1268530

Service and Repair Manual
Serial Number Range
Z®-45/25 DC
from Z452513A-48153
to Z452516N-57199
This manual includes:
Repair procedures
Fault Codes
Z®-45/25J DC
from Z452513B-3078
to Z452516M-6699 Electrical and
from Z452513D-101 Hydraulic Schematics
to Z452516D-939
from Z4525D-940
from Z4525M-6700
from Z4525N-57200
For detailed maintenance

procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268530GT

Rev A3
November 2017
Service and Repair Manual November 2017
Introduction
Intr oducti on Intr oducti on
Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical skills are communications will be carefully considered for
required to perform most procedures. However, future printings of this and all other manuals.
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that Contact Us:
maintenance and repair be performed at an
authorized Genie dealer service center. Internet: www.genielift.com
E-mail: awp.techpub@terex.com
Compliance Find a Manual for this Model

Go to http://www.genielift.com
Machine Classification
Use the links to locate Service Manuals,
Group B/Type 3 as defined by ISO 16368
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2015 by Terex Corporation
1268530GT Rev A, September 2016
First Edition, First Printing
Genie and “Z” are registered trademarks of Terex South Dakota,
Inc. in the U.S.A. and many other countries.
ii Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

November 2017 Service and Repair Manual
Introduction
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
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC iii

Introduction
Serial Number Legend

To August 31, 2016
1 Model 4 Sequence number

2 Model year 5 Serial label (located under cover)
3 Facility code 6 Serial number (stamped on chassis)
From September 1, 2016
1 Model 4 Serial label (located under cover)

2 Facility code 5 Serial number (stamped on chassis)
3 Sequence number
iv Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Safety Rules
Section 1 Safety R ules
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.
Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC v

Safety Rules
Personal Safety Workplace Safety

Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
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.
vi Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

November 2017
Table of Contents
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
Hydraulic Hose and Fitting Torque Specifications ................................................. 7
Torque Procedure .................................................................................................. 8
SAE and Metric Fasteners Torque Charts ........................................................... 10
Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC vii

November 2017
Table of Contents
Section 3 Repair Procedures ............................................................................................. 11

Introduction .......................................................................................................... 11
Platform Controls ............................................................................................... 13

1-1 Controllers...................................................................................................... 13
Platform Components ....................................................................................... 15

2-1 Platform Leveling Slave Cylinder ................................................................... 15
How to Bleed the Slave Cylinder .................................................................... 16
2-2 Platform Rotator ............................................................................................. 17
Jib Boom Components ...................................................................................... 19

3-1 Jib Boom ........................................................................................................ 19
3-2 Jib Boom Lift Cylinder .................................................................................... 20
Primary Boom Components ............................................................................. 22

4-1 Cable Track.................................................................................................... 22
How to Remove the Cable Track, Z-45/25 ..................................................... 22
How to Remove the Cable Track, Z-45/25J ................................................... 24
How to Repair the Primary Boom Cable Track ............................................... 26
4-2 Primary Boom ................................................................................................ 26
How to Disassemble the Primary Boom ......................................................... 28
4-3 Primary Boom Lift Cylinder ............................................................................ 29
4-4 Primary Boom Extension Cylinder ................................................................. 30
4-5 Platform Leveling Master Cylinder ................................................................. 31
Secondary Boom Components ........................................................................ 32

5-1 Secondary Boom ........................................................................................... 33
5-2 Secondary Boom Lift Cylinders ..................................................................... 38
Hydraulic Pumps ................................................................................................ 39

6-1 Auxiliary Pump ............................................................................................... 39
6-2 Function Pump ............................................................................................... 40
viii Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

November 2017
Table of Contents
Manifolds ............................................................................................................. 41
7-1 Function Manifold Components ..................................................................... 41
7-2 Valve Adjustments - Function Manifold .......................................................... 43
How to Adjust the System Relief Valve ........................................................... 43
How to Adjust the Secondary Boom Down Relief Valve ................................. 43
7-3 Jib Boom / Platform Rotate Manifold Components ........................................ 44
7-4 Turntable Rotation Manifold Components ..................................................... 45
7-5 Valve Coils ..................................................................................................... 46
Turntable Rotation Components ...................................................................... 47

8-1 Turntable Rotation Assembly ......................................................................... 47
Motor Controllers ............................................................................................... 48

9-1 Motor Controller ............................................................................................. 48
Steer Axle Components ..................................................................................... 49

10-1 Hub and Bearings ........................................................................................ 49
How to Remove the Hub and Bearings ........................................................... 49
How to Install the Hub and Bearings ............................................................... 49
Section 4 Fault Codes ......................................................................................................... 51

Introduction ........................................................................................................... 51
Fault Code Charts ........................................................................................... 53
Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC ix

November 2017
Table of Contents
Section 5 Schematics ......................................................................................................... 57

Introduction .......................................................................................................... 57
Electrical Symbol Legend .................................................................................... 58
Hydraulic Symbols Legend .................................................................................. 59
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
x Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Specifications
Section 2 Specific ati ons
Machine Specifications Performance Specifications

Tires and wheels Drive speed, maximum
Tire size 9-14.5 LT Stowed position 3 mph
4.8 km/h
Tire ply rating Tread 8
Sidewall 6 40 ft / 9 sec
12.2 m / 9 sec
Overall tire diameter 28 in
71 cm Raised or extended 0.6 mph
0.98 km/h
Wheel diameter 14.5 in
37 cm 40 ft / 45 sec
12.2 m / 45 sec
Wheel width 7 in Gradeability See Operator's Manual
18 cm Braking distance, maximum
Wheel lugs 9 @ 5/8 -18 High range on paved surface 5 to 7 ft
Lug nut torque, lubricated 83 ft-lbs 1.5 to 2 m
112.5 Nm
Joystick function speeds, maximum from platform
Lug nut torque, dry 110 ft-lbs controls
149 Nm
Jib boom up, Z-45/25J 26 to 40 seconds
Tire contact area 43.5 sq in
Jib boom down, Z-45/25J 22 to 28 seconds
280 sq cm
Primary boom up 32 to 40 seconds
Fluid capacities
Primary boom down 26 to 30 seconds
Hydraulic tank 8 gallons
30.3 liters Primary boom extend 14 to 18 seconds
Hydraulic system (including 11 gallons Primary boom retract 17 to 21 seconds
tank) 41.6 liters Secondary boom up 38 to 46 seconds
Drive hubs (refer to tag on drive hub to determine type) Secondary boom down 38 to 46 seconds
EW1 type 17 fl oz Turntable rotate, 355ø 95 to 125 seconds
503 cc primary boom retracted
W1 type 23 fl oz Platform rotate, 180°, Z-45/25 6 to 10 seconds
680 cc
Platform rotate, 160°, Z-45/25J 6 to 10 seconds
Turntable rotation drive hub 25.5 fl oz
750 CC For operational specifications, refer to the
Operator's Manual.
Drive hub oil type: SAE 90 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 minutes
Weight, each 106 lbs
48 kg
Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC 1

Specifications
Hydraulic Oil Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties. component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium Hydraulic Fluid Temperature
Viscosity grade 32 Range
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 Ambient air temperature
the approved optional fluids. Consult Genie
Product Support before use. 1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
Optional fluids may not have 3 UCON Hydrolube HP-5046D
the same hydraulic lifespan and 4 Chevron Rando HD premium oil MV
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.
2 Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Specifications
Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Brookfield Viscosity
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310
Pour point -81°F / -63°C
Flash point 375°F / 190°C
Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
Maximum continuous operating 171°F / 77°C Note: Use of Chevron 5606A hydraulic fluid, or
temperature equivalent, is required when ambient temperatures
Note: A hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil
recommended when the ambient temperature is heating system is used.
consistently below 0°F / -18°C.
Continued use of Chevron
Note: Do not operate the machine when the 5606A hydraulic fluid, or
ambient temperature is below -20°F / -29°C with equivalent, when ambient
Rando HD Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage

Specifications
Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid

Fluid Properties Properties
ISO Grade 46 ISO Grade 46
Viscosity index 154 Viscosity index 192
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 8.0 cSt @ 149°F / 65°C 22
cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C 46
cSt @ 0°F / -18°C 1300
Flash point 482°F / 250°C
Flash point None
Maximum continuous operating 180°F / 82°C Pour point -81°F / -63°C
temperature Maximum continuous operating 189°F / 87°C
temperature
Shell Tellus S4 VX Fluid

Properties
ISO Grade 32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
Maximum continuous operating 103°F / 75°C
temperature

Specifications
Hydraulic Component Manifold Component Specifications
Specifications Plug torque

SAE No. 2 36 in-lbs / 4 Nm
Function pump
SAE No. 4 10 ft-lbs / 13 Nm
Type Fixed displacement gear pump
Displacement per 0.183 cu in
revolution 3 cc
Flow rate 2.1 gpm
7.9 L/min SAE No. 12 56 ft-lbs / 76 Nm
Hydraulic tank return filter 10 micron with Valve Coil Resistance Specification
25 psi / 1.7 bar bypass
Description Specification
Function manifold Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω
System relief valve pressure, 3200 psi (schematic items B, C, D, E, F and H)
maximum 220.6 bar Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω
Secondary boom down relief 2100 psi (schematic items A, K, S and AA)
valve pressure 145 bar Proportional solenoid valve, 24V DC 17 to 21 Ω
Platform level flow regulator 0.6 gpm (schematic item I)
2.27 L/min
Jib boom / platform rotate flow 0.4 gpm
regulator 1.5 L/min
Auxiliary pump
Type: fixed displacement gear pump

Displacement per revolution 0.5 gpm
1.9 L/min

Specifications
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, 80 ft-lbs
lubricated 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

Specifications
Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be -4 14 ft-lbs / 19 Nm
torqued to specification when they are removed -6 23 ft-lbs / 31.2 Nm
and installed or when new hoses or fittings are -8 36 ft-lbs / 54.2 Nm
installed.
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings -16 125 ft-lbs / 169.5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204.7 Nm
SAE Dash Size Torque
-24 184 ft-lbs / 249.5 Nm
-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
Adjustable Fitting Non-adjustable fitting
-24 180 ft-lbs / 245 Nm
1 jam nut
JIC 37° Fittings

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats (tube fitting - installed into Steel)
-4 7/16-20 2 SAE Dash Size Torque
-6 9/16-18 1¼ -4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-8 3/4-16 1 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-10 7/8-14 1
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-12 1 1/16-12 1
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-24 1 7/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 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

Specifications
Torque Procedure JIC 37° fittings

1 Align the tube flare (hex nut) against the nose
Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
1 Replace the O-ring. The O-ring must be
approximately 30 in-lbs / 3.4 Nm.
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or 2 Using a permanent ink marker, make a
hose end has been tightened beyond finger reference mark on one the flats of the hex nut
tight. and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
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. Illustration 1
5 Tighten the nut or fitting to the appropriate 1 hex nut

torque. Refer to the appropriate torque chart in 2 reference mark
this section. 3 body hex fitting
6 Operate all machine functions and inspect the

hose, fittings and related components to
confirm there are no leaks.

Specifications
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.

Specifications

Repair Procedures
Machine Configuration:
Section 3 Repair Pr oc edures
 Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
Observe and Obey: removed
 Repair procedures shall be completed by a • The red Emergency Stop button in the off
person trained and qualified on the repair of position at both the ground and platform
this machine. controls
 Immediately tag and remove from service a • Wheels chocked
damaged or malfunctioning machine.
• All external AC power supply disconnected
 Repair any machine damage or malfunction from the machine
before operating the machine.
• Boom in the stowed position
• Turntable secured with the turntable rotation
Before Repairs Start: lock
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and parts are
available and ready for use.
 Use only Genie approved replacement parts.
 Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.

Repair Procedures
About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the appropriate
repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to
re-assemble, perform the disassembly steps in
reverse order.
Symbols Legend
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.

situation which, if not avoided,
could result in death or serious
injury.

may cause minor or moderate
injury.

may result in property damage.
Indicates that a specific result is expected

after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

Platform Controls
1-1 Boom Function Speed Controller

Controllers Adjustments
The drive joystick is connected to the drive motor Electrocution/burn hazard.
controller located under the non-steer end drive Contact with electrically charged
chassis cover. The drive motor controller can also circuits could result in death or
recognize machine drive malfunctions and display serious injury. Remove all rings,
controller fault codes by flashing an LED at the watches and other jewelry.
ground controls. Refer to the Fault Codes section
for a list of fault codes and additional information. Note: Do not adjust the boom function speed
There are no adjustments needed on the drive controller unless the static battery supply voltage is
joystick controller. For further information or above 24V DC.
assistance, consult the Genie Product Support. 1 Turn the key switch to platform controls and
pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
2 Open the platform control box lid and locate
the boom function speed controller.
1 boom function speed controller

2 drive joystick 1 white/red wire to TP6
2 boom function speed controller
3 threshold trimpot
4 max out trimpot

Platform Controls
3 Disconnect the blk/red wire of the boom

function speed controller from the wht/red
wire.
4 Connect the red (+) lead from an amp meter to
the blk/red wire. Connect the black (-) lead to
the wht/red wire.
5 Turn the boom function speed controller to the
creep position.
6 Set the threshold: With the boom in the stowed
position, press down the foot switch and move
the primary boom toggle switch in the down
position until the amperage reading appears.
Adjust the amperage to 0.17 to 0.18A. Turn
the threshold trimpot adjustment screw
clockwise to increase the amperage or
counterclockwise to decrease the amperage.
7 Turn the boom function speed controller to the
9 position.
8 Set the max-out: Press down the foot switch,
then move the primary boom toggle switch in
the down position. Adjust the amperage to
0.54 to 0.55A. Turn the max-out trimpot
adjustment screw clockwise to increase the
amperage or counterclockwise to decrease
the amperage.
Boom function speed controller specifications
Threshold 0.17 to 0.18A
Max out 0.45 to 0.46A

Platform Components
2-1 4 Tag, disconnect and plug the hydraulic hoses

from the slave cylinder at the unions and
Platform Leveling Slave Cylinder connect them together using a connector.
Connect the hoses from the cylinder together
The slave cylinder and the rotator pivot are the two
using a connector.
primary supports for the platform. The slave
cylinder keeps the platform level through the entire Bodily injury hazard. Spraying
range of boom motion. It operates in a hydraulic oil can penetrate and
closed-circuit hydraulic loop with the master burn skin. Loosen hydraulic
cylinder. The slave cylinder is equipped with connections very slowly to allow
counterbalance valves to prevent movement in the the oil pressure to dissipate
event of a hydraulic line failure. gradually. Do not allow oil to
squirt or spray.
How to Remove the Platform 5 Remove the pin retaining fastener from the
Leveling Slave Cylinder slave cylinder rod-end pivot pin. Do not
remove the pin.
Note: Before cylinder removal is considered, bleed
the slave cylinder to be sure there is no air in the 6 Z-45/25J: Remove the external snap rings
closed loop. from the slave cylinder barrel-end pivot pin. Do
not remove the pin.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Z-45/25: Remove the pin retaining fastener
end must be replaced. All connections must be from the slave cylinder barrel-end pivot pin. Do
torqued to specification during installation. Refer to not remove the pin.
Specifications, Hydraulic Hose and Fitting Torque 7 Place a block under the slave cylinder for
Specifications. support. Protect the cylinder rod from damage.
1 Z-45/25J: Extend the primary boom until the 8 Z-45/25: Support the platform rotator with a
slave cylinder barrel-end pivot pin is suitable lifting device.
accessible.
2 Raise the primary boom slightly and place
blocks under the platform for support.
3 Lower the primary boom until the platform is
resting on the blocks just enough to support
the platform.
Note: Do not rest the entire weight of the boom on
the blocks.

Platform Components
How to Bleed the Sl av e Cylinder
9 Use a soft metal drift to drive the rod-end pivot How to Bleed the Slave Cylinder
pin out.
Note: This procedure will have to be preformed
Crushing hazard. The platform outside.
could fall when the slave cylinder
rod-end pivot pin is removed if 1 Z45/25J: Raise the jib to a horizontal postion
not properly supported. and raise the secondary boom 3 feet.
Z45/25: Raise the secondary boom 4 feet.
Component damage hazard.
The slave cylinder rod may 2 Move the function enable toggle switch to
become damaged if it is allowed either side. Simultaneously activate and hold
to fall if not properly supported the primary boom up and platform level up
by the lifting device. toggle switches until the primary boom is fully
raised.
10 Use a soft metal drift and drive the barrel-end The platform should be facing in an upward
pin out. position. As shown.
11 Carefully pull the cylinder out of the primary
boom.
Z45/25 Z45/25J

Platform Components
3 While still holding the function enable toggle 2-2

switch, simultaneously activate the primary
boom down and platform level down toggle Platform Rotator
switches until the primary boom is fully
lowered.
How to Bleed the Platform
The platform should be facing in a down
position. As shown. Rotator
Note: This procedure will require two people. Do
not start the engine. Use auxiliary power for this
procedure.
1 Move the function enable toggle switch to

either side and activate the platform rotate
toggle switch to the right then the left through
Z45/25 two platform rotation cycles, then hold the
switch to the right position until the platform is
fully rotated to the right.
2 Place a suitable container underneath the
platform rotator.
3 Open the top bleed screw on the rotator, but
do not remove it.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
Z45/25J
gradually. Do not allow oil to
squirt or spray.

either side and hold the platform rotate toggle
switch to the left position until the platform is
fully rotated to the left. Continue holding the
toggle switch until air stops coming out of the
bleed screw. Close the bleed screw.
Crushing hazard. Keep clear of
the platform during rotation.

Platform Components
5 Open the bottom bleed screw on the rotator,

but do not remove it.
squirt or spray.

either side and hold the platform rotate toggle
switch to the right position until the platform is
fully rotated to the right. Continue holding the
toggle switch until air stops coming out of the
bleed screw. Close the bleed screw.
Crushing hazard. Keep clear of
the platform during rotation.
7 Clean up any hydraulic oil that may have

spilled.
8 Rotate the platform fully in both directions and
inspect the bleed screws for leaks.

Jib Boom Components
3-1 7 Remove the pin retaining fasteners from both

platform rotator pivot pins. Do not remove the
Jib Boom pins.
8 Use a soft metal drift to remove the leveling
How to Remove the Jib Boom arm pivot pin and let the leveling arms hang
down.
Note: Perform this procedure with the boom in the
stowed position. 9 Use a soft metal drift to remove the platform
rotator pivot pin and remove the platform
Note: When removing a hose assembly or fitting, rotator from the machine.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 10 Slide both of the jib boom leveling arms off of
torqued to specification during installation. Refer to the jib boom cylinder rod-end pivot pin.
Specifications, Hydraulic Hose and Fitting Torque
11 Remove the hose and cable cover from the
Specifications.
side of the jib boom. Remove the hose and
1 Remove the platform. cable separators.
2 Disconnect the electrical connector from the 12 Attach a lifting strap from an overhead crane
jib boom/platform rotate select valve manifold to the jib boom.
mounted to the platform support. 13 Support the barrel end of the jib boom lift
3 Tag, disconnect and plug all of the hydraulic cylinder with a suitable lifting device.
hoses from the jib boom/platform rotate select 14 Tag, disconnect and plug the jib boom lift
valve manifold. Cap the fittings on the cylinder hydraulic hoses. Cap the fittings on
manifold and pull the hoses out through the the cylinder.
platform rotator.
Bodily injury hazard. Spraying hydraulic oil can penetrate and
hydraulic oil can penetrate and burn skin. Loosen hydraulic
burn skin. Loosen hydraulic connections very slowly to allow
connections very slowly to allow the oil pressure to dissipate
the oil pressure to dissipate gradually. Do not allow oil to
gradually. Do not allow oil to squirt or spray.
squirt or spray.
15 Remove the pin retaining fastener from the jib
4 Remove the platform mounting weldment. boom lift cylinder barrel-end pivot pin.
5 Attach a lifting strap from an overhead crane
to the platform rotator for support.
boom lift cylinder rod-end pivot pin. Do not
remove the pin.

Jib Boom Components
16 Use a soft metal drift to remove the pin and let 3-2
the cylinder hang down.
Jib Boom Lift Cylinder
Crushing hazard. The jib boom
could fall when the barrel-end
pivot pin is removed if not How to Remove the Jib Boom Lift
properly supported by the Cylinder
overhead crane.
17 Remove the pin retaining fastener from the jib stowed position.
boom pivot pin. Use a soft metal drift to Note: When removing a hose assembly or fitting,
remove the pin, then remove the jib boom from the O-ring (if equipped) on the fitting and/or hose
the bellcrank. end must be replaced. All connections must be
Crushing hazard. The jib boom torqued to specification during installation. Refer to
may become unbalanced and fall Specifications, Hydraulic Hose and Fitting Torque
when it is removed from the Specifications.
machine if it is not properly
1 Raise the jib boom slightly and place blocks
supported by the overhead
under the platform mounting weldment. Then
crane.
lower the jib boom until the platform is resting
on the blocks just enough to support the
platform.
to the lug on the rod end of the jib boom lift
cylinder. Note: Do not rest the entire weight of the boom on
the blocks.
19 Use a soft metal drift to remove the jib boom
lift cylinder rod-end pivot pin, then remove the 2 Tag, disconnect and plug the jib boom lift
jib boom lift cylinder from the bellcrank. cylinder hydraulic hoses. Cap the fittings on
the cylinder.
lift cylinder may become Bodily injury hazard. Spraying
unbalanced and fall when it is hydraulic oil can penetrate and
removed from the machine if it is burn skin. Loosen hydraulic
not properly supported by the connections very slowly to allow
overhead crane. the oil pressure to dissipate
squirt or spray.
3 Remove the pin retaining fasteners from the

jib boom lift cylinder rod-end pivot pin. Do not
remove the pin.

Jib Boom Components
4 Use a soft metal drift to tap the jib boom lift

cylinder rod-end pivot pin half way out. Then
lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
opposite leveling arm. Do not remove the pin.
5 Support the jib boom lift cylinder with a
suitable lifting device.
boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the barrel-end pin
and let the cylinder hang down.
may become unbalanced and fall
when it is removed from the
machine if it is not properly
crane.

to the lug on the rod end of the jib boom lift
cylinder.
8 Use a soft metal drift to remove the jib boom
lift cylinder rod-end pin. Remove the jib boom
lift cylinder from the machine.
lift cylinder may become
unbalanced and fall when it is
removed from the machine if it is
not properly supported by the
overhead crane.

Primary Boom Components
4-1 5 Tag, disconnect and plug the platform rotator

hydraulic hoses at the union located above the
Cable Track primary boom lift cylinder. Cap the fittings on
the unions.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
How to R emove the Cable Track , Z- 45/25
squirt or spray.
How to Remove the Cable Track, 6 Tag, disconnect and plug the hydraulic hoses
from the "PR1" and "PR2" ports on the
Z-45/25 counterbalance valve manifold located on the
Note: When removing a hose assembly or fitting, platform rotator. Cap the fittings on the
the O-ring (if equipped) on the fitting and/or hose manifold.
end must be replaced. All connections must be Bodily injury hazard. Spraying
torqued to specification during installation. Refer to hydraulic oil can penetrate and
Specifications, Hydraulic Hose and Fitting Torque burn skin. Loosen hydraulic
Specifications. connections very slowly to allow
1 Locate the cables from the primary boom
cable track to the platform control box.
squirt or spray.
Number each cable and its entry location at
the platform control box.
7 Tag, disconnect and plug the hydraulic hoses
2 Disconnect the cables from the platform from the platform leveling master cylinder.
control box. Cap the fittings on the cylinder.
3 Pull all of the electrical cables out of the plastic Bodily injury hazard. Spraying
cable track. Do not pull out the hydraulic hydraulic oil can penetrate and
hoses. burn skin. Loosen hydraulic
4 Raise the primary boom to a horizontal
position.
squirt or spray.

8 Tag and disconnect the hydraulic hoses from 13 Remove the mounting fasteners from the
the platform leveling slave cylinder and upper cable track at the platform end of the
connect them together using a connector. Cap extension boom.
the fittings on the cylinder.
14 Remove the cable track mounting fasteners
Bodily injury hazard. Spraying that attach the lower cable track to the primary
hydraulic oil can penetrate and boom.
connections very slowly to allow 15 Remove the cable track from the machine and
the oil pressure to dissipate place it on a structure capable of supporting it.
Crushing hazard. The cable
squirt or spray.
track could become
unbalanced and fall if not
9 Pull the four hydraulic hoses toward the
properly attached to the
platform to clear the rod end of the primary
overhead crane.
boom lift cylinder.
10 Place blocks in between the upper and lower Component damage hazard.
cable tracks and secure the upper and lower Cables and hoses can be
tracks together. damaged if they are kinked or
pinched.
Crushing hazard. If the upper
and lower cable tracks are not
properly secured together, the
cable track could become
unbalanced and fall when
removed from the machine.
11 Remove all hose and cable clamps from the

underside of the primary boom.
12 Attach a strap from an overhead crane to the
cable track.

7 Tag and disconnect the hydraulic hoses from

How to R emove the Cable Track , Z- 45/25J
How to Remove the Cable Track,

the platform leveling slave cylinder at the
Z-45/25J union and connect them together using a
connector. Connect the hoses from the
Note: When removing a hose assembly or fitting,
cylinder together using a connector.
end must be replaced. All connections must be Bodily injury hazard. Spraying
torqued to specification during installation. Refer to hydraulic oil can penetrate and
Specifications, Hydraulic Hose and Fitting Torque burn skin. Loosen hydraulic
Specifications. connections very slowly to allow
1 Locate the cables from the primary boom
cable track to the platform control box.
squirt or spray.
Number each cable and its entry location at
the platform control box.
8 Tag, disconnect and plug the hydraulic hoses
2 Disconnect the cables from the platform from the jib boom/platform rotate manifold.
control box. Cap the fittings on the manifold.
3 Remove the hose and cable cover from the Bodily injury hazard. Spraying
side of the jib boom. Remove the hose and hydraulic oil can penetrate and
cable separators. burn skin. Loosen hydraulic
4 Remove the hose clamp on the primary boom
bellcrank.
5 Pull all of the electrical cables out of the plastic squirt or spray.
cable track. Do not pull out the hydraulic
hoses. 9 Tag, disconnect and plug the platform rotator
hydraulic hoses at the union located above the
6 Tag, disconnect and plug the hydraulic hoses primary boom lift cylinder. Cap the fittings on
from the "V1" and "V2" ports on the the unions.
counterbalance valve manifold located on the
platform rotator. Cap the fittings on the Bodily injury hazard. Spraying
manifold. hydraulic oil can penetrate and
Bodily injury hazard. Spraying connections very slowly to allow
hydraulic oil can penetrate and the oil pressure to dissipate
burn skin. Loosen hydraulic gradually. Do not allow oil to
connections very slowly to allow squirt or spray.
squirt or spray.

10 Tag, disconnect and plug the hydraulic hoses 18 Use a soft metal drift to remove the primary
from the platform leveling master cylinder. boom lift cylinder rod-end pivot pin.
Cap the fittings on the cylinder.
Crushing hazard. The primary
Bodily injury hazard. Spraying boom lift cylinder could become
hydraulic oil can penetrate and unbalanced and fall if not
burn skin. Loosen hydraulic properly supported by the lifting
connections very slowly to allow device.
gradually. Do not allow oil to 19 Lower the rod end of the primary boom lift
squirt or spray. cylinder approximately 12 inches / 30 cm.
11 Raise the boom to a horizontal position. 20 Pull all of the hoses and cables out and away
from the mounting ears for the rod end of the
12 Place blocks between the upper and lower primary boom lift cylinder.
cable tracks and secure the upper and lower
tracks together. 21 Raise the rod end of the primary boom lift
cylinder back into position and install the
Crushing hazard. If the upper rod-end pivot pin. Install the pin retaining
and lower cable tracks are not fasteners.
properly secured together, the
cable track could become 22 Attach a strap from an overhead crane to the
unbalanced and fall when cable track.
removed from the machine. 23 Remove the mounting fasteners from the
upper cable track at the platform end of the
13 Attach a lifting strap from an overhead 5 ton / extension boom.
5,000 kg capacity crane to the platform end of
the primary boom for support. Do not lift it. 24 Remove the cable track mounting fasteners
that attach the lower cable track to the primary
14 Remove all hose and cable clamps from the boom.
underside of the primary boom.
25 Remove the cable track from the machine and
15 Support the rod end of the primary boom lift place it on a structure capable of supporting it.
cylinder with a suitable lifting device.
Crushing hazard. The cable
track could become
primary boom lift cylinder rod-end pivot pin. Do
unbalanced and fall if not
not remove the pin.
17 Raise the primary boom slightly with the overhead crane.
overhead crane to relieve the pressure on the
primary boom lift cylinder rod-end pivot pin. Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.


How to R epair the Primary Boom C abl e Tr ack
How to Repair the Primary Boom 4-2

Cable Track Primary Boom
The boom cable track can be How to Remove the Primary
damaged if it is twisted.
Boom
Note: A 7 link repair section of cable track is
Bodily injury hazard. This
available through the Genie Service Parts
procedure requires specific repair
Department.
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these skills
and tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.

stowed position.
1 link separation point Note: When removing a hose assembly or fitting,

2 lower clip
end must be replaced. All connections must be
1 Use a slotted screwdriver to pry down on the torqued to specification during installation. Refer to
lower clip. Specifications, Hydraulic Hose and Fitting Torque
Specifications.
2 To remove a single link, open the lower clip
and then use a screw driver to pry the link to 1 Remove the platform.
the side.
2 Z-45/25: Remove the platform rotator and
3 Repeat steps 1 and 2 for each link. platform mounting weldment.
Z-45/25J: Remove the jib boom. Refer to
Repair Procedure, How to Remove the Jib
Boom.
3 Remove the cable track. Refer to Repair
Procedure, How to Remove the Cable Track.
4 Raise the primary boom to a horizontal
position.
5 Remove the hose and cable cover from the
upper pivot.

6 Remove the pin retaining fastener from the 14 Attach a 5 ton / 5,000 kg overhead crane to
master cylinder barrel-end pivot pin. Use a soft the center point of the primary boom.
metal drift to remove the pin. Then lower the
15 Attach a similar lifting device to the primary
cylinder and let it hang down.
boom lift cylinder.
16 Place support blocks under the primary boom
When lowering the master
lift cylinder.
cylinder down, be sure not to
damage the master cylinder 17 Remove the pin retaining fasteners from the
hoses or fittings. primary boom lift cylinder rod-end pivot pin.
Use a soft metal drift to remove the pin.
7 Locate the primary boom drive speed limit
switch inside of the upper pivot. Crushing hazard. The boom lift
cylinder and primary boom will
8 Remove the primary boom drive speed limit fall if not properly supported.
switch mounting fasteners. Do not disconnect
the wiring. 18 Lower the rod end of the primary boom lift
cylinder onto support blocks. Protect the
9 Locate the primary extension boom drive
speed limit switch inside of the extension cylinder rod from damage.
boom. 19 Remove the pin retaining fasteners from the
primary boom pivot pin.
10 Remove the primary extension boom drive
speed limit switch mounting fasteners. Do not 20 Remove the primary boom pivot pin with a soft
disconnect the wiring. metal drift, then carefully remove the primary
boom from the machine and place it on a
11 Pull the limit switch and the wiring out of the
extension tube and move it out of the way. structure capable of supporting it.
12 Tag, disconnect and plug the primary boom Crushing hazard. The primary
extension cylinder hydraulic hoses. Cap the boom could become unbalanced
fittings on the cylinder. and fall when removed from the
machine if not properly attached
Bodily injury hazard. Spraying to the overhead crane.
squirt or spray.
13 Remove the hose clamp at the pivot end of the

boom.


How to Dis ass embl e the Primary Boom
How to Disassemble the Primary 6 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the
Boom platform end of the extension tube. Use a soft
Complete disassembly of the boom is only metal drift to remove the pin.
necessary if the outer or inner boom tube must be
7 Support and slide the extension cylinder out of
replaced. The extension cylinder can be removed
the base end of the extension tube. Place the
without completely disassembling the boom. Refer
extension cylinder on blocks for support.
to Repair Procedure, How to Remove the Primary
Boom Extension Cylinder. Crushing hazard. The extension
cylinder could become
1 Remove the primary boom. Refer to Repair unbalanced and fall when
Procedure, How to Remove the Primary
removed from primary boom
Boom. extension tube if not properly
2 Place blocks under the barrel end of the supported.
primary boom extension cylinder for support.
Note: During removal, the overhead crane strap will
3 Remove the pin retaining fastener from the need to be carefully adjusted for proper balancing.
extension cylinder barrel-end pivot pin at the
pivot end of the primary boom. Use a soft
metal drift to remove the pin.
4 Remove and label the location of the wear
pads from the platform end of the primary
boom.
Note: Pay careful attention to the location and
amount of shims used with each wear pad.
5 Support and slide the extension tube and

extension cylinder assembly out of the boom
tube.
Crushing hazard. The primary
boom extension tube could
become unbalanced and fall
when removed from the primary
boom tube if not properly
supported.
Note: During removal, the overhead crane strap will

need to be carefully adjusted for proper balancing.

4-3 6 Tag, disconnect and plug the primary boom lift

cylinder hydraulic hoses. Cap the fittings on
Primary Boom Lift Cylinder the cylinder.
The primary boom lift cylinder raises and lowers Bodily injury hazard. Spraying
the primary boom. The primary boom lift cylinder is hydraulic oil can penetrate and
equipped with a counterbalance valve to prevent burn skin. Loosen hydraulic
movement in the event of a hydraulic line failure. connections very slowly to allow
How to Remove the Primary squirt or spray.
Boom Lift Cylinder
Bodily injury hazard. This primary boom lift cylinder rod-end pivot pin.
procedure requires specific repair Use a soft metal drift to remove the pin.
suitable workshop. Attempting Crushing hazard. The primary
this procedure without these skills boom will fall if not properly
and tools could result in death or supported when the primary
serious injury and significant boom rod-end pivot pin is
component damage. Dealer removed.
8 Place a support block across both turntable
Note: When removing a hose assembly or fitting, covers under the primary boom lift cylinder.
end must be replaced. All connections must be 9 Lower the rod end of the lift cylinder onto the
torqued to specification during installation. Refer to block. Protect the cylinder rod from damage.
Specifications, Hydraulic Hose and Fitting Torque Crushing hazard. The primary
Specifications. boom lift cylinder could become
1 Raise the primary boom to a horizontal unbalanced and fall if not
position. properly supported by the lifting
device.
2 Raise the secondary boom until the primary
boom lift cylinder barrel-end pivot pin is above 10 Remove the primary boom lift cylinder
the turntable covers. barrel-end pivot pin retaining fasteners. Do not
remove the pin.
3 Attach a 5 ton / 5000 kg overhead crane to the
primary boom for support. 11 Use a slide hammer to remove the barrel-end
pivot pin. Carefully remove the primary boom
4 Raise the primary boom with the overhead
lift cylinder from the machine.
crane slightly to take the pressure off the
primary boom lift cylinder pivot pins. Crushing hazard. The lift cylinder
5 Support the rod end and the barrel end of the could become unbalanced and
primary boom lift cylinder with a second fall if not properly supported and
overhead crane or similar lifting device. secured to the lifting device.

4-4 4 Tag, disconnect and plug the primary boom

extension cylinder hydraulic hoses. Cap the
Primary Boom Extension fittings on the cylinder.
Cylinder
The primary boom extension cylinder extends and hydraulic oil can penetrate and
retracts the primary boom extension tube. The burn skin. Loosen hydraulic
primary boom extension cylinder is equipped with connections very slowly to allow
counterbalance valves to prevent movement in the the oil pressure to dissipate
event of a hydraulic line failure. gradually. Do not allow oil to
squirt or spray.
How to Remove the Primary 5 At the platform end of the boom, remove the
Boom Extension Cylinder external snap rings from the extension
cylinder rod-end pivot pin. Use a soft metal
Bodily injury hazard. This drift to remove the pin.
procedure requires specific repair
6 Remove the barrel-end pivot pin retaining
fasteners.
suitable workshop. Attempting
this procedure without these skills 7 Place a rod through the barrel-end pivot pin
and tools could result in death or and twist to remove the pin.
component damage. Dealer 8 Support and slide the extension cylinder out of
service is strongly recommended. the upper pivot.
Crushing hazard. The extension
Note: When removing a hose assembly or fitting, cylinder could fall when removed
the O-ring (if equipped) on the fitting and/or hose from the extension boom if not
end must be replaced. All connections must be properly supported.
torqued to specification during installation. Refer to
Specifications. Component damage hazard. Be
careful not to damage the
1 Raise the primary boom to a horizontal counterbalance valves on the
position. primary boom extension cylinder
when removing the cylinder from
2 Extend the primary boom until the primary the primary boom.
boom extension cylinder rod-end pivot pin is
accessible in the primary boom extension
tube. Hoses and cables can be
3 Remove the hose and cable guard from the damaged if the primary boom
upper pivot. extension cylinder is dragged
across them.
Note: Note the length of the cylinder after removal.

The cylinder must be at the same length for
installation.

4-5 4 Remove the pin retaining fasteners from the

master cylinder barrel-end pivot pin.
Platform Leveling Master
Cylinder 5 Place a rod through the barrel-end pivot pin
and twist to remove the pin.
The master cylinder acts as a pump for the slave 6 Remove the pin retaining fastener from the
cylinder. It’s part of the closed circuit hydraulic loop rod-end pivot pin.
that keeps the platform level through the entire
range of boom motion. The master cylinder is 7 Place a rod through the rod-end pivot pin and
located at the base of the primary boom. twist to remove the pin.
8 Remove the master cylinder from the
How to Remove the Platform machine.
Leveling Master Cylinder Crushing hazard. The master

cylinder could become
Note: When removing a hose assembly or fitting, unbalanced and fall if not
the O-ring (if equipped) on the fitting and/or hose properly attached to the
end must be replaced. All connections must be overhead crane.
torqued to specification during installation. Refer to
Specifications.
1 Raise the secondary boom until both the

rod-end and barrel-end pivot pins on the
master cylinder are accessible.
2 Tag, disconnect and plug the master cylinder
hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.
3 Attach overhead crane or similar lifting device

to the master cylinder.

Secondary Boom Components
Secondary Boom components 6 secondary boom lift cylinder (2)

1 upper secondary boom (number 1 arm) 7 lower secondary boom (number 4 arm)
2 upper tension link (number 2 arm) 8 turntable pivot
3 lower tension link (number 3 arm) 9 boom rest
4 mid-pivot 10 upper pivot
5 compression link

5-1 5 Attach a lifting strap from an overhead crane

to the lug on the rod end of the primary boom
Secondary Boom lift cylinder. Then raise the primary boom lift
cylinder with the crane, to a vertical position.
How to Disassemble the 6 Tag, disconnect and plug the hydraulic hoses
Secondary Boom at the primary boom lift cylinder. Cap the
fittings on the cylinder.
Bodily injury hazard. This
procedure requires specific repair Bodily injury hazard. Spraying
skills, lifting equipment and a hydraulic oil can penetrate and
suitable workshop. Attempting burn skin. Loosen hydraulic
this procedure without these skills connections very slowly to allow
and tools could result in death or the oil pressure to dissipate
serious injury and significant gradually. Do not allow oil to
component damage. Dealer squirt or spray.
7 Remove the pin retaining fastener from the
Follow the disassembly steps to the point required primary boom lift cylinder barrel-end pivot pin.
to complete the repair. Then re-assemble the 8 Use a slide hammer to remove the pin.
secondary boom by following the disassembly Remove the primary boom lift cylinder from
steps in reverse order. the machine.
Note: When removing a hose assembly or fitting, Crushing hazard. The primary
the O-ring (if equipped) on the fitting and/or hose boom lift cylinder could become
end must be replaced. All connections must be unbalanced and fall if not
torqued to specification during installation. Refer to properly supported by the lifting
Specifications, Hydraulic Hose and Fitting Torque device.
Specifications.
1 Remove the platform. 9 Tag, disconnect and plug the hydraulic hoses
on both of the secondary boom lift cylinders.
2 Z-45/25J: Remove the jib boom. Refer to Cap the fittings on the cylinders.
Repair Procedure, How to Remove the Jib
Boom. Bodily injury hazard. Spraying
3 Remove the primary boom. Refer to Repair burn skin. Loosen hydraulic
Procedure, How to Remove the Primary connections very slowly to allow
Boom. the oil pressure to dissipate
4 Remove the master cylinder. Refer to Repair gradually. Do not allow oil to
Procedure, How to Remove the Master squirt or spray.
Cylinder.
10 Remove the pin retaining fasteners from both
sides of the secondary boom lift cylinder
rod-end pivot pin and barrel-end pivot pin. Do
not remove the pins.

11 Attach a strap from an overhead crane to the 17 Attach a lifting strap from a second overhead
lug on the rod end of one of the secondary crane to the number 1 arm at the mid-point
boom lift cylinders for support. Do not apply between the upper pivot and mid-pivot.
any lifting pressure.
12 Use a soft metal drift to drive the barrel-end number 1 arm pivot pins at the mid-pivot and
pivot pin half way out. Lower the barrel end of the upper pivot. Do not remove the pins.
the secondary boom lift cylinder and let it hang
down. 19 Use a soft metal drift to drive both pins out.
13 Use a soft metal drift to drive the rod-end pivot 20 Remove the number 1 arm from the machine.
pin half way out. Crushing hazard. The number 1
14 Remove the secondary boom lift cylinder from arm could become unbalanced
the machine. and fall when removed from the
machine if not properly attached
15 Repeat steps 11 through 14 for the other to the overhead crane.
secondary boom lift cylinder.
Crushing hazard. The secondary Crushing hazard. The upper
boom lift cylinder could become pivot could fall when the number
unbalanced and fall when 1 arm is removed from the
removed from the machine if not machine if not properly
properly attached to the supported by the overhead
overhead crane. crane.
Component damage hazard. 21 Using the overhead crane attached to the

When removing a secondary upper pivot, raise the secondary boom
boom lift cylinder from the assembly approximately 30 inches / 76 cm.
machine, be careful not to 22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block
damage the counterbalance between the number 2 arm and the boom rest.
valve at the barrel end of the Then lower the secondary boom assembly
cylinder. onto the block.
16 Attach a lifting strap from an overhead crane Crushing hazard. The secondary
to the upper pivot for support. Do not lift it. boom assembly could fall if not
properly supported by the4 x 4 x
11 inch / 10 x 10 x 28 cm block.

23 Pull all of the cables and hoses out through 31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm
the upper pivot. block between the number 3 arm and the
number 4 arm at the mid-pivot end.
Cables and hoses can be 32 Attach a lifting strap from the overhead crane
damaged if they are kinked or to the mid-pivot for support. Do not lift it.
pinched.
number 2, 3 and 4 arm pivot pins at the
24 Remove the hose and cable covers from the
mid-pivot. Do not remove the pins.
top of the number 2 arm.
34 Use a soft metal drift to drive each pin out.
25 Pull all of the hoses and cables out of the
Then remove the mid-pivot from the
upper pivot and out through the mid-pivot. Lay
secondary boom assembly.
the hoses and cables on the ground.
Crushing hazard. The mid-pivot
could become unbalanced and
Cables and hoses can be
fall when removed from the
damaged if they are kinked or
secondary boom assembly if not
pinched.
properly supported by the
overhead crane.
26 Remove the pin retaining fastener from the
number 2 arm pivot pin at the upper pivot. Use
35 Attach the lifting strap from an overhead crane
a soft metal drift to remove the pin.
to the center point of the number 2 arm for
27 Remove the upper pivot from the machine. support. Do not lift it.
Crushing hazard. The upper 36 Remove the pin retaining fasteners from both
pivot could become unbalanced compression link pivot pins. Do not remove
and fall when removed from the the pins.
machine if not properly attached 37 Use a soft metal drift to remove the lower
to the overhead crane. compression link pivot pin at the number 3
arm.
28 Attach the lifting strap from an overhead crane
to the number 2 arm at the upper pivot end. 38 Support the compression link with an
appropriate lifting device.
29 Raise the number 2 arm slightly and remove
the 4 x 4 x 11 inch / 10 x 10 x 28 cm block.
30 Lower the number 2 arm onto the boom rest
pad.

39 Use a soft metal drift to remove the upper 45 Using an approved hand-operated pump,
compression link pivot pin from the number 2 drain the fuel tank into a container of suitable
arm. Remove the compression link from the capacity. Refer to Specifications, Machine
machine. Specifications.
Crushing hazard. The number 2 Explosion and fire hazard.
arm could fall when the Engine fuels are combustible.
compression link is disconnected Perform this procedure in an
from the number 2 arm if not open, well-ventilated area away
properly supported by the from heaters, sparks, flames and
overhead crane. lighted tobacco. Always have an
approved fire extinguisher within
Crushing hazard. The easy reach.
compression link may fall if not
properly supported when Explosion and fire hazard. When
removed from the secondary transferring fuel, connect a
boom assembly. grounding wire between the
machine and pump or container.
40 Remove the number 2 arm from the machine.
Note: Be sure to only use a hand-operated pump
Crushing hazard. The number 2 suitable for use with gasoline and diesel fuel.
arm could become unbalanced
and fall when removed from the 46 Tag, disconnect and plug the fuel hoses from
secondary boom assembly if the fuel tank. Clean up any fuel that may have
not properly supported by the spilled.
overhead crane.
47 Remove the fuel tank mounting fasteners.
Carefully remove the fuel tank from the
41 Remove the upper and lower hose and cable
machine.
covers from the number 3 arm.
42 Pull all of the cables and hoses from the Component damage hazard.
number 3 arm and lay them over the turntable The fuel tank is plastic and may
counterweight. become damaged if allowed to
fall.
Cables and hoses can be Note: Clean the fuel tank and inspect for cracks
damaged if they are kinked or and other damage before installing it onto the
pinched. machine.
43 Open the ground controls side turntable cover.

44 Remove the fuel tank filler cap.

48 Remove the retaining fastener from the 56 Remove the secondary boom drive speed limit
ground control box and function manifold pivot switch mounting fasteners from the number 4
plate. arm at the mid-pivot end. Do not disconnect
the wiring.
49 Lower the ground control box and function
manifold pivot plate to access the number 3 57 Remove the pin retaining fasteners from the
arm pivot pin. number 4 arm at the turntable riser. Do not
remove the pin.
50 Attach the lifting strap from the overhead
crane to the centerpoint of the number 3 arm 58 Attach a lifting strap from the overhead crane
for support. Do not lift it. to the center point of the number 4 arm. Do not
lift it.
51 Remove the mounting fasteners from the
cover located in the boom storage area to 59 Use a slide hammer to remove the number 4
access the number 3 and number 4 arm pivot arm from the turntable riser through the
pin retaining fasteners at the turntable riser. ground controls side bulkhead.
52 Remove the pin retaining fasteners from the 60 Remove the number 4 arm from the machine.
number 3 arm at the turntable riser. Do not
remove the pin. Crushing hazard. The number 4
53 Use a slide hammer to remove the number 3 and fall when removed from the
arm pivot pin from the turntable pivot through machine if not properly
the access hole behind the ground control supported by the overhead
box. crane.
54 Remove the number 3 arm from the machine.
Crushing hazard. The number 3
and fall when removed from the
machine if not properly
crane.
55 Remove the upper and lower hose and cable

covers from the number 3 arm.

5-2 3 Tag, disconnect and plug the hydraulic hoses

on the secondary boom lift cylinder.
Secondary Boom Lift Cylinders
There are two secondary boom lift cylinders hydraulic oil can penetrate and
incorporated in the structure of the secondary burn skin. Loosen hydraulic
boom assembly. These cylinders operate in connections very slowly to allow
parallel and require hydraulic pressure to extend the oil pressure to dissipate
and retract. Each secondary boom lift cylinder is gradually. Do not allow oil to
equipped with a counterbalance valve to prevent squirt or spray.
movement in the event of a hydraulic line failure.
secondary boom lift cylinder rod-end pivot pin
How to Remove a Secondary and barrel-end pivot pin. Do not remove the
Boom Lift Cylinder pins.
Bodily injury hazard. This 5 Attach a strap from an overhead crane to the
procedure requires specific repair lug on the rod end of the secondary boom lift
skills, lifting equipment and a cylinder for support. Do not apply any lifting
suitable workshop. Attempting pressure.
this procedure without these skills
6 Use a soft metal drift to drive the barrel-end
and tools could result in death or
pivot pin half way out. Lower the barrel end of
the secondary boom lift cylinder and let it hang
component damage. Dealer
down.
7 Use a soft metal drift to drive the rod-end pivot
Note: When removing a hose assembly or fitting, pin half way out.
end must be replaced. All connections must be 8 Remove the secondary boom lift cylinder from
torqued to specification during installation. Refer to the machine.
Specifications, Hydraulic Hose and Fitting Torque Crushing hazard. The secondary
Specifications. boom lift cylinder could become
1 Lower the secondary boom to the stowed unbalanced and fall when
position. removed from the machine if not
2 Raise the primary boom so that it is above the overhead crane.
secondary boom lift cylinder rod-end pivot pin.
When removing a secondary
boom lift cylinder from the
machine, be careful not to
damage the counterbalance
valve at the barrel end of the
cylinder.

Hydraulic Pumps
2 Remove the engine pivot plate latch retainer.

6-1
Auxiliary Pump 3 Open the engine pivot plate latch and swing
the engine pivot plate out away from the
machine.
How to Remove the Auxiliary 4 Tag, disconnect and plug the hydraulic hoses
Pump from the auxiliary pump.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
1 Models with hydraulic tank shutoff valves:
Locate the two hydraulic tank valves at the 5 Remove the auxiliary pump mounting bolts.
hydraulic tank through the access hole Carefully remove the pump.
underneath the turntable. Close the valves.
open closed

The engine must not be started
with the hydraulic tank shut-off
valves in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the
condition.
Models without hydraulic tank shutoff

valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a container of suitable capacity. Refer to
Specifications, Machine Specifications.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.

Hydraulic Pumps
6-2 2 Remove the engine pivot plate latch retainer.
Function Pump 3 Open the engine pivot plate latch and swing
the engine pivot plate out away from the
machine.
How to Remove the Function 4 Tag, disconnect and plug the hydraulic hoses
Pump from the pump.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
1 Models with hydraulic tank shutoff valves:
Locate the two hydraulic tank valves at the 5 Remove the function pump mounting bolts.
hydraulic tank through the access hole Carefully remove the pump.
underneath the turntable. Close the valves.
open closed

The engine must not be started
with the hydraulic tank shut-off
valves in the closed position or
component damage will occur. If
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the
condition.
Models without hydraulic tank shutoff

valves: Remove the drain plug from the
hydraulic tank and completely drain the tank
into a container of suitable capacity. Refer to
Specifications, Machine Specifications.
Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.

Manifolds
7-1
Function Manifold Components
The function manifold is located next to the hydraulic tank underneath the ground controls side cover.
Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 2 position 3 way A Primary boom retract 20 ft-lbs / 27 Nm
2 Solenoid valve, 3 position 4 way B Primary boom up/down 25 ft-lbs / 34 Nm
3 Solenoid valve, 3 position 4 way C Secondary boom up/down 25 ft-lbs / 34 Nm
4 Solenoid valve, 3 position 4 way D Turntable rotate left/right 25 ft-lbs / 34 Nm
5 Solenoid valve, 3 position 4 way E Platform rotate left/right andjib 25 ft-lbs / 34 Nm
boom up/down (Z-45/25J)
6 Solenoid valve, 3 position 4 way F Platform level up/down 25 ft-lbs / 34 Nm
7 Shuttle valve G Platform level circuit 4-5 ft-lbs / 5.5-6.7
Nm
8 Solenoid valve, 3 position 4 way H Steer left/right 25 ft-lbs / 34 Nm
9 Proportional solenoid valve I Controls flow to functions 27 ft-lbs / 37 Nm
10 Pressure switch J Brake circuit
11 Solenoid valve, 2 position 3 way K Primary boom extend 20 ft-lbs / 27 Nm
12 Flow regulator valve, 0.4 gpm / 1.5 L/min L Platform rotate and 20 ft-lbs / 27 Nm
turntablerotate circuits
13 Needle valve M Platform level circuit 20 ft-lbs / 27 Nm
14 Relief valve, 2500 psi / 172 bar N Platform level circuit 20 ft-lbs / 27 Nm
15 Relief valve, 3200 psi / 220.6 bar O System relief 20 ft-lbs / 27 Nm
16 Check valve, 5 psi / 0.3 bar P Brake circuit 12-14 ft-lbs / 16-19
Nm
17 Orifice, 0.060 inch / 1.5 mm Q Steer circuit
18 Orifice, 0.030 inch / 0.76 mm R Proportional valve circuit
19 Solenoid valve, 2 position 3 way S Brake circuit 20 ft-lbs / 27 Nm
— Orifice, 0.030 inch / 0.76 mm(located under T Brake circuit
item S)
20 Orifice, 0.037 inch / 0.94 mm U
21 Check valve, pilot operated V Platform level circuit 20 ft-lbs / 27 Nm
22 Relief valve, 2100 psi / 145 bar W Secondary boom down circuit 20 ft-lbs / 27 Nm

Manifolds

Manifolds
How to Adj ust the Sec ondary Boom D own R elief Valv e
7-2 Valve Adjustments - Function How to Adjust the Secondary

Manifold Boom Down Relief Valve
How to Adj ust the Sy stem Reli ef Valve

stowed position.
How to Adjust the System Relief Note: Refer to Function Manifold Component list to
Valve locate the secondary boom down relief valve.
Note: Perform this procedure with the boom in the 1 Connect a 0 to 5000 psi / 0 to 350 bar
stowed position. pressure gauge to the test port on the function
manifold.
Note: Refer to Function Manifold Component list to
locate the system relief valve. 2 Move and hold the function enable toggle
switch to either side and hold the secondary
1 Connect a 0 to 5000 psi / 0 to 350 bar boom up/down toggle switch in the down
pressure gauge to the test port on the function direction with the secondary boom fully
manifold. lowered.
2 Move and hold the function enable toggle 3 Observe the pressure reading on the pressure
switch to either side and hold the primary gauge. Refer to Specifications, Hydraulic
boom extend/retract toggle switch in the Specifications.
retract direction with the primary boom fully
retracted. 4 Turn the machine off. Hold the secondary
boom down relief valve with a wrench and
3 Observe the pressure reading on the pressure remove the cap.
gauge. Refer to Specifications, Hydraulic
Specifications. 5 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
4 Turn the machine off. Hold the system relief counterclockwise to decrease the pressure.
valve with a wrench and remove the cap. Install the relief valve cap.
5 Adjust the internal hex socket. Turn it
Tip-over hazard. Do not adjust
clockwise to increase the pressure or
the relief valve higher than
counterclockwise to decrease the pressure.
specified.
Install the relief valve cap.
Tip-over hazard. Do not adjust 6 Repeat steps 2 through 4 and recheck relief
the relief valve higher than valve pressure.
specified. 7 Remove the pressure gauge.
6 Repeat steps 2 through 4 and recheck relief
valve pressure.
7 Remove the pressure gauge.

Manifolds
7-3
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to the platform support.
Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 2 position 3 way AA Jib boom / platform rotate select 20 ft-lbs / 27 Nm

Manifolds
7-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Schematic
Index No. Description Function Torque
Item
1 Counterbalance valve Y Turntable rotate right 30-35 ft-lbs / 41-47 Nm
2 Counterbalance valve Z Turntable rotate left 30-35 ft-lbs / 41-47 Nm

Manifolds
7-5
Valve Coils
How to Test a Coil

A properly functioning coil provides an
electromotive force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil that provides this force field.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
1 Tag and disconnect the wiring from the coil to

be tested.
2 Test the coil resistance.
Result: The resistance should be within
specification, plus or minus 30%.
Result: If the resistance is not within
specification, plus or minus 30%, replace the
coil.
Valve Coil Resistance Specification
Solenoid valve, 3 position 4 way, 20V DC 25 to 29 Ω
(schematic items B, C, D, E, F and H)
Solenoid valve, 2 position 3 way, 20V DC 25 to 29 Ω
(schematic items A, K, S and AA)
Proportional solenoid valve, 24V DC 17 to 21 Ω
(schematic item I)

Turntable Rotation Components
8 Tag and disconnect the fuel hose from the fuel

8-1 filter and drain the fuel tank into a suitable
Turntable Rotation Assembly container. Refer to Specifications, Machine
Specifications.
How to Remove the Turntable 9 Tag, disconnect and plug the fuel hoses from
the fuel tank.
Rotation Assembly
10 Remove the fuel tank strap fasteners and
Note: When removing a hose assembly or fitting, remove the tank strap.
end must be replaced. All connections must be 11 Remove the fuel tank from the machine.
torqued to specification during installation. Refer to 12 Tag, disconnect and plug the hydraulic hoses
Specifications, Hydraulic Hose and Fitting Torque from the turntable rotation motor manifold.
Specifications. Cap the fittings on the manifold.
1 Raise the secondary boom until the upper Bodily injury hazard. Spraying
pivot is above the turntable covers. Turn the hydraulic oil can penetrate and
machine off. burn skin. Loosen hydraulic
2 Secure the turntable from rotating with the connections very slowly to allow
turntable rotation lock. the oil pressure to dissipate
Tip-over hazard. The machine squirt or spray.
could tip over when the turntable
rotation assembly is removed if 13 Attach a lifting strap from and overhead crane
the turntable rotation lock is not or other suitable lifting device to the turntable
in the locked position. rotator assembly.
3 Remove the engine pivot plate latch retainer. 14 Remove the turntable rotation assembly
mounting fasteners.
4 Open the engine pivot plate latch and swing
the engine out and away from the machine to 15 Carefully remove the turntable rotation
access the turntable rotation assembly. assembly from the machine.
5 Remove the retaining fasteners from the Tip-over hazard. The machine
center turntable cover. Remove the cover from could tip over when the turntable
the machine. rotation assembly is removed if
the turntable rotation lock is not
6 Disconnect the battery backs from the in the locked position.
machine
Electrocution/burn hazard. Crushing hazard. The turntable
Contact with electrically charged rotation assembly could become
circuits could result in death or unbalanced and fall when
serious injury. Remove all rings, removed from the machine if not
watches and other jewelry. properly supported by the
overhead crane.
7 Place a suitable container under the engine
plate.

Motor Controllers
9-1 4 Set an ohmmeter to diode test mode.

Motor Controller 5 Connect the leads from an ohmmeter to test
each motor controller terminal combination
The drive motor controller is located under the listed below and check the forward / reverse
non-steer end drive chassis cover. The drive motor bias (diode test).
controller can recognize machine drive
Result: All desired results must be within the
malfunctions and display controller fault codes by
flashing a LED at the ground controls and on the specified range. If any test has a result not
motor controller. See the Fault Code section of this within the specified range, replace the motor
controller.
manual for a list of fault codes and additional
information. There are no adjustments needed on Forward Bias:
the drive joystick controller. For further information Test Desired result
or assistance, consult the Genie Industries Service
Department. Positive Lead Negative Lead
M- B+ 0.4 to 0.45
B- M- 0.4 to 0.45
How to Test the Motor Controller
F1 B+ 0.45 to 0.5
Note: Use the following procedure to test the motor
F2 B+ 0.45 to 0.5
controller. If the motor controller is found to be
faulty, note which test failed and which fault code (if B- F1 0.45 to 0.5
any) was present at the time of failure. B- F2 0.45 to 0.5
Reverse Bias:
1 Turn the key switch to the off position and
disconnect the battery packs from the Test Desired result
machine. Positive Lead Negative Lead
2 Tag and disconnect all power cables from the B+ M- Rises to .0L V
motor controller. M- B- Rises to .0L V
Electrocution/burn hazard. B+ F1 Rises to .0L V
Contact with electrically charged B+ F2 Rises to .0L V
circuits could result in death or F1 B- Rises to .0L V
watches and other jewelry. F2 B- Rises to .0L
3 Press the release tab on the motor controller

harness connector and remove the motor
controller harness connector from the motor
controller.

Steer Axle Components

How to Ins tall the H ub and Bearings
10-1 Hub and Bearings How to Install the Hub and

How to R emove the Hub and Bearings
Bearings
Note: When replacing a wheel bearing, both the
How to Remove the Hub and inner and outer bearings, including the pressed-in
Bearings races, must be replaced.
1 Loosen the wheel lug nuts. Do not remove 1 Be sure that both bearings are packed with
them. clean, fresh grease.
2 Block the non-steer wheels and place a lifting 2 Place the large inner bearing into the rear of
jack under the steer axle. the hub.
3 Raise the machine. Place blocks under the 3 Install a new bearing grease seal into the hub
drive chassis for support. by pressing it evenly into the hub until it is
flush.
4 Remove the lug nuts. Remove the tire and
wheel assembly. Note: Always replace the bearing grease seal when
removing the hub.
5 Remove the dust cap, cotter pin and castle
nut. 4 Slide the hub onto the yoke spindle.
Note: Always use a new cotter pin when installing a Component damage hazard. Do
castle nut. not apply excessive force or
damage to the lip of the seal may
6 Pull the hub off the yoke spindle. The washer occur.
and outer bearing should fall loose from the
hub. 5 Fill the hub cavity with clean, fresh grease.
7 Place the hub on a flat surface and gently pry 6 Place the outer bearing into the hub.
the grease seal out of the hub. Remove the
inner bearing. 7 Install the washer and castle nut.
Note: When removing a bearing, always use a new 8 Tighten the castle nut to 158 ft-lbs / 214 Nm to
inner bearing seal. seat the bearings.
Note: Rotate the hub by hand while torquing the
castle nut to make sure the bearings seat properly.

Steer Axle Components
9 Loosen the castle nut one full turn and then

torque to 35 ft-lbs / 47 Nm.
10 Install a new cotter pin. Bend the cotter pin to
lock it in place.
Note: Always use a new cotter pin when installing a
castle nut.
11 Install the dust cap, then the tire and wheel

assembly.
12 Lower the machine and remove the blocks.
13 Torque the wheel lug nuts to specification.
Refer to Specifications, Machine
Specifications.

Fault Codes
Before Troubleshooting:
Section 4 Faul t Codes

 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
 Troubleshooting and repair procedures shall Attempting short cuts may produce hazardous
be completed by a person trained and qualified conditions.
on the repair of this machine  Be aware of the following hazards and follow
 Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Boom in the stowed position
• Turntable secured with the turntable rotation
lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)

Fault Codes
Fault Codes For example: the indicator light blinks 4

consecutive times, pauses for 1 second, and then
blinks 1 time. That would indicate Fault Code 41.
Tip-over hazard. When
adjusting the raised drive speed
settings, the maximum raised
drive speed must not exceed
0.6 mph / 1Km/h or 40 feet / 45
seconds / 12.2 meters / 45
seconds. If the machine is
allowed to drive faster than
specification, the machine could
become unstable and will tip
over.
Note: Additional troubleshooting of the fault codes

may by accomplished by using the hand-held
pendant motor controller programmer (Genie part
number 128551).
Note: When using the hand-held pendant motor
controller programmer, the M1 MAX SPEED needs
to be set to 33. If needed, adjust the M1 MAX
SPEED higher or lower to achieve the maximum
raised drive speed of 0.6 mph / 1Km/h or 40 feet /
45 seconds / 12.2 meters / 45 seconds.
The controller status indicator light will flash a fault
code to aid in troubleshooting. This indicator light is
mounted on the left side of the ground control box.
Fault codes are two digits. The controller status
indicator light will blink the first digit of a two digit
code, pause for 1 second, and then blink the
second digit. There will be a 2 second pause
between codes.

Fault Codes
Faul t Code C harts
Fault Code Chart

Fault Code Programmer Condition Possible Causes Solution
Diagnostic Display
Fault code LED COMMUNICATION Machine will not drive. The key switch or Push in the ground
is off or is on, but ERROR Emergency Stop control red Emergency
not blinking button(s) was cycled Stop button to the off
on and off faster than 5 position and wait for 5
seconds OR controller seconds. Pull out the
sensed an internal ground control red
error during start up. Emergency Stop
button to the on
position. If problem
persists, replace the
motor controller.
1 Normal operation.
12 HW FAILSAFE 1-2-3 Machine will not drive. The motor controller Replace the motor
failed self test. controller.
13 M- SHORTED Machine will not drive. The motor controller Test the motor
has a internal short controller. See Repair
between M- and B- Section.
terminals.
FIELD OPEN Machine will not drive. Motor wiring is loose Check for loose or
OR motor is defective open connections at
OR motor controller the drive motors and
has an internal short. motor controller OR
replace the defective
drive motor OR test the
motor controller. See
Repair Section.
ARM SENSOR Machine will not drive. Defective motor Replace the motor
controller. controller.
FLD SENSOR Machine will not drive. Defective motor Replace the motor
controller. controller.

Fault Codes
Fault Code Chart

Diagnostic Display
21 THROTTLE FAULT 1 Machine will not drive. Open in wht/red wire Consult Genie Product
#32 at pin 14 or Support.
red/wht wire #29 at pin
16 on the motor
controller going from
drive joystick to pins 14
and 16 at the motor
controller OR pin 14 is
internally shorted to
power or ground OR
the potentiometer on
the drive joystick is
defective.
THROTTLE FAULT 2 Machine will not drive. Pin 14 (wht/red #32) is Consult Genie Product
shorted to power or Support.
ground OR the
potentiometer on the
drive joystick is
defective.
31 CONT DRVR OC Machine will not drive. Main contactor (PR1) Replace main
coil defective OR brake contactor PR1 or brake
release relay CR5 release relay CR5 OR
defective. replace the motor
controller.
32 MAIN CONT WELDED Machine will not drive. Main contactor (PR1) Consult Genie Product
contacts stuck closed Support.
OR grn wire at pin 17
on motor controller
shorted to ground OR
open in motor armature
wiring OR motor
controller has an
internal short to
ground.
33 PRECHARGE FAULT Machine will not drive. External short between Repair short between
B+ terminal on motor B+ terminal on motor
controller and ground controller and ground
OR motor controller is OR replace motor
defective. controller.
Note: Short can be on
any part of circuit
connected to the B+
terminal on the motor
controller.

Fault Codes
Fault Code Chart

Diagnostic Display
34 MISSING Machine will not drive. Motor controller does Consult Genie Product
CONTACTOR not detect the main Support.
contactor PR1 or brake
release relay CR5.
MAIN CONT DNC Machine will not drive. Main contactor PR1 or Consult Genie Product
brake release relay Support.
CR5 did not close OR
open in org/red wire to
PR1 and/or CR5 OR
main contactor and/or
brake release relay is
defective.
41 LOW BATTERY Machine will not drive. Battery supply voltage Completely charge
to motor controller less batteries OR check
than 32V DC. battery cable condition
OR check for corrosion
or loose connections at
battery terminals and
motor controller.
42 OVERVOLTAGE Machine will not drive. Battery supply voltage Be sure the battery
to motor controller charger is
more than 55V DC OR disconnected OR
machine is being check for loose battery
operated with the cables or poor
battery charger connections.
plugged in.
43 THERMAL CUTBACK Machine will not drive. Machine being Operate machine
operated outside of within specified
temperature range of temperature limits OR
-13°F to 185°F / -25°C check for debris
to 85°C OR machine around motor
being driven under controller preventing
excessive load OR proper cooling of the
motor controller is not controller OR check for
being cooled mechanical restrictions
sufficiently. causing excessive load
on the machine.

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Schematics
About This Section

Section 5 Schem atics
There are two groups of schematics in this section.
Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
 Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and qualified
on the repair of this machine
Hydraulic Schematics
 Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
 Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: gradually. Do not allow oil to
squirt or spray.
 Be sure that all necessary tools and test
equipment are available and ready for use.

Electrical Symbol Legend
Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge
Diode Hour meter LED Fuse with amperage Foot switch
T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid
T-circuits connect at Circuits crossing - no Quick disconnect Circuit breaker with

Connection - no terminal
terminal connection terminal amperage
Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor
Horn button - normally Emergency stop button -

Resistor with ohm value Battery seperator Gauge sending unit
open normally closed
Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow
normally open switch - normally open normally closed normally open plug or flame ignitor

Hydraulic Symbols Legend
Orifice with size Check valve Shut off valve Brake
Pump, bi-directional Motor, 2 speed

Pump, fixed displacement Motor, bi-directional
variable displacement bi-directional
Pump, prime mover (engine Shuttle valve. 2 position, 3

Double acting cylinder Differential sensing valve
or motor) way
Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator valve
valve setting proportional valve
Solenoid operated 2
Directional valve Pilot operated 3 position, 3
Flow divider/combiner valve position, 3 way directional
(mechanically activated) way shuttle valve
valve
Solenoid operated 3 Solenoid operated 3

Counterbalance valve with 2 position, 2 way solenoid
position, 4 way directional position, 4 way proportional
pressure and pilot ratio valve
valve directional valve

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Platform Options Wiring Diagram
61
Platform Options Wiring Diagram

Power Panel Wiring Diagram

Power Panel Wiring Diagram
64
CTE Option Wiring Diagram, (CE)
65
CTE Option Wiring Diagram, (CE)

Charger Interlock Option

Charger Interlock Option
68
Hydraulic Schematic
69
Hydraulic Schematic

Electrical Schematic, (ANSI / CSA / AS)
71


74
Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS)
75
Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA / AS)

Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA / AS)

Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA / AS)
78
Platform Control Box Wiring Diagram, (ANSI / CSA / AS)
79
Platform Control Box Wiring Diagram, (ANSI / CSA / AS)

Electrical Schematic, (CE)
81


84
Ground Control Box Terminal Strip Wiring Diagram, (CE)
85
Ground Control Box Terminal Strip Wiring Diagram, (CE)

Ground Control Box Switch Panel Wiring Diagram, (CE)

Ground Control Box Switch Panel Wiring Diagram, (CE)
88
Platform Control Box Wiring Diagram, (CE)
89
Platform Control Box Wiring Diagram, (CE)
Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT Servic e and R epair M anual Novem ber 2017

1268530

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Service and Repair Manual

Serial Number Range

For detailed maintenance

Part No. 1268530GT

Important Technical Publications

Compliance Find a Manual for this Model

ii Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC iii

Serial Number Legend

1 Model 4 Sequence number

1 Model 4 Serial label (located under cover)

iv Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Do Not Perform Maintenance

Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC v

Personal Safety Workplace Safety

vi Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Section 1 Safety Rules .......................................................................................................... v

Section 2 Specifications ....................................................................................................... 1

Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC vii

Section 3 Repair Procedures ............................................................................................. 11

Platform Controls ............................................................................................... 13

Platform Components ....................................................................................... 15

Jib Boom Components ...................................................................................... 19

Primary Boom Components ............................................................................. 22

Secondary Boom Components ........................................................................ 32

Hydraulic Pumps ................................................................................................ 39

viii Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Turntable Rotation Components ...................................................................... 47

Motor Controllers ............................................................................................... 48

Steer Axle Components ..................................................................................... 49

Section 4 Fault Codes ......................................................................................................... 51

Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC ix

Section 5 Schematics ......................................................................................................... 57

Electrical Schematics – Options ...................................................................... 61

Hydraulic Schematics ........................................................................................ 69

Electrical Schematics – ANSI / CSA / AS Models ......................................... 71

Electrical Schematics – CE Models ................................................................. 81

x Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Machine Specifications Performance Specifications

Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC 1

Hydraulic Oil Specifications Do not top off with incompatible

Note: Extended machine operation can cause the

2 Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC 3

Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid

Shell Tellus S4 VX Fluid

4 Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Hydraulic Component Manifold Component Specifications

Specifications Plug torque

Type: fixed displacement gear pump

Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC 5

Machine Torque Specifications

6 Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

Hydraulic Hose and Fitting SAE O-ring Boss Port

JIC 37° Fittings

Part No. 1268530GT Z®-45/25 DC • Z®-45/25J DC 7

Torque Procedure JIC 37° fittings

2 Lubricate the O-ring before installation.

5 Tighten the nut or fitting to the appropriate 1 hex nut

6 Operate all machine functions and inspect the

8 Z®-45/25 DC • Z®-45/25J DC Part No. 1268530GT

3 Working clockwise on the body hex fitting,

4 Tighten the hex nut until the mark on the hex