Terex Genie Z-45 FE Installation and operating manual

1.
Service and Repair Manual
Part No. 1297714GT
Rev A1
July 2020
From Z45EM-101
Serial Number Range
Z®-45 FE
Z®-45 DC
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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Service 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
1297714GT Rev A1 July 2020
First Edition, First Printing
"Genie" and "Z" are registered trademarks of Terex
South Dakota, Inc. in the USA and many other countries.

July 2020
Part No. 1297714GT Z®-45 DC • Z®-45 FE iii
Service and Repair Manual
Revision History
Revision Date Section Procedure / Page / Description
A 03/2020 Initial Release
A1 07/2020 Section 6 Schematic page 120
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

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Service and Repair Manual
Introduction
Serial Number Legend
Z45EM-001
2020
Z45E M101
123
54
1 Model
2 Facility code
3 Sequence number
4 Serial number (stemped on chassis)
5 Serial label (located under cover)

July 2020
Part No. 1297714GT Z®-45 DC • Z®-45 FE 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

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Service 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

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Part No. 1297714GT Z®-45 DC • Z®-45 FE 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.........................................................................2
Hydraulic Specifications ..............................................................................3
Hydraulic Component Specifications...........................................................5
Manifold Component Specifications ............................................................5
Kubota D1105 Engine Specificatios ............................................................6
Machine Torque Specifications ...................................................................7
Machine Component Weights .....................................................................7
Hydraulic Hose and Fitting Torque Specifications.......................................8
Torque Procedure........................................................................................9
Section 3 Repair Procedures...................................................................................10
Introduction................................................................................................ 10
Calibration Process Steps ......................................................................... 11
Platform Controls ....................................................................................12
1-1 Platform Controls.............................................................................12
How to Adjust the Joystick Treshold Setting ...................................13
How to Adjust the Joystick Max Speed Setting ...............................14
How to Adjust the Joystick Ramp Rate Setting ...............................16
1-2 How to Calibrate Booms Angle Sensors .............................................18
1-3 How to Clear the fault History..............................................................19
Table of Contents

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Section 3 Repair Procedures, continued
Platform Components.............................................................................20
2-1 Platform Leveling Cylinder ..............................................................20
2-2 Platform Rotator ..............................................................................21
2-3 Platform Overload System ..............................................................23
2-4 How to Reset Overload Recovery Fault..........................................24
Jib Boom Components ...........................................................................25
3-1 Jib Boom .........................................................................................25
3-2 Boom Lift Cylinder...........................................................................26
Primary Boom Components...................................................................28
4-1 Cable Track.....................................................................................28
How to Repair the Cable Track ......................................................30
4-2 Primary Boom..................................................................................30
How to Disassemble the Primary Boom..........................................32
4-3 Primary Boom Lift Cylinder..............................................................33
4-4 Primary Boom Extension Cylinder...................................................34
4-5 Platform Leveling Master Cylinder ..................................................35
Secondary Boom Components..............................................................36
5-1 Secondary Boom Lift Cylinder.........................................................37
Engines.....................................................................................................43
6-1 RPM Adjustment .............................................................................43
How to Replace the Motor Tach Sensor..........................................43
Ground Controls......................................................................................44
7-1 Control System Fault Recovery Switch...........................................44
How to use the Control System Fault Recovery Switch ..................45
Hydraulic pumps .....................................................................................46
8-1 Function Pump ................................................................................46
How to Check the Function Pump Calibration.................................47
TABLE OF CONTENTS

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Part No. 1297714GT Z®-45 DC • Z®-45 FE ix
Section 3 Repair Procedures, continued
Manifolds..................................................................................................48
9-1 Function Manifold Components.......................................................49
9-2 Valve Adjustments-Function Manifold.............................................53
How to Adjust the Proportional Relief Valve and Hydraulic Pressure
Sensor.............................................................................................53
How to Adjust the Secondary Boom Down Relief Valve .................54
9-3 Jib Boom / Platform Rotate Manifold Components .........................55
9-4 Turntable Rotation Manifold Components.......................................56
9-5 Directional Valve Manifold Components .........................................57
9-6 How to Set Up the Oscillate Directional Valve ................................58
9-7 Valve Coils ......................................................................................59
How to Test a Coil Diode.................................................................59
Turntable Rotation Components............................................................61
10-1 Turntable Rotation Assembly ..........................................................61
10-2 How to Replace the Universal Tilt Sensor.......................................62
How to Calibrate the Universal Tilt Sensor......................................62
Axle Components....................................................................................63
11-1 Oscillating Axle Cylinders................................................................63
11-2 How to Remove the Steer Cylinder.................................................64
How to Calibrate the Steer Angle Sensor........................................64
TABLE OF CONTENTS

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Section 4 Fault Codes..............................................................................................67
Introduction................................................................................................67
Control System Fault Codes ..................................................................68
Fault Codes Ground Controls....................................................................68
How to Retrieve Control System Fault Codes - Platform Controls............69
Control System Fault Codes......................................................................70
Section 5 Navigation Menus....................................................................................95
Faults Navigation Menu.............................................................................95
Options Navigation Menu ..........................................................................96
Settings Navigation Menu..........................................................................97
Section 6 Schematics...............................................................................................99
Introduction................................................................................................99
Electrical Symbol Legends ......................................................................100
Hydraulic Symbol Legends......................................................................101
Electrical Component and Wire Color Legends.......................................102
Kubota Engine Fuse and Relay Module................................................. 105
12V DC Charger Wiring (DC Option)...................................................... 106
AC Input Wiring (DC Option) .................................................................. 107
AC Input Wiring CE Option..................................................................... 108
CAN BUS Wiring Diagram - DC Models..................................................109
Limit Switch/Angle Sensor Legend......................................................... 110
Electrical Schematics - Options...........................................................111
Wiring Diagram - Options Schematics.....................................................111
Schematics - Options, DC and FE Models Schematics ..........................115
Power Cable Wiring Diagram .................................................................117
Hydraulic Schematics ...........................................................................119
Hydraulic Schematic - DC and FE Models ..............................................120
Electrical Schematics............................................................................121
Electrical Schematic - DC and FE Models...............................................122
Ground Control Box Terminal Strip Wiring Dagram ................................127
TABLE OF CONTENTS

July 2020
Part No. 1297714GT Z®-45 DC • Z®-45 FE 1
Service and Repair Manual
Machine Specifications
Tires and wheels Rough terrain
Tire size 315/55 D20
Tire ply rating 12
Tire and wheel weigh
foam filled (minimum)
290 lbs
131.5 kg
Overall tire diameter 32.5 in
82.5 cm
Wheel diameter 20 in
50.8 cm
Wheel width 11 in
27.9 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 10.5 gallons
40 liters
Hydraulic system
(including tank)
17 gallons
65 liters
Drive hubs 24 fl oz
710 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 L16G-AC lead acid
AGM dry cell
Group 903-L16
Quantity 8
Capacity (lead acid) (dry cell) 390 AH
370 AH
Reserve capacity @ 25A rate 789 minutes
817 minutes
Weight, each Refer to Machine
Component Weights
Battery Box Screws Torque 128 ft-lbs
174 Nm
L16-AGM battery with
DT terminal-Torque
88 in lb
10 Nm
For operational specifications, refer to the
Operator's Manual.
Specifications

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Service and Repair Manual
Performance Specifications
Drive speed, maximum
stowed position
2WD/4WD models Stowed 4.5 mph
7.2 km/h
40 ft / 6.1 sec
12.2 m / 6.1 sec
Elevated 0.3 mph
0.5 km/h
40 ft / 90 sec
12.2 m / 90 sec
Gradeability See Operator's
Manual
Braking distance
High range on paved surface 3 to 6 feet
0.9 to 1.8 m
Boom function speeds, maximum from
platform controls
Jib boom up 13 to 17 seconds
Jib boom down 13 to 17 seconds
Primary boom up 26 to 30 seconds
Primary boom down 26 to 30 seconds
Primary boom extend 12 to 20 seconds
Primary boom retract 12 to 20 seconds
Secondary boom up 26 to 30 seconds
Secondary boom down 26 to 30 seconds
Turntable rotate, per 90°
Stowed
67 to 80 seconds
Turntable rotate, per 90°
Not stowed
105 to 130 seconds
Platform Level (10° range of
motion)
6 to 7 seconds
Platform Rotate, per 90° 10 to 14 seconds
For operational specifications, refer to the
Operator's Manual.
Specifications

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Part No. 1297714GT Z®-45 DC • Z®-45 FE 3
Service 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

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Service and Repair Manual
Specifications
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
NOTICE

July 2020
Part No. 1297714GT Z®-45 DC • Z®-45 FE 5
Service and Repair Manual
Hydraulic Component
Specifications
Functions Pump
Type: Single unit
gear pump
Displacement per revolution .40 cu in / 6.6 cc
Max flow rate 6.97 gpm / 26.4
Auxiliary pump
Type Fixed displacement
gear pump
Displacement per revolution 1.7 gpm
6.44 L/min
Function Manifold
Proportional relief valve pressure,
variable
50 to 3200 psi
3.4 to 220.6 bar
Platform level relief valve
pressure
3500 psi
241 bar
Oscillate reducing valve pressure 500 psi
34.5 bar
Platform level flow regulator Variable
1 to 1.5 gpm
3.8 to 5.7 L/min
Hydraulic Filters
High pressure filter: Beta 5 ˆ 200
Hydraulic tank return filter Beta 10 ˆ 1000
Manifold Component
Specifications
Plug Torque
SAE No. 4 14 ft-lbs / 19 Nm
SAE No. 6 23 ft-lbs / 31.2 Nm
SAE No. 8 36 ft-lbs / 49 Nm
SAE No. 10 62 ft-lbs / 84 Nm
SAE No. 12 84ft-lbs / 114 Nm
Valve Coil Resistance
Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically increase
or decrease by 4% for each 18°F / 10°C that your
air temperature increases or decreases from 68°F /
20°C.
Valve Coil Resistance Specification
Description Specification
Proportional solenoid relief valve, 24V DC
(schematic item AA)
22 Ω
Proportional solenoid valve, 3 position
4 way, 20V DC (schematic items B, G,
and S
19 Ω
Proportional solenoid valve, 3 position 4
way, 20V DC (schematic items AE, E, I,
O, R, and Z)
24 Ω
Solenoid valve, 2 position 3way, 12V
DC (schematic item JA)
9 Ω
Specifications

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Service and Repair Manual
Specifications
Kubota D1105 Engine
Displacement 68.53 cu in
1.123 liters
Number of cylinders 3
Bore and Stroke 3.07 x 3.09
inches
78 x 78.4 mm
Horsepower, gross
intermittent
24.8 @ 3000
rpm 18.5 kW @
3000 rpm
Combustion system Indirect injection
Firing order 1 - 2 - 3
Low idle 2150 rpm
208 Hz
High idle 3000 rpm
500 Hz
Compression ratio 24:1
Compression pressure 412 to 469 psi
28.4 to 32.3 bar
Governor mechanical
Valve Clearance, cold 0.0014 to 0.0025
in 0.145 to 0.185
mm
Lubrication system
Oil pressure 28 to 64 psi
1.9 to 4.4 bar
Oil capacity
(including filter)
5.4 quarts
5.1 liters
Oil viscosity requirements
Below -10°C (14° F) SAE 10W-30
-10 to 25° C (14° to 77° F) SAE 10W-30/
SAE 15W-40
Above 25° C (77° F) SAE30,
SAE10W-30/
SAE15W-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.
Engine coolant
Capacity 3.3 quarts
3.1 liters
Fuel injection system
Injection pump make Bosch MD
Injection pump pressure,
maximum
Injection timing
1991 psi
137 bar
18° BTDC
Fuel requirement
For fuel requirements, refer to the engine
Operator Manual for your engine.
Starter motor
Cranking speed 200 - 300 RPM
Current draw, normal load 155A
Battery
Type 12V DC
Group 70
Quantity 1
Ampere hour 75AH
Cold cranking ampere 450A
Reserve capacity @ 25A rate 70 minutes
Alternator output 40A @ 12V DC
Fan belt deflection 1/4 to 3/8 inch
7 to 9 mm
Electric clutch 1.6A @ 48 V DC
29.22 Ω+/- 5%

July 2020
Part No. 1297714GT Z®-45 DC • Z®-45 FE 7
Service and Repair Manual
Machine Torque Specifications
Platform Rotator
1-8 center bolt, GR 5
Lubricated 480 ft-lbs
650 Nm
Dry 547 ft-lbs
742 Nm
3/8 -16 bolts, GR 8
Lubricated 39 ft-lbs
53 Nm
Dry 36 ft-lbs
49 Nm
Turntable rotate assembly
Rotate bearing mounting bolts,
lubricated
159 ft-lbs
216 Nm
Rotate drive hub mounting bolts,
lubricated
93 ft-lbs
126 Nm
Drive motor and hubs
Drive hub mounting bolts, lubricated 93 ft-lbs
126 Nm
Drive motor leads square nuts
(requires 12 point socket)
10 ft lbs
13.6 Nm
Specifications
Machine Component Weights
Tire and wheel assembly 300 lbs 136
kg
Drive motor and hub 114.6 lbs 52
kg
Engine assembly 640 lbs
290.3 kg
Primary boom 981.6 lbs
445.2 kg
Primary boom cylinder 128 lbs
58 kg
Primary boom extend cylinder 87.8 lbs
40 kg
Secondary boom linkage 1668.6 lbs
757 kg
Secondary boom cylinder 60 lbs
27 kg
Jib boom assembly 355.6 lbs
161.3 kg
Jib boom cylinder 61.3 lbs
27.8 kg
Oscillate cylinder 37 lbs
16.8 kg
6 ft / 1.8 m platform 275 lbs
125 kg
Battery box assembly
(without batteries)
272.6 lbs
123.7 kg
Battery 6volt (wet) 107.5 lbs
48.8 kg
Battery 6 volt (maintenance free) 115 lbs
52.2 kg

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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
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 / 49 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
                                     
     
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
Specifications

July 2020
Part No. 1297714GT Z®-45 DC • Z®-45 FE 9
Service and Repair Manual
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.
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° Fittings table in this section
to determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate that 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.
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
hoses and fittings and related components to
confirm that there are no leaks.
a
b
c
a
b
c
b
Figure 1
a hex nut
b reference mark
c body hex fitting
Figure 2
a body hex fitting
b reference mark
c second mark
Specifications

10 Z®-45 DC • Z®-45 FE Part No. 1297714GT
July 2020
Service and Repair Manual
Repair Procedures
Observe and Obey:
Repair procedures shall be completed by a
person trained and qualified on the repair of
this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and parts are
available and ready for use.
Use only Genie approved replacement parts.
Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Unless otherwise specified, perform each repair
procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Boom in the stowed position
• Turntable secured with the turntable rotation
lock
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to re-
assemble, perform the disassembly steps in
reverse order.
Symbols Legend
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.
DANGER
Indicates an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
NOTICE
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.