Terex Genie Z-45 DC Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-45 DC
from Z45EM-101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
Z®-45 FE
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Original Instructions
Part No. 1297714GT
Rev B
October 2022

Service and Repair Manual October 2022
Introduction
ii Z®-45 DC • Z®-45 FE Part No. 1297714GT
Intro ductio n Intro ductio n
Importan t Inf or matio n
Important
Read, understand and obey the safety rules
and operating instructions in the appropriate
Operator's Manual on your machine before
attempting any maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine
owner and user. It also 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 © 2019 by Terex Corporation
1297714GT Rev B, October 2022
First Edition, Second Printing
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.

October 2022 Service and Repair Manual
Introduction
Part No. 1297714GT Z®-45 DC • Z®-45 FE iii
RevisionHistory
Revision History
Revision Date Section Procedure / Page / Description
A 3/2020 Initial Release
A1 7/2020 Schematics Hydraulic schematics
B 10/2022 Specifications Kohler engine
Repair Calibration process steps
Procedure 2-3, 6-1, 9-2
Fault Codes Update fault codes
Navigation Menus Update navigation menus
Schematics Kohler engine fuse / relay module
Electrical schematics
Hydraulic schematics
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 October 2022
Safety Rules
iv Z®-45 DC • Z®-45 FE Part No. 1297714GT
Sec ti on 1 Safety Rul es
Gene ralS af ety 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 modify or alter a MEWP without prior
written permission from the manufacturer.
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.

October 2022 Service and Repair Manual
Safety Rules
Part No. 1297714GT Z®-45 DC • Z®-45 FE v
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—used to
alert personnel to potential
personal injury hazards. Obey all
safety messages that follow this
symbol to avoid possible injury or
death.
Indicates a imminently hazardous
situation which, if not avoided,
will result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoid
ed,
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 mainta
ined 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
we
ight 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.

October 2022
Table of Contents
vi Z®-45 DC • Z®-45 FE Part No. 1297714GT
Introduction Introduction...................................................................................................... ii
Important Information ..........................................................................................ii
Find a Manual for this Model ...............................................................................ii
Revision History .................................................................................................iii
Section 1 Safety Rules .................................................................................................... iv
General Safety Rules .........................................................................................iv
Section 2 Specifications................................................................................................... 1
Machine Specifications....................................................................................... 1
Performance Specifications................................................................................ 2
Hydraulic Oil Specifications ................................................................................ 2
Hydraulic Component Specifications .................................................................. 5
Manifold Component Specifications.................................................................... 5
Kubota D1105 Engine Specifications.................................................................. 6
Kohler KDW1404 Engine Specifications ............................................................. 7
Machine Torque Specifications........................................................................... 8
Machine Component Weights............................................................................. 8
Hydraulic Hose and Fitting Torque Specifications............................................... 9
Torque Procedure ............................................................................................ 10

October 2022
Table of Contents
Part No. 1297714GT Z®-45 DC • Z®-45 FE vii
Section 3 Repair Procedures..........................................................................................12
Introduction ......................................................................................................12
Cailbration Process Steps.................................................................................14
Platform Controls ...........................................................................................15
1-1 Platform Controls........................................................................................15
How to Adjust the Joystick Threshold Setting...............................................16
How to Adjust the Maximum Speed Setting (Hydraulic Functions)................17
How to Adjust the Function Ramp Rate Setting............................................19
1-2 How to Calibrate Booms Angle Sensors......................................................21
1-3 How to Clear the Fault History ....................................................................22
Platform Components ....................................................................................23
2-1 Platform Leveling Slave Cylinder ................................................................23
2-2 Platform Rotator .........................................................................................24
2-3 Platform Overload System ..........................................................................25
How to Perform a Zero Load Platform Calibration ........................................25
How to Perform a Full Load Platform Calibration..........................................26
How to Replace the Platform Overload Load Cell.........................................28
How to Reset Overload Recovery Message.................................................29
Jib Boom Components ..................................................................................30
3-1 Jib Boom ....................................................................................................30
3-2 Jib Boom Lift Cylinder.................................................................................31
Primary Boom Components...........................................................................32
4-1 Cable Track................................................................................................32
How to Repair the Cable Track ....................................................................34
4-2 Primary Boom ............................................................................................34
How to Disassemble the Primary Boom .......................................................35
4-3 Primary Boom Lift Cylinder .........................................................................37
4-4 Primary Boom Extension Cylinder...............................................................38
4-5 Platform Leveling Master Cylinder ..............................................................39

October 2022
Table of Contents
viii Z®-45 DC • Z®-45 FE Part No. 1297714GT
Secondary Boom Components ..................................................................... 40
5-1 Secondary Boom ....................................................................................... 41
5-2 Secondary Boom Lift Cylinders .................................................................. 45
Engines........................................................................................................... 46
6-1 RPM Adjustment ................................................................................... 46
How to Replace the Motor Tach Sensor ...................................................... 46
Ground Controls ............................................................................................ 47
7-1 Control System Fault Recovery Switch....................................................... 47
How to Use Control System Fault Recovery Switch..................................... 47
Hydraulic Pumps............................................................................................ 48
8-1 Function Pump........................................................................................... 48
How to Check the Function Pump Calibration.............................................. 49
Manifolds........................................................................................................ 50
9-1 Function Manifold Components.................................................................. 50
9-2 Valve Adjustments - Function Manifold....................................................... 54
How to Adjust the Proportional Relief Valve and
Hydraulic Pressure Sensor .................................................................. 54
How to Adjust the Secondary Boom Down Relief Valve............................... 55
9-3 Jib Boom / Platform Rotate Manifold Components...................................... 56
9-4 Turntable Rotation Manifold Components................................................... 57
9-5 Directional Valve Manifold Components ..................................................... 58
How to Set Up the Directional Valve Linkage............................................... 59
How to Test a Coil Diode............................................................................. 61
Turntable Rotation Components................................................................... 62
10-1 Turntable Rotation Assembly.................................................................... 62
10-2 How to Replace the Universal Tilt Sensor................................................. 63
How to Calibrate the Universal Tilt Sensor................................................... 63
Axle Components........................................................................................... 64
11-1 Oscillating Axle Cylinders......................................................................... 64
11-2 How to Remove the Steer Cylinder........................................................... 65
How to Calibrate the Steer Angle Sensor..................................................... 65

October 2022
Table of Contents
Part No. 1297714GT Z®-45 DC • Z®-45 FE ix
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 .............................................................................71
Section 5 Navigation Menus...........................................................................................95
Top Menu.........................................................................................................95
Faults Navigation Menu ....................................................................................96
Options Navigation Menu .................................................................................97
Settings Navigation Menu.................................................................................98
Advanced and Drive Navigation Menu ..............................................................99

October 2022
Table of Contents
x Z®-45 DC • Z®-45 FE Part No. 1297714GT
Section 6 Schematics................................................................................................... 101
Introduction.................................................................................................... 101
Electrical Symbol Legend............................................................................... 102
Hydraulic Symbols Legend............................................................................. 103
Electrical Component and Wire Color Legends............................................... 104
Kubota Engine Fuse and Relay Module.......................................................... 108
Kohler Engine Fuse and Relay Module........................................................... 109
Limit Switch/Angle Sensor Legend ................................................................. 110
Electrical Schematics .................................................................................. 111
Electrical Schematic, Chassis and Turntable .................................................. 112
Electrical Schematic, TCON ........................................................................... 113
Electrical Schematic, PCON........................................................................... 116
Electrical Schematic, Kubota Engine Models.................................................. 117
Electrical Schematic, Kohler Engine Models ................................................... 120
Electrical Schematic, Front Motor Controllers ................................................. 121
CAN Bus Wiring Diagram............................................................................... 124
Power Cable Wiring Diagram ......................................................................... 125
AC / DC Junction Box Wiring Diagram............................................................ 128
RCBO Option Wiring Diagram ........................................................................ 129
Hydraulic Schematics.................................................................................. 131
Hydraulic Schematic ...................................................................................... 132

October 2022 Service and Repair Manual
Specifications
Part No. 1297714GT Z®-45 DC • Z®-45 FE 1
Sec ti on 2 Speci fic ati o ns
Machin e Spec ific atio ns
Machine Specifications
Tires and Wheels
Tire size
315/55 D20
Wheel diameter
20 i
n
50,8 c
m
Wheel width
11 in
27,9 c
m
Overall tire diameter
32.5 i
n
82,6 c
m
Tire ply rating
12
Wheel lugs
9 @ 5/8 -
18
Lug nut torque, dry
125 ft-
lbs
169,5 Nm
Lug nut torque, lubricated
94 ft-lbs
127,5 Nm
Fluid capacities
Fuel tank
17 g
allons
64,4 l
iters
Hydraulic tank
11.6 g
allons
43,9 l
iters
Hydraulic system (including
tank)
17 g
allons
64,4 l
iters
Drive hubs
24 f
l oz
710 c
c
Turntable rotation drive hub
25.5 f
l oz
750 c
c
Drive hub oil type: SAE 9
0 multipurpose hypoid gear oil
API service
classification GL5
Batteries
Type
AGM
Group
903-L16
Quantity
8
Ampere hour
370 AH
Reserve capacity @ 25A rate
817 m
inutes
Type
L16G-
AC
Group
903
Quantity
8
Ampere hour
390 AH
Reserve capacity @ 25A rate
789 minutes
Battery box torque
128 ft-
lbs
173,5 Nm
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual October 2022
Specifications
2 Z®-45 DC • Z®-45 FE Part No. 1297714GT
Perfor man ce S peci fi catio ns
Performance Specifications
Drive speed
- stowed 40 ft / 6.1 s
ec
12.2 m / 6,1 sec
Drive speed
- raised or
extended
40 ft / 90 s
ec
12,2 m / 90 sec
Gradeability
See Operator's Manual
Braking distance,
high range on paved surface
3 - 6 f
t
0,9 - 1,8
m
Function speeds, maximum from platform controls
Jib boom up
13 - 17 s
econds
Jib boom down
13 - 17 s
econds
Primary boom up
26 - 30 seconds
Primary boom down
26 - 30 seconds
Primary boom extend
12 - 20 s
econds
Primary boom retract
12 - 20 s
econds
Secondary boom up
26 - 30 s
econds
Secondary boom up/down
26 - 30 s
econds
Turntable rotate stowed, 90°
67 - 80 s
econds
Turntable rotate raised or
extended, 90°
105 - 130 s
econds
Platform level
(10° range of motion)
6 - 7 s
econds
Platform rotate
10 - 14 s
econds
For operational specifications, refer to the
Operator's Manual.
Hydrauli c Oi l Speci fic ations
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
ISO Grade
32
Viscosity index,
maximum
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 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 its
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

October 2022 Service and Repair Manual
Specifications
Part No. 1297714GT Z®-45 DC • Z®-45 FE 3
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompa
tible
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
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO
Grade
32
Viscosity index, maximum
200
Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity, maximum
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.

Service and Repair Manual October 2022
Specifications
4 Z®-45 DC • Z®-45 FE Part No. 1297714GT
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index, maximum
300
Kinematic Viscosity, maximum
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, maximum
154
Kinematic Viscosity, maximum
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, maximum
300
Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity, maximum
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, maximum
192
Kinematic Viscosity, maximum
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

October 2022 Service and Repair Manual
Specifications
Part No. 1297714GT Z®-45 DC • Z®-45 FE 5
Hydrauli c Com pon ent S p ecifi cati ons
Hydraulic Component
Specifications
Function Pump
Type
gear pump
Displacement
.40 cu in / 6,6 cc
Maximum flow rate
DC
models
FE models
6.7 g
pm / 25,4 L/min
5 gpm / 19 L/min
Auxiliary pump
Type
gear pump
Maximum flow rate
0.5 g
pm
1,9 L/min
Function manifold
Proportional relief valve
pressure, variable
50 - 3000 p
si
3,4 - 207 b
ar
Secondary boom down relief
valve pressure
2100 p
si
145 b
ar
Platform level relief valve
pressure
3500 p
si
241 b
ar
Oscillate reducing valve
pressure
500 p
si
34,5 bar
Platform level flow regulator,
variable
1 - 1.5 g
pm
3,8 -
5,7 L/min
Hydraulic Filters
High pressure
filter:
Beta 5 ˆ 200
Hydraulic tank return filter
Beta 10 ˆ 1000
Manif old Co mpo nent S peci fica ti ons
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
84 ft-
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.
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

Service and Repair Manual October 2022
Specifications
6 Z®-45 DC • Z®-45 FE Part No. 1297714GT
Kubota D 110 5 E ngin e S pecif ic ati o ns
Kubota D1105-E4-GNI-1 Engine
Displacement
68.53 c
u in
1,123 liters
Number of cylinders
3
Bore and Stroke
3.07 x 3.09 i
nches
78 x 78,4 m
m
Horsepower, gross
intermittent
24.8 @ 3000 r
pm
18,5 kW @ 3000 r
pm
Combustion system
Indirect injection
Firing order
1 - 2 -
3
Low idle
2150 r
pm
208 Hz
High idle
3000 r
pm
500 Hz
Compression ratio
24:1
Compression pressure
412 - 469 p
si
28,4 - 32,3 b
ar
Governor
mechanical
Valve clearance, cold
0.0057 - 0.0072 i
n
0,145 - 0,185 m
m
Lubrication system
Oil pressure
28 - 64 p
si
1,9 - 4,4 bar
Oil capacity
(including filter)
5.4 q
uarts
5,1 l
iters
Oil viscosity requirements
Below -10°C (14° F)
SAE 10W-
30/
SAE 10W-
40
-
10 to 25° C (14° to 77° F) SAE 10W-
30/
SAE 10W-
40/
SAE 15W-40
Above 25° C (77° F)
SAE 10W-
30/
SAE 10W-
40/
SAE 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.
Engine coolant
Capacity
3.3 q
uarts
3,1 l
iters
Fuel injection system
Injection pump make
Bosch MD
Injection pump pressure,
maximum
1991 p
si
137 bar
Injection timing
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 m
inutes
Alternator output
40A @ 12V DC
Fan belt deflection
1/4 - 3/8 i
nches
7 - 9 m
m
Electric clutch
1.6A @ 48 V DC
29.22 Ω+/-
5%

October 2022 Service and Repair Manual
Specifications
Part No. 1297714GT Z®-45 DC • Z®-45 FE 7
Kohler K DW 1 404 En gine S peci fica ti ons
Kohler KDW 1404 Engine
Displacement
88.72 c
u in
1,372 l
iters
Number of cylinders
3
Bore and Stroke
2.95 x 3.05 i
nches
75 x 77,6 m
m
Horsepower, gross
intermittent
25.2 @ 3000 r
pm
18,8 kW @ 3000 r
pm
Firing order
1 - 3 - 4 -
2
Low idle
2150 rpm
High idle
3000 r
pm
Compression ratio
22.8:1
Governor
mechanical
Valve clearance, cold
0.0059 - 0.0078 i
n
0,15 - 0,20 mm
Engine coolant
Capacity
4.23 q
uarts
4 l
iters
Lubrication system
Oil pressure
22 - 80 p
si
1,5 - 5,5 b
ar
Oil capacity (including filter)
3.4 q
uarts
3,2 liters
Oil viscosity requirements
Below
-10°C (14° F) SAE 5W-
40
SAE 10W-
30
SAE 10W-40
-
10 to 25° C (14° to 77° F) SAE 5W-
40
SAE 15W-
40
Above 25° C (77° F)
SAE 5W-
40
SAE 15W-40
Unit ships with 5W
-40. Extreme operating temperatures
may require the use of alternative engine oils. For oil
requirements, refer to the Engine Operator Manual for
your engin
e.
Injection system
Injection pump
Bosch PDM
Injection timing
11° BTDC
Injection pump pressure,
maximum
2030 - 2248 p
si
140 - 155 b
ar
Fuel requirement
For fuel requirements, refer to the engine Operator
Manual for your engine.
Battery
Type
12V DC
Group
70
Quantity
1
Ampere hour
54AH
Cold cranking ampere
530A
Reserve capacity @ 25A rate
86 m
inutes
Alternator
Alternator output
45A, 12V DC
Fan belt deflection
0.4 - 0.6 i
nches
10 - 15 m
m

Service and Repair Manual October 2022
Specifications
8 Z®-45 DC • Z®-45 FE Part No. 1297714GT
Machin e T orq ue Sp eci ficati ons
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 motors and hubs
Drive hub mounting bolts, lubricated
93 ft-
lbs
126 Nm
Drive motor leads square nuts (requires
1
2 point socket)
10 f
t lbs
13,6 Nm
Machin e Co mpo nent W eigh ts
Machine Component Weights
Tire and wheel assembly
343 l
bs
156 kg
Drive motor and hub
120 l
bs
54 k
g
Engine assembly
- Kubota 640 l
bs
290 k
g
Engine assembly
- Kohler 807 l
bs
333 k
g
Primary boom
982 l
bs
445 k
g
Primary boom
lift cylinder 133 l
bs
60 k
g
Primary boom extend cylinder
88 l
bs
40 k
g
Secondary boom linkage
1670 l
bs
756 kg
Secondary boom lift cylinder
66 l
bs
30 k
g
Jib boom assembly
356 l
bs
162 k
g
Jib boom cylinder
66 l
bs
30 k
g
Oscillate cylinder
40 l
bs
18 k
g
Counterweight
770 l
bs
350 kg
6
ft / 1.8 m platform 275 l
bs
125 k
g
Battery box assembly
(without batteries)
240 l
bs
109 kg
Battery 6V (Flooded lead acid)
101 l
bs
46 k
g
Battery 6V (AGM)
115 l
bs
52 kg

October 2022 Service and Repair Manual
Specifications
Part No. 1297714GT Z®-45 DC • Z®-45 FE 9
Hydrauli c Hose and Fitti ng Torque Speci fi cat i ons
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends
be torqued to specification when they are removed
and installed or when new hoses or fittings are
installed.
Seal-Lok™ Fittings
(hose end - ORFS)
SAE Dash Size
Torque
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 41 Nm
-8
40 ft-lbs / 55 Nm
-10 60 ft-lbs / 81 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 150 ft-lbs / 205 Nm
-24 230 ft-lbs / 315 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 1/2
-8 3/4-16 1 1/2
-10 7/8-14 1 1/2
-12 1 1/16-12 1 1/4
-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
Adjustable Fitting Non-adjustable fitting
1 jam nut
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash Size Torque
-4
ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)
15 ft-lbs / 20,3 Nm
26 ft-lbs / 35,3 Nm
22 ft-lbs / 30 Nm
-6
ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
35 ft-lbs / 47,5 Nm
29 ft-lbs / 39,3 Nm
-8 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
60 ft-lbs / 81,3 Nm
52 ft-lbs / 70,5 Nm
-10 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
100 ft-lbs / 135,6 Nm
85 ft-lbs / 115,3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16
(All types)
200 ft-lbs / 271,2 Nm
-20
(All types)
250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413,5 Nm

Service and Repair Manual October 2022
Specifications
10 Z®-45 DC • Z®-45 FE Part No. 1297714GT
Torque P roce dur e
Torque Procedure
Seal-Lok™ fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the O-
ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight.
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart
in this section.
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and
tighten the hex nut to the body hex fitting to
hand tight, approximately 30 in-lbs / 3.4 Nm.
2 Using a permanent ink marker, make a
reference mark on one the flats of the hex nut
and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
Illustration 1
1 hex nut
2 reference mark
3 body hex fitting