Terex Genie Z-45/25 DC Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-45/25 DC
from Z452513A-48153
to Z452516N-57199
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic
Schematics
Z®-45/25J DC
from Z452513B-3078
to Z452516M-
6699
from Z452513D-101
to Z452516D-
939
from Z4525D-940
to Z4525D-39
77
from Z4524M-6700
to Z4525M-
9726
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
from Z4525N-57200
to Z4525N-
58604
from Z4525F-58605
to Z4525F-
61999
Original Instructions
Part No. 1268530GT
Rev B
May 2022

Service and Repair Manual May 2022
Introduction
ii Z®-45/25 DC Part No. 1268530GT
Intro ductio n Intro ductio n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2015 by Terex Corporation
1268530GT Rev B, May 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.

May 2022 Service and Repair Manual
Introduction
Part No. 1268530GT Z®-45/25 DC iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
A2 9/2016 Repair 10-1
A3 11/2017 Specifications Machine Specifications
B 5/2022 Front cover Add ending serial break
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 May 2022
Introduction
iv Z®-45/25 DC Part No. 1268530GT
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label (located under cover)
6 Serial number (stamped on chassis)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)

May 2022 Service and Repair Manual
Safety Rules
Part No. 1268530GT Z®-45/25 DC v
Sec ti on 1 Safety R ul 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.

Service and Repair Manual May 2022
Safety Rules
vi Z®-45/25 DC Part No. 1268530GT
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. Alway
s 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 f
or
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.

May 2022
Table of Contents
Part No. 1268530GT Z®-45/25 DC vii
Introduction Introduction ......................................................................................................ii
Important Information ......................................................................................... ii
Find a Manual for this Model............................................................................... ii
Revision History ................................................................................................ iii
Serial Number Legend....................................................................................... iv
Section 1 Safety Rules......................................................................................................v
General Safety Rules .........................................................................................v
Section 2 Specifications...................................................................................................1
Machine Specifications .......................................................................................1
Performance Specifications ................................................................................1
Hydraulic Oil Specifications ................................................................................2
Hydraulic Component Specifications...................................................................5
Machine Torque Specifications ...........................................................................6
Machine Component Weights .............................................................................6
Hydraulic Hose and Fitting Torque Specifications ...............................................7
Torque Procedure ..............................................................................................8
SAE and Metric Fasteners Torque Charts.........................................................10

May 2022
Table of Contents
viii Z®-45/25 DC Part No. 1268530GT
Section 3 Repair Procedures ......................................................................................... 11
Introduction...................................................................................................... 11
Platform Controls........................................................................................... 13
1-1 Controllers ................................................................................................. 13
Platform Components.................................................................................... 15
2-1 Bellcrank Platform Leveling Cylinder .......................................................... 15
How to Bleed the Platform Leveling Cylinder ............................................... 16
2-2 Platform Rotator......................................................................................... 17
2-3 Platform Overload System.......................................................................... 18
Jib Boom Components.................................................................................. 21
3-1 Jib Boom.................................................................................................... 21
3-2 Jib Boom Lift Cylinder ................................................................................ 22
Primary Boom Components .......................................................................... 24
4-1 Cable Track ............................................................................................... 24
How to Remove the Cable Track, Z-45/25 ................................................... 24
How to Remove the Cable Track, Z-45/25J ................................................. 25
How to Repair the Primary Boom Cable Track............................................. 27
4-2 Primary Boom ............................................................................................ 28
How to Disassemble the Primary Boom....................................................... 29
4-3 Primary Boom Lift Cylinder......................................................................... 30
4-4 Primary Boom Extension Cylinder .............................................................. 31
4-5 Upper Pivot Platform Leveling Cylinder ...................................................... 32
Secondary Boom Components ..................................................................... 34
5-1 Secondary Boom ....................................................................................... 35
5-2 Secondary Boom Lift Cylinders .................................................................. 39
Hydraulic Pump.............................................................................................. 40
6-1 Auxiliary Pump........................................................................................... 40
6-2 Function Pump........................................................................................... 41

May 2022
Table of Contents
Part No. 1268530GT Z®-45/25 DC ix
Manifolds ........................................................................................................42
7-1 Function Manifold Components ..................................................................42
7-2 Valve Adjustments - Function Manifold .......................................................44
How to Adjust the System Relief Valve ........................................................44
How to Adjust the Secondary Boom Down Relief Valve ...............................44
7-3 Jib Boom / Platform Rotate Manifold Components ......................................45
7-4 Turntable Rotation Manifold Components ...................................................46
7-5 Valve Coils .................................................................................................47
Turntable Rotation Components ...................................................................48
8-1 Turntable Rotation Assembly ......................................................................48
Motor Controllers ...........................................................................................49
9-1 Motor Controller..........................................................................................49
Steer Axle Components .................................................................................50
10-1 Hub and Bearings.....................................................................................50
How to Remove the Hub and Bearings ........................................................50
How to Install the Hub and Bearings ............................................................50

May 2022
Table of Contents
x Z®-45/25 DC Part No. 1268530GT
Section 4 Fault Codes .................................................................................................... 52
Introduction...................................................................................................... 52
Fault Code Charts....................................................................................... 54
Section 5 Schematics..................................................................................................... 58
Introduction...................................................................................................... 58
Electrical Symbol Legend................................................................................. 59
Hydraulic Symbols Legend............................................................................... 60
Electrical Schematics – Options ................................................................... 61
Platform Options Wiring Diagram ..................................................................... 62
Power Panel Wiring Diagram ........................................................................... 63
CTE Option Wiring Diagram, (CE).................................................................... 66
Charger Interlock Option .................................................................................. 67
Hydraulic Schematics.................................................................................... 69
Hydraulic Schematic ........................................................................................ 70
Electrical Schematics – ANSI / CSA / AS Models .................................... 71
Electrical Schematic, (ANSI / CSA / AS)........................................................... 72
Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS) ............ 76
Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA / AS).............. 77
Platform Control Box Wiring Diagram, (ANSI / CSA / AS) ................................. 80
Electrical Schematics – CE Models............................................................... 81
Electrical Schematic, (CE)................................................................................ 82
Ground Control Box Terminal Strip Wiring Diagram, (CE)................................. 86
Ground Control Box Switch Panel Wiring Diagram, (CE) .................................. 87
Platform Control Box Wiring Diagram, (CE) ...................................................... 90