Genie Z-51/30J Installation and operating manual

1.
Service and Repair Manual
Part No. 1268553GT
Rev A3
October 2020
From Z513014B-1201
to Z513016M-1999
Serial Number Range
Z-51/30J
From Z5130M-2000
This manual includes:
Repair procedures
Fault Codes
Electrical and Hydraulic
Schematics
For detailed maintenance
procedures, Refer to the
appropriate Maintenance
Manual for your machine.

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October 2020Service and Repair Manual
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
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.
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.
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.
Contact Us:
http://www.genielift.com
e-mail: [email protected]
Introduction
Copyright © 2019 by Terex Corporation
1268553GT Rev A3 October 2020
First Edition, First Printing
"Genie" and "Z" are registered trademarks of Terex
South Dakota, Inc. in the USA and many other countries

October 2020
Part No. 1268553GT Z®-51/31J iii
Service and Repair Manual
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
A2 11/2017 Specifications Machine Specifications
A3 10/2020 All Sections Add Deutz TD 2.2 L3 engine
REFERENCE EXAMPLES:
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics
Electronic Version
Click on any content or procedure in the
Table of Contents to view the update.
Introduction

iv Z®-51/31J Part No. 1268553GT
October 2020Service and Repair Manual
Introduction
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial number (stemped on chassis)
5 Serial label (located under cover)
To August 31, 2016
From September 1, 2016
1 Model
2 Model Year
3 Facility code
4 Sequence number
5 Serial number (stemped on chassis)
6 Serial label (located under cover)

October 2020
Part No. 1268553GT Z®-51/31J v
Service and Repair Manual
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.
Safety Rules

vi Z®-51/31J Part No. 1268553GT
October 2020Service and Repair Manual
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 an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
DANGER
WARNING
CAUTION
NOTICE
Workplace Safety
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.
SAFETY RULES

October 2020
Part No. 1268553GT Z®-51/31J vii
Introduction Introduction................................................................................................ii
Important Information .................................................................................. ii
Find a Manual for this Model ....................................................................... ii
Revision History...........................................................................................iii
Serial Number Legend................................................................................ iv
Section 1 Safety Rules............................................................................................... v
General Safety Rules .................................................................................. v
Section 2 Specifications ............................................................................................1
Machine Specifications................................................................................1
Performance Specifications.........................................................................1
Hydraulic Specifications ..............................................................................2
Hydraulic Component Specifications...........................................................4
Manifold Component Specifications ............................................................5
Deutz D2011 L30i Engine Specifications ....................................................6
Deutz TD 2.2 L3 Engine Specifications.......................................................7
Machine Torque Specifications ...................................................................8
Hydraulic Hose and Fitting Torque Specifications.......................................9
Torque Procedure......................................................................................10
Section 3 Repair Procedures...................................................................................12
Introduction................................................................................................ 13
Platform Controls ....................................................................................15
1-1 ALC 500 Circuit Board.....................................................................15
1-2 Joysticks..........................................................................................16
How to Adjust the Joystick Max-out Setting ....................................17
How to Adjust the Joystick Ramp Rate Setting ...............................18
How to Adjust the Joystick Treshold Setting ...................................19
Table of Contents

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October 2020
Section 3 Repair Procedures, continued
Platform Components.............................................................................21
2-1 Platform Leveling Slave Cylinder ....................................................21
2-2 Platform Rotator ..............................................................................22
2-3 Platform Overload System ..............................................................23
Jib Boom Components ...........................................................................26
3-1 Jib Boom .........................................................................................26
3-2 Boom Lift Cylinder...........................................................................27
Primary Boom Components...................................................................29
4-1 Cable Track.....................................................................................29
How to Repair the Cable Track ......................................................31
4-2 Primary Boom..................................................................................32
How to Disassemble the Primary Boom..........................................33
4-3 Primary Boom Lift Cylinder..............................................................34
4-4 Primary Boom Extension Cylinder...................................................35
4-5 Platform Leveling Master Cylinder ..................................................36
Secondary Boom Components..............................................................38
5-1 Secondary Boom.............................................................................39
5-2 Secondary Boom Lift Cylinder.........................................................43
Engines.....................................................................................................45
6-1 RPM Adjustment .............................................................................45
6-2 Flex Plate ........................................................................................45
How to Install the Flex Plate............................................................46
How to Install the Pump and Bell Housing Assembly......................46
6-3 Engine Fault Codes - Deutz TD 2.2 L3 Models...............................47
6-4 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 Engine ........47
Hydraulic pumps .....................................................................................48
7-1 Lift/Steer Pump................................................................................48
7-2 Drive Pump......................................................................................49
TABLE OF CONTENTS

October 2020
Part No. 1268553GT Z®-51/31J ix
Section 3 Repair Procedures, continued
Manifolds..................................................................................................51
8-1 Function Manifold Components.......................................................51
8-2 Valve Adjustments-Function Manifold.............................................55
How to Adjust the System Relief Valve ...........................................55
How to Adjust the Secondary Boom Down Relief Valve .................55
8-3 Jib Boom / Platform Rotate Manifold Components .........................56
8-4 Turntable Rotation Manifold Components.......................................57
8-5 Directional Valve Manifold Components .........................................58
How to Set Up the Directional Valve Linkage..................................59
8-6 Traction Manifold Components .......................................................60
8-7 Valve Adjustment, Traction Manifold...............................................62
8-8 Valve Coils ......................................................................................63
Turntable Rotation Components............................................................65
9-1 Turntable Rotation Assembly ..........................................................65
Axle Components....................................................................................67
10-1 Oscillating Axle Cylinders................................................................67
Section 4 Fault Codes..............................................................................................68
Introduction................................................................................................68
Control System Fault Codes ..................................................................69
How to Retrieve Control System Fault Codes...........................................69
Control System Fault Codes......................................................................70
Fault Codes Display ..................................................................................74
Deutz TD 2.2 L3 Engine Fault Codes........................................................77
TABLE OF CONTENTS

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October 2020
Section 5 Schematics...............................................................................................87
Introduction................................................................................................87
Electrical Symbol Legends ........................................................................88
Hydraulic Symbol Legends........................................................................89
Electrical Component and Wire Color Legends.........................................90
Electrical Schematics - Options.............................................................93
Ground Control Box Terminal Strip Wiring Diagram - Options..................94
Platform Control Box Wiring Diagram - Options........................................95
Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options ..97
Electrical Schematics Options ..................................................................99
Electrical Schematics - AS Models......................................................101
Electrical Schematics (AS) ......................................................................102
Ground Control Box Terminal Strip Wiring Diagram (AS) .......................105
Ground Control Box Switch Panel Wiring Diagram (AS) ........................107
Platform Control Box Wiring Diagram (AS) ............................................109
Platform Control Box Switch Panel Wiring Diagram (AS) .......................111
Electrical Schematics - CE Models......................................................113
Electrical Schematics (CE)......................................................................114
Ground Control Box Terminal Strip Wiring Diagram (CE) .......................117
Ground Control Box Switch Panel Wiring Diagram (CE) ........................119
Platform Control Box Wiring Diagram (CE) ............................................121
Platform Control Box Switch Panel Wiring Diagram (CE) ......................123
Electrical Schematics - Deutz TD 2.2 L3, CE Models .........................125
Electrical Schematics - Deutz TD 2.2 L3, CE Models .............................125
Hydraulic Schematics ...........................................................................132
Hydraulic Schematic - 4WD Models........................................................133
TABLE OF CONTENTS

October 2020
Part No. 1268553GT Z®-51/31J 1
Service and Repair Manual
Machine Specifications
Tires and wheels
Tire size 355/55 D625
Tire ply rating 14
Tire weight, new foam-filled
(minimum) (Rough terrain)
390 lbs
177 kg
Overall tire diameter 36.9 in
93.7 cm
Wheel diameter 24.5 inches
62.2 cm
Wheel width 11.75 inches
29.8 cm
Wheel lugs 9 @ 5/8 -18
Lug nut torque, lubricated
Lug nut torque, dry
94 ft-lbs
127.4 Nm
125 ft-lbs
169.5 Nm
Fluid capacities
Fuel tank 17 gallons
64.4 liters
Hydraulic tank 24 gallons
91 liters
Hydraulic system
(including tank)
30 gallons
113.6 liters
Drive hubs - Steer end 17 fl oz
503 cc
Drive hubs with brake, 57:1,
Non-steer end
24 fl oz
1242 cc
Turntable rotation drive hub 25.5 fl oz
750 cc
Specifications
Performance Specifications
Drive speed, maximum
Stowed position 5 mph
8 km/h
40 ft/5.5 sec
12.2 m/5.5 sec
Raised or extended position 0.6 mph
1 km/h
40 ft/45 sec
12.2 m/45 sec
Braking distance, maximum
High range on paved surface 3 to 6 ft
0.9 to 1.8 m
Gradeability See Operator's
Manual
Boom function speeds, maximum from
platform controls
Jib boom up 48 to 52 seconds
Jib boom down 28 to 32 seconds
Primary boom up 36 to 40 seconds
Primary boom down 36 to 40 seconds
Secondary boom up 26 to 30 seconds
Secondary boom down 26 to 30 seconds
Primary boom extend 20 to 24 seconds
Primary boom retract 20 to 24 seconds
Turntable rotate, 355° 82 to 88 seconds
For operational specifications, refer to the
Operator's Manual.

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October 2020Service and Repair Manual
Hydraulic Specifications
Hydraulic Oil Specification
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 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 the 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
Specifications
NOTICE
NOTICE

October 2020
Part No. 1268553GT Z®-51/31J 3
Service and Repair Manual
Chevron Rando HD Premium
Oil MV Fluid Properties
ISO Grade 32
Viscosity index 200
Kinematic Viscosity
cSt @ 200°F / 100°C 7.5
cSt @ 104°F / 40°C 33.5
Brookfield Viscosity
cP @ -4°F / -20°C 1040
cP @ -22°F / -30°C 3310
Flash point 375°F / 190°C
Pour point -58°F / -50°C
Maximum continuous operating 171°F / 77°C
temperature
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 5.5
cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Flash point 180°F / 82°C
Pour point -81°F / -63°C
Maximum continuous operating 124°F / 51°C
temperature
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 8.0
cSt @ 104°F / 40°C 44.4
Flash point 482°F / 250°C
Pour point -49°F / -45°C
Maximum continuous operating 180°F / 82°C
temperature
Shell Tellus S4 VX Fluid
Properties
ISO Grade 32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cP @ -4°F / -20°C 481
cP @ -13°F / -25°C 702.4
cP @ -40°F / -40°C 2624
Flash point >100
Pour point -76°F / -60°C
Maximum continuous operating 103°F / 75°C
temperature
UNCON Hydrolube HP-5046
Fluid Properties
ISO Grade 46
Viscosity index 192
Kinematic Viscosity
cSt @ 149°F / 65°C 22
cSt @ 104°F / 40°C 46
cSt @ 0°F / 18°C 1300
Flash point None
Pour point -81°F / -63°C
Maximum continuous operating 189°F / 87°C
temperature
Specifications
NOTICE

4 Z®-51/31J Part No. 1268553GT
October 2020Service and Repair Manual
Specifications
Hydraulic Component
Specifications
Drive pump
Type: bi-directional, variable
displacement piston
pump
Flow rate @ 2500 rpm 32 gpm
121 L/min
Drive pressure, maximum 3500 psi
241 bar
Charge pump
Type gear
Displacement 0.84 cu in
13.76 cc
Flow rate @ 2500 rpm 9.1 gpm
34.4 L/min
Charge pressure @ 2500 rpm 315 psi
21.7 bar
Function pump
Type gear
Displacement 0.67 cu in
11 cc
Flow rate @ 2500 rpm 7.25 gpm
27.4 L/min
Auxiliary pump
Type: gear, fixed
displacement
Displacement per revolution 0.067 cu in
1.1 cc
Auxiliary pump relief pressure 3200 psi
220.6 bar
Function Manifold
System relief valve pressure 3200 psi
220.6 bar
Secondary boom down relief
valve pressure
2100 psi
145 bar
Platform level relief valve
pressure
2500 psi
172 bar
Steer flow regulator 1.5 gpm
5.7 L/min
Boom extend flow regulator 2 gpm
7.6 L/min
Jib boom / platform rotate flow
regulator
0.4 gpm
1.5 L/min
Drive manifold
Hot oil relief pressure 250 psi
17.2 bar
Steer end drive motors
Displacement per revolution 1.53 cu in
25 cc
Non-steer end drive motors
Displacement per revolution,
variable (2 speed motor)
0.01 to 1.83 cu in
1.61 to 30 cc
Hydraulic Filters
High pressure filter Beta 3 ³ 200
High pressure filter bypass
pressure
100 psi
6.89 bar
Medium pressure filter Beta 3 ³ 200
Medium pressure filter
bypass pressure
50 psi
3.4 bar
Hydraulic return filter 10 micron with 25 psi /
1.7 bar bypass

October 2020
Part No. 1268553GT Z®-51/31J 5
Service and Repair Manual
Manifold Component Specifications
Plug Torque
SAE No. 4 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
Proportional directional solenoid valve, 10V
DC (schematic items BP, BU and BY)
6 to 8Ω
3 position 4 way directional valve, 10V DC
(schematic items BF, BM and CG)
6 to 8Ω
2 position 3 way solenoid valve, 10V DC
(schematic items CA, CC, G, AF and AG)
6 to 8Ω
Specifications

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October 2020Service and Repair Manual
Specifications
Deutz D2011 L03i Engine
Displacement 142 cu in
2.33 liters
Number of cylinders 3
Bore and Stroke 3.7 x 4.4 inches
94 x 112 mm
Horsepower 48 @ 2800 rpm
36 kW @ 2800
rpm
Firing order 1 - 2 - 3
Low idle 1500 rpm
313 Hz
High idle 2500 rpm
521.7 Hz
Compression ratio 19:01
Compression pressure 362 to 435 psi
25 to 30 ba
Governor centrifugal
mechanical
Valve Clearance, cold
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Lubrication system
Oil pressure 20 to 44 psi
1.4 to 3 bar
Oil capacity
(including filter)
9.5 quarts
9 liters
Oil viscosity requirements
-22° F to 86° F/ -30° C to 30°
C
5W-30
(synthetic)
-4° F to 90° F / -20° C to 32° C 10W-40
Above 23° F / -5° C 20W-50
Unit ships with 15W-40. Extreme operating
temperatures may require the use of alternative
engine oils. For oil requirements, refer to the Engine
Operator Manual for your engine.
Oil temperature switch
Temperature switch point 300°F
149°C
Oil pressure switch
Oil pressure switch point 22 psi
1.5 bar
Fuel injection system
Injection pump make Bosch
Injection pump pressure,
maximum
15000 psi
1034 bar
Injector opening pressure 3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine
Operator's Manual on your machine.
Starter motor
Current draw, no load 90A
Brush length, new 0.72 in
18.5 mm
Brush length, minimum 0.27 in
7 mm
Battery
Type 12V DC,
Group 34/78
Quantity 1
Cold cranking ampere 900A
Reserve capacity @ 25A rate 200 minutes
Alternator output 60A @ 14V DC
Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm

October 2020
Part No. 1268553GT Z®-51/31J 7
Service and Repair Manual
Deutz TD 2.2 L3 Engine
Displacement 134 cu. in
2,2 liters
Number of cylinders 3
Bore and Stroke 3.6 x 4.3 inches
92 x 110 mm
Horsepower net intermittent
@ 2600 rpm
49 hp
36 kW
Induction system turbocharged
Firing order 1 - 2 - 3
Low idle, standby 1000 rpm
Low idle, function enable 1500 rpm
High idle 2500 rpm
Governor electronic
Lubrication system Low ash oil required
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2,8 to 4,1 bar
Oil capacity (including filter) 8 quarts
7,6 liters
Oil viscosity requirements
-22° F to 86° F/ -30° C to 30° C 5W-30
(synthetic)
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40. Extreme operating
temperatures may require the use of alternative
engine oils. For oil requirements, refer to the Engine
Operator Manual for your engine.
Oil temperature switch
Installation torque 8 - 18 ft-lbs
11 - 24 Nm
Temperature switch point 257°F
125°C
Oil pressure switch
Installation torque 8 - 18 ft-lbs
11 - 24 Nm
Pressure switch point 17.4 psi
1,2 bar
Fuel requirement
For fuel requirements, refer to the engine
Operator's Manual for your engine.
Engine coolant capacity 2.5 gallons
9,5 liters
Unit ships with Ethylene Glycol engine coolant.
Consult your local supplier for compatibility before
mixing alternative engine coolants.
Starter motor
Current draw, normal load 140 - 200A
Cranking speed 250 - 350 rpm
Battery – Engine starting and control system
Type 12V DC, Group 31
Quantity 1
Battery capacity, maximum 1000A
Reserve capacity @ 25A rate 200 Minutes
Alternator output 95A @ 14V DC
Specifications

8 Z®-51/31J Part No. 1268553GT
October 2020Service and Repair Manual
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 motor and hubs
Drive hub mounting bolts, lubricated 180 ft-lbs
244 Nm
Drive motor mounting bolts,
lubricated
55 ft-lbs
75 Nm
Specifications

October 2020
Part No. 1268553GT Z®-51/31J 9
Service and Repair Manual
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-LokTM Fittings
(hose end - ORFS)
SAE Dash size Torque
-4 18 ft-lbs / 24.4 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
-20 150 ft-lbs / 203.4 Nm
-24 230 ft-lbs / 312 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 1/4
-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
Specifications
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
1
Adjustable Fitting1 Non-adjustable tting
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

10 Z®-51/31J Part No. 1268553GT
October 2020Service and Repair Manual
Specifications
Torque Procedure
Seal-LokTM 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-rings used in the Parker Seal Lok™
fittings and hose ends are custom-size O-rings.
They are not standard SAE 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 that the face seal O-ring 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 hoses, fittings and related components to
confirm that 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.
a
b
c
Figure 1
a hex nut
b reference mark
c body hex fitting