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

May 2022 Service and Repair Manual
Specifications
Part No. 1268530GT Z®-45/25 DC 1
Sec ti on 2 Speci fic ati o ns
Machine Specifications
Tires and wheels
Tire size
9-
14.5 LT
Tire ply rating
Tread 8
Sidewall 6
Overall tire diameter
28 i
n
71 cm
Wheel diameter
14.5 i
n
37 c
m
Wheel width
7 i
n
18 c
m
Wheel
lugs 9 @ 5/8 -
18
Lug nut torque, lubricated
83 ft-
lbs
112,5 Nm
Lug nut torque, dry
110 ft-
lbs
149 Nm
Fluid capacities
Hydraulic tank
8 g
allons
30,3 l
iters
Hydraulic system (including
tank)
11 g
allons
41,6 l
iters
Drive hubs (refer to tag on
drive hub to determine type)
EW
1 type 17 f
l oz
503 c
c
W
1 type 23 f
l oz
680 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
6V DC
Group
L-
16
Quantity
8
Capacity
350 AH
Reserve capacity @ 25A rate
750 m
inutes
Performance Specifications
Drive speed, maximum
Stowed position
3 m
ph
4,8 k
m/h
40 ft / 9 s
ec
12,2 m / 9 s
ec
Raised or extended
0.6 m
ph
0,98 k
m/h
40 ft / 45 s
ec
12,2 m / 45 s
ec
Gradeability
See Operator's Manual
Braking distance, maximum
High range on paved surface
5 - 7 f
t
1,5 - 2 m
Joystick function speeds, maximum from platform
controls
Jib boom up, Z-45/25J
32 - 55 s
econds
Jib boom down, Z-45/25J
24 - 35 s
econds
Primary boom up
32 - 40 s
econds
Primary boom down
26 - 30 s
econds
Primary boom extend
12 - 20 seconds
Primary boom retract
15 - 23 s
econds
Secondary boom up
38 - 46 s
econds
Secondary boom down
38 - 46 s
econds
Turntable rotate, 355°
primary boom retracted
95 - 125 s
econds
Platform rotate, 180°, Z
-45/25 10 - 14 s
econds
Platform rotate, 160°, Z
-45/25J 10 - 14 s
econds
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual May 2022
Specifications
2 Z®-45/25 DC Part No. 1268530GT
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 v
iscosity 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
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.
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
flui
ds 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

May 2022 Service and Repair Manual
Specifications
Part No. 1268530GT Z®-45/25 DC 3
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.
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

Service and Repair Manual May 2022
Specifications
4 Z®-45/25 DC Part No. 1268530GT
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
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

May 2022 Service and Repair Manual
Specifications
Part No. 1268530GT Z®-45/25 DC 5
Hydraulic Component
Specifications
Function Pump
Type
Fixed displacement gear pump
Displacement per
revolution
0.183 c
u in
3 c
c
Flow rate
2.1 g
pm
7.9 L/min
Hydraulic tank return filter
10 m
icron with
25 psi / 1.7 bar
bypass
Function manifold
System relief valve pressure,
maximum
3200 p
si
220.6 bar
Secondary boom down relief
valve pressure
2100 p
si
145 b
ar
Platform level flow regulator
0.6 g
pm
2.27 L/min
Jib boom / platform rotate flow
regulator
0.4 g
pm
1.5
L/min
Auxiliary Pump
Type
Fixed displacement gear pump
Displacement per revolution
0.5 g
pm
1.9 L/min
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
Valve Coil Resistance Specification
Description
Specification
Solenoid valve, 3 position 4 way, 20V DC
(schematic items B, C, D, E, F and H)
25 to 29
Ω
Solenoid valve,
2 position 3 way, 20V DC
(schematic items A, K, S and AA)
25 to 29
Ω
Proportional solenoid valve, 24V DC
(schematic item I)
17 to 21
Ω

Service and Repair Manual May 2022
Specifications
6 Z®-45/25 DC Part No. 1268530GT
Machine Torque Specifications
Platform Rotator
3/4
-10 center bolt, GR 8 380 ft-
lbs
515 Nm
3/8 -16 bolts, GR 8
44 ft-lbs
60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated
180 ft-
lbs
244 Nm
Drive motor/brake mounting bolts, dry
110 ft-
lbs
149 Nm
Drive motor/brake mounting bolts,
lubricated
80 ft-
lbs
108 Nm
Drive motors and hubs
Drive hub mounting bolts, lubricated
180 ft-
lbs
244 Nm
Drive motor mounting bolts, lubricated
55 ft-
lbs
75 Nm
Machine Component Weights
Primary boom assembly
(does not
include jib assembly)
950 l
bs
431 k
g
Secondary boom assembly
1675 l
bs
760 k
g
Turntable assembly
(does not include booms, jib or
counterweight)
2500 l
bs
1134 k
g
Counterweight,
5921 l
bs
2686 k
g
Drive chassis assembly
6200 l
bs
2812 k
g
Tire and wheel
assembly 180 l
bs
82 k
g
Drive hub
100 l
bs
46 kg
Drive motor
68 l
bs
31 k
g
Primary boom lift cylinder
110 l
bs
50 kg
Primary boom extend cylinder
75 l
bs
34 k
g
Secondary boom lift cylinder
57 l
bs
26 kg
Jib boom assembly
(does not include
platform)
283 l
bs
128 k
g
Jib boom cylinder
40 l
bs
18 k
g
Battery
106 l
bs
48 kg

May 2022 Service and Repair Manual
Specifications
Part No. 1268530GT Z®-45/25 DC 7
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 May 2022
Specifications
8 Z®-45/25 DC Part No. 1268530GT
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

May 2022 Service and Repair Manual
Specifications
Part No. 1268530GT Z®-45/25 DC 9
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° Fitting table in this section
to determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate 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.
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
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
hose, fittings and related components to
confirm there are no leaks.

Service and Repair Manual May 2022
Specifications
10 Z®-45/25 DC Part No. 1268530GT