Terex Genie Z452513A-48153 Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-45/25
from Z452513A-48153
to Z452516N-
57199
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic
Schematics
Z®-45/25J
from Z4525N-57200
to Z4525N-
58604
Bi-Energy Power
to Z452516D-93
9
from Z452513D
from Z452515B-4574
to Z452516B-54
52
from Z452516M-5453
to Z452516M-
6699
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
from Z4525F-58605
from Z4525D-
940
from Z4525M-6700
Part No.
1268546GT
Rev A
4
August 2023

Service and Repair Manual August 2023
Introduction
ii Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
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
1268546GT 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.

August 2023 Service and Repair Manual
Introduction
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 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 12-1
A3 11/2017 Specifications Machine Specifications
A4 8/2023 Front cover Serial number range
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 August 2023
Introduction
iv Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
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)

August 2023 Service and Repair Manual
Safety Rules
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 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 August 2023
Safety Rules
vi Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or
serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to wear protective eye
wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in
good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

August 2023
Table of Contents
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 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 2 Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................1
Hydraulic Oil Specifications....................................................................................2
Hydraulic Component Specifications......................................................................5
Machine Torque Specifications ..............................................................................6
Generator Specifications ........................................................................................6
Kubota Z482-E2B/E3B Engine Specifications .......................................................7
Hydraulic Hose and Fitting Torque Specifications .................................................8
Torque Procedure ..................................................................................................9
SAE and Metric Fasteners Torque Charts ...........................................................11

August 2023
Table of Contents
viii Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Section 3 Repair Procedures..............................................................................................12
Introduction ...........................................................................................................12
Platform Controls ...............................................................................................14
1-1 Controllers ......................................................................................................14
Platform Components ........................................................................................16
2-1 Platform Leveling Slave Cylinder ...................................................................16
How to Bleed the Slave Cylinder.....................................................................17
2-2 Platform Rotator .............................................................................................18
Jib Boom Components ......................................................................................20
3-1 Jib Boom.........................................................................................................20
3-2 Jib Boom Lift Cylinder ....................................................................................21
Primary Boom Components ..............................................................................23
4-1 Cable Track ....................................................................................................23
How to Remove the Cable Track, Z-45/25......................................................23
How to Remove the Cable Track, Z-45/25J ....................................................25
How to Repair the Primary Boom Cable Track ...............................................27
4-2 Primary Boom.................................................................................................27
How to Disassemble the Primary Boom..........................................................29
4-3 Primary Boom Lift Cylinder.............................................................................30
4-4 Primary Boom Extension Cylinder .................................................................31
4-5 Platform Leveling Master Cylinder .................................................................32
Secondary Boom Components .........................................................................33
5-1 Secondary Boom............................................................................................34
5-2 Secondary Boom Lift Cylinders ......................................................................39
Engines................................................................................................................40
6-1 Timing Adjustment..........................................................................................40
6-2 RPM Adjustment ............................................................................................40
6-3 Engine Drive Pulley ........................................................................................40
How to Remove the Engine Drive Pulley ........................................................40
How to Install the Engine Drive Pulley ............................................................41

August 2023
Table of Contents
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy ix
Generator ............................................................................................................43
7-1 Generator Pulley ............................................................................................43
How to Remove the Generator Pulley ............................................................43
How to Install the Generator Pulley ................................................................43
7-2 Generator Belts ..............................................................................................44
7-3 Generator Voltage Regulator .........................................................................44
How to Adjust the Generator Voltage Regulator.............................................44
How to Replace the Voltage Regulator ...........................................................45
Hydraulic Pumps ................................................................................................47
8-1 Auxiliary Pump ...............................................................................................47
8-2 Function Pump ...............................................................................................48
Manifolds.............................................................................................................49
9-1 Function Manifold Components .....................................................................49
9-2 Valve Adjustments - Function Manifold..........................................................51
How to Adjust the System Relief Valve...........................................................51
How to Adjust the Secondary Boom Down Relief Valve.................................51
9-3 Jib Boom / Platform Rotate Manifold Components ........................................52
9-4 Turntable Rotation Manifold Components .....................................................53
9-5 Valve Coils .....................................................................................................54
How to Test a Coil Diode ................................................................................54
Turntable Rotation Components ......................................................................56
10-1 Turntable Rotation Assembly .......................................................................56
Motor Controllers ...............................................................................................57
11-1 Motor Controller ...........................................................................................57
Steer Axle Components.....................................................................................58
12-1 Hub and Bearings ........................................................................................58
How to Remove the Hub and Bearings...........................................................58
How to Install the Hub and Bearings...............................................................58

August 2023
Table of Contents
x Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT
Section 4 Fault Codes .........................................................................................................60
Introduction ...........................................................................................................60
Fault Code Charts ...........................................................................................62
Section 5 Schematics..........................................................................................................66
Introduction ...........................................................................................................66
Electrical Symbol Legend .....................................................................................67
Hydraulic Symbols Legend...................................................................................68
Electrical Schematics – Options.......................................................................69
Platform Options Wiring Diagram .........................................................................70
Engine Panel Wiring Diagram ..............................................................................71
Power Panel Wiring Diagram ...............................................................................74
CTE Option Wiring Diagram, (CE)........................................................................75
Charger Interlock Option ......................................................................................78
Hydraulic Schematics ........................................................................................79
Hydraulic Schematic.............................................................................................80
Electrical Schematics – ANSI and CSA Models ..............................................81
Electrical Schematic, (ANSI / CSA) ......................................................................82
Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA) .....................86
Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA).......................87
Platform Control Box Wiring Diagram, (ANSI / CSA) ...........................................90
Electrical Schematics – CE Models ..................................................................91
Electrical Schematic, (CE)....................................................................................92
Ground Control Box Terminal Strip Wiring Diagram, (CE) ...................................96
Ground Control Box Switch Panel Wiring Diagram, (CE) ....................................97
Platform Control Box Wiring Diagram, (CE) .......................................................100
Electrical Schematics – AS Models ................................................................101
Electrical Schematic, (AS) ..................................................................................102
Ground Control Box Terminal Strip Wiring Diagram, (AS) .................................106
Ground Control Box Switch Panel Wiring Diagram, (AS)...................................107
Platform Control Box Wiring Diagram, (AS) .......................................................110