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Service and Repair ManualSerial Number RangeZ -45XCZ -45 HFfrom Z4525XCF-101from Z4525XCM-101This manual includes:Repair proceduresFault CodesElectrical andHydraulic SchematicsFor detailed maintenanceprocedures, refer to theappropriate MaintenanceManual for your machine.Part No. 1268197GTRev ENovember 2020
Service and Repair ManualNovember 2020IntroductionIntr oducti onIntr oducti onImportantTechnical PublicationsRead, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anyprocedure.Genie has endeavored to deliver the highestdegree of accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject tochange without notice.This manual provides troubleshooting and repairprocedures for qualified service professionals.Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealer servicecenter.Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.Contact Us:Internet: www.genielift.comE-mail: awp.techpub@terex.comFind a Manual for this ModelComplianceGo to http://www.genielift.comMachine ClassificationUse the links to locate Service Manuals,Maintenance Manuals, Service and RepairManuals, Parts Manuals and Operator's Manuals.Group B/Type 3 as defined by ISO 16368Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.Copyright 2017 by Terex Corporation1268197GT Rev E, November 2020First Edition, Fifth PrintingGenie and "Z" are registered trademarks of Terex SouthDakota, Inc. in the U.S.A. and many other countries."XC" is a trademark of Terex South Dakota, Inc.iiZ -45 XC Z -45 HFPart No. 1268197GT
November 2020Service and Repair ManualIntroductionRevision rocedure / Page / DescriptionInitial ReleaseFault CodesControl System Fault CodesSpecificationsHydraulic Component SpecificationsRepairFunction Manifold ComponentsSchematicsHydraulic Schematic,RepairProcedure 2-3, 2-4Fault CodesIntroduction, Control System and Platform Overload FaultCodesSchematicsHour Meter Pin LegendB9/2017SchematicsAdd wiring diagramsB111/2017SpecificationsMachine SpecificationsB26/2018SchematicsGCON Terminal Strip Wiring DiagramC1/2019SpecificationsAdded ANSI / CSA enginesSchematicsAdded ANSI / CSA SchematicsSpecificationsMachine SpecificationsRepairProcedure 2-3All SectionsAdd Deutz TD 2.2 L3 engineDE10/201911/2020Reference Examples:Electronic VersionClick on any content or procedure in the Table of Contents to viewthe update.Section – Repair Procedure, 4-2Section – Fault Codes, All chartsSection – Schematics, Legends and schematicsPart No. 1268197GTZ -45 XC Z -45 HFiii
Service and Repair ManualNovember 2020Safety RulesSection 1Safety R ulesDangerFailure to obey the instructions and safety rules inthis manual and the appropriate Operator's Manualon your machine will result in death or seriousinjury.Many of the hazards identified in the operator'smanual are also safety hazards whenmaintenance and repair procedures areperformed.Do Not Perform MaintenanceUnless: You are trained and qualified to performmaintenance on this machine. You read, understand and obey: manufacturer's instructions and safety rules employer's safety rules and worksiteregulations applicable governmental regulations You have the appropriate tools, liftingequipment and a suitable workshop.ivZ -45 XC Z -45 HFPart No. 1268197GT
November 2020Service and Repair ManualSafety RulesPersonal SafetyWorkplace SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.Any person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:Safety alert symbol—used toalert personnel to potentialpersonal injury hazards. Obey allsafety messages that follow thissymbol to avoid possible injury ordeath.Indicates a imminently hazardoussituation which, if not avoided,will result in death or seriousinjury.Indicates a potentially hazardoussituation which, if not avoided,could result in death or seriousinjury.Indicates a potentially hazardoussituation which, if not avoided,may cause minor or moderateinjury.Indicates a potentially hazardoussituation which, if not avoided,may result in property damage.Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.Be sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have anapproved fire extinguisher within easyreach.Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and freeof debris that could get into machinecomponents and cause damage.Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted. Use only chains orstraps that are in good condition and ofample capacity.Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second time.Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.Be sure that your workshop or work areais properly ventilated and well lit.Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting orplacing loads. Always wear approvedsteel-toed shoes.Part No. 1268197GTZ -45 XC Z -45 HFv
November 2020Table of ContentsIntroductionIntroduction . iiImportant Information . iiFind a Manual for this Model. iiRevision History . iiiSection 1Safety Rules. ivGeneral Safety Rules . ivSection 2Specifications . 1Machine Specifications . 1Performance Specifications . 2Hydraulic Oil Specifications . 2Hydraulic Component Specifications . 5Deutz D 2.9 L4 Engine Specifications . 7Deutz TD 2.2 L3 Engine Specifications . 8Deutz D2011 L03i Engine Specifications . 9Perkins 404D-22 Engine Specifications . 10Perkins 404F-E22T Engine Specifications . 11Ford MSG-425 EFI Engine Specifications . 12Machine Torque Specifications . 13Hydraulic Hose and Fitting Torque Specifications . 13Torque Procedure . 15viZ -45 XC Z -45 HFPart No. 1268197GT
November 2020Table of ContentsSection 3Repair Procedures . 17Introduction . 17Platform Controls . 191-1 ALC-500 Circuit Board . 191-2 Joysticks . 20How to Adjust the Joystick Max-out Setting . 20How to Adjust the Joystick Ramp Rate Setting . 21How to Adjust the Joystick Threshold Setting . 23Platform Components . 242-1 Platform Leveling Slave Cylinder . 24How to Bleed the Slave Cylinder . 252-2 Platform Rotator . 252-3 Platform Overload System . 26How to Replace the Platform Overload Load Cell . 292-4 Platform Overload Recovery Fault . 29Jib Boom Components . 303-1 Jib Boom . 303-2 Jib Boom Lift Cylinder . 31Primary Boom Components . 334-1 Cable Track . 33How to Remove the Cable Track . 33How to Repair the Primary Boom Cable Track . 354-2 Primary Boom . 35How to Disassemble the Primary Boom . 374-3 Primary Boom Lift Cylinder . 384-4 Primary Boom Extension Cylinder . 394-5 Platform Leveling Master Cylinder . 40Secondary Boom Components . 415-1 Secondary Boom . 425-2 Secondary Boom Lift Cylinders . 46Part No. 1268197GTZ -45 XC Z -45 HFvii
November 2020Table of ContentsEngines . 476-1 RPM Adjustment - Deutz D2011L03i Models . 476-2 RPM Adjustment - Perkins 404D-22 Models . 476-3 Flex Plate . 47How to Install the Flex Plate . 49How to install the Pump and Bell Housing Assembly . 505-4 Engine Fault Codes . 516-7 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 . 52Hydraulic Pumps . 537-1 Lift/Steer Pump . 537-2 Drive Pump . 54How to Prime the Pump . 55Manifolds . 568-1 Function Manifold Components - CE (to Z4525XCM-1500). 568-1.1 Function Manifold Components ANSI / CSA / CE (from Z4525XCF-101, Z4525XCM-1501) . 598-2 Valve Adjustments - Function Manifold . 64How to Adjust the System Relief Valve . 64How to Adjust the Secondary Boom Down Relief Valve . 648-3 Jib Boom / Platform Rotate Manifold Components. 658-4 Turntable Rotation Manifold Components . 668-5 Directional Valve Manifold Components . 67How to Set Up the Directional Valve Linkage . 688-6 Traction Manifold Components, 4WD . 708-7 Valve Adjustments, 4WD Traction Manifold . 728-8 Hydraulic Generator Manifold Components, 2.2kW . 738-8.1 Generator Manifold Components . 748-9 Valve Coils . 75How to Test a Coil Diode . 75Turntable Rotation Components . 779-1 Turntable Rotation Assembly. 77Axle Components.
Deutz D 2.9 L4 Engine Fault Codes . 105 Perkins 404F-E22T Engine Fault Codes. 116 Ford MSG-425 Engine Fault Codes . 118
