GineiBoomZ 45

Service and Repair Manual
Serial Number Range
Z®-45/25
from Z452513A-48153
to Z452516N-57199
This manual includes:
Repair procedures
Z®-45/25J
from Z4525N-57200
to Z4525N-58604
Fault Codes
Electrical and
from Z452513D
Hydraulic Schematics
Bi-Energy Power to Z452516D-939
from Z452515B-4574
to Z452516B-5452
from Z452516M-5453
to Z452516M-6699
For detailed maintenance
from Z4525F-58605
from Z4525D-940
procedures, refer to the
from Z4525M-6700 appropriate Maintenance
Manual for your machine.
Part No. 1268546GT

Rev A4
August 2023
Service and Repair Manual August 2023
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
1268546GT Rev A, September 2015
First Edition, First Printing
Genie and “Z” are registered trademarks of Terex South Dakota,
Inc. in the U.S.A. and many other countries.
ii Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

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

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. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 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 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

August 2023
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
Generator Specifications ........................................................................................ 6
Kubota Z482-E2B/E3B Engine Specifications ....................................................... 7
Hydraulic Hose and Fitting Torque Specifications ................................................. 8
Torque Procedure .................................................................................................. 9
SAE and Metric Fasteners Torque Charts ........................................................... 11
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy vii

August 2023
Table of Contents
Section 3 Repair Procedures ..............................................................................................12

Introduction ...........................................................................................................12
Platform Controls ...............................................................................................14

1-1 Controllers ......................................................................................................14
Platform Components ........................................................................................16

2-1 Platform Leveling Slave Cylinder ...................................................................16
How to Bleed the Slave Cylinder .....................................................................17
2-2 Platform Rotator .............................................................................................18
Jib Boom Components ......................................................................................20

3-1 Jib Boom.........................................................................................................20
3-2 Jib Boom Lift Cylinder ....................................................................................21
Primary Boom Components ..............................................................................23

4-1 Cable Track ....................................................................................................23
How to Remove the Cable Track, Z-45/25 ......................................................23
How to Remove the Cable Track, Z-45/25J ....................................................25
How to Repair the Primary Boom Cable Track ...............................................27
4-2 Primary Boom .................................................................................................27
How to Disassemble the Primary Boom ..........................................................29
4-3 Primary Boom Lift Cylinder.............................................................................30
4-4 Primary Boom Extension Cylinder .................................................................31
4-5 Platform Leveling Master Cylinder .................................................................32
Secondary Boom Components .........................................................................33

5-1 Secondary Boom ............................................................................................34
5-2 Secondary Boom Lift Cylinders ......................................................................39
Engines ................................................................................................................40
6-1 Timing Adjustment ..........................................................................................40
6-2 RPM Adjustment ............................................................................................40
6-3 Engine Drive Pulley ........................................................................................40
How to Remove the Engine Drive Pulley ........................................................40
How to Install the Engine Drive Pulley ............................................................41
viii Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

August 2023
Table of Contents
Generator ............................................................................................................ 43
7-1 Generator Pulley ............................................................................................ 43
How to Remove the Generator Pulley ............................................................ 43
How to Install the Generator Pulley ................................................................ 43
7-2 Generator Belts .............................................................................................. 44
7-3 Generator Voltage Regulator ......................................................................... 44
How to Adjust the Generator Voltage Regulator ............................................. 44
How to Replace the Voltage Regulator ........................................................... 45
Hydraulic Pumps ................................................................................................ 47

8-1 Auxiliary Pump ............................................................................................... 47
8-2 Function Pump ............................................................................................... 48
Manifolds ............................................................................................................. 49
9-1 Function Manifold Components ..................................................................... 49
9-2 Valve Adjustments - Function Manifold .......................................................... 51
How to Adjust the System Relief Valve ........................................................... 51
How to Adjust the Secondary Boom Down Relief Valve ................................. 51
9-3 Jib Boom / Platform Rotate Manifold Components ........................................ 52
9-4 Turntable Rotation Manifold Components ..................................................... 53
9-5 Valve Coils ..................................................................................................... 54
How to Test a Coil Diode ................................................................................ 54
Turntable Rotation Components ...................................................................... 56

10-1 Turntable Rotation Assembly ....................................................................... 56
Motor Controllers ............................................................................................... 57

11-1 Motor Controller ........................................................................................... 57
Steer Axle Components ..................................................................................... 58

12-1 Hub and Bearings ........................................................................................ 58
How to Remove the Hub and Bearings ........................................................... 58
How to Install the Hub and Bearings ............................................................... 58
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy ix

August 2023
Table of Contents
Section 4 Fault Codes .........................................................................................................60

Introduction ...........................................................................................................60
Fault Code Charts ...........................................................................................62
Section 5 Schematics ..........................................................................................................66

Introduction ...........................................................................................................66
Electrical Symbol Legend .....................................................................................67
Hydraulic Symbols Legend ...................................................................................68
Electrical Schematics – Options .......................................................................69

Platform Options Wiring Diagram .........................................................................70
Engine Panel Wiring Diagram ..............................................................................71
Power Panel Wiring Diagram ...............................................................................74
CTE Option Wiring Diagram, (CE)........................................................................75
Charger Interlock Option ......................................................................................78
Hydraulic Schematics ........................................................................................79

Hydraulic Schematic .............................................................................................80
Electrical Schematics – ANSI and CSA Models ..............................................81

Electrical Schematic, (ANSI / CSA) ......................................................................82
Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA) .....................86
Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA) .......................87
Platform Control Box Wiring Diagram, (ANSI / CSA) ...........................................90
Electrical Schematics – CE Models ..................................................................91

Electrical Schematic, (CE) ....................................................................................92
Ground Control Box Terminal Strip Wiring Diagram, (CE) ...................................96
Ground Control Box Switch Panel Wiring Diagram, (CE) ....................................97
Platform Control Box Wiring Diagram, (CE) .......................................................100
Electrical Schematics – AS Models ................................................................101

Electrical Schematic, (AS) ..................................................................................102
Ground Control Box Terminal Strip Wiring Diagram, (AS) .................................106
Ground Control Box Switch Panel Wiring Diagram, (AS) ...................................107
Platform Control Box Wiring Diagram, (AS) .......................................................110
x Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

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
Tread 8 4.8 km/h
Tire ply rating
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 33 to 39 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
Fuel tank 9 gallons
34.1 liters Primary boom extend 14 to 18 seconds
Hydraulic tank 8 gallons Primary boom retract 17 to 21 seconds
30.3 liters Secondary boom up 38 to 46 seconds
Hydraulic system (including 11 gallons Secondary boom down 38 to 46 seconds
tank) 41.6 liters
Turntable rotate, 355ø 95 to 125 seconds
Drive hubs (refer to tag on drive hub to determine type) primary boom retracted
EW1 type 17 fl oz Platform rotate, 180°, Z-45/25 6 to 10 seconds
503 cc
Platform rotate, 160°, Z-45/25J 6 to 10 seconds
W1 type 23 fl oz
680 cc For operational specifications, refer to the
Turntable rotation drive hub 25.5 fl oz Operator's Manual.
750 cc
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
Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 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 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

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
SAE No. 6 14 ft-lbs / 19 Nm
Displacement per 0.183 cu in
revolution 3 cc SAE No. 8 38 ft-lbs / 51 Nm
Flow rate 2.1 gpm SAE No. 10 41 ft-lbs / 55 Nm

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 Generator

Platform Rotator Generator output with engine @ 3000 rpm 54V DC,
100A
3/4 -10 center bolt, GR 8 380 ft-lbs
515 Nm Generator pulley to engine pulley offset, 1/16 inch
maximum 1.6 mm
3/8 -16 bolts, GR 8 44 ft-lbs
60 Nm Belt deflection, maximum 1/4 inch
6.5 mm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs
244 Nm Generator Torque Specifications
Drive motor/brake mounting bolts, dry 110 ft-lbs
149 Nm Generator pulley retaining nut torque 80-90 ft-lbs
108-122 Nm
Drive motor/brake mounting bolts, 80 ft-lbs
lubricated 108 Nm Engine pulley retaining bolts 108 in-lbs
12.2 Nm
Drive motors and hubs
#10 screw 25 in-lbs
Drive hub mounting bolts, lubricated 180 ft-lbs 2.8 Nm
244 Nm
#10 nut 25 in-lbs
Drive motor mounting bolts, lubricated 55 ft-lbs 2.8 Nm
75 Nm
#4 nut 8-10 in-lbs
0.9-1.1 Nm
Voltage regulator mounting fasteners 25 in-lbs
2.8 Nm

Specifications
Kubota Z482-E2B Engine Fuel requirement

Kubota Z482-E3B Engine For fuel requirements, refer to the engine Operator
Manual for your engine.
Displacement 29.23 cu in Injection system
0.48 liters
Injection pump make Bosch MD
Number of cylinders 2
Injection timing 21° BTDC
Bore and Stroke 2.64 x 2.68 inches
Injection pump pressure 1991 psi
67 x 68 mm
137 bar
Horsepower 13.3 @ 3600 rpm
9.9 kW Starter motor
Brush length, new 0.5188 in
Firing order 1-2
13 mm
Low idle 2000 rpm
Brush length, minimum 0.3346 in
High idle 3000 rpm 8.5 mm
Governor centrifugal mechanical Alternator
Valve clearance, cold 0.0057 to 0.0072 in Alternator output 12V DC, 150 watts
0.145 to 0.185 mm
Fan belt deflection 1/4 to 3/8 inch
Compression ratio 23:1 7 to 9 mm
Compression pressure 412 to 469 psi Battery
28.4 to 32.3 bar
Type 12V DC, Group 70
Lubrication system Quantity 1
Oil pressure 36 to 64 psi Cold cranking ampere 450A
2.48 to 4.41 bar
Reserve capacity @ 25A rate 125 minutes
Oil capacity (including filter)
Z482-E2B 2.2 quarts
2.1 liters
Z482-E3B 2.6 quarts
2.5 liters
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.

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
-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
-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
-10 7/8-14 1 37° (Non-adj) 22 ft-lbs / 30 Nm
-12 1 1/16-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm

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 0.54 to 0.55A

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 Slave Cylinder

How to Bleed the Sl av e Cylinder
9 Use a soft metal drift to drive the rod-end pivot

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
toggle switches until the primary boom is fully
by the lifting device.
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 Rotator
The platform should be facing in a down
position. As shown. 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
two platform rotation cycles, then hold the
switch to the right position until the platform is
Z45/25 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
gradually. Do not allow oil to
Z45/25J 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
18 Attach a lifting strap from an overhead crane 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
supported by the overhead
crane.
7 Attach a lifting strap from an overhead 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 the oil pressure to dissipate
cable track to the platform control box. gradually. Do not allow oil to
Number each cable and its entry location at squirt or spray.
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 connections very slowly to allow
position. the oil pressure to dissipate
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.
gradually. Do not allow oil to 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.

How to Remove the Cable Track,

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

Z-45/25J burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting, connections very slowly to allow
the O-ring (if equipped) on the fitting and/or hose the oil pressure to dissipate
end must be replaced. All connections must be gradually. Do not allow oil to
torqued to specification during installation. Refer to squirt or spray.
Specifications, Hydraulic Hose and Fitting Torque
Specifications. 8 Tag, disconnect and plug the hydraulic hoses
from the jib boom/platform rotate manifold.
1 Locate the cables from the primary boom Cap the fittings on the manifold.
cable track to the platform control box.
Number each cable and its entry location at Bodily injury hazard. Spraying
the platform control box. hydraulic oil can penetrate and
2 Disconnect the cables from the platform connections very slowly to allow
control box. the oil pressure to dissipate
3 Remove the hose and cable cover from the gradually. Do not allow oil to
side of the jib boom. Remove the hose and squirt or spray.
cable separators.
9 Tag, disconnect and plug the platform rotator
4 Remove the hose clamp on the primary boom hydraulic hoses at the union located above the
bellcrank. primary boom lift cylinder. Cap the fittings on
5 Pull all of the electrical cables out of the plastic the unions.
cable track. Do not pull out the hydraulic Bodily injury hazard. Spraying
hoses. hydraulic oil can penetrate and
6 Tag, disconnect and plug the hydraulic hoses burn skin. Loosen hydraulic
from the "V1" and "V2" ports on the connections very slowly to allow
counterbalance valve manifold located on the the oil pressure to dissipate
platform rotator. Cap the fittings on the gradually. Do not allow oil to
manifold. squirt or spray.
Bodily injury hazard. Spraying 10 Tag, disconnect and plug the hydraulic hoses
hydraulic oil can penetrate and from the platform leveling master cylinder.
burn skin. Loosen hydraulic Cap the fittings on the cylinder.
the oil pressure to dissipate Bodily injury hazard. Spraying
gradually. Do not allow oil to hydraulic oil can penetrate and
squirt or spray. burn skin. Loosen hydraulic
7 Tag and disconnect the hydraulic hoses from the oil pressure to dissipate
the platform leveling slave cylinder at the gradually. Do not allow oil to
union and connect them together using a squirt or spray.
connector. Connect the hoses from the
cylinder together using a connector.


11 Raise the boom to a horizontal position. 21 Raise the rod end of the primary boom lift
cylinder back into position and install the
12 Place blocks between the upper and lower
rod-end pivot pin. Install the pin retaining
cable tracks and secure the upper and lower
fasteners.
tracks together.
22 Attach a strap from an overhead crane to the
Crushing hazard. If the upper cable track.
and lower cable tracks are not
properly secured together, the 23 Remove the mounting fasteners from the
cable track could become upper cable track at the platform end of the
unbalanced and fall when extension boom.
removed from the machine. 24 Remove the cable track mounting fasteners
that attach the lower cable track to the primary
13 Attach a lifting strap from an overhead 5 ton / boom.
5,000 kg capacity crane to the platform end of
the primary boom for support. Do not lift it. 25 Remove the cable track from the machine and
place it on a structure capable of supporting it.
14 Remove all hose and cable clamps from the
underside of the primary boom. Crushing hazard. The cable
track could become
15 Support the rod end of the primary boom lift
cylinder with a suitable lifting device.
16 Remove the pin retaining fasteners from the overhead crane.
primary boom lift cylinder rod-end pivot pin. Do
not remove the pin. Component damage hazard.
17 Raise the primary boom slightly with the Cables and hoses can be
overhead crane to relieve the pressure on the damaged if they are kinked or
primary boom lift cylinder rod-end pivot pin. pinched.
18 Use a soft metal drift to remove the primary

boom lift cylinder rod-end pivot pin.
Crushing hazard. The primary
boom lift cylinder could become
properly supported by the lifting
device.
19 Lower the rod end of the primary boom lift

cylinder approximately 12 inches / 30 cm.
20 Pull all of the hoses and cables out and away
from the mounting ears for the rod end of the
primary boom lift cylinder.

How to Repair the Primary Boom 4-2

How to R epair the Primary Boom C abl e Tr ack
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.
Component damage hazard. 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
cylinder rod from damage.
speed limit switch inside of the extension
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
structure capable of supporting it.
extension tube and move it out of the way.
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 Disassemble the Primary

How to Dis ass embl e the Primary Boom
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
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 gradually. Do not allow oil to
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.
skills, lifting equipment and a
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
3 Attach a 5 ton / 5000 kg overhead crane to the remove the pin.
primary boom for support. 11 Use a slide hammer to remove the barrel-end
4 Raise the primary boom with the overhead pivot pin. Carefully remove the primary boom
crane slightly to take the pressure off the lift cylinder from the machine.
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 Cylinder fittings on the cylinder.
The primary boom extension cylinder extends and Bodily injury hazard. Spraying
retracts the primary boom extension tube. The hydraulic oil can penetrate and
primary boom extension cylinder is equipped with burn skin. Loosen hydraulic
counterbalance valves to prevent movement in the connections very slowly to allow
event of a hydraulic line failure. the oil pressure to dissipate
How to Remove the Primary squirt or spray.
Boom Extension Cylinder 5 At the platform end of the boom, remove the
external snap rings from the extension
Bodily injury hazard. This cylinder rod-end pivot pin. Use a soft metal
procedure requires specific repair
drift to remove the pin.
skills, lifting equipment and a
suitable workshop. Attempting 6 Remove the barrel-end pivot pin retaining
this procedure without these skills fasteners.
7 Place a rod through the barrel-end pivot pin
and twist to remove the pin.
service is strongly recommended. 8 Support and slide the extension cylinder out of
the upper pivot.
the O-ring (if equipped) on the fitting and/or hose Crushing hazard. The extension
end must be replaced. All connections must be cylinder could fall when removed
torqued to specification during installation. Refer to from the extension boom if not
Specifications, Hydraulic Hose and Fitting Torque properly supported.
Specifications.
Component damage hazard. Be
1 Raise the primary boom to a horizontal careful not to damage the
position. counterbalance valves on the
2 Extend the primary boom until the primary primary boom extension cylinder
boom extension cylinder rod-end pivot pin is when removing the cylinder from
accessible in the primary boom extension the primary boom.
tube.
3 Remove the hose and cable guard from the Hoses and cables can be
upper pivot. damaged if the primary boom
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
The master cylinder acts as a pump for the slave and twist to remove the pin.
cylinder. It’s part of the closed circuit hydraulic loop
that keeps the platform level through the entire 6 Remove the pin retaining fastener from the
range of boom motion. The master cylinder is rod-end pivot pin.
located at the base of the primary boom. 7 Place a rod through the rod-end pivot pin and
twist to remove the pin.
How to Remove the Platform 8 Remove the master cylinder from the
Leveling Master Cylinder machine.
Note: When removing a hose assembly or fitting, Crushing hazard. The master
the O-ring (if equipped) on the fitting and/or hose cylinder could become
end must be replaced. All connections must be unbalanced and fall if not
torqued to specification during installation. Refer to properly attached to the
Specifications, Hydraulic Hose and Fitting Torque overhead crane.
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
19 Use a soft metal drift to drive both pins out.
down.
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. 33 Remove the pin retaining fasteners from the
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
Component damage hazard. 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.
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.
Crushing hazard. The number 3
and fall when removed from the
machine if not properly
supported by the overhead
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
pivot pin half way out. Lower the barrel end of
the secondary boom lift cylinder and let it hang
down.
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.

Engines
6-1 6-3
Timing Adjustment Engine Drive Pulley
How to R emove the Engi ne Drive Pulley
Complete information to perform this procedure is

available in the Kubota Z482-E2B Workshop
Manual (Kubota part number 97897-01165). How to Remove the Engine Drive
Kubota Z482-E3B Operator's Manual (Kubota part Pulley
number 1G689-89160).
1 Remove the engine pivot plate latch retainer.
Kubota Z482-E2B Workshop Manual 2 Open the engine pivot plate latch and swing
Genie part number 52956 the engine out away from the machine to
Kubota Z482-E3B Operator's Manual access the engine drive pulley.
Genie part number 139420 3 Loosen the tension adjustment bolt on the
generator.
4 Pull the generator away from the machine and
6-2 remove the belts from the generator pulley.
RPM Adjustment 5 Remove the 3 bolts that attach the engine
drive pulley to the shaft bushing.
Refer to Maintenance Procedure in the appropriate
Service or Maintenance Manual for your machine, 6 Install the same 3 bolts that were removed in
Check and Adjust the Engine RPM. step 5 into the threaded holes of the engine
drive pulley.

Engines
How to Install the Engine Drive

How to Ins tall the Engi ne Drive Pull ey
7 Carefully tighten each bolt evenly until the

engine drive pulley slides off the shaft.
Pulley
Component damage hazard. Note: The generator pulley must already be
The engine drive pulley and/or installed before performing this procedure. Refer to
shaft can be damaged if the bolts Repair Procedure, How to Install the Generator
are not tightened evenly. Pulley.
8 Loosen the set screw on the pulley bushing, 1 Align the woodruff key on the engine shaft with
then slide the pulley bushing off of the engine the slot in the pulley bushing and slide the
shaft. pulley bushing onto the engine shaft. Do not
tighten the set screw.
2 Align the flywheel side of the pulley bushing on
the engine shaft with the outer face of the
generator pulley using a straightedge.
1 gap
2 shaft
3 set screw
4 engine drive pulley
5 engine drive pulley bolt
6 shaft bushing
7 woodruff key
1 pulley shaft
2 pulley bushing
3 engine flywheel
4 straightedge
5 generator pulley
6 generator

Engines
3 Tighten the set screw on the pulley bushing 6 Check the alignment between the engine drive
hand tight. pulley and the generator pulley using a
straightedge. Refer to Specifications,
4 Slide the engine pulley onto the pulley
Generator.
bushing.
Note: If the pulley alignment is not within
5 Install the pulley mounting bolts and tighten
specification, remove the engine pulley and repeat
them to specification. Refer to Specifications,
steps 2 through 6. Refer to Repair Procedure, How
Generator Specifications.
to Remove the Engine Drive Pulley.
Component damage hazard. Do
not overtighten the pulley
mounting bolts. There must be a
gap visible between the engine
drive pulley and the pulley
bushing.
1 gap
2 shaft
3 set screw
4 engine drive pulley
5 engine drive pulley bolt
6 shaft bushing
7 woodruff key

Generator
How to Install the Generator

How to Ins tall the Generator Pull ey
7-1
Generator Pulley Pulley
How to R emove the Generator Pulley
Note: The pulley on the generator must be installed

How to Remove the Generator before installing the engine drive pulley.
Pulley 1 Align the woodruff key on the generator shaft

with the slot in the pulley and slide the pulley
1 Remove the engine pivot plate latch retainer. all the way onto the generator shaft.
2 Open the engine pivot plate latch and swing 2 Install the flat washer and pulley retaining nut
the engine out away from the machine to onto the generator shaft, then torque the nut to
access the generator pulley. specification. Refer to Specifications,
3 Loosen the tension adjustment bolt on the Generator.
generator. 3 Adjust the tension of the generator belts. Refer
4 Pull the generator away from the machine and to Repair Procedure, How to Adjust the
remove the belts from the generator pulley. Generator Belts.
5 Disconnect the battery cables from the engine
battery.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
6 Remove the engine battery hold down, then

remove the battery from the machine.
7 Remove the generator pulley retaining nut
from the generator shaft.
8 Slide the pulley off of the generator shaft.

Generator
7-2 7-3
Generator Belts Generator Voltage Regulator
w to Adjus t the Gener ator Voltage R egul ator
How to Adjust the Generator Belts How to Adjust the Generator

1 Disconnect the battery packs. Voltage Regulator
Electrocution/burn hazard. The voltage regulator regulates the output voltage
Contact with electrically charged of the generator. A properly adjusted voltage
circuits could result in death or regulator is essential to good generator
serious injury. Remove all rings, performance and service life. A defective or
watches and other jewelry. improperly adjusted voltage regulator could result
in component damage.
2 Remove the engine pivot plate latch retainer. Note: Be sure the batteries are fully charged before
3 Open the engine pivot plate latch and swing performing this procedure.
the engine out away from the machine to
access the generator belts. 1 Remove the engine pivot plate latch retainer.
4 Loosen the tension adjustment bolt on the 2 Open the engine pivot plate latch and swing
generator. the engine out away from the machine to
access the generator.
5 Push the generator towards the machine and
tighten the adjustment bolt. 3 Connect the positive lead of a voltmeter to the
pos terminal on the generator and the
6 Check the generator belts for proper tension. negative lead of the voltmeter to the neg
Refer to Specifications, Generator. If the belt terminal on the generator.
deflection is not within specification, perform
steps 4 and 5 and re-check the belt tension. Electrocution/burn hazard.
1 engine pulley
2 generator belts
3 generator pulley

Generator
How to Replace the Voltage

How to R eplac e the Voltage Regulator
4 Start the engine from the ground controls and

move the rpm select toggle switch to the
maintained high idle position. Check the
Regulator
voltage on the generator. 1 Disconnect the battery packs from the
machine.
Result: The voltage should be 54V DC.
5 If the voltage reading is not 54V DC, insert a Electrocution/burn hazard.
small flat blade screwdriver into the Contact with electrically charged
potentiometer located inside of the generator. circuits could result in death or
Use the access hole on the back of the serious injury. Remove all rings,
generator labeled volt adj. watches and other jewelry.
Component damage hazard. Be 2 Remove the engine pivot plate latch retainer.
sure that the screwdriver is
3 Open the engine pivot plate latch and swing
properly inserted into the
the engine out away from the machine to
potentiometer or the generator
access the generator.
and/or voltage regulator may
become damaged. 4 Tag and disconnect the positive and negative
battery cables from the generator.
6 Carefully adjust the potentiometer to obtain a
54V DC voltage reading. Turn the 5 Loosen the tension adjustment bolt on the
potentiometer clockwise to increase the generator.
voltage or counterclockwise to decrease the 6 Pull the generator away from the machine and
voltage. Do not rotate the potentiometer past remove the belts from the generator pulley.
the internal stops.
7 Remove the generator mounting fasteners
Component damage hazard. then remove the generator from the machine.
The voltage regulator inside the
8 Remove the 3 nuts from the battery cable
generator will become
terminal posts.
damaged if the potentiometer is
rotated past the internal stops. 9 Remove the 3 screws that hold the plastic
cover onto the generator. Carefully remove
Note: The maximum range of motion of the the cover.
potentiometer on the voltage regulator is 280° and
the maximum allowed torque is 5 oz-in / 0.035 Nm.

Generator
10 Locate the 3 white wires that lead from the 12 Locate the red wire that leads from the voltage
voltage regulator to the negative rectifier regulator to the positive rectifier assembly.
assembly.
13 Remove the screw that attaches the red wire
to the positive rectifier assembly.
14 Remove the #4 nut that attaches the black
wire to the voltage regulator.
15 Remove the voltage regulator mounting
screws.
16 Remove the voltage regulator while carefully
guiding the red and black wires from
underneath the bottom support of the positive
and negative rectifier assembly.
17 Install the new voltage regulator by following
the previous steps in reverse order.
18 Apply Loctite® removable thread sealant onto
the voltage regulator mounting fasteners and
torque to specification. Refer to Specifications,
Machine Torque Specifications.
1 white wires (#10 nuts) 19 Torque all other fasteners to specification.

2 negative rectifier assembly Refer to Specifications, Machine Torque
3 black wire (#10 screw)
Specifications.
4 black wire (#4 nut) 20 Install the plastic cover onto the generator
5 voltage regulator mounting fastener (#8 then install the generator onto the machine.
screw)
21 Adjust the generator belts. Refer to repair
6 voltage regulator
procedure, How to Adjust the Generator Belts.
7 red wire (#10 screw)
8 positive rectifier assembly 22 Adjust the voltage regulator. See How to
Adjust the Voltage Regulator.
11 Remove the nuts on those 3 wires from the
negative rectifier assembly, then remove the Component damage hazard.
wires. The voltage regulator and/or
generator may become
Note: Do not remove the spacers from the damaged if the voltage
underneath the wires on the negative rectifier regulator is not properly
assembly. adjusted after replacement

Hydraulic Pumps
8-1 2 Models without hydraulic tank shutoff

valves: Remove the drain plug from the
Auxiliary Pump hydraulic tank and completely drain the tank
into a container of suitable capacity. Refer to
How to Remove the Auxiliary Specifications, Machine Specifications.
Pump Bodily injury hazard. Beware of

hot oil. Contact with hot oil may
Note: When removing a hose assembly or fitting, cause severe burns.
end must be replaced. All connections must be 3 Remove the engine pivot plate latch retainer.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 4 Open the engine pivot plate latch and swing
Specifications. the engine pivot plate out away from the
machine.
1 Models with hydraulic tank shutoff valves:
Locate the two hydraulic tank valves at the 5 Tag, disconnect and plug the hydraulic hoses
hydraulic tank through the access hole from the auxiliary pump.
underneath the turntable. Close the valves. Bodily injury hazard. Spraying
squirt or spray.
6 Remove the auxiliary pump mounting bolts.

Carefully remove the pump.
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.

Hydraulic Pumps
8-2 2 Models without hydraulic tank shutoff

valves: Remove the drain plug from the
Function Pump hydraulic tank and completely drain the tank
into a container of suitable capacity. Refer to
How to Remove the Function Specifications, Machine Specifications.
Pump Bodily injury hazard. Beware of
hot oil. Contact with hot oil may
cause severe burns.
end must be replaced. All connections must be 3 Remove the engine pivot plate latch retainer.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 4 Open the engine pivot plate latch and swing
Specifications. the engine pivot plate out away from the
machine.
1 Models with hydraulic tank shutoff valves:
Locate the two hydraulic tank valves at the 5 Tag, disconnect and plug the hydraulic hoses
hydraulic tank through the access hole from the pump.
underneath the turntable. Close the valves. Bodily injury hazard. Spraying
squirt or spray.
6 Remove the function pump mounting bolts.

open closed
Carefully remove the pump.

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.

Manifolds
9-1
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
9-2 Valve Adjustments - Function How to Adjust the Secondary

How to Adj ust the Sec ondary Boom D own R elief Valv e
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
Note: Refer to Function Manifold Component list to manifold.
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
clockwise to increase the pressure or Tip-over hazard. Do not adjust
counterclockwise to decrease the pressure. the relief valve higher than
Install the relief valve cap. specified.
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
9-3
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
9-4
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 Shuttle valve 2 position 3 way X Turntable rotation brake 10-13 ft-lbs / 14-18 Nm
release
2 Counterbalance valve Y Turntable rotate right 30-35 ft-lbs / 41-47 Nm
3 Counterbalance valve Z Turntable rotate left 30-35 ft-lbs / 41-47 Nm

Manifolds
9-5 How to Test a Coil Diode

How to T est a Coil Di ode
Valve Coils Properly functioning coil diodes protect the

electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
How to Test a Coil circuit following the interruption of electrical current
A properly functioning coil provides an to a coil. Faulty diodes can fail to protect the
electromotive force which operates the solenoid electrical system, resulting in a tripped circuit
valve. Critical to normal operation is continuity breaker or component damage.
within the coil that provides this force field.
Electrocution/burn hazard. Contact with electrically charged
Contact with electrically charged circuits could result in death or
circuits could result in death or serious injury. Remove all rings,
serious injury. Remove all rings, watches and other jewelry.
1 Test the coil for resistance. Refer to Repair
1 Tag and disconnect the wiring from the coil to Procedure, How to Test a Coil.
be tested. 2 Connect a 10Ω resistor to the negative
2 Test the coil resistance. terminal of a known good 9V DC battery.
Connect the other end of the resistor to a
Result: The resistance should be within terminal on the coil.
specification, plus or minus 30%.
Resistor, 10Ω
Result: If the resistance is not within
specification, plus or minus 30%, replace the Genie part number 27287
coil. Note: The battery should read 9V DC or more when
measured across the terminals.
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)

Manifolds
6 At the battery or coil terminals, reverse the

connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
1 multimeter
2 9V DC battery
3 10Ω resistor
4 coil
Note: Dotted lines in illustration indicate a reversed

connection as specified in step 6.
3 Set a multimeter to read DC current.
Note: The multimeter, when set to read DC current,
should be capable of reading up to 800 mA.
4 Connect the negative lead to the other
terminal on the coil.
5 Momentarily connect the positive lead from
the multimeter to the positive terminal on the
9V DC battery. Note and record the current
reading.

Turntable Rotation Components
10-1 7 Place a suitable container under the engine

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

Motor Controllers
11-1 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
malfunctions and display controller fault codes by Result: All desired results must be within the
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
manual for a list of fault codes and additional controller.
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
Positive Lead Negative Lead
Department.
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
1 Turn the key switch to the off position and Reverse Bias:
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
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 Install the Hub and

How to Ins tall the H ub and Bearings
12-1 Hub and Bearings

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
Section 4 Faul t Codes
Before Troubleshooting:
 Be sure that all necessary tools and test
Observe and Obey: equipment are available and ready for use.
 Troubleshooting and repair procedures shall  Read each appropriate fault code thoroughly.
be completed by a person trained and qualified Attempting short cuts may produce hazardous
on the repair of this machine conditions.
 Immediately tag and remove from service a  Be aware of the following hazards and follow
damaged or malfunctioning machine. generally accepted safe workshop practices.
 Repair any machine damage or malfunction Electrocution/burn hazard.
before operating the machine. Contact with electrically charged
 Unless otherwise specified, perform each serious injury. Remove all rings,
procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface Note: Two persons will be required to safely
perform some troubleshooting procedures.
• 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
Tip-over hazard. When blinks 1 time. That would indicate Fault Code 41.
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.

This page intentionally left blank.

Schematics
About This Section

Section 5 Schem atics
There are two groups of schematics in this section.
Electrical Schematics
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 burn skin. Loosen hydraulic
before operating the machine.
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

Platform Options Wiring Diagram
69
Platform Options Wiring Diagram

Engine Panel Wiring Diagram

Engine Panel Wiring Diagram
72
Power Panel Wiring Diagram
73
Power Panel Wiring Diagram

CTE Option Wiring Diagram, (CE)

CTE Option Wiring Diagram, (CE)
76
Charger Interlock Option
77
Charger Interlock Option

Hydraulic Schematic
79
Hydraulic Schematic

Electrical Schematic, (ANSI / CSA)
81


84
Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA)
85
Ground Control Box Terminal Strip Wiring Diagram, (ANSI / CSA)

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

Ground Control Box Switch Panel Wiring Diagram, (ANSI / CSA)
88
Platform Control Box Wiring Diagram, (ANSI / CSA)
89
Platform Control Box Wiring Diagram, (ANSI / CSA)

Electrical Schematic, (CE)
91


94
Ground Control Box Terminal Strip Wiring Diagram, (CE)
95
Ground Control Box Terminal Strip Wiring Diagram, (CE)

Ground Control Box Switch Panel Wiring Diagram, (CE)

Ground Control Box Switch Panel Wiring Diagram, (CE)
98
Platform Control Box Wiring Diagram, (CE)
99
Platform Control Box Wiring Diagram, (CE)

Electrical Schematic, (AS)
101


104
Ground Control Box Terminal Strip Wiring Diagram, (AS)
105
Ground Control Box Terminal Strip Wiring Diagram, (AS)

Ground Control Box Switch Panel Wiring Diagram, (AS)

Ground Control Box Switch Panel Wiring Diagram, (AS)
108
Platform Control Box Wiring Diagram, (AS)
109
Platform Control Box Wiring Diagram, (AS)
Z®-45/25 Bi-Ener gy • Z ®-45/25J Bi-Energy Part No. 1268546GT Servic e and R epair M anual August 2023

GineiBoomZ 45

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Service and Repair Manual

Serial Number Range

Part No. 1268546GT

Important Technical Publications

Compliance Find a Manual for this Model

ii Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy iii

Serial Number Legend

1 Model 4 Sequence number

1 Model 4 Serial label (located under cover)

iv Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

Do Not Perform Maintenance

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy v

Personal Safety Workplace Safety

vi Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

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

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

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy vii

Section 3 Repair Procedures ..............................................................................................12

Platform Controls ...............................................................................................14

Platform Components ........................................................................................16

Jib Boom Components ......................................................................................20

Primary Boom Components ..............................................................................23

Secondary Boom Components .........................................................................33

viii Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

Hydraulic Pumps ................................................................................................ 47

Turntable Rotation Components ...................................................................... 56

Motor Controllers ............................................................................................... 57

Steer Axle Components ..................................................................................... 58

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy ix

Section 4 Fault Codes .........................................................................................................60

Section 5 Schematics ..........................................................................................................66

Electrical Schematics – Options .......................................................................69

Hydraulic Schematics ........................................................................................79

Electrical Schematics – ANSI and CSA Models ..............................................81

Electrical Schematics – CE Models ..................................................................91

Electrical Schematics – AS Models ................................................................101

x Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

Machine Specifications Performance Specifications

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 1

Hydraulic Oil Specifications Do not top off with incompatible

Note: Extended machine operation can cause the

2 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 3

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

Shell Tellus S4 VX Fluid

4 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

Hydraulic Component Manifold Component Specifications

Flow rate 2.1 gpm SAE No. 10 41 ft-lbs / 55 Nm

Type: fixed displacement gear pump

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 5

Machine Torque Specifications Generator

6 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

Kubota Z482-E2B Engine Fuel requirement

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 7

Hydraulic Hose and Fitting SAE O-ring Boss Port

JIC 37° Fittings

-12 1 1/16-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm

8 Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy Part No. 1268546GT

Torque Procedure JIC 37° fittings

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

Part No. 1268546GT Z®-45/25 Bi-Energy • Z®-45/25J Bi-Energy 9