17.2 b
ar
Steer end drive motors (4WD models)
Displacement per revolution
variable
0.54 to 1.53 c
u in
8.77 to 25 c
c
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

Service and Repair Manual September 2016
Specifications
6 Z-45/25 • Z-45/25J Part No. 1268548
Non
-steer end drive motors
Displacement per revolution
variable 4WD (
2 speed motor) 0.54 to 1.53 c
u in
8.85 to 25.1 c
c
Displacement per revolution
variable 2WD
0.99 to 1.83 c
u in
16.2 to 30 c
c
Hydraulic Filters
High pressure filter:
Beta 3 ˆ 200
High
pressure filter bypass
pressure
100 p
si
6.89 b
ar
Medium pressure filter
Beta 3 ˆ 200
Medium pressure filter bypass
pressure
50 p
si
3.4 b
ar
Hydraulic tank return filter
10 m
icron with
25 psi / 1.7 b
ar
bypass
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
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.