Terex Genie Z-45 XC Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-45 XC
from Z4525XCF-101
from Z4525XCM-101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
Z®-45 HF
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268197GT
Rev E
November 2020

Service and Repair Manual November 2020
Introduction
ii Z®-45 XC™• Z®-45 HF Part No. 1268197GT
Introduction Introd uction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2017 by Terex Corporation
1268197GT Rev E, November 2020
First Edition, Fifth Printing
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
"XC" is a trademark of Terex South Dakota, Inc.

November 2020 Service and Repair Manual
Introduction
Part No. 1268197GT Z®-45 XC™• Z®-45 HF iii
Revision History
Revision
Date
Section
Procedure / Page / Description
A
5/2017
Initial Release
A1
8/2017
Fault Codes
Control System Fault Codes
Specifications
Hydraulic Component Specifications
Repair
Function Manifold Components
Schematics
Hydraulic Schematic,
A2
9/2017
Repair
Procedure 2-3, 2-4
Fault Codes
Introduction, Control System and Platform Overload Fault
Codes
Schematics
Hour Meter Pin Legend
B
9/2017
Schematics
Add wiring diagrams
B1
11/2017
Specifications
Machine Specifications
B2
6/2018
Schematics
GCON Terminal Strip Wiring Diagram
C
1/2019
Specifications
Added ANSI / CSA engines
Schematics
Added ANSI / CSA Schematics
D
10/2019
Specifications
Machine Specifications
Repair
Procedure 2-3
E
11/2020
All Sections
Add Deutz TD 2.2 L3 engine
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 November 2020
Safety Rules
iv Z®-45 XC™• Z®-45 HF Part No. 1268197GT
Section 1 Safety Rules
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.

November 2020 Service and Repair Manual
Safety Rules
Part No. 1268197GT Z®-45 XC™• Z®-45 HF 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 avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

November 2020
Table of Contents
vi Z®-45 XC™• Z®-45 HF Part No. 1268197GT
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
Deutz D 2.9 L4 Engine Specifications ...................................................... 7
Deutz TD 2.2 L3 Engine Specifications .................................................... 8
Deutz D2011 L03i Engine Specifications.................................................. 9
Perkins 404D-22 Engine Specifications.................................................. 10
Perkins 404F-E22T Engine Specifications ............................................. 11
Ford MSG-425 EFI Engine Specifications.............................................. 12
Machine Torque Specifications............................................................... 13
Hydraulic Hose and Fitting Torque Specifications.................................. 13
Torque Procedure................................................................................... 15

November 2020
Table of Contents
Part No. 1268197GT Z®-45 XC™• Z®-45 HF vii
Section 3 Repair Procedures ................................................................................17
Introduction..............................................................................................17
Platform Controls..................................................................................19
1-1 ALC-500 Circuit Board......................................................................19
1-2 Joysticks............................................................................................20
How to Adjust the Joystick Max-out Setting.......................................20
How to Adjust the Joystick Ramp Rate Setting .................................21
How to Adjust the Joystick Threshold Setting....................................23
Platform Components...........................................................................24
2-1 Platform Leveling Slave Cylinder......................................................24
How to Bleed the Slave Cylinder .......................................................25
2-2 Platform Rotator................................................................................25
2-3 Platform Overload System................................................................26
How to Replace the Platform Overload Load Cell .............................29
2-4 Platform Overload Recovery Fault....................................................29
Jib Boom Components.........................................................................30
3-1 Jib Boom ...........................................................................................30
3-2 Jib Boom Lift Cylinder.......................................................................31
Primary Boom Components.................................................................33
4-1 Cable Track.......................................................................................33
How to Remove the Cable Track.......................................................33
How to Repair the Primary Boom Cable Track..................................35
4-2 Primary Boom ...................................................................................35
How to Disassemble the Primary Boom ............................................37
4-3 Primary Boom Lift Cylinder ...............................................................38
4-4 Primary Boom Extension Cylinder ....................................................39
4-5 Platform Leveling Master Cylinder....................................................40
Secondary Boom Components............................................................41
5-1 Secondary Boom...............................................................................42
5-2 Secondary Boom Lift Cylinders.........................................................46

November 2020
Table of Contents
viii Z®-45 XC™• Z®-45 HF Part No. 1268197GT
Engines .................................................................................................. 47
6-1 RPM Adjustment - Deutz D2011L03i Models................................... 47
6-2 RPM Adjustment - Perkins 404D-22 Models.................................... 47
6-3 Flex Plate.......................................................................................... 47
How to Install the Flex Plate.............................................................. 49
How to install the Pump and Bell Housing Assembly........................ 50
5-4 Engine Fault Codes .......................................................................... 51
6-7 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 ..................... 52
Hydraulic Pumps................................................................................... 53
7-1 Lift/Steer Pump................................................................................. 53
7-2 Drive Pump....................................................................................... 54
How to Prime the Pump..................................................................... 55
Manifolds ............................................................................................... 56
8-1 Function Manifold Components - CE (to Z4525XCM-1500)............. 56
8-1.1 Function Manifold Components -
ANSI / CSA / CE (from Z4525XCF-101, Z4525XCM-1501) ........... 59
8-2 Valve Adjustments - Function Manifold ............................................ 64
How to Adjust the System Relief Valve ............................................. 64
How to Adjust the Secondary Boom Down Relief Valve ................... 64
8-3 Jib Boom / Platform Rotate Manifold Components........................... 65
8-4 Turntable Rotation Manifold Components........................................ 66
8-5 Directional Valve Manifold Components........................................... 67
How to Set Up the Directional Valve Linkage.................................... 68
8-6 Traction Manifold Components, 4WD............................................... 70
8-7 Valve Adjustments, 4WD Traction Manifold ..................................... 72
8-8 Hydraulic Generator Manifold Components, 2.2kW ......................... 73
8-8.1 Generator Manifold Components .................................................. 74
8-9 Valve Coils........................................................................................ 75
How to Test a Coil Diode................................................................... 75
Turntable Rotation Components......................................................... 77
9-1 Turntable Rotation Assembly............................................................ 77
Axle Components.................................................................................. 78
10-1 Oscillating Axle Cylinders ............................................................... 78

November 2020
Table of Contents
Part No. 1268197GT Z®-45 XC™• Z®-45 HF ix
Section 4 Fault Codes............................................................................................79
Introduction..............................................................................................79
Control System Fault Codes................................................................80
How to Retrieve Control System Fault Codes ...................................80
Control System Fault Codes..............................................................81
How to Retrieve Platform Overload System Fault Codes -
Deutz D2011L03i, Perkins 404D-22 and Ford MSG-425
Models........................................................................................84
Platform Overload System Fault Codes.............................................85
Fault Code Display - Deutz and Perkins Models................................87
How to Retrieve Active Engine Fault Codes -
Deutz D 2.9 L4 and Perkins 404F-E22T Models .......................87
How to Retrieve Active Engine Fault Codes - Deutz TD 2.2 L3
Models........................................................................................88
Fault Code Display - Flashing and Solid LED's -
Deutz D 2.9 L4 and Perkins 404F-E22T Models .......................89
Soft Key Functions and Icons -
Deutz D 2.9 L4 and Perkins 404F-E22T Models .......................90
Soft Key Functions and Icons - Deutz TD 2.2 L3 Models..................91
Main Menu Structure - Deutz D 2.9 L4 Models..................................92
Main Menu Structure - Deutz TD 2.2 L3 Models ...............................93
Main Menu Structure - Perkins 404F-E22T Models...........................94
Deutz TD 2.2 L3 Engine Fault Codes...................................................95
Deutz D 2.9 L4 Engine Fault Codes...................................................105
Perkins 404F-E22T Engine Fault Codes............................................116
Ford MSG-425 Engine Fault Codes ...................................................118
How to Retrieve Ford MSG-425 Engine Fault Codes......................118

November 2020
Table of Contents
x Z®-45 XC™• Z®-45 HF Part No. 1268197GT
Section 5 Schematics .......................................................................................... 123
Introduction ........................................................................................... 123
Electrical Symbol Legend ..................................................................... 124
Hydraulic Symbols Legend................................................................... 125
Limit Switch Location Legend ............................................................... 126
Electrical Component and Wire Color Legends.................................... 127
Hour Meter Legend............................................................................... 130
Electrical Schematics......................................................................... 131
Electrical Schematic, Ford MSG425..................................................... 132
Electrical Schematic, Deutz D2011L03i and Perkins 404D-22............. 133
Electrical Schematic, Deutz D 2.9 L4.................................................... 136
Engine Wire Harness, Deutz D 2.9 L4.................................................. 137
Electrical Schematic, Deutz TD 2.2 L3 ................................................. 140
Engine Wire Harness, Deutz TD 2.2 L3 - Page 1................................. 141
Engine Wire Harness, Deutz TD 2.2 L3 - Page 2................................. 143
Electrical Schematic, Perkins 404F-22T............................................... 146
Perkins 404F-E22T Engine Wire Harness............................................ 147
Electrical Schematic, Function Controls - ANSI / CSA......................... 150
Electrical Schematic, Function Controls - CE....................................... 151
Electrical Schematic, Platform Overload .............................................. 154
Electrical Schematic, Options Wiring Diagram ..................................... 155

November 2020
Table of Contents
Part No. 1268197GT Z®-45 XC™• Z®-45 HF xi
Ground Control Box Switch Panel Wiring Diagram,
Deutz D2011L03i and Perkins 404D-22 - ANSI / CSA..................158
Ground Control Box Terminal Strip Wiring Diagram,
Deutz D2011L03i and Perkins 404D-22 - ANSI / CSA..................159
Ground Control Box Switch Panel Wiring Diagram,
Deutz D 2.9 L4 and Perkins 404F-E22T - ANSI / CSA.................162
Ground Control Box Terminal Strip Wiring Diagram,
Deutz D 2.9 L4 and Perkins 404F-E22T - ANSI / CSA.................163
Ground Control Box Switch Panel Wiring Diagram,
Ford MSG425 - ANSI / CSA..........................................................166
Ground Control Box Terminal Strip Wiring Diagram,
Ford MSG425 - ANSI / CSA..........................................................167
Ground Control Box Switch Panel Wiring Diagram - CE ......................170
Ground Control Box Terminal Strip Wiring Diagram - CE.....................171
Platform Control Box Switch Panel Wiring Diagram .............................174
Platform Control Box Terminal Strip Wiring Diagram............................175
Platform Control Box Relayl Wiring Diagram - ANSI / CSA..................178
Platform Control Box Relay Wiring Diagram- CE..................................179
Hydraulic Schematics.........................................................................181
Hydraulic Schematic - CE (to Z4525XCM-1500) ..................................182
Hydraulic Schematic -
ANSI / CSA / CE (from Z4525XCF-101, Z4525XCM-1501)..........183

Service and Repair Manual November 2020
12 Z®-45 XC™• Z®-45 HF Part No. 1268197GT
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November 2020 Service and Repair Manual
Specifications
Part No. 1268197GT Z®-45 XC™• Z®-45 HF 1
Section 2 Specifications
Machine Specifications
Tires and wheels
rough terrain
Tire size
315/55 D20
Tire ply rating
12
Tire weight, new 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
high flotation
Tire size
33/16LL 500
Tire ply rating
10
Tire weight
145 lbs
66 kg
Overall tire diameter
33 in
88,8 cm
Wheel diameter
19.5 in
49,5
Wheel width
14 in
35,5
Tire pressure
38 psi
2,62 bar
Wheel lugs
9 @ 5/8 -18
Lug nut torque, lubricated
94 ft-lbs
127,4 Nm
Lug nut torque, dry
125 ft-lbs
169,5 Nm
Fuel capacities
LPG tank
33.5 pounds
15,2 kg
Fuel tank
17 gallons
64,4 liters
Hydraulic tank
22 gallons
83 liters
Hydraulic system (including
tank)
30 gallons
113,6 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
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual November 2020
Specifications
2 Z®-45 XC™• Z®-45 HF Part No. 1268197GT
Performance Specifications
Drive speed, maximum
Stowed position
4.5 mph
7,2 km/h
40 ft / 6.1 sec
12,2 m / 6,1 sec
Raised or extended
0.33 mph
0,5 km/h
40 ft / 90 sec
12,2 m / 90 sec
Gradeability
See Operator's Manual
Braking distance, maximum
High range on paved surface
3 to 6 ft
0,9 to 1,8 m
Joystick function speeds, maximum from platform
controls
Primary boom up
26 to 30 seconds
Primary boom down
26 to 30 seconds
Primary boom extend
14 to 18 seconds
Primary boom retract
14 to 18 seconds
Secondary boom up
26 to 30 seconds
Secondary boom down
26 to 30 seconds
Turntable rotate, 355°
67 to 73 seconds
For operational specifications, refer to the
Operator's Manual.
Hydraulic Oil Specifications
Hydraulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 ppm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32
Shell 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.

November 2020 Service and Repair Manual
Specifications
Part No. 1268197GT Z®-45 XC™• Z®-45 HF 3
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
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @ -4°F / -20°C
cP @ -22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.

Service and Repair Manual November 2020
Specifications
4 Z®-45 XC™• Z®-45 HF Part No. 1268197GT
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @ -40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @ -4°F / -20°C
cSt @ -13°F / -25°C
cSt @ -40°F / -40°C
481
702.4
2624
Flash point
>100
Pour point
-76°F / -60°C
Maximum continuous operating
temperature
103°F / 75°C

November 2020 Service and Repair Manual
Specifications
Part No. 1268197GT Z®-45 XC™• Z®-45 HF 5
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F / -18°C
22
46
1300
Flash point
None
Pour point
-81°F / -63°C
Maximum continuous operating
temperature
189°F / 87°C
Hydraulic Component
Specifications
Drive Pump
Type: bi-directional variable displacement piston pump
Flow rate @ 2500 psi / 172 bar
32 gpm
121 L/min
Drive pressure, maximum
3500 psi
241 bar
Charge Pump
Type
gear
Displacement per revolution
0.84 cu in
13,76 cc
Flow rate @ 2500 psi / 172 bar
9.1 gpm
34,4 L/min
Charge pressure @ 2500 rpm
315 psi
21,7 bar
Function Pump
Type
gear
Displacement per revolution
0.67 cu in
11 cc
Flow rate @ 2500 psi / 172 bar
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

Service and Repair Manual November 2020
Specifications
6 Z®-45 XC™• Z®-45 HF Part No. 1268197GT
Function manifold
System relief valve pressure,
maximum
3200 psi
220,6 bar
Secondary boom down relief
valve pressure
2100 psi
145 bar
Platform level relief valve
pressure
3000 psi
207 bar
Steer flow regulator
2.0 gpm
7,6 L/min
Boom extend flow regulator
2 gpm
7,6 L/min
Jib boom / platform rotate flow
regulator
0.8 gpm
3 L/min
Traction Manifold
Hot oil relief pressure
250 psi
17,2 bar
Steer end drive motors
Displacement per revolution
variable
0.54 to 1.53 cu in
8,77 to 25 cc
Non-steer end drive motors
Displacement per revolution
variable (2 speed motor)
0.54 to 1.53 cu in
8,85 to 25,1 cc
Hydraulic Filters
High pressure filter:
Beta 3 ˆ 200
High pressure filter bypass
pressure
102 psi
7 bar
Medium pressure filter
Beta 3 ˆ 200
Medium pressure filter bypass
pressure
51 psi
3,5 bar
Hydraulic tank return filter
10 micron with
25 psi / 1,7 bar
bypass
Manifold Component Specifications
Plug torque
SAE No. 2
36 in-lbs / 4 Nm
SAE No. 4
10 ft-lbs / 13 Nm
SAE No. 6
14 ft-lbs / 19 Nm
SAE No. 8
38 ft-lbs / 51 Nm
SAE No. 10
41 ft-lbs / 55 Nm
SAE No. 12
56 ft-lbs / 76 Nm

November 2020 Service and Repair Manual
Specifications
Part No. 1268197GT Z®-45 XC™• Z®-45 HF 7
Deutz D2.9 L4 Engine
Displacement
177 cu in
2,9 liters
Number of cylinders
4
Bore and Stroke
3.6 x 4.3 inches
92 x 110 mm
Horsepower
48.8 @ 2600 rpm
37 kW @ 2600 rpm
Firing order
1 - 3 - 4 - 2
Low idle
1500 rpm
313 Hz
High idle
2500 rpm
521,7 Hz
Compression ratio
18.4:1
Compression pressure
362 to 435 psi
25 to 30 bar
Governor
electronic
Lubrication system
Oil pressure (@ 2000 rpm)
40 to 60 psi
1,4 to 3 bar
Oil capacity
(including filter)
9.4 quarts
9 liters
Oil viscosity requirements
Low ash oil required
-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
257°F
125°C
Oil Pressure switch
Oil pressure switch point
20 psi
1,4 bar
Engine coolant
Capacity
10 quarts
9,4 liters
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
Manual for your engine.
Starter motor
Cranking speed
150-250 RPM
Current draw, normal load
250A to 400A
Output
3.2kW
Battery
Type
12V DC
Quantity
1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
200 minutes
Alternator output
95A @ 14V DC
Fan belt deflection
3/8 to 1/2 inch
9 to 12 mm

Service and Repair Manual November 2020
Specifications
8 Z®-45 XC™• Z®-45 HF Part No. 1268197GT
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
2400 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
Manual for your engine.
Engine coolant capacity
2.2 gallons
8,3 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