Terex Genie Z-45/25J Bi-Energy Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-45/25
from Z4525D-4536
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
Z®-45/25J
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1312350GT
Rev A
July 2021

Service and Repair Manual July 2021
Introduction
ii Z®-45/25 • Z®-45/25J Part No. 1312350GT
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
1312350GT Rev A, July 2021
Second Edition, First Printing
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.

July 2021 Service and Repair Manual
Introduction
Part No. 1312350GT Z®-45/25 • Z®-45/25J iii
Revision History
Revision Date Section Procedure / Page / Description
A 7/2021 Initial Release
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 July 2021
Introduction
iv Z®-45/25 • Z®-45/25J Part No. 1312350GT
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)
54
Z4525 M - 12345
Model:
Serial number:
Electrical schematic number:
Year of manufacture:
Machine unladen weight:
Rated work load (including occupants):
Maximum number of platform occupants:
Maximum allowable side force:
Maximum allowable inclination of the chassis:
Z4525M-12345
1 2 3

July 2021 Service and Repair Manual
Safety Rules
Part No. 1312350GT Z®-45/25 • Z®-45/25J v
Sec ti on 1 Safety 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.

Service and Repair Manual July 2021
Safety Rules
vi Z®-45/25 • Z®-45/25J Part No. 1312350GT
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
perso
nal 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.

July 2021
Table of Contents
Part No. 1312350GT Z®-45/25 • Z®-45/25J 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
Machine Component Weights.............................................................................2
Performance Specifications ................................................................................3
Hydraulic Oil Specifications ................................................................................3
Hydraulic Component Specifications...................................................................7
Deutz D2011 L03i Engine Specifications.............................................................9
Deutz D 2.9 L4 Engine Specifications ...............................................................10
Kubota D1105-E4B Engine Specifications ........................................................11
Machine Torque Specifications .........................................................................12
Hydraulic Hose and Fitting Torque Specifications .............................................13
Torque Procedure ............................................................................................14

July 2021
Table of Contents
viii Z®-45/25 • Z®-45/25J Part No. 1312350GT
Section 3 Repair Procedures ......................................................................................... 16
Introduction...................................................................................................... 16
Platform Controls........................................................................................... 18
1-1 ALC-500 Circuit Board ............................................................................... 18
1-2 Joysticks.................................................................................................... 19
How to Adjust the Joystick Max-out Setting ................................................. 19
How to Adjust the Joystick Ramp Rate Setting ............................................ 20
How to Adjust the Joystick Threshold Setting .............................................. 22
Platform Components.................................................................................... 23
2-1 Platform Leveling Slave Cylinder ................................................................ 23
How to Bleed the Slave Cylinder ................................................................. 24
2-2 Platform Rotator......................................................................................... 25
2-3 Platform Overload System.......................................................................... 26
Jib Boom Components.................................................................................. 29
3-1 Jib Boom.................................................................................................... 29
3-2 Jib Boom Lift Cylinder ................................................................................ 30

July 2021
Table of Contents
Part No. 1312350GT Z®-45/25 • Z®-45/25J ix
Primary Boom Components...........................................................................32
4-1 Cable Track................................................................................................32
How to Remove the Cable Track, Z-45/25 ...................................................32
How to Remove the Cable Track, Z-45/25J..................................................33
How to Repair the Primary Boom Cable Track.............................................36
4-2 Primary Boom ............................................................................................36
How to Disassemble the Primary Boom .......................................................38
4-3 Primary Boom Lift Cylinder .........................................................................39
4-4 Primary Boom Extension Cylinder...............................................................40
4-5 Platform Leveling Master Cylinder ..............................................................41
Secondary Boom Components......................................................................43
5-1 Secondary Boom........................................................................................44
5-2 Secondary Boom Lift Cylinders...................................................................49
Engines...........................................................................................................50
6-1 RPM Adjustment - Deutz D2011L03i and Kubota D1105 Models.................50
6-2 Flex Plate ...................................................................................................50
How to Install the Flex Plate ........................................................................51
How to install the Pump and Bell Housing Assembly....................................52
6-3 Engine Fault Codes - Deutz D 2.9 L4 Models..............................................53
Hydraulic Pumps ............................................................................................54
7-1 Lift/Steer Pump...........................................................................................54
7-2 Drive Pump ................................................................................................55
How to Prime the Pump...............................................................................56

July 2021
Table of Contents
x Z®-45/25 • Z®-45/25J Part No. 1312350GT
Manifolds........................................................................................................ 58
8-1 Function Manifold Components.................................................................. 58
8-2 Valve Adjustments - Function Manifold....................................................... 62
How to Adjust the System Relief Valve........................................................ 62
How to Adjust the Secondary Boom Down Relief Valve............................... 62
8-3 Jib Boom / Platform Rotate Manifold Components...................................... 63
8-4 Turntable Rotation Manifold Components................................................... 64
8-5 Directional Valve Manifold Components ..................................................... 65
How to Set Up the Directional Valve Linkage............................................... 66
8-6 Traction Manifold Components, 2WD ......................................................... 67
8-7 Valve Adjustments, 2WD Traction Manifold ................................................ 69
8-8 Traction Manifold Components, 4WD ......................................................... 70
8-9 Valve Adjustments, 4WD Traction Manifold ................................................ 72
8-10 Hydraulic Generator Manifold Components, 2.2kW................................... 73
8-11 Valve Coils............................................................................................... 74
How to Test a Coil Diode............................................................................. 74
Turntable Rotation Components................................................................... 76
9-1 Turntable Rotation Assembly ..................................................................... 76
Axle Components........................................................................................... 77
10-1 Hub and Bearings, 2WD Models............................................................... 77
How to Remove the Hub and Bearings........................................................ 77
How to Install the Hub and Bearings............................................................ 77
10-2 Oscillating Axle Cylinders......................................................................... 78

July 2021
Table of Contents
Part No. 1312350GT Z®-45/25 • Z®-45/25J xi
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
Fault Code Display - Deutz Models................................................................84
How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 Models.............84
Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 Models......85
Soft Key Functions and Icons - Deutz D 2.9 L4 Models................................85
Main Menu Structure - Deutz D 2.9 L4 Models.............................................86
Deutz D 2.9 L4 Engine Fault Codes ...............................................................88

July 2021
Table of Contents
xii Z®-45/25 • Z®-45/25J Part No. 1312350GT
Section 5 Schematics..................................................................................................... 99
Introduction...................................................................................................... 99
Electrical Symbol Legend............................................................................... 100
Hydraulic Symbols Legend............................................................................. 101
Electrical Component and Wire Color Legends............................................... 102
Engine Relay Layout - Deutz D 2.9 L4............................................................ 106
Electrical Schematics - Options .................................................................. 107
Electrical Schematic, Options [ALC500-2] ...................................................... 108
Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options .......... 109
Wiring Diagram, 2.2kW Hydraulic Generator .................................................. 112
Electrical Schematics – CE Models............................................................. 113
Electrical Schematic, Kubota D1105 Models................................................... 114
Functions, Electrical Schematic...................................................................... 115
Electrical Schematic, Deutz D2.9 Models ....................................................... 118
Deutz D2.9 L4 Engine Wire Harness .............................................................. 119
Electrical Schematic, Deutz 2011 L03i Models ............................................... 122
Electrical Schematic, Deutz D436 CN3 Models 1............................................ 123
Electrical Schematic, Deutz D436 - 2.............................................................. 126
Hydraulic Schematics - All Models.............................................................. 127
Hydraulic Schematic, 2WD Models................................................................. 128
Hydraulic Schematic, 4WD Models................................................................. 129

July 2021 Service and Repair Manual
Specifications
Part No. 1312350GT Z®-45/25 • Z®-45/25J 1
Sec ti on 2 Speci fic ati o ns
Machine Specifications
Tires and wheels
rough terrain
Tire size
315/55 D20
Tire ply rating
12
Tire and wheel weight, air filled
140 l
bs
63.5 k
g
foam filled (minimum)
290 l
bs
131.5 k
g
Overall tire diameter
32.5 i
n
82.5 c
m
Wheel
diameter 20 i
n
50.8 c
m
Wheel width
11 i
n
27.9 c
m
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
Tire pressure
60 p
si
4.1 b
ar
Tires and wheels
Hi-flotation (option)
Tire size
33/16LL500
Tire ply rating
10
Overall tire diameter
33 i
n
84 c
m
Wheel diameter
19.5 i
n
49.5 cm
Wheel width
14 i
n
35.6 c
m
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
Tire
pressure 38 p
si
2.6 b
ar
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual July 2021
Specifications
2 Z®-45/25 • Z®-45/25J Part No. 1312350GT
Fuel capacities
LPG tank
33.5 p
ounds
15.2 kg
Fuel tank
17 g
allons
64.4 l
iters
Hydraulic tank
22 g
allons
83 l
iters
Hydraulic system
(including tank)
30 g
allons
113.6 l
iters
Drive hubs
24 f
l oz
710 c
c
Turntable rotation drive
hub
25.5 f
l oz
750 cc
Drive hub oil type: SAE 9
0 multipurpose hypoid gear oil
API service classification GL5
Machine Component Weights
Drive motor
26.7 l
bs
12.1 kg
Drive hub
138.8 l
bs
63 k
g
Primary boom assembly
946.8 l
bs
429.5 k
g
Primary boom lift cylinder
98.4 l
bs
44.6 k
g
Primary boom extend cylinder
72.8 l
bs
33 k
g
Secondary boom assembly
1679.6 l
bs
761.9 k
g
Secondary boom
lift cylinder
(each)
56.2 l
bs
25.5 k
g
Jib boom assembly
283.4 l
bs
128.5 kg
Jib boom lift cylinder
36.7 l
bs
16.6 k
g
Counterweight
2875 l
bs
1304 k
g
Turntable assembly
(without counterweight)
3145 l
bs
1426.5 k
g
Drive chassis
4950 l
bs
2245.3 k
g
Platform
210.7 l
bs
95.6 kg

July 2021 Service and Repair Manual
Specifications
Part No. 1312350GT Z®-45/25 • Z®-45/25J 3
Performance Specifications
Drive speed, maximum
Stowed position (Deutz
D2.9L, D436, and D2011)
4.5 m
ph
7.2 k
m/h
40 ft / 6.1 s
ec
12.2 m / 6.1 s
ec
Stowed position (Kubota
D1105
-E4B)
3.1 mph
5 k
m/h
40 ft / 8.8 s
ec
12.2 m / 8.8 s
ec
Raised or extended
0.6 m
ph
0.98 k
m/h
40 ft / 45 s
ec
12.2 m / 45 sec
Gradeability
See Operator's Manual
Braking distance, maximum
High range on paved surface
3 to 6 f
t
0.9 to 1.8
m
Joystick function
speeds, maximum from platform
controls
Primary boom up
24 to 28 s
econds
Primary boom down
24 to 28 s
econds
Primary boom extend
18 to 22 seconds
Primary boom retract
18 to 22 s
econds
Secondary boom up
24 to 28 s
econds
Secondary boom down
24 to 28 s
econds
Turntable rotate, 355°
62 to 68 s
econds
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual July 2021
Specifications
4 Z®-45/25 • Z®-45/25J Part No. 1312350GT
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, se
al
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
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydraulic lines, filt
ers,
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

July 2021 Service and Repair Manual
Specifications
Part No. 1312350GT Z®-45/25 • Z®-45/25J 5
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 Viscos
ity
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 July 2021
Specifications
6 Z®-45/25 • Z®-45/25J Part No. 1312350GT
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

July 2021 Service and Repair Manual
Specifications
Part No. 1312350GT Z®-45/25 • Z®-45/25J 7
Hydraulic Component
Specifications
Drive Pump
Type: bi
-directional variable displacement piston pump
Flow rate @ 250
0 psi / 172 bar 32 g
pm
121 L/min
Drive pressure, maximum
3500 p
si
241 bar
Charge Pump
Type
gear
Displacement per revolution
0.84 c
u in
13.76 c
c
Flow rate @ 250
0 psi / 172 bar 9.1 g
pm
34.4 L/min
Charge pressure @ 250
0 rpm 315 p
si
21.7 b
ar
Function Pump
Type
gear
Displacement per revolution
0.67 c
u in
11 c
c
Flow rate @ 2500 psi / 172 bar
7.25 g
pm
27.4 L/min
Auxiliary Pump
Type
gear, fixed
displacement
Displacement per
revolution 0.067 c
u in
1.1 c
c
Auxiliary pump relief pressure
3200 p
si
220.6 b
ar
Function manifold
System relief valve pressure,
maximum
3200 p
si
220.6 b
ar
Secondary boom down relief
valve pressure
2100 p
si
145 b
ar
Platform level relief valve
pressure
2500 psi
172 b
ar
Steer flow regulator
2.0 g
pm
7.6 L/min
Boom extend flow regulator
2 gpm
7.6 L/min
Jib boom / platform rotate flow
regulator
0.4 g
pm
1.5 L/min
Traction Manifold
Hot oil relief pressure
250 p
si
17.2 bar
Steer end drive motors (4WD models)
Displacement per revolution
variable
0.54 to 1.53 c
u in
8.77 to 25 c
c

Service and Repair Manual July 2021
Specifications
8 Z®-45/25 • Z®-45/25J Part No. 1312350GT
Non-steer end drive motors
Displacement per revolution
variable 4WD (
2 speed motor)
0.54 to 1.53 c
u in
8.85 to 25.1 cc
Displacement per revolution
variable 2WD
0.99 to 1.83 c
u in
16.2 to 30 c
c
Hydraulic Filters
High pressure filter:
Beta 3 ˆ 200
High pressure filter bypass
pressure
100 p
si
6.89 b
ar
Medium pressure filter
Beta 3 ˆ 200
Medium pressure filter bypass
pressure
50 p
si
3.4 bar
Hydraulic tank return filter
10 m
icron with
25 psi / 1.7 b
ar
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