Terex Genie Z-51/30J Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-51/30J
from Z513014B-1201
to
Z513016M-
1999
This manual includes:
Repair
procedures
Fault Codes
Electrical and
Hydraulic Schematics
from Z5130M-2000
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268553
GT
Rev A2
November 2017

Service and Repair Manual November 2017
Introduction
ii Z®-51/31J Part No. 1268553GT
Intr od ucti o n Intr od ucti o 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
1268553 Rev A, September 2015
First Edition, First Printing
Genie and “Z” are registered trademarks of Terex South Dakota,
Inc. in the U.S.A. and many other countries.

November 2017 Service and Repair Manual
Introduction
Part No. 1268553GT Z®-51/31J iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
A2 11/2017 Specifications Machine Specifications
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 2017
Introduction
iv Z®-51/31J Part No. 1268553GT
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label (located under cover)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

November 2017 Service and Repair Manual
Safety Rules
Part No. 1268553GT Z®-51/31J v
Section 1 Safet y 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 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 November 2017
Safety Rules
vi Z®-51/31J Part No. 1268553GT
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 potential
ly 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 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.

November 2017
Table of Contents
Part No. 1268553GT Z®-51/31J vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules ..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................1
Hydraulic Specification ...........................................................................................2
Hydraulic Component Specifications......................................................................4
Deutz D2011 L03i Engine Specifications ...............................................................6
Machine Torque Specifications ..............................................................................7
Hydraulic Hose and Fitting Torque Specifications .................................................8
Torque Procedure ..................................................................................................9
Section 3 Repair Procedures .............................................................................................11
Introduction...........................................................................................................11
Platform Controls ...............................................................................................13
1-1 ALC-500 Circuit Board ...................................................................................13
1-2 Joysticks.........................................................................................................14
How to Adjust the Joystick Max-out Setting....................................................15
How to Adjust the Joystick Ramp Rate Setting...............................................16
How to Adjust the Joystick Threshold Setting.................................................17

November 2017
Table of Contents
viii Z®-51/31J Part No. 1268553GT
Platform Components ....................................................................................... 19
2-1 Platform Leveling Slave Cylinder................................................................... 19
2-2 Platform Rotator............................................................................................. 20
2-3 Platform Overload System............................................................................. 21
Jib Boom Components...................................................................................... 24
3-1 Jib Boom ........................................................................................................ 24
3-2 Jib Boom Lift Cylinder .................................................................................... 25
Primary Boom Components ............................................................................. 27
4-1 Cable Track.................................................................................................... 27
How to Repair the Primary Boom Cable Track............................................... 29
4-2 Primary Boom ................................................................................................ 30
How to Disassemble the Primary Boom ......................................................... 31
4-3 Primary Boom Lift Cylinder ............................................................................ 32
4-4 Primary Boom Extension Cylinder ................................................................. 33
4-5 Platform Leveling Master Cylinder................................................................. 34
Secondary Boom Components ........................................................................ 36
5-1 Secondary Boom ........................................................................................... 37
5-2 Secondary Boom Lift Cylinders ..................................................................... 41
Engines ............................................................................................................... 43
6-1 RPM Adjustment - Deutz D2011L03i Models ................................................ 43
6-2 Flex Plate ....................................................................................................... 43
How to Install the Flex Plate ........................................................................... 44
How to install the Pump and Bell Housing Assembly ..................................... 44

November 2017
Table of Contents
Part No. 1268553GT Z®-51/31J ix
Hydraulic Pumps ................................................................................................45
7-1 Lift/Steer Pump ..............................................................................................45
7-2 Drive Pump.....................................................................................................46
Manifolds.............................................................................................................48
8-1 Function Manifold Components .....................................................................48
8-2 Valve Adjustments - Function Manifold..........................................................52
How to Adjust the System Relief Valve...........................................................52
How to Adjust the Secondary Boom Down Relief Valve.................................52
8-3 Jib Boom / Platform Rotate Manifold Components ........................................53
8-4 Turntable Rotation Manifold Components .....................................................54
8-5 Directional Valve Manifold Components ........................................................55
How to Set Up the Directional Valve Linkage .................................................56
8-6 Traction Manifold Components ......................................................................58
8-7 Valve Adjustments, Traction Manifold............................................................60
8-8 Valve Coils .....................................................................................................61
Turntable Rotation Components ......................................................................63
9-1 Turntable Rotation Assembly .........................................................................63
Axle Components...............................................................................................65
10-1 Oscillating Axle Cylinders.............................................................................65
Section 4 Fault Codes .........................................................................................................67
Introduction...........................................................................................................67
Control System Fault Codes .............................................................................68
How to Retrieve Control System Fault Codes ................................................68
Control System Fault Codes ...........................................................................69

November 2017
Table of Contents
x Z®-51/31J Part No. 1268553GT
Section 5 Schematics ......................................................................................................... 73
Introduction .......................................................................................................... 73
Electrical Symbol Legend .................................................................................... 74
Hydraulic Symbols Legend .................................................................................. 75
Electrical Component and Wire Color Legends................................................... 76
Electrical Schematics – Options ...................................................................... 79
Ground Control Box Terminal Strip Wiring Diagram, Options ............................. 80
Platform Control Box Wiring Diagram, Options ................................................... 81
Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options ............. 84
Electrical Schematic, Options .............................................................................. 85
Electrical Schematics – AS Models ................................................................. 87
Electrical Schematic (AS) .................................................................................... 88
Ground Control Box Terminal Strip Wiring Diagram (AS) ................................... 92
Ground Control Box Switch Panel Wiring Diagram (AS) ..................................... 93
Platform Control Box Wiring Diagram (AS).......................................................... 96
Platform Control Box Switch Panel Wiring Diagram (AS).................................... 97
Electrical Schematics – CE Models ................................................................. 99
Electrical Schematic (CE) .................................................................................. 100
Ground Control Box Terminal Strip Wiring Diagram (CE) ................................. 104
Ground Control Box Switch Panel Wiring Diagram (CE) ................................... 105
Platform Control Box Wiring Diagram (CE) ....................................................... 108
Platform Control Box Switch Panel Wiring Diagram (CE).................................. 109
Hydraulic Schematics...................................................................................... 111
Hydraulic Schematic, 4WD Models.................................................................... 112

November 2017 Service and Repair Manual
Specifications
Part No. 1268553GT Z®-51/31J 1
Section 2 Speci fi c ati ons
Machine Specifications
Tires and wheels
Tire size
355/55 D625
Tire ply rating
14
Tire weight, new foam
-filled
(minimum) (Rough terrain)
390 l
bs
177 k
g
Overall tire diameter
36.9 i
n
93.7 c
m
Wheel diameter
24.5 i
nches
62.2 c
m
Wheel width
11.75 i
nches
29.8 c
m
Wheel lugs
9 @ 5/8 -
18
Lug nut torque
(lubricated)
94 ft-
lbs
127.4 Nm
(dry)
125 ft-
lbs
169.5 Nm
Fluid capacities
Fuel tank
17 g
allons
64.4 l
iters
Hydraulic tank
24 g
allons
91 l
iters
Hydraulic system (including tank)
30 g
allons
113.6 l
iters
Drive hubs
- Steer end 17 f
l oz
503 c
c
Drive hubs with brake, 57:1,
Non
-steer end
24 f
l oz
1242 c
c
Turntable rotation drive hub
25.5 fl oz
750 cc
Performance Specifications
Drive speed, maximum
Stowed position
5 m
ph
8 k
m/h
40 ft/5.5 s
ec
12.2 m/5.5 s
ec
Raised or extended position
0.6 m
ph
1 k
m/h
40 ft/45 s
ec
12.2 m/45 s
ec
Braking distance,
maximum
High range on paved surface
3 to 6 f
t
0.9 to 1.8
m
Gradeability
See Operator's Manual
Boom function speeds, maximum from platform
controls
Jib boom up
48 to 52 s
econds
Jib boom down
28 to 32 s
econds
Primary boom up
36 to 40 s
econds
Primary
boom down 36 to 40 s
econds
Secondary boom up
26 to 30 s
econds
Secondary boom down
26 to 30 s
econds
Primary boom extend
20 to 24 s
econds
Primary boom retract
20 to 24 s
econds
Turntable rotate, 355°
82 to 88 s
econds
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual November 2017
Specifications
2 Z®-51/31J Part No. 1268553GT
Hydraulic Specification
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,
oxidati
on 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
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 it's
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, 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

November 2017 Service and Repair Manual
Specifications
Part No. 1268553GT Z®-51/31J 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 Viscosit
y
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
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

Service and Repair Manual November 2017
Specifications
4 Z®-51/31J Part No. 1268553GT
Hydraulic Component
Specifications
Drive pump
Type:
bi-
directional, variable
displacement piston
pump
Flow rate @ 250
0 rpm 32 g
pm
121 L/min
Drive pressure, maximum
3500 p
si
241 b
ar
Charge pump
Type:
gear
Displacement
0.84 c
u in
13.76 c
c
Flow rate @ 250
0 rpm 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
0.67 c
u in
11 c
c
Flow rate @ 250
0 rpm 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 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 p
si
172 b
ar
Steer flow regulator
1.5 g
pm
5.7 L/min
Boom extend flow regulator
2 g
pm
7.6 L/min
Jib boom / platform rotate
flow
regulator
0.4 g
pm
1.5 L/min
Drive manifold
Hot oil relief pressure
250 p
si
17.2 b
ar
Steer end drive motors
Displacement per revolution
1.53 cu in
25 c
c
Non-steer end drive motors
Displacement per revolution,
variable (
2 speed motor)
0.01 to 1.83 cu in
1.61 to 30 c
c
Hydraulic filters
High pressure filter
Beta 3 ³ 200
High pressure filter bypass
pressure
100 p
si
6.89 b
ar
Medium pressure filter
Beta 3 ³ 200
Medium pressure filter bypass
pressure
50 p
si
3.4 b
ar
Hydraulic return filter
10 micron with 25 p
si /
1.7 bar bypass

November 2017 Service and Repair Manual
Specifications
Part No. 1268553GT Z®-51/31J 5
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 specifications
Proportional directional solenoid valve,
10V DC (schematic items BP, BU and
BY)
6 to 8
Ω
3
position 4 way directional valve, 10V DC
(schematic items BF, BM and CG)
6 to 8
Ω
2
position 3 way solenoid valve, 10V DC
(schematic items CA, CC, G, AF and AG)
6 to 8
Ω

Service and Repair Manual November 2017
Specifications
6 Z®-51/31J Part No. 1268553GT
Deutz D2011 L03i Engine
Displacement
142 c
u in
2.33 l
iters
Number of cylinders
3
Bore and stroke
3.7 x 4.4 i
nches
94 x 112 m
m
Horsepower
48 @ 2800 r
pm
36 kW @ 2800 r
pm
Firing order
1 - 2 -
3
Low idle
1500 r
pm
313 Hz
High idle
2500 r
pm
521.7 Hz
Compression ratio
19:01
Compression pressure
362 to 435 p
si
25 to 30 b
ar
Governor
centrifugal mechanical
Valve clearance, cold
Intake
0.012 i
n
0.3 m
m
Exhaust
0.020 i
n
0.5 m
m
Lubrication system
Oil pressure
20 to 44 p
si
1.4 to 3 b
ar
Oil capacity
(including filter)
9.5 quarts
9 liters
Oil viscosity requirements
-
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
Units ship with 15W
-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Oil temperature switch
Temperature switch point
300°F
149°C
Oil pressure switch
Oil pressure switch point
22 p
si
1.5 b
ar

November 2017 Service and Repair Manual
Specifications
Part No. 1268553GT Z®-51/31J 7
Deutz D2011 L03i Engine, continued
Fuel injection system
Injection pump make
Bosch
Injection pump pressure,
maximum
15000 p
si
1034 b
ar
Injector opening pressure
3046 p
si
210 b
ar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your
machine.
Starter motor
Current draw, no load
90A
Brush length, new
0.72 i
n
18.5 m
m
Brush length, minimum
0.27 i
n
7 m
m
Battery
Type
12V DC, Group 34/78
Quantity
1
Cold cranking ampere
900A
Reserve capacity @ 25A rate
200 m
inutes
Alternator
output
60A @ 14V DC
Fan belt deflection
3/8 to 1/2 i
nch
9 to 12 m
m
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 motor and hubs
Drive hub mounting bolts, lubricated
180 ft-
lbs
244 Nm
Drive motor mounting bolts, lubricated
55 ft-
lbs
75 Nm

Service and Repair Manual November 2017
Specifications
8 Z®-51/31J Part No. 1268553GT
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 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 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 ¼
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-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 / 54.2 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

November 2017 Service and Repair Manual
Specifications
Part No. 1268553GT Z®-51/31J 9
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

Service and Repair Manual November 2017
Specifications
10 Z®-51/31J Part No. 1268553GT
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.