This Manual Includes: Repair Procedures Fault Codes Electrical and Hydraulic Schematics

Service and Repair Manual
Serial Number Range
Z®-45 XC™
from Z4525XCM-101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance

procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268197GT

Rev B2
June 2018
Service and Repair Manual June 2018
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 © 2017 by Terex Corporation
1268197GT Rev B, September 2017
First Edition, Second Printing
Genie and Z are registered trademarks of Terex South Dakota,
Inc. in the U.S.A. and many other countries.
"XC"is a trademark of Terex South Dakota, Inc.
ii Z®-45 XC™ Part No. 1268197GT

June 2018 Service and Repair Manual
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 5/2017 Initial Release
A1 8/2017 Fault Codes Control System Fault Codes
Specifications Hydraulic Component Specifications
Repair Function Manifold Components
Schematics Hydraulic Schematic
A2 9/2017 Repair Procedure 2-3, 2-4
Fault Codes Introduction, Control System and Platform Overload Fault
Codes
Schematics Hour Meter Pin Legend
B 9/2017 Schematics Add wiring diagrams
B1 11/2017 Specifications Machine Specifications
B2 6/2018 Schematics GCON Terminal Strip Wiring Diagram
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. 1268197GT Z®-45 XC™ iii

Introduction
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)
iv Z®-45 XC™ Part No. 1268197GT

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. 1268197GT Z®-45 XC™ 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 XC™ Part No. 1268197GT

June 2018
Table of Contents
Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
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
Deutz D2011 L03i Engine Specifications ............................................................... 7
Machine Torque Specifications .............................................................................. 8
Hydraulic Hose and Fitting Torque Specifications ................................................. 9
Torque Procedure ................................................................................................ 10
SAE and Metric Fasteners Torque Charts ........................................................... 12
Part No. 1268197GT Z®-45 XC™ vii

June 2018
Table of Contents
Section 3 Repair Procedures ............................................................................................. 13

Introduction .......................................................................................................... 13
Platform Controls ............................................................................................... 15

1-1 ALC-500 Circuit Board ................................................................................... 15
1-2 Joysticks ........................................................................................................ 16
How to Adjust the Joystick Max-out Setting ................................................... 16
How to Adjust the Joystick Ramp Rate Setting .............................................. 17
How to Adjust the Joystick Threshold Setting ................................................ 19
Platform Components ....................................................................................... 20

2-1 Platform Leveling Slave Cylinder ................................................................... 20
How to Bleed the Slave Cylinder .................................................................... 21
2-2 Platform Rotator ............................................................................................. 21
2-3 Platform Overload System ............................................................................. 22
How to Replace the Platform Overload Load Cell .......................................... 24
2-4 Platform Overload Recovery Fault................................................................. 24
Jib Boom Components ...................................................................................... 25

3-1 Jib Boom ........................................................................................................ 25
3-2 Jib Boom Lift Cylinder .................................................................................... 26
Primary Boom Components ............................................................................. 28

4-1 Cable Track.................................................................................................... 28
How to Remove the Cable Track .................................................................... 28
How to Repair the Primary Boom Cable Track ............................................... 30
4-2 Primary Boom ................................................................................................ 31
How to Disassemble the Primary Boom ......................................................... 32
4-3 Primary Boom Lift Cylinder ............................................................................ 33
4-4 Primary Boom Extension Cylinder ................................................................. 34
4-5 Platform Leveling Master Cylinder ................................................................. 35
viii Z®-45 XC™ Part No. 1268197GT

June 2018
Table of Contents
Secondary Boom Components ......................................................................... 37

5-1 Secondary Boom ............................................................................................ 38
5-2 Secondary Boom Lift Cylinders ...................................................................... 42
Engines ................................................................................................................ 43
6-1 RPM Adjustment - Deutz D2011L03i Models ................................................ 43
6-2 Flex Plate ....................................................................................................... 43
How to Install the Flex Plate............................................................................ 44
How to install the Pump and Bell Housing Assembly ..................................... 44
Hydraulic Pumps ................................................................................................ 45

7-1 Lift/Steer Pump .............................................................................................. 45
7-2 Drive Pump..................................................................................................... 46
How to Prime the Pump .................................................................................. 47
Manifolds ............................................................................................................. 48
8-1 Function Manifold Components ..................................................................... 48
8-2 Valve Adjustments - Function Manifold .......................................................... 52
How to Adjust the System Relief Valve ........................................................... 52
How to Adjust the Secondary Boom Down Relief Valve ................................. 52
8-3 Jib Boom / Platform Rotate Manifold Components ........................................ 53
8-4 Turntable Rotation Manifold Components ..................................................... 54
8-5 Directional Valve Manifold Components ........................................................ 55
How to Set Up the Directional Valve Linkage ................................................. 56
8-6 Traction Manifold Components, 4WD ............................................................ 58
8-7 Valve Adjustments, 4WD Traction Manifold ................................................... 60
8-8 Hydraulic Generator Manifold Components, 2.2kW ...................................... 61
8-9 Valve Coils ..................................................................................................... 62
How to Test a Coil Diode ................................................................................ 62
Turntable Rotation Components ...................................................................... 64

9-1 Turntable Rotation Assembly ......................................................................... 64
Axle Components ............................................................................................... 65

10-1 Oscillating Axle Cylinders............................................................................. 65
Part No. 1268197GT Z®-45 XC™ ix

June 2018
Table of Contents
Section 4 Fault Codes......................................................................................................... 66

Introduction .......................................................................................................... 66
Control System Fault Codes ............................................................................. 67

How to Retrieve Control System Fault Codes ................................................ 67
Control System Fault Codes ........................................................................... 68
How to Retrieve Platform Overload System Fault Codes .............................. 71
Platform Overload System Fault Codes ......................................................... 72
Section 5 Schematics ......................................................................................................... 74

Introduction .......................................................................................................... 74
Electrical Symbol Legend .................................................................................... 75
Hydraulic Symbols Legend .................................................................................. 76
Electrical Component and Wire Color Legends ................................................... 77
Hour Meter Legend .............................................................................................. 80
Hydraulic Schematics ........................................................................................ 81

Hydraulic Schematic ............................................................................................ 82
Electrical Schematics – Options ...................................................................... 83

Options Wiring Diagram ....................................................................................... 84
Electrical Schematics – CE Models ................................................................. 85

Electrical Schematic, Deutz D2011 L03i .............................................................. 86
Ground Control Box Switch Panel Wiring Diagram ............................................. 90
Ground Control Box Terminal Strip Wiring Diagram ............................................ 91
Platform Control Box Switch Panel Wiring Diagram ............................................ 94
Platform Control Box Terminal Strip Wiring Diagram .......................................... 95
Platform Control Box Relayl Wiring Diagram ....................................................... 98
Electrical Schematic, Platform Overload ............................................................. 99
x Z®-45 XC™ Part No. 1268197GT

Specifications
Section 2 Specific ati ons
Machine Specifications Performance Specifications

Tires and wheels rough terrain Drive speed, maximum
Tire size 315/55 D20 Stowed position 4.5 mph
7.2 km/h
Tire ply rating 12
40 ft / 6.1 sec
Tire and wheel weigh 290 lbs
12.2 m / 6.1 sec
foam filled (minimum) 131.5 kg
Raised or extended 0.33 mph
Overall tire diameter 32.5 in
0.5 km/h
82.5 cm
40 ft / 90 sec
Wheel diameter 20 in
12.2 m / 90 sec
50.8 cm
Gradeability See Operator's Manual
Wheel width 11 in Braking distance, maximum
27.9 cm High range on paved surface 3 to 6 ft
Wheel lugs 9 @ 5/8 -18 0.9 to 1.8 m
Lug nut torque, lubricated 94 ft-lbs Joystick function speeds, maximum from platform
127.4 Nm controls
Lug nut torque, dry 125 ft-lbs Primary boom up 26 to 30 seconds
169.5 Nm
Primary boom down 26 to 30 seconds
Fuel capacities
Primary boom extend 14 to 18 seconds
LPG tank 33.5 pounds
Primary boom retract 14 to 18 seconds
15.2 kg
Secondary boom up 26 to 30 seconds
Fuel tank 17 gallons
64.4 liters Secondary boom down 26 to 30 seconds
Hydraulic tank 22 gallons Turntable rotate, 355° 67 to 73 seconds
83 liters
For operational specifications, refer to the
Hydraulic system (including 30 gallons Operator's Manual.
tank) 113.6 liters
Drive hubs 24 fl oz
710 cc
Turntable rotation drive hub 25.5 fl oz
750 cc
Drive hub oil type: SAE 90 multipurpose hypoid gear oil
API service classification GL5
For operational specifications, refer to the
Operator's Manual.
Part No. 1268197GT Z®-45 XC™ 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 XC™ Part No. 1268197GT

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
Part No. 1268197GT Z®-45 XC™ 3

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
4 Z®-45 XC™ Part No. 1268197GT

Specifications
Hydraulic Component Function manifold
Specifications System relief valve pressure,

maximum
3200 psi
220.6 bar
Drive Pump Secondary boom down relief 2100 psi
Type: bi-directional variable displacement piston pump valve pressure 145 bar
Flow rate @ 2500 psi / 172 bar 32 gpm Platform level relief valve 3000 psi
121 L/min pressure 207 bar
Drive pressure, maximum 3500 psi Steer flow regulator 2.0 gpm
241 bar 7.6 L/min
Charge Pump Boom extend flow regulator 2 gpm

7.6 L/min
Type gear
Jib boom / platform rotate flow 0.8 gpm
Displacement per revolution 0.84 cu in regulator 3 L/min
13.76 cc
Traction Manifold
Flow rate @ 2500 psi / 172 bar 9.1 gpm
34.4 L/min Hot oil relief pressure 250 psi
17.2 bar
Charge pressure @ 2500 rpm 315 psi
21.7 bar Steer end drive motors (4WD models)
Function pump Displacement per revolution 0.54 to 1.53 cu in

variable 8.77 to 25 cc
Type gear
Non-steer end drive motors
Displacement per revolution 0.67 cu in
11 cc Displacement per revolution 0.54 to 1.53 cu in
variable 4WD (2 speed motor) 8.85 to 25.1 cc
Flow rate @ 2500 psi / 172 bar 7.25 gpm
27.4 L/min Hydraulic Filters
Auxiliary Pump High pressure filter: Beta 3 ˆ 200
Type gear, fixed High pressure filter bypass 102 psi

displacement pressure 7 bar
Displacement per revolution 0.067 cu in Medium pressure filter Beta 3 ˆ 200

1.1 cc Medium pressure filter bypass 51 psi
pressure 3.5 bar
Auxiliary pump relief pressure 3200 psi Hydraulic tank return filter 10 micron with
220.6 bar 25 psi / 1.7 bar bypass
Part No. 1268197GT Z®-45 XC™ 5

Specifications
Manifold Component Specifications

Plug torque
SAE No. 2 36 in-lbs / 4 Nm
SAE No. 4 10 ft-lbs / 13 Nm
6 Z®-45 XC™ Part No. 1268197GT

Specifications
Deutz D2011 L03i Engine Lubrication system

Oil pressure 20 to 44 psi
Displacement 142 cu in 1.4 to 3 bar
2.33 liters
Oil capacity 9.5 quarts
Number of cylinders 3 (including filter) 9 liters
Bore and Stroke 3.7 x 4.4 inches Oil viscosity requirements
94 x 112 mm
-22° F to 86° F/ -30° C to 30° C 5W-30 (synthetic)
Horsepower 48 @ 2800 rpm
36 kW @ 2800 rpm -4° F to 90° F / -20° C to 32° C 10W-40
1-2-3 Above 23° F / -5° C 20W-50

Firing order
Unit ships with 15W-40. Extreme operating
Low idle 1500 rpm
temperatures may require the use of alternative engine
313 Hz
oils. For oil requirements, refer to the Engine Operator
High idle 2500 rpm Manual for your engine.
521.7 Hz
Oil temperature switch
Compression ratio 19:01 Temperature switch point 300°F
Compression pressure 362 to 435 psi 149°C
25 to 30 bar Oil Pressure switch
Governor centrifugal mechanical Oil pressure switch point 22 psi
Valve Clearance, cold 1.5 bar
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Part No. 1268197GT Z®-45 XC™ 7

Specifications
Deutz D2011 L03i Engine, continued Machine Torque Specifications

Fuel injection system
Platform Rotator
Injection pump make Bosch
3/4 -10 center bolt, GR 8, dry 380 ft-lbs
Injection pump pressure, 15000 psi Zinc plated 515 Nm
maximum 1034 bar
3/4 -10 center bolt, GR 8, dry 265 ft-lbs
Injector opening pressure 3046 psi ZAG coated 359 Nm
210 bar
3/8 -16 bolts, GR 8, Dry 44 ft-lbs
Fuel requirement Zinc plated 60 Nm
For fuel requirements, refer to the engine Operator 3/8 -16 bolts, GR 8, dry 46 ft-lbs
Manual for your engine. ZAG coated 62 Nm
Starter motor Turntable rotate assembly
Current draw, no load 90A Rotate bearing mounting bolts, lubricated 180 ft-lbs
Brush length, new 0.72 in Zinc plated 244 Nm
18.5 mm Rotate bearing mounting bolts, lubricated 159 ft-lbs
Brush length, minimum 0.27 in ZAG coated 215 Nm
7 mm Drive motor/brake mounting bolts, 105 ft-lbs
Battery lubricated, Zinc plated 142 Nm
Type 12V DC, Group 34/78 Drive motor/brake mounting bolts, 93 ft-lbs
lubricated, ZAG coated 126 Nm
Quantity 1
Drive motors and hubs
Cold cranking ampere 900A
Drive hub mounting bolts, lubricated 180 ft-lbs
Reserve capacity @ 25A rate 200 minutes 244 Nm
Alternator output 60A @ 14V DC Drive motor mounting bolts, lubricated 55 ft-lbs
Fan belt deflection 3/8 to 1/2 inch 75 Nm
9 to 12 mm
8 Z®-45 XC™ Part No. 1268197GT

Specifications
Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be -4 14 ft-lbs / 19 Nm
torqued to specification when they are removed -6 23 ft-lbs / 31.2 Nm
and installed or when new hoses or fittings are -8 36 ft-lbs / 54.2 Nm
installed.
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings -16 125 ft-lbs / 169.5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204.7 Nm
SAE Dash Size Torque
-24 184 ft-lbs / 249.5 Nm
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
Adjustable Fitting Non-adjustable fitting
-24 180 ft-lbs / 245 Nm
1 jam nut
JIC 37° Fittings

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats (tube fitting - installed into Steel)
-4 7/16-20 2 SAE Dash Size Torque
-6 9/16-18 1¼ -4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-8 3/4-16 1 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-10 7/8-14 1
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-12 1 1/16-12 1
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-24 1 7/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
Part No. 1268197GT Z®-45 XC™ 9

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.
10 Z®-45 XC™ Part No. 1268197GT

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.
Part No. 1268197GT Z®-45 XC™ 11

Specifications
12 Z®-45 XC™ Part No. 1268197GT

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.
Part No. 1268197GT Z®-45 XC™ 13

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.
14 Z®-45 XC™ Part No. 1268197GT

Platform Controls
Platform Controls 1-1

The platform control box contains one printed
ALC-500 Circuit Board
circuit board. The ALC-500 circuit board inside the Note: When the ALC-500 circuit board is replaced,
platform control box controls all proportional the joystick controllers will need to be calibrated.
machine functions from the platform. The joystick Refer to Repair Procedure, How to Calibrate a
controllers at the platform controls utilize Hall Effect Joystick.
technology and require no adjustment. The
operating parameters of the joysticks are stored in
memory at the ECM circuit board at the platform How to Remove the ALC-500
controls. If a joystick error occurs or if a joystick is
replaced, it will need to be calibrated before that Circuit Board
particular machine function will operate. Refer to 1 Push in the red Emergency Stop button to the
Repair Procedure, How to Calibrate a Joystick. off position at both the ground and platform
Each joystick controller should operate smoothly controls.
and provide proportional speed control over its 2 Remove the platform control box lid retaining
entire range of motion. fasteners. Open the control box lid.
3 Locate the ALC-500 circuit board mounted to
the inside of the platform control box.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
4 Attach a grounded wrist strap to the ground

screw inside the platform control box.
Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
1 ALC-500 circuit board grounded wrist strap.
2 drive/steer joystick controller
3 secondary boom up/down joystick 5 Carefully disconnect the wire connectors from
controller the circuit board.
4 primary boom up/down and turntable rotate
6 Remove the ALC-500 circuit board mounting
left/right joystick controller
fasteners.
7 Carefully remove the ALC-500 circuit board
from the platform control box.
Part No. 1268197GT Z®-45 XC™ 15

Platform Controls
How to Adj ust the Joystick Max- out Setting
1-2 How to Adjust the Joystick

Joysticks Max-out Setting
The max-out setting of a joystick controls the
How to Calibrate a Joystick maximum speed of a joystick-controlled machine
function. Whenever a hydraulic cylinder, drive
The joystick controllers on this machine utilize motor or hydraulic pump is replaced, the max-out
digital Hall Effect technology for proportional setting should be adjusted to maintain optimum
control. If a joystick controller is disconnected or performance. The max-out settings on the joystick
replaced, it must be calibrated before that particular can be changed to compensate for hydraulic pump
machine function will operate. wear to maintain peak performance from the
machine.
Note: The joystick must be calibrated before the
threshold, max-out or ramping can be set. Note: Perform this procedure with the boom in the
stowed position.
Note: Perform this procedure with the engine off.
1 Pull out the red Emergency Stop button to the
1 Open the platform control box. on position at both the ground and platform
2 Pull out the red Emergency Stop button to the controls.
on position at both the ground and platform 2 Turn the key switch to platform control. Do not
controls. start the engine.
3 Turn the key switch to platform control. Do not 3 Push in the platform controls red Emergency
start the engine. Stop button to the off position.
4 Select a joystick to calibrate. 4 Do not press down the foot switch.
5 Disconnect the wire harness connector from 5 Move and hold the drive enable toggle switch
the joystick for approximately 10 seconds or in the right position and pull out the red
until the alarm sounds. Connect the wire Emergency Stop button to the on position.
harness connector to the joystick.
6 When the alarm sounds, release the drive
6 Move the joystick full stroke in either direction enable toggle switch.
and hold for 5 seconds.
7 Momentarily activate the drive enable toggle
7 Return the joystick to the neutral position, switch in the right direction 4 times.
pause for a moment, then move the joystick
full stroke in the opposite direction. Hold for 5 Result: There should be a pause and the
seconds and return the joystick to the neutral alarm should sound 4 times indicating that the
position. machine is in max-out calibration mode.
Result: The alarm should sound indicating Result: The alarm does not sound. Repeat
successful joystick calibration. steps 3 through 7.
Result: The alarm does not sound. Check the
electrical connections or replace the joystick.
8 Repeat this procedure for each joystick
controlled machine function including the
thumb rocker steer switch.
Note: No machine function should operate while
performing the joystick calibration procedure.
16 Z®-45 XC™ Part No. 1268197GT

Platform Controls
How to Adj ust the Joystick Ram p R ate Setting
8 Start the engine from the platform controls and How to Adjust the Joystick Ramp
press down the foot switch.
Rate Setting
9 Start a timer and activate the machine function
The ramp rate setting of a joystick controls the time
that needs to be adjusted. Record the time it
at which it takes for the joystick to reach maximum
takes for that function to complete a full cycle
output, when moved out of the neutral position. The
(ie; boom up).
ramp rate settings of a joystick can be changed to
10 Compare the machine function time with the compensate for hydraulic pump wear to maintain
function times listed in Refer to Specifications, peak performance from the machine.
Performance Specifications. Determine
whether the function time needs to increase or Note: Perform this procedure with the boom in the
decrease. stowed position.
11 While the joystick is activated, adjust the 1 Pull out the red Emergency Stop button to the
max-out setting to achieve the proper function on position at both the ground and platform
cycle time. Momentarily move the drive enable controls.
toggle switch in the right direction to increase 2 Turn the key switch to platform control. Do not
the function speed or momentarily move the start the engine.
drive enable toggle switch in the left direction
to decrease the function speed. 3 Push in the platform controls red Emergency
Stop button to the off position.
Note: Each time the drive enable toggle switch is
momentarily moved, the function speed will change 4 Do not press down the foot switch.
in 2% increments from a default of 100%, with a
minimum of 60% and a maximum of 120%. 5 Move and hold the drive enable toggle switch
in the right position and pull out the red
12 Repeat steps 9 through 11 for each joystick Emergency Stop button to the on position.
controlled machine function. 6 When the alarm sounds, release the drive
13 Return the joystick to the neutral position and enable toggle switch.
wait for approximately 10 seconds to allow the 7 Momentarily activate the drive enable toggle
settings to be saved. switch in the right direction 6 times.
Result: The alarm should sound indicating that Result: There should be a pause and the
the settings have been saved in memory. alarm should sound 6 times indicating that the
Note: Do not operate any machine function during machine is in ramp rate calibration mode.
the 10 second waiting time.
Part No. 1268197GT Z®-45 XC™ 17

Platform Controls
8 Start the engine from the platform controls and 13 Return the joystick to the neutral position and
press down the foot switch. wait for approximately 10 seconds to allow the
settings to be saved.
9 Start a timer and simultaneously move the
joystick in either direction full stroke. Note how Result: The alarm should sound indicating that
long it takes the function to reach maximum the settings have been saved in memory.
speed. This is the ramp rate.
Note: Do not operate any machine function during
10 Compare the function ramp rate time with the the 10 second waiting time.
table below and determine whether the ramp
rate time needs to increase or decrease. Ramp rate (factory settings)
Primary boom up/down
11 While the joystick is activated, set the ramp
rate. Momentarily move the drive enable accelerate 4 seconds
toggle switch in the right direction to increase decelerate 0.5 second
the time or momentarily move the drive enable Secondary boom up/down
toggle switch in the left direction to decrease
accelerate 2 seconds
the time.
decelerate 0.5 second
Note: Each time the drive enable toggle switch is
momentarily moved, the time will change in 10% Turntable rotate
increments. accelerate 2 seconds
decelerate 0.5 second
12 Repeat steps 9 through 11 for each joystick
controlled machine function. Drive
accelerate 3 seconds
decelerate to neutral 0.5 second
decelerate, change of direction 0.5 second
decelerate, coasting 0.75 second
decelerate, braking 1 second
decelerate, shift from low to high 1 seconds
speed
decelerate, shift from high to low 2 seconds
speed
18 Z®-45 XC™ Part No. 1268197GT

Platform Controls
How to Adj ust the Joystick Thr es hol d Setting
How to Adjust the Joystick 9 Select a boom function joystick to set the
threshold.
Threshold Setting
10 Slowly move the joystick off center in either
The threshold setting of a joystick is the minimum
direction just until the function begins to move.
output at which a function proportional valve can
open and allow the function to operate. 11 Slowly move the joystick back towards the
neutral position. Just before the function stops
Note: Perform this procedure with the boom in the moving, move the drive enable toggle switch
stowed position. to either side to set the threshold.
1 Pull out the red Emergency Stop button to the Result: The alarm should sound indicating a
on position at both the ground and platform successful calibration.
controls.
Note: For each joystick axis, the threshold must be
2 Turn the key switch to platform control. Do not set for both directions.
start the engine.
12 Repeat steps 9 through 11 for each direction
3 Push in the platform controls red Emergency of boom joystick controlled machine function
Stop button to the off position. (boom up/down, boom extend/retract and
4 Do not press down the foot switch. turntable rotate left/right).
5 Move and hold the drive enable toggle switch 13 Return the joystick to the neutral position and
in the right position and pull out the red wait for approximately 10 seconds to allow the
Emergency Stop button to the on position. settings to be saved.
6 When the alarm sounds, release the drive Result: The alarm should sound indicating that
enable toggle switch. the settings have been saved in memory.
7 Momentarily activate the drive enable toggle Note: Do not operate any machine function during
switch in the right direction 8 times. the 10 second waiting time.
Result: There should be a pause and the 14 Cycle the red Emergency Stop button off, then
alarm should sound 8 times indicating that the back on.
machine is in threshold calibration mode.
Result: The alarm does not sound. Repeat
steps 3 through 7.
8 Start the engine from the platform controls and
press down the foot switch.
Part No. 1268197GT Z®-45 XC™ 19

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 Remove the external snap rings from the slave
closed loop. 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 7 Place a block under the slave cylinder for
end must be replaced. All connections must be support. Protect the cylinder rod from damage.
torqued to specification during installation. Refer to 8 Use a soft metal drift to drive the rod-end pivot
Specifications, Hydraulic Hose and Fitting Torque pin out.
Specifications.
Crushing hazard. The platform
1 Extend the primary boom until the slave could fall when the slave cylinder
cylinder barrel-end pivot pin is accessible. rod-end pivot pin is removed if
2 Raise the primary boom slightly and place not properly supported.
blocks under the platform for support.
3 Lower the primary boom until the platform is The slave cylinder rod may
resting on the blocks just enough to support become damaged if it is allowed
the platform. to fall if not properly supported
Note: Do not rest the entire weight of the boom on by the lifting device.
the blocks.
9 Use a soft metal drift and drive the barrel-end
pin out.
10 Carefully pull the cylinder out of the primary
boom.
20 Z®-45 XC™ Part No. 1268197GT

Platform Components
How to Bleed the Sl av e Cylinder
How to Bleed the Slave Cylinder 2-2

Note: This procedure will have to be preformed Platform Rotator
outside.
1 Raise the jib to a horizontal postion and raise How to Bleed the Platform
the secondary boom 3 feet. Rotator
2 Move the function enable toggle switch to
Note: This procedure will require two people. Do
either side. Simultaneously activate and hold
not start the engine. Use auxiliary power for this
the primary boom up and platform level up
procedure.
toggle switches until the primary boom is fully
raised. 1 Move the function enable toggle switch to
The platform should be facing in an upward either side and activate the platform rotate
position. As shown. 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
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
squirt or spray.
3 While still holding the function enable toggle 4 Move the function enable toggle switch to
switch, simultaneously activate the primary either side and hold the platform rotate toggle
boom down and platform level down toggle switch to the left position until the platform is
switches until the primary boom is fully fully rotated to the left. Continue holding the
lowered. toggle switch until air stops coming out of the
The platform should be facing in a down bleed screw. Close the bleed screw.
position. As shown.
Crushing hazard. Keep clear of
the platform during rotation.
Part No. 1268197GT Z®-45 XC™ 21

Platform Components
5 Open the bottom bleed screw on the rotator, 2-3

but do not remove it.
Platform Overload System
burn skin. Loosen hydraulic How to Calibrate the Platform
Overload System
gradually. Do not allow oil to Calibration of the platform overload system is
squirt or spray. essential to safe machine operation. Continued use
of an improperly calibrated platform overload
6 Move the function enable toggle switch to system could result in the system failing to sense
either side and hold the platform rotate toggle an overloaded platform. The stability of the
switch to the right position until the platform is machine is compromised and it could tip over.
fully rotated to the right. Continue holding the
toggle switch until air stops coming out of the Note: Perform this procedure with the machine on
bleed screw. Close the bleed screw. a firm, level surface.
Crushing hazard. Keep clear of Full load cell calibration:

the platform during rotation.
This calibration procedure allows unrestricted and
7 Clean up any hydraulic oil that may have restricted range of motion using boom functions.
spilled.
1 Remove all weight, tools, accessories and
8 Rotate the platform fully in both directions and equipment from the platform.
inspect the bleed screws for leaks.
Note: Failure to remove all weight, tools,
accessories and equipment from the platform will
result in an incorrect calibration.
2 Turn the key switch to ground controls.

3 Pull out the red Emergency Stop button and
momentarily activate the calibration toggle
switch located on the left side of the control
box in the up position 3 times to enter
calibration mode.
Note: The calibration toggle switch must be
activated within 5 seconds.
Result: The green LED on the SCON located
under the ground control box is flashing
confirming calibration mode is active.
22 Z®-45 XC™ Part No. 1268197GT

Platform Components
4 Activate and hold the calibration toggle switch Zero load cell calibration:
in the down position for 2 seconds to store the Perform this procedure when the required weight
zero load calibration. for full load calibration is not available. This
Result: An audible alarm sounds for 1 second. procedure will re-calibrate the zero load point
Calibration has been stored. without effecting a previous full load calibration.
The platform load capacity will be reduced until a
5 Add maximum rated load of 1000 lbs / 454kg full load calibration has been performed. A full load
to the center of the platform. calibration is required for rated load performance.
6 Activate and hold the calibration toggle switch 1 Remove all weight, tools, accessories and
in the up position for 2 seconds to store the equipment from the platform.
rated load calibration.
Note: Failure to remove all weight, tools,
Result: An audible alarm sounds for 1 second. accessories and equipment from the platform will
Calibration has been stored. result in an incorrect calibration.
2 Turn the key switch to ground controls.

3 Pull out the red Emergency Stop button and
momentarily activate the calibration toggle
switch located on the left side of the control
box in the up position 3 times to enter
calibration mode.
Note: The calibration toggle switch must be
activated within 5 seconds.
Result: The green LED on the SCON located
under the ground control box is flashing
confirming calibration mode is active.
4 Activate and hold the calibration toggle switch
in the down position for 2 seconds to store the
zero load calibration.
Result: An audible alarm sounds for 1 second.
Calibration has been stored.
5 Activate and hold the calibration toggle switch
in the up position for 2 seconds to store the
rated load calibration.
Result: An audible alarm sounds for 1 second.
Calibration has been stored.
Part No. 1268197GT Z®-45 XC™ 23

Platform Components
How to R eplac e the Platform Ov erload Load C ell
How to Replace the Load Cell 2-4

Sensor Platform Overload Recovery
Note: The preload adjustment should only be Fault
performed after the load cell sensor has been
replaced. If the ground controls hour meter displays fault
code 8221, the emergency lowering system has
1 Remove all equipment or tools from the been used while the platform was overloaded.
platform. Remove the welder if equipped.
2 At the platform, remove the plastic instruction How to Clear the Platform
holder from the document mount plate.
Overload Recovery Fault
3 Tag and disconnect the load cell sensor
harness. Note: This message shall be cleared by a person
trained and qualified on the troubleshooting and
4 Loosen the jam nut securing the load cell repair of this machine.
sensor foot and rotate the foot screw
clockwise to remove the preload. 1 Turn the key switch to ground control and pull
out the red Emergency Stop button to the on
5 Remove the fasteners securing the load cell position.
sensor and remove the sensor.
2 Wait 10 seconds and activate the calibration
Install the new Load Cell Sensor toggle switch in the following sequence
(gain)(gain)(gain)(zero).
6 Screw the foot with jam nut into the top of the
load cell sensor until the foot bolt extends out
of the bottom of the sensor.The foot should
not contact the flex plate when assembling
onto the platform support.
7 Assemble the load cell and foot assembly to
the platform and securely tighten the two
mounting screws. Torque the bolts to 101
ft-lbs / 137 Nm.
Set the Load Cell Sensor Preload
8 Rotate the foot screw counter clockwise until

the foot just contacts the flex plate (finger 1 gain
tight). 2 zero
9 Using an open end wrench, continue to rotate
the foot counter clockwise an additional 1/2 3 Turn the key switch to the off position.
turn (180°). Then, while holding the foot bolt,
securely tighten the jam nut. Torque the jam
nut to 55 ft-lbs / 75 Nm.
10 Attach the load cell sensor harness.
11 Install the plastic instruction holder.
12 Calibrate the platform overload system. Refer
to Repair Procedure How to Calibrate the
Platform Overload System.
24 Z®-45 XC™ Part No. 1268197GT

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 Slide both of the jib boom leveling arms off of
the jib boom cylinder rod-end pivot pin.
the O-ring (if equipped) on the fitting and/or hose 10 Remove the hose and cable cover from the
end must be replaced. All connections must be side of the jib boom. Remove the hose and
torqued to specification during installation. Refer to cable separators.
Specifications, Hydraulic Hose and Fitting Torque
11 Attach a lifting strap from an overhead crane
Specifications.
to the jib boom.
1 Remove the platform. 12 Support the barrel end of the jib boom lift
2 Disconnect the electrical connector from the cylinder with a suitable lifting device.
jib boom/platform rotate select valve manifold 13 Tag, disconnect and plug the jib boom lift
mounted to the platform support. cylinder hydraulic hoses. Cap the fittings on
3 Tag, disconnect and plug all of the hydraulic the cylinder.
hoses from the jib boom/platform rotate select
valve manifold. Cap the fittings on the
manifold and pull the hoses out through the
platform rotator.
Bodily injury hazard. Spraying the oil pressure to dissipate
hydraulic oil can penetrate and gradually. Do not allow oil to
burn skin. Loosen hydraulic squirt or spray.
the oil pressure to dissipate 14 Remove the pin retaining fastener from the jib
gradually. Do not allow oil to boom lift cylinder barrel-end pivot pin.
squirt or spray.
4 Remove the platform mounting weldment.

to the platform rotator for support.
6 Remove the pin retaining fastener from the jib
boom lift cylinder rod-end pivot pin. Do not
remove the pin.
Part No. 1268197GT Z®-45 XC™ 25

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

jib boom lift cylinder rod-end pivot pin. Do not
remove the pin.
26 Z®-45 XC™ Part No. 1268197GT

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.
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
7 Use a soft metal drift to remove the pin and let
the cylinder hang down. Remove the platform
rotator from the machine.
may become unbalanced and fall
when it is removed from the
machine if it is not properly
crane.

to the lug on the rod end of the jib boom lift
cylinder.
9 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.
Part No. 1268197GT Z®-45 XC™ 27

Primary Boom Components

from the "V1" and "V2" ports on the
Cable Track counterbalance valve manifold located on the
platform rotator. Cap the fittings on the
The primary boom cable track guides the cables
manifold.
and hoses running up the boom. It can be repaired
link by link without removing the cables and hoses Bodily injury hazard. Spraying
that run through it. Removing the entire primary hydraulic oil can penetrate and
boom cable track is only necessary when burn skin. Loosen hydraulic
performing major repairs that involve removing the connections very slowly to allow
primary boom. the oil pressure to dissipate
How to R emove the Cable Track

squirt or spray.
How to Remove the Cable Track
7 Tag and disconnect the hydraulic hoses from
Note: When removing a hose assembly or fitting, the platform leveling slave cylinder at the
the O-ring (if equipped) on the fitting and/or hose union and connect them together using a
end must be replaced. All connections must be connector. Connect the hoses from the
torqued to specification during installation. Refer to cylinder together using a connector.
Specifications. Bodily injury hazard. Spraying
1 Locate the cables from the primary boom burn skin. Loosen hydraulic
cable track to the platform control box. connections very slowly to allow
Number each cable and its entry location at the oil pressure to dissipate
the platform control box. gradually. Do not allow oil to
squirt or spray.
2 Disconnect the cables from the platform
control box.
8 Tag, disconnect and plug the hydraulic hoses
3 Remove the hose and cable cover from the from the jib boom/platform rotate manifold.
side of the jib boom. Remove the hose and Cap the fittings on the manifold.
cable separators.
4 Remove the hose clamp on the primary boom hydraulic oil can penetrate and
bellcrank. burn skin. Loosen hydraulic
5 Pull all of the electrical cables out of the plastic the oil pressure to dissipate
cable track. Do not pull out the hydraulic gradually. Do not allow oil to
hoses. squirt or spray.
28 Z®-45 XC™ Part No. 1268197GT

9 Tag, disconnect and plug the platform rotator 14 Remove all hose and cable clamps from the
hydraulic hoses at the union located above the underside of the primary boom.
primary boom lift cylinder. Cap the fittings on 15 Support the rod end of the primary boom lift
the unions. cylinder with a suitable lifting device.
Bodily injury hazard. Spraying 16 Remove the pin retaining fasteners from the
hydraulic oil can penetrate and primary boom lift cylinder rod-end pivot pin. Do
burn skin. Loosen hydraulic not remove the pin.
the oil pressure to dissipate 17 Raise the primary boom slightly with the
gradually. Do not allow oil to overhead crane to relieve the pressure on the
squirt or spray. primary boom lift cylinder rod-end pivot pin.
18 Use a soft metal drift to remove the primary
10 Tag, disconnect and plug the hydraulic hoses boom lift cylinder rod-end pivot pin.
from the platform leveling master cylinder.
Cap the fittings on the cylinder. Crushing hazard. The primary
boom lift cylinder could become
Bodily injury hazard. Spraying unbalanced and fall if not
hydraulic oil can penetrate and properly supported by the lifting
burn skin. Loosen hydraulic device.
the oil pressure to dissipate 19 Lower the rod end of the primary boom lift
gradually. Do not allow oil to cylinder approximately 12 inches / 30 cm.
squirt or spray.
20 Pull all of the hoses and cables out and away
11 Raise the boom to a horizontal position. from the mounting ears for the rod end of the
primary boom lift cylinder.
12 Place blocks between the upper and lower
cable tracks and secure the upper and lower 21 Raise the rod end of the primary boom lift
tracks together. cylinder back into position and install the
rod-end pivot pin. Install the pin retaining
Crushing hazard. If the upper fasteners.
and lower cable tracks are not
properly secured together, the 22 Attach a strap from an overhead crane to the
cable track could become cable track.
unbalanced and fall when 23 Remove the mounting fasteners from the
removed from the machine. upper cable track at the platform end of the
extension boom.
13 Attach a lifting strap from an overhead 5 ton /
5,000 kg capacity crane to the platform end of
the primary boom for support. Do not lift it.
Part No. 1268197GT Z®-45 XC™ 29

24 Remove the cable track mounting fasteners

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

that attach the lower cable track to the primary
boom. Cable Track
25 Remove the cable track from the machine and Component damage hazard.
place it on a structure capable of supporting it. The boom cable track can be
damaged if it is twisted.
Crushing hazard. The cable
track could become Note: A 7 link repair section of cable track is
unbalanced and fall if not available through the Genie Service Parts
properly attached to the Department.
overhead crane.

Cables and hoses can be
damaged if they are kinked or
pinched.
1 link separation point

2 lower clip
1 Use a slotted screwdriver to pry down on the

lower clip.
2 To remove a single link, open the lower clip
and then use a screw driver to pry the link to
the side.
3 Repeat steps 1 and 2 for each link.
30 Z®-45 XC™ Part No. 1268197GT

4-2 6 Remove the pin retaining fastener from the

master cylinder barrel-end pivot pin. Use a soft
Primary Boom metal drift to remove the pin. Then lower the
cylinder and let it hang down.
How to Remove the Primary Component damage hazard.
Boom When lowering the master
cylinder down, be sure not to
Bodily injury hazard. This damage the master cylinder
procedure requires specific repair hoses or fittings.
skills, lifting equipment and a
suitable workshop. Attempting 7 Locate the primary boom drive speed limit
this procedure without these skills switch inside of the upper pivot.
and tools could result in death or
serious injury and significant 8 Remove the primary boom drive speed limit
component damage. Dealer switch mounting fasteners. Do not disconnect
service is strongly recommended. the wiring.
9 Locate the primary extension boom drive
Note: Perform this procedure with the boom in the speed limit switch inside of the extension
stowed position. boom.
Note: When removing a hose assembly or fitting, 10 Remove the primary extension boom drive
the O-ring (if equipped) on the fitting and/or hose speed limit switch mounting fasteners. Do not
end must be replaced. All connections must be disconnect the wiring.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 11 Pull the limit switch and the wiring out of the
Specifications. extension tube and move it out of the way.
1 Remove the platform. 12 Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the
2 Remove the jib boom. Refer to Repair fittings on the cylinder.
Procedure, How to Remove the Jib Boom.
3 Remove the cable track. Refer to Repair hydraulic oil can penetrate and
Procedure, How to Remove the Cable Track. burn skin. Loosen hydraulic
4 Raise the primary boom to a horizontal connections very slowly to allow
position. the oil pressure to dissipate
5 Remove the hose and cable cover from the squirt or spray.
upper pivot.
13 Remove the hose clamp at the pivot end of the
boom.
Part No. 1268197GT Z®-45 XC™ 31


How to Dis ass embl e the Primary Boom
14 Attach a 5 ton / 5,000 kg overhead crane to How to Disassemble the Primary

the center point of the primary boom.
Boom
15 Attach a similar lifting device to the primary
Complete disassembly of the boom is only
boom lift cylinder.
necessary if the outer or inner boom tube must be
16 Place support blocks under the primary boom replaced. The extension cylinder can be removed
lift cylinder. without completely disassembling the boom. Refer
to Repair Procedure, How to Remove the Primary
17 Remove the pin retaining fasteners from the Boom Extension Cylinder.
primary boom lift cylinder rod-end pivot pin.
Use a soft metal drift to remove the pin. 1 Remove the primary boom. Refer to Repair
Procedure, How to Remove the Primary
Crushing hazard. The boom lift Boom.
cylinder and primary boom will
fall if not properly supported. 2 Place blocks under the barrel end of the
primary boom extension cylinder for support.
18 Lower the rod end of the primary boom lift
cylinder onto support blocks. Protect the 3 Remove the pin retaining fastener from the
extension cylinder barrel-end pivot pin at the
cylinder rod from damage.
pivot end of the primary boom. Use a soft
19 Remove the pin retaining fasteners from the metal drift to remove the pin.
primary boom pivot pin.
4 Remove and label the location of the wear
20 Remove the primary boom pivot pin with a soft pads from the platform end of the primary
metal drift, then carefully remove the primary boom.
boom from the machine and place it on a
Note: Pay careful attention to the location and
structure capable of supporting it.
amount of shims used with each wear pad.
Crushing hazard. The primary
5 Support and slide the extension tube and
boom could become unbalanced
and fall when removed from the extension cylinder assembly out of the boom
tube.
machine if not properly attached
to the overhead crane. 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.
32 Z®-45 XC™ Part No. 1268197GT

6 Remove the external snap rings from the 4-3

extension cylinder rod-end pivot pins at the
platform end of the extension tube. Use a soft
Primary Boom Lift Cylinder
metal drift to remove the pins. The primary boom lift cylinder raises and lowers
7 Support and slide the extension cylinder out of the primary boom. The primary boom lift cylinder is
the base end of the extension tube. Place the equipped with a counterbalance valve to prevent
extension cylinder on blocks for support. movement in the event of a hydraulic line failure.
Crushing hazard. The extension

cylinder could become How to Remove the Primary
unbalanced and fall when Boom Lift Cylinder
removed from primary boom
extension tube if not properly Bodily injury hazard. This
supported. procedure requires specific repair
skills, lifting equipment and a
Note: During removal, the overhead crane strap will suitable workshop. Attempting
need to be carefully adjusted for proper balancing. this procedure without these skills
serious injury and significant
component damage. Dealer
service is strongly recommended.

the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
Specifications.
1 Raise the primary boom to a horizontal

position.
2 Raise the secondary boom until the primary
boom lift cylinder barrel-end pivot pin is above
the turntable covers.
3 Attach a 5 ton / 5000 kg overhead crane to the
primary boom for support.
4 Raise the primary boom with the overhead
crane slightly to take the pressure off the
primary boom lift cylinder pivot pins.
5 Support the rod end and the barrel end of the
primary boom lift cylinder with a second
overhead crane or similar lifting device.
Part No. 1268197GT Z®-45 XC™ 33

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

cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Primary Boom Extension
Cylinder
hydraulic oil can penetrate and The primary boom extension cylinder extends and
burn skin. Loosen hydraulic retracts the primary boom extension tube. The
connections very slowly to allow primary boom extension cylinder is equipped with
the oil pressure to dissipate counterbalance valves to prevent movement in the
gradually. Do not allow oil to event of a hydraulic line failure.
squirt or spray.
7 Remove the pin retaining fasteners from the How to Remove the Primary
primary boom lift cylinder rod-end pivot pin. Boom Extension Cylinder
Use a soft metal drift to remove the pin.
Bodily injury hazard. This
Crushing hazard. The primary procedure requires specific repair
boom will fall if not properly skills, lifting equipment and a
supported when the primary suitable workshop. Attempting
boom rod-end pivot pin is this procedure without these skills
removed. and tools could result in death or
8 Place a support block across both turntable component damage. Dealer
covers under the primary boom lift cylinder. service is strongly recommended.
9 Lower the rod end of the lift cylinder onto the
block. Protect the cylinder rod from damage. Note: When removing a hose assembly or fitting,
Crushing hazard. The primary end must be replaced. All connections must be
boom lift cylinder could become torqued to specification during installation. Refer to
unbalanced and fall if not Specifications, Hydraulic Hose and Fitting Torque
properly supported by the lifting Specifications.
device.
1 Raise the primary boom to a horizontal
10 Remove the primary boom lift cylinder position.
barrel-end pivot pin retaining fasteners. Do not 2 Extend the primary boom until the primary
remove the pin. boom extension cylinder rod-end pivot pin is
11 Use a slide hammer to remove the barrel-end accessible in the primary boom extension
pivot pin. Carefully remove the primary boom tube.
lift cylinder from the machine. 3 Remove the hose and cable guard from the
Crushing hazard. The lift cylinder upper pivot.
could become unbalanced and
fall if not properly supported and
secured to the lifting device.
34 Z®-45 XC™ Part No. 1268197GT

4 Tag, disconnect and plug the primary boom 4-5

extension cylinder hydraulic hoses. Cap the
fittings on the cylinder.
Platform Leveling Master
Cylinder
hydraulic oil can penetrate and The master cylinder acts as a pump for the slave
burn skin. Loosen hydraulic cylinder. It’s part of the closed circuit hydraulic loop
connections very slowly to allow that keeps the platform level through the entire
the oil pressure to dissipate range of boom motion. The master cylinder is
gradually. Do not allow oil to located at the base of the primary boom.
squirt or spray.
5 At the platform end of the boom, remove the How to Remove the Platform
external snap rings from the extension Leveling Master Cylinder
cylinder rod-end pivot pins. Use a soft metal
drift to remove the pins. Note: When removing a hose assembly or fitting,
6 Remove the barrel-end pivot pin retaining end must be replaced. All connections must be
fasteners. torqued to specification during installation. Refer to
7 Place a rod through the barrel-end pivot pin Specifications, Hydraulic Hose and Fitting Torque
and twist to remove the pin. Specifications.
8 Support and slide the extension cylinder out of 1 Raise the primary and secondary booms until
the upper pivot. both the rod-end and barrel-end pivot pins on
the master cylinder are accessible.
Crushing hazard. The extension
cylinder could fall when removed 2 Tag, disconnect and plug the master cylinder
from the extension boom if not hydraulic hoses. Cap the fittings on the
properly supported. cylinder.
Component damage hazard. Be hydraulic oil can penetrate and
careful not to damage the burn skin. Loosen hydraulic
counterbalance valves on the connections very slowly to allow
primary boom extension cylinder the oil pressure to dissipate
when removing the cylinder from gradually. Do not allow oil to
the primary boom. squirt or spray.
Component damage hazard. 3 Attach overhead crane or similar lifting device

Hoses and cables can be to the master cylinder.
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.
Part No. 1268197GT Z®-45 XC™ 35


master cylinder barrel-end pivot pin.
5 Place a rod through the barrel-end pivot pin
and twist to remove the pin.
6 Remove the pin retaining fastener from the
rod-end pivot pin.
7 Place a rod through the rod-end pivot pin and
twist to remove the pin.
8 Remove the master cylinder from the
machine.
Crushing hazard. The master
cylinder could become
unbalanced and fall if not
properly attached to the
overhead crane.
36 Z®-45 XC™ Part No. 1268197GT

Secondary Boom Components
Secondary Boom components 5 compression link

1 upper secondary boom (number 1 arm) 6 secondary boom lift cylinder (2)
2 upper tension link (number 2 arm) 7 lower secondary boom (number 4 arm)
3 lower tension link (number 3 arm) 8 upper pivot
4 mid-pivot
Part No. 1268197GT Z®-45 XC™ 37


at the primary boom lift cylinder. Cap the
Secondary Boom fittings on the cylinder.
How to Disassemble the hydraulic oil can penetrate and
Secondary Boom burn skin. Loosen hydraulic
Bodily injury hazard. This the oil pressure to dissipate
procedure requires specific repair gradually. Do not allow oil to
skills, lifting equipment and a squirt or spray.
suitable workshop. Attempting
this procedure without these skills 7 Remove the pin retaining fastener from the
and tools could result in death or primary boom lift cylinder barrel-end pivot pin.
component damage. Dealer 8 Use a slide hammer to remove the pin.
service is strongly recommended. Remove the primary boom lift cylinder from
the machine.
Follow the disassembly steps to the point required
Crushing hazard. The primary
to complete the repair. Then re-assemble the
secondary boom by following the disassembly
steps in reverse order.
properly supported by the lifting
Note: When removing a hose assembly or fitting, device.
end must be replaced. All connections must be 9 Tag, disconnect and plug the hydraulic hoses
torqued to specification during installation. Refer to on both of the secondary boom lift cylinders.
Specifications, Hydraulic Hose and Fitting Torque Cap the fittings on the cylinders.
Specifications.
1 Remove the platform. hydraulic oil can penetrate and
2 Remove the jib boom. Refer to Repair connections very slowly to allow
Procedure, How to Remove the Jib Boom. the oil pressure to dissipate
3 Remove the primary boom. Refer to Repair gradually. Do not allow oil to
Procedure, How to Remove the Primary squirt or spray.
Boom.
10 Remove the pin retaining fasteners from both
4 Remove the master cylinder. Refer to Repair sides of the secondary boom lift cylinder
Procedure, How to Remove the Master rod-end pivot pin and barrel-end pivot pin. Do
Cylinder. not remove the pins.
to the lug on the rod end of the primary boom
lift cylinder. Then raise the primary boom lift
cylinder with the crane, to a vertical position.
38 Z®-45 XC™ Part No. 1268197GT

11 Attach a strap from an overhead crane to the 20 Remove the number 1 arm from the machine.
lug on the rod end of one of the secondary
boom lift cylinders for support. Do not apply Crushing hazard. The number 1
any lifting pressure. arm could become unbalanced
and fall when removed from the
12 Use a soft metal drift to drive the barrel-end machine if not properly attached
pivot pin half way out. Lower the barrel end of to the overhead crane.
the secondary boom lift cylinder and let it hang
down.
Crushing hazard. The upper
13 Use a soft metal drift to drive the rod-end pivot pivot could fall when the number
pin half way out. 1 arm is removed from the
machine if not properly
14 Remove the secondary boom lift cylinder from supported by the overhead
the machine. crane.
15 Repeat steps 11 through 14 for the other
secondary boom lift cylinder. 21 Using the overhead crane attached to the
upper pivot, raise the secondary boom
Crushing hazard. The secondary assembly approximately 30 inches / 76 cm.
unbalanced and fall when 22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block
removed from the machine if not between the number 2 arm and the boom rest.
properly attached to the Then lower the secondary boom assembly
overhead crane. onto the block.
Crushing hazard. The secondary
Component damage hazard. boom assembly could fall if not
When removing a secondary properly supported by the4 x 4 x
boom lift cylinder from the 11 inch / 10 x 10 x 28 cm block.
machine, be careful not to
damage the counterbalance 23 Pull all of the cables and hoses out through
valve at the barrel end of the the upper pivot.
cylinder.
16 Attach a lifting strap from an overhead crane Cables and hoses can be
to the upper pivot for support. Do not lift it. damaged if they are kinked or
pinched.
17 Attach a lifting strap from a second overhead
crane to the number 1 arm at the mid-point 24 Remove the hose and cable covers from the
between the upper pivot and mid-pivot. top of the number 2 arm.
18 Remove the pin retaining fasteners from the 25 Pull all of the hoses and cables out of the
number 1 arm pivot pins at the mid-pivot and upper pivot and out through the mid-pivot. Lay
the upper pivot. Do not remove the pins. the hoses and cables on the ground.
19 Use a soft metal drift to drive both pins out. Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.
Part No. 1268197GT Z®-45 XC™ 39

26 Remove the pin retaining fastener from the 37 Use a soft metal drift to remove the lower
number 2 arm pivot pin at the upper pivot. Use compression link pivot pin at the number 3
a soft metal drift to remove the pin. arm.
27 Remove the upper pivot from the machine. 38 Support the compression link with an
appropriate lifting device.
Crushing hazard. The upper
pivot could become unbalanced 39 Use a soft metal drift to remove the upper
and fall when removed from the compression link pivot pin from the number 2
machine if not properly attached arm. Remove the compression link from the
to the overhead crane. machine.
28 Attach the lifting strap from an overhead crane Crushing hazard. The number 2
to the number 2 arm at the upper pivot end. arm could fall when the
compression link is disconnected
29 Raise the number 2 arm slightly and remove from the number 2 arm if not
the 4 x 4 x 11 inch / 10 x 10 x 28 cm block. properly supported by the
overhead crane.
30 Lower the number 2 arm onto the boom rest
pad.
Crushing hazard. The
31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm compression link may fall if not
block between the number 3 arm and the properly supported when
number 4 arm at the mid-pivot end. removed from the secondary
boom assembly.
32 Attach a lifting strap from the overhead crane
to the mid-pivot for support. Do not lift it.
40 Remove the number 2 arm from the machine.
number 2, 3 and 4 arm pivot pins at the Crushing hazard. The number 2
mid-pivot. Do not remove the pins. arm could become unbalanced
34 Use a soft metal drift to drive each pin out. secondary boom assembly if
Then remove the mid-pivot from the not properly supported by the
secondary boom assembly. overhead crane.
Crushing hazard. The mid-pivot 41 Remove the upper and lower hose and cable
could become unbalanced and covers from the number 3 arm.
fall when removed from the
secondary boom assembly if not 42 Pull all of the cables and hoses from the
properly supported by the number 3 arm and lay them over the turntable
overhead crane. counterweight.
35 Attach the lifting strap from an overhead crane Component damage hazard.
to the center point of the number 2 arm for Cables and hoses can be
support. Do not lift it. damaged if they are kinked or
pinched.
36 Remove the pin retaining fasteners from both
compression link pivot pins. Do not remove 43 Open the ground controls side turntable cover.
the pins.
44 Remove the fuel tank filler cap.
40 Z®-45 XC™ Part No. 1268197GT

45 Using an approved hand-operated pump, 51 Remove the mounting fasteners from the
drain the fuel tank into a container of suitable cover located in the boom storage area to
capacity. Refer to Specifications, Machine access the number 3 and number 4 arm pivot
Specifications. pin retaining fasteners at the turntable riser.
Explosion and fire hazard. 52 Remove the pin retaining fasteners from the
Engine fuels are combustible. number 3 arm at the turntable riser. Do not
Perform this procedure in an remove the pin.
open, well-ventilated area away
53 Use a slide hammer to remove the number 3
from heaters, sparks, flames and
arm pivot pin from the turntable pivot through
lighted tobacco. Always have an
the access hole behind the ground control
approved fire extinguisher within
box.
easy reach.
54 Remove the number 3 arm from the machine.
Explosion and fire hazard. When
Crushing hazard. The number 3
transferring fuel, connect a
arm could become unbalanced
grounding wire between the
machine and pump or container.
Note: Be sure to only use a hand-operated pump supported by the overhead
suitable for use with gasoline and diesel fuel. crane.
46 Tag, disconnect and plug the fuel hoses from 55 Remove the upper and lower hose and cable
the fuel tank. Clean up any fuel that may have covers from the number 3 arm.
spilled.
56 Remove the secondary boom drive speed limit
47 Remove the fuel tank mounting fasteners. switch mounting fasteners from the number 4
Carefully remove the fuel tank from the arm at the mid-pivot end. Do not disconnect
machine. the wiring.
Component damage hazard. 57 Remove the pin retaining fasteners from the
The fuel tank is plastic and may number 4 arm at the turntable riser. Do not
become damaged if allowed to remove the pin.
fall. 58 Attach a lifting strap from the overhead crane
to the center point of the number 4 arm. Do not
Note: Clean the fuel tank and inspect for cracks
lift it.
and other damage before installing it onto the
machine. 59 Use a slide hammer to remove the number 4
arm from the turntable riser through the
48 Remove the retaining fastener from the ground controls side bulkhead.
ground control box and function manifold pivot
plate. 60 Remove the number 4 arm from the machine.
49 Lower the ground control box and function Crushing hazard. The number 4
manifold pivot plate to access the number 3 arm could become unbalanced
arm pivot pin. and fall when removed from the
50 Attach the lifting strap from the overhead
crane to the center point of the number 3 arm
crane.
for support. Do not lift it.
Part No. 1268197GT Z®-45 XC™ 41


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.
service is strongly recommended.
7 Use a soft metal drift to drive the rod-end pivot
Note: When removing a hose assembly or fitting, pin half way out.
end must be replaced. All connections must be 8 Remove the secondary boom lift cylinder from
torqued to specification during installation. Refer to the machine.
Specifications, Hydraulic Hose and Fitting Torque Crushing hazard. The secondary
Specifications. boom lift cylinder could become
1 Lower the secondary boom to the stowed unbalanced and fall when
position. removed from the machine if not
properly attached to the
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.
42 Z®-45 XC™ Part No. 1268197GT

Engines
6-1 6-2
RPM Adjustment - Deutz Flex Plate
D2011L03i Models The flex plate acts as a coupler between the engine
and the pump. It is bolted to the engine flywheel
Refer to Maintenance Procedure in the appropriate
and has a splined center to drive the pump.
Service or Maintenance Manual for your machine,
Check and Adjust the Engine RPM.
How to Remove the Flex Plate
1 Disconnect the battery cables from the
battery.
circuits could result in death or
2 Disconnect the electrical connectors at the

electrical proportional controller, located on
the drive pump.
3 Remove the engine starter mounting
fasteners. Remove the starter from the
engine. Do not disconnect the wiring.
4 Support the drive pump with an appropriate
lifting device. Then remove all of the bell
housing to engine mounting bolts. Leave the
pump connected to the bell housing.
5 Carefully pull the pump and bell housing away
from the engine and secure it from moving.
Hoses can be damaged if they
are kinked or pinched.
6 Remove the flex plate mounting fasteners,

then remove the flex plate from the engine
flywheel.
Part No. 1268197GT Z®-45 XC™ 43

Engines
How to Ins tall the Fl ex Plate How to i nstall the Pum p and Bell H ousing Ass embly
How to Install the Flex Plate How to Install the Pump and Bell
1 Install the flex plate onto the engine flywheel Housing Assembly
with the rubber vibration isolators towards the
1 Install the pump and bell housing assembly.
pump.
2 Torque the bell housing mounting bolts
2 Apply Loctite® removable thread sealant to
labeled "C" in sequence to 28 ft-lbs / 38 Nm.
the flex plate fasteners and loosely install the
Then torque the bell housing mounting bolts
fasteners.
labeled "C" in sequence to 40 ft-lbs / 54 Nm.
3 Torque the flex plate mounting bolts in
sequence to 28 ft-lbs / 38 Nm. Then torque the
When installing the pump, do not
flex plate mounting bolts in sequence to 40
force the pump coupler into the
ft-lbs / 54 Nm.
flexplate or damage to the pump
4 Apply a high viscosity coupling grease (Genie shaft seal may occur.
part number 128025) to the splines of the
pump shaft and flex plate. Component damage hazard. Do
not force the drive pump during
Grease Specification
installation or the flex plate teeth
Shell Alvania® Grease CG, NLGI 0/1 or equivalent. may become damaged.
Deutz Models
Deutz Models
44 Z®-45 XC™ Part No. 1268197GT

Hydraulic Pumps
7-1 2 Tag, disconnect and plug the lift/steer pump

hydraulic hoses. Cap the fittings on the pump.
Lift/Steer Pump
How to Remove the Lift/Steer burn skin. Loosen hydraulic
Pump connections very slowly to allow
Note: When removing a hose assembly or fitting, gradually. Do not allow oil to
the O-ring (if equipped) on the fitting and/or hose squirt or spray.
torqued to specification during installation. Refer to 3 Remove the pump mounting bolts. Carefully
Specifications, Hydraulic Hose and Fitting Torque remove the pump.
Specifications.
Component damage hazard. Be
1 Locate the two hydraulic tank valves at the sure to open the two hydraulic
hydraulic tank through the access hole tank valves and prime the pump
underneath the turntable. Close the valves. after installing 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.
open closed
Part No. 1268197GT Z®-45 XC™ 45

Hydraulic Pumps
7-2 2 Locate the two hydraulic tank valves at the

hydraulic tank through the access hole
Drive Pump underneath the turntable. Close the valves.
The drive pump is a bi-directional variable Component damage hazard.
displacement piston pump. The pump output is The engine must not be started
controlled by the electro-proportional controller, with the hydraulic tank shut-off
located on the pump. The only adjustment that can valves in the closed position or
be made to the pump is the neutral or null component damage will occur. If
adjustment. Any internal service to the pump the tank valves are closed,
should only be performed at an authorized Eaton remove the key from the key
Hydraulics center. Call Genie Service Department switch and tag the machine to
to locate your local authorized service center. inform personnel of the
condition.
How to Remove the Drive Pump
Component damage hazard. The
work area and surfaces where
this procedure will be performed
must be clean and free of debris
that could get into the hydraulic
system and cause severe
service is recommended. open closed
Note: When removing a hose assembly or fitting, 3 Tag and disconnect and plug the hydraulic
the O-ring (if equipped) on the fitting and/or hose hoses from the drive and lift/steer pumps. Cap
end must be replaced. All connections must be the fittings on the pumps.
torqued to specification during installation. Refer to Bodily injury hazard. Spraying
Specifications, Hydraulic Hose and Fitting Torque hydraulic oil can penetrate and
Specifications. burn skin. Loosen hydraulic
1 Disconnect the electrical connectors at the connections very slowly to allow
electrical proportional controller located on the the oil pressure to dissipate
drive pump. gradually. Do not allow oil to
squirt or spray.
4 Support the pump with a lifting device and

remove the two drive pump mounting
fasteners.
46 Z®-45 XC™ Part No. 1268197GT

Hydraulic Pumps
How to Prime the Pum p
5 Carefully pull the drive pump out until the How to Prime the Pump
pump coupler separates from the flex plate.
1 Connect a 0 to 600 psi / 0 to 41 bar pressure
6 Remove the drive pump from the machine. gauge to the test port on the drive pump.
Component damage hazard. The 2 Remove the safety pin from the engine pivot
pump(s) may become plate latch.
Note: The engine pivot plate latch is located under
properly supported.
the engine turntable pivot plate at the
counterweight end of the machine.
When installing the pump, do 3 Open the engine pivot plate latch and swing
not force the pump coupler into the engine pivot plate out and away from the
the flexplate or damage to the machine.
pump shaft seal may occur.
4 Hold the manual fuel shutoff valve clockwise
to the closed position.
Component damage hazard. Be
sure to open the two hydraulic
tank valves and prime the pump
after installing the pump.
1 manual fuel shutoff valve
5 Have another person crank the engine with

the starter motor for 15 seconds, wait 15
seconds, then crank the engine an additional
15 seconds or until the pressure reaches 320
psi / 22 bar.
6 Release the manual fuel shutoff valve.
7 Start the engine from the ground controls and
check for hydraulic leaks.
Part No. 1268197GT Z®-45 XC™ 47

Manifolds
8-1 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, 3 position 4 way BM Platform level up/down 25 ft-lbs / 34 Nm
2 Solenoid valve, 3 position 4 way CG Platform rotate left/right and jib 25 ft-lbs / 34 Nm
boom up/down
3 Flow regulator valve, 2 gpm / 7.6 L/min BZ Boom extend/retract circuit 20 ft-lbs / 27 Nm
4 Solenoid valve, 2 position 3 way CA Primary boom extend 20 ft-lbs / 27 Nm
5 Proportional directional solenoid valve, 3 BY Primary boom up/down 16-20 ft-lbs / 22-27
position 4 way Nm
6 Differential sensing valve 160 psi / 11 bar BG Meters flow to functions 25 ft-lbs / 34 Nm
7 Proportional directional solenoid valve, 3 BP Turntable rotate left/right 16-20 ft-lbs / 22-27
position 4 way Nm
8 Proportional directional solenoid valve, 3 BU Secondary boom up/down 16-20 ft-lbs / 22-27
position 4 way Nm
9 Solenoid valve, 3 position 4 way BF Steer left/right 25 ft-lbs / 34 Nm
10 Relief valve, 2100 psi / 145 bar BV Secondary boom down 20 ft-lbs / 27 Nm
11 Orifice, 0.046 inch / 1.17 mm CF Secondary boom down circuit
12 Check valve, 5 psi / 0.3 bar BT Differential sensing circuit, 12-14 ft-lbs / 16-19
secondary boom down Nm
13 Check valve, 5 psi / 0.3 bar BW Secondary boom circuit 25 ft-lbs / 34 Nm
14 Check valve, 5 psi / 0.3 bar BS Differential sensing circuit, 12-14 ft-lbs / 16-19
secondary boom up Nm
15 Priority flow regulator valve, 2.0 gpm / 7.6 BB Steer circuit 25 ft-lbs / 34 Nm
L/min
16 Relief valve, 3200 psi / 221 bar BA System relief 20 ft-lbs / 27 Nm
17 Shuttle valve BO Turntable rotate circuit 12-14 ft-lbs / 16-19
Nm
48 Z®-45 XC™ Part No. 1268197GT

Manifolds
Part No. 1268197GT Z®-45 XC™ 49

Manifolds
Function Manifold Components, continued

Index Schematic
No. Item
18 Check valve, 5 psi / 0.3 bar BQ Differential sensing circuit, turntable 12-14 ft-lbs / 16-19
rotate Nm
19 Check valve, 5 psi / 0.3 bar CB Differential sensing circuit, primary 12-14 ft-lbs / 16-19
boom retract Nm
20 Check valve, 5 psi / 0.3 bar BC Differential sensing circuit, platform 25 ft-lbs / 34 Nm
rotate left and jib boom up
21 Check valve, 5 psi / 0.3 bar BD Differential sensing circuit, platform 25 ft-lbs / 34 Nm
rotate right and jib boom down
22 Flow regulator valve, 0.1 gpm / 0.38 BX Primary boom load sense circuit 20 ft-lbs / 27 Nm
L/min
23 Counterbalance valve, 3000 psi / 207 bar CD Primary boom down circuit 30-35 ft-lbs / 45-50
Nm
24 Pressure compensator valve, 80 psi / 5.5 BR Turntable rotate circuit 25 ft-lbs / 34 Nm
bar
25 Shuttle valve CE Differential sensing circuit, primary 12-14 ft-lbs / 16-19
boom up/down Nm
26 Flow regulator valve, 0.8 gpm / 3 L/min BE Jib boom and platform rotate circuit 20 ft-lbs / 27 Nm
27 Needle valve BN Platform level flow control 20 ft-lbs / 27 Nm
28 Relief valve, 3000 psi / 207 bar BH Platform level circuit 20 ft-lbs / 27 Nm
29 Check valve, 5 psi / 0.3 bar BK Differential sensing circuit, platform 12-14 ft-lbs / 16-19
level up Nm
30 Check valve, 5 psi / 0.3 bar BL Differential sensing circuit, platform 12-14 ft-lbs / 16-19
level down Nm
31 Solenoid valve, 2 position 3 way CC Primary boom retract 20 ft-lbs / 27 Nm
32 Shuttle valve BI Platform level circuit 12-14 ft-lbs / 16-19
Nm
33 Check valve, dual pilot operated, 135 psi BJ Platform level circuit 20 ft-lbs / 27 Nm
/ 9.3 bar
50 Z®-45 XC™ Part No. 1268197GT

Manifolds
Part No. 1268197GT Z®-45 XC™ 51

Manifolds
How to Adj ust the Sec ondary Boom D own R elief Valv e
8-2 Valve Adjustments - Function How to Adjust the Secondary

Manifold Boom Down Relief Valve
How to Adj ust the Sy stem Reli ef Valve
Note: Perform this procedure with the boom in the

How to Adjust the System Relief stowed position.
Valve Note: Refer to Function Manifold Component list to
Note: Perform this procedure with the boom in the locate the secondary boom down relief valve.
stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar
Note: Refer to Function Manifold Component list to pressure gauge to the test1 port on the
locate the system relief valve. function manifold.
1 Connect a 0 to 5000 psi / 0 to 350 bar 2 Start the engine from the ground controls.
pressure gauge to the test1 port on the 3 Hold the function enable switch to the high
function manifold. rpm position and activate and hold the
2 Start the engine from the ground controls. secondary boom down switch with the
secondary boom fully lowered.
3 Hold the function enable switch to the high
rpm position and activate and hold the primary 4 Observe the pressure reading on the pressure
boom retract switch with the boom fully gauge. Refer to Specifications, Hydraulic
retracted. Specifications.
4 Observe the pressure reading on the pressure 5 Turn the engine off. Use a wrench to hold the
gauge. Refer to Specifications, Hydraulic relief valve and remove the cap.
Specifications. 6 Adjust the internal hex socket. Turn it
5 Turn the engine off. Use a wrench to hold the clockwise to increase the pressure or
relief valve and remove the cap. counterclockwise to decrease the pressure.
Install the relief valve cap.
6 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 7 Repeat steps 2 through 5 and recheck relief
the relief valve higher than valve pressure.
specified.
8 Remove the pressure gauge.
7 Repeat steps 2 through 5 and recheck relief
valve pressure.
8 Remove the pressure gauge.
52 Z®-45 XC™ Part No. 1268197GT

Manifolds
8-3
Jib Boom / Platform Rotate Manifold Components
The jib boom / platform rotate manifold is mounted to the platform support.
Index Schematic
No. Item
1 Solenoid valve, 2 position 3 way G Platform rotate/jib boom select 8-10 ft-lbs / 11-14 Nm
Part No. 1268197GT Z®-45 XC™ 53

Manifolds
8-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage
compartment.
Index No. Description Schematic Item Function

1 Counterbalance valve L Turntable rotate right
2 Counterbalance valve J Turntable rotate left
54 Z®-45 XC™ Part No. 1268197GT

Manifolds
8-5
Directional Valve Manifold Components
The directional valve manifold is mounted inside the drive chassis at the non-steer end.
Index No. Description Schematic Item Function Torque

1 Cap Breather 20-25 ft-lbs / 27-33
Nm
2 Spool valve CH Directional control
Part No. 1268197GT Z®-45 XC™ 55

Manifolds
How to Set U p the Direc tional Valve Li nk age
How to Set Up the Directional 9 Adjust the ball joint until the hole lines up with
the retaining fastener hole in the bracket.
Valve Linkage
10 Install the ball joint to the axle and tighten the
Note: Adjustment of the oscillate directional valve
jam nut.
linkage is only necessary when the linkage or valve
has been replaced. 11 Check to be sure the drive chassis is
completely level.
1 Lower the boom to the stowed position.
12 Measure the distance between the drive
2 Use a "bubble type" level to be sure the floor is chassis and the non-steer axle on both sides
completely level. (from the inside of the drive chassis).
Tip-over hazard. Failure to Note: If the distance is not equal and the
perform this procedure on a level adjustment to the linkage was completed with the
floor could compromise the ground and drive chassis level, repeat steps 6
stability of the machine resulting through 11 OR consult Genie Product Support.
in the machine tipping over.
3 Check the tire pressure in all four tires and add

air if needed to meet specification.
Note: The tires on some machines are foam-filled
and do not need air added to them.
4 Remove the drive chassis cover and the

non-steer axle covers.
5 Place a "bubble type" level across the drive
chassis non-steer end. Check to be sure the
drive chassis is completely level.
6 Remove the ball joint retaining fastener from
the bracket.
7 To level the drive chassis, start the engine and
push up or pull down on the threaded rod until
the machine is completely level.
8 Verify that the ground and drive chassis are
completely level.
56 Z®-45 XC™ Part No. 1268197GT

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Part No. 1268197GT Z®-45 XC™ 57

Manifolds
8-6
Traction Manifold Components, 4WD
The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
No. Item
1 Flow divider/combiner valve AA Controls flow to flow divider/combiner 25-30 ft-lbs / 34-41
valves 2 and 4 Nm
2 Flow divider/combiner valve AB Controls flow to non-steer end drive motors 25-30 ft-lbs / 34-41
in forward and reverse Nm
3 Orifice, 0.047 in / 1.2 mm AC Drive circuit
4 Flow divider/combiner valve AD Controls flow to steer end drive motors in 25-30 ft-lbs / 34-41
forward and reverse Nm
5 Orifice, 0.040 in / 1.02 mm AE Drive circuit
6 Check valve AF Non-steer end drive motor circuit 10-12 ft-lbs / 14-16
Nm
7 Solenoid valve, 2 position 3 way AG Braking 10-12 ft-lbs / 14-16
Nm
8 Relief valve, 250 psi / 17.2 bar AH Charge pressure circuit 10-12 ft-lbs / 14-16
Nm
9 Solenoid valve, 2 position 3 way AI 2-speed motor shift 10-12 ft-lbs / 14-16
Nm
10 Check valve AJ Steer end drive motor circuit 10-12 ft-lbs / 14-16
Nm
11 Check valve AK Steer end drive motor circuit 10-12 ft-lbs / 14-16
Nm
12 Check valve AL Non-steer end drive motor circuit 10-12 ft-lbs / 14-16
Nm
13 Check valve AM Non-steer end drive motor circuit 10-12 ft-lbs / 14-16
Nm
14 Check valve AN 2 speed motor shift circuit 10-12 ft-lbs / 14-16
Nm
15 Orifice, 0.030 inch / 0.76 mm AO Brake circuit
16 Check valve AP Steer end drive motor circuit 10-12 ft-lbs / 14-16
Nm
17 Shuttle valve, 3 position 3 way AQ Charge pressure circuit that directs hot oil 15-18 ft-lbs / 20-24
out of low pressure side of drive pump and Nm
allows low pressure flow path for brake
release and 2-speed motor shift
18 Orifice, 0.040 in / 1.01 mm AR Drive circuit
58 Z®-45 XC™ Part No. 1268197GT

Manifolds
Part No. 1268197GT Z®-45 XC™ 59

Manifolds
8-7
Valve Adjustments, 4WD Traction
Manifold
How to Adjust the Charge

Pressure Relief Valve
Note: Refer to 4WD Traction Manifold Component
list to locate the charge pressure relief valve.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure

gauge to the test port on the drive pump.
2 Hold the charge pressure relief valve and
remove the cap.
3 Turn the internal hex socket clockwise fully
until it stops. Install the cap.
4 Start the engine and move and hold the
function enable/rpm select toggle switch to the
high rpm (rabbit symbol) position. Note the
reading on the pressure gauge.
5 Turn the engine off.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
7 Hold the charge pressure relief valve and
remove the cap.
8 Start the engine and move and hold the
function enable/rpm select toggle switch to the
high rpm (rabbit symbol) position.
9 Adjust the internal hex socket until the
pressure reading on the gauge is 40 psi / 2.8
bar less than the pressure reading on the
pump. Turn it clockwise to increase the
pressure or counterclockwise to decrease the
pressure. Install the valve cap.
10 Turn the engine off and remove the pressure
gauge.
60 Z®-45 XC™ Part No. 1268197GT

Manifolds
8-8 Hydraulic Generator Manifold Components, 2.2kW

The generator manifold is mounted to the hydraulic generator located in the engine compartment.
Index Schematic
No. Item
1 Proportional solenoid valve HH Generator speed 33-37 ft-lbs / 45-50
Nm
2 Relief valve, 3000 psi / 207 bar GG Generator circuit 20-25 ft-lbs / 27-34
Nm
Part No. 1268197GT Z®-45 XC™ 61

Manifolds
How to T est a Coil Di ode
8-9 How to Test a Coil Diode

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
Proportional directional solenoid valve, 10V 6 to 8Ω
DC
(schematic items BP, BU and BY)
3 position 4 way directional valve, 10V DC 6 to 8Ω
(schematic items BF, BM and CG)
2 position 3 way solenoid valve, 10V DC 6 to 8Ω
(schematic items CA, CC, AF, AG and AI)
62 Z®-45 XC™ Part No. 1268197GT

Manifolds
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.
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.
Part No. 1268197GT Z®-45 XC™ 63

Turntable Rotation Components
9-1 3 Remove the safety pin from the engine pivot

plate latch.
Turntable Rotation Assembly
Note: The engine pivot plate latch is located under
the engine turntable pivot plate at the
How to Remove the Turntable counterweight end of the machine.
Rotation Assembly 4 Remove the center turntable cover retaining
Note: When removing a hose assembly or fitting, fasteners. Remove the center turntable cover
the O-ring (if equipped) on the fitting and/or hose from the machine.
end must be replaced. All connections must be 5 Open the engine pivot plate latch and swing
torqued to specification during installation. Refer to the engine pivot plate out and away from the
Specifications, Hydraulic Hose and Fitting Torque machine.
Specifications.
6 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 hydraulic oil can penetrate and
turntable rotation lock. burn skin. Loosen hydraulic
Tip-over hazard. The machine
could tip over when the turntable
rotation assembly is removed if
squirt or spray.
the turntable rotation lock is not
in the locked position.
7 Attach a lifting strap from and overhead crane
or other suitable lifting device to the turntable
rotator assembly.
8 Remove the turntable rotation assembly
mounting fasteners.
9 Carefully remove the turntable rotation
assembly from the machine.
Tip-over hazard. The machine
could tip over when the turntable
rotation assembly is removed if
Unlocked position the turntable rotation lock is not
in the locked position.
Crushing hazard. The turntable

rotation assembly could become
unbalanced and fall when
removed from the machine if not
properly supported by the
overhead crane.
Locked position
64 Z®-45 XC™ Part No. 1268197GT

Axle Components
10-1 3 Attach a lifting strap from an overhead crane

to the barrel end of the oscillating cylinder.
Oscillating Axle Cylinders
The oscillating axle cylinders extend and retract barrel-end pivot pin. Use a soft metal drift to
between the drive chassis and the oscillating axle. remove the pin.
The cylinders are equipped with counterbalance
valves to prevent movement in the event of a Crushing hazard. The oscillate
hydraulic line failure. The valves are not adjustable. cylinder may become
unbalanced and fall when
removed from the machine if not
How to Remove an Oscillating properly attached to the
overhead crane.
Axle Cylinder
Note: Perform this procedure on a firm, level 5 Remove the oscillate cylinder from the
surface with the boom in the stowed position. machine.

Specifications.
1 Tag, disconnect and plug the oscillating axle

cylinder hydraulic hoses. Cap the fittings on
the oscillate cylinder.
squirt or spray.

rod-end pivot pin. Use a soft metal drift to
remove the pin.
Part No. 1268197GT Z®-45 XC™ 65

Fault Codes
Before Troubleshooting:
Section 4 Faul t Codes
 Read, understand and obey the safety rules

 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
 Troubleshooting and repair procedures shall Attempting short cuts may produce hazardous
be completed by a person trained and qualified conditions.
on the repair of this machine  Be aware of the following hazards and follow
 Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Key switch in the off position with the key About This Section
removed
There are two types of system faults in this section.
• The red Emergency Stop button in the off
position at both the ground and platform Control System Faults: Faults are indicated by
controls the ALC500 operating system with two short beeps
every 30 seconds when an abnormal condition or
• Wheels chocked component failure occurs with the machine
operating system. This could include machine
• All external AC power supply disconnected functions, limit switches, angle sensors and
from the machine hydraulic valves. Control system faults can be
• Boom in the stowed position retrieved inside the platform control box.
• Turntable secured with the turntable rotation Platform Overload System Fault Codes: Faults
lock are indicated on the hour meter display, a red LED
and with one short beep every second when an
• Welder disconnected from the machine (if abnormal condition or component failure occurs
equipped with the weld cable to platform with the platform overload system. Platform
option) overload system fault codes can be retrieved on
the hour meter display located at the ground
controls.
66 Z®-45 XC™ Part No. 1268197GT

Control System Fault Codes

How to R etrieve Contr ol Sy stem F ault Codes
Control System 3 Determine the error source: The red LED

indicates the error source and will flash two
separate codes. The first code will indicate the
How to Retrieve Control System first digit of the two digit code, flashing once
per second. It will then pause for 1.5 seconds
Fault Codes and flash the second digit once per 0.5
At least one fault code is present when the alarm at second.
the platform controls produces two short beeps
Note: When the red LED is flashing the code, the
every 30 seconds for 10 minutes.
yellow LED will be on solid.
Perform this procedure with the engine off, the key
4 Determine the error type: The yellow LED
switch turned to platform controls and the red
indicates the error type and will flash two
Emergency Stop button pulled out to the on
separate codes. The first code will indicate the
position at both the ground and platform controls.
first digit of the two digit code, flashing once
1 Open the platform control box lid. per second. It will then pause for 1.5 seconds
and flash the second digit once per 0.5
Electrocution/burn hazard. second.
circuits could result in death or Note: When the yellow LED is flashing the code,
serious injury. Remove all rings, the red LED will be on solid.
watches and other jewelry. 5 Use the fault code table on the following pages
to aid in troubleshooting the machine by
2 Locate the red and yellow fault LEDs on the pinpointing the area or component affected.
ALC-500 circuit board inside the platform
control box. Do not touch the circuit board.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.
Part No. 1268197GT Z®-45 XC™ 67


Control System F ault C odes
Error Source Error Type Condition Solution

ID Name ID Name
21 Primary Up / 11 Value at 5.0 V Limited Speed and Direction frozen at Power up controller with
Down Joystick zero and neutral, Alarm sounds. problem corrected.
12 Value Too High
15 Value Too Low
16 Value at 0 V
17 Not calibrated Joystick Speed and Direction frozen at Calibrate Joystick.
zero and neutral.
22 Primary Up / 21 Fault Limited Speed and Direction frozen at Power up controller with
Down Directional zero and neutral, Alarm sounds. problem corrected.
Valves
23 Primary Up / 12 Value Too High Limited Speed and Direction frozen at Power up controller with
Down Flow Valve zero and neutral, Alarm sounds. problem corrected.
15 Value Too Low
17 Not calibrated Normal function except threshold for Calibrate valve threshold.
one or both directions is zero.
24 Angle sensor 11 Value at 5.0 V Reduced function speed. Retract before lowering
required. Dual capacity
12 Value Too High
models.
15 Value Too Low Power up controller with
problem corrected.
16 Value at 0 V
17 Not calibrated Calibrate angle sensor.
31 Invalid setup Initiate 1 -second beep of Alarm. Retract before lowering
required. Dual capacity
models.
Calibrate angle sensor.
26 Angle sensor 19 Out of Range Reduced function speed. Retract before lowering
cross check required. Dual capacity
models.
Power up controller with
problem corrected.
31 Secondary Up / 11 Value at 5.0 V Limited Speed and Direction frozen at Power up controller with
Down. Joystick zero and neutral, Alarm sounds. problem corrected.
12 Value Too High
15 Value Too Low
16 Value at 0 V
zero and neutral.
68 Z®-45 XC™ Part No. 1268197GT


ID Name ID Name
32 Secondary Up / 21 Fault Limited Speed and Direction frozen at Power up controller with
Down. Directional zero and neutral, Alarm sounds. problem corrected.
Valves
33 Secondary Up / 12 Value Too High Limited Speed and Direction frozen at Power up controller with
Down Flow Valve zero and neutral, Alarm sounds. problem corrected.
15 Value Too Low
34 primary Boom 31 Invalid setup Initiate 1 -second beep of Alarm. Fully retract, then lower
Extend / Retract 1000lb. Mode: Required retract into boom.
Limit Switches FULLY RETRACTED state before Check and service ext/ret
lowering. and fully stowed switches.
500lb. Mode: Operates normally.
Dual capacity models.
41 Turntable Rotate 11 Value at 5.0 V Limited Speed and Direction frozen at Power up controller with
Joystick zero and neutral, Alarm sounds. problem corrected.
12 Value Too High
15 Value Too Low
16 Value at 0 V
17 Not calibrated Initiate 1 -second beep of Alarm. Calibrate Joystick.
42 Turntable Rotate 21 Fault Limited Speed and Direction frozen at Power up controller with
Directional Valves zero and neutral, Alarm sounds. problem corrected.
43 Turntable Rotate 12 Value Too High Limited Speed and Direction frozen at Power up controller with
Flow Valve zero and neutral, Alarm sounds. problem corrected.
15 Value Too Low
one or the other direction is zero.
Display message on LCD.
44 Drive Enable 21 Fault Drive enable override direction is Power up controller with
Override Switch frozen at neutral. problem corrected.
45 Platform Level 21 Fault Platform level frozen at neutral. Power up controller with
Switch problem corrected.
46 Primary Extend / 21 Fault Platform Extend / Retract frozen at Power up controller with
Retract Switch neutral. problem corrected.
Part No. 1268197GT Z®-45 XC™ 69


ID Name ID Name
51 Drive Joystick 11 Value at 5.0 V Limited Speed and Direction frozen at Power up controller with
zero and neutral, Alarm sounds. problem corrected.
12 Value Too High
15 Value Too Low
16 Value at 0 V
zero and neutral.
53 Drive Flow Valve 12 Value Too High Limited Speed and Direction frozen at Power up controller with
(EDC) zero and neutral, Alarm sounds. problem corrected.
15 Value Too Low
54 Propel Brake 21 Fault Limited Speed and Direction frozen at Power up controller with
Valve zero and neutral, Alarm sounds. problem corrected.
55 Propel High Motor 21 Fault Motor speed frozen in the low state. Power up controller with
Speed Valve problem corrected.
56 Platform Level 21 Fault Direction frozen at zero and neutral. Power up controller with
Valve problem corrected.
57 Foot switch / ECU 12 Value Too High Direction frozen at zero and neutral. Power up controller with
Power problem corrected.
Crosscheck
15 Value Too Low
61 Steer Joystick 11 Value at 5.0 V Limited Speed and Direction frozen at Power up controller with
zero and neutral, Alarm sounds. problem corrected.
12 Value Too High
15 Value Too Low
16 Value at 0 V
zero and neutral.
62 Steer Direction 21 Fault Limited Speed and Direction frozen at Power up controller with
Valves zero and neutral, Alarm sounds. problem corrected.
81 Platform Load 21 Fault Limited Speed and Direction frozen at Self-clearing (transient)
Sense Overload zero and neutral, Alarm sounds.
70 Z®-45 XC™ Part No. 1268197GT


How to R etrieve Pl atform Overload System F ault C odes
Platform Overload System Fault Codes
How to Retrieve Platform Overload System Fault Codes

At least one or more fault codes are present when the alarm at the platform and ground controls produces
one short beep every second and a solid or flashing red LED is displayed on the hour meter at the ground
controls.
The last two digits of the fault code are the Error Type. The first two or three digits of the fault code are the
Error Source.
1 LCD display
2 red LED - fault indicator
3 yellow LED - battery indicator
4 green LED - engine hours indicator
1 Read and record the fault code(s) shown on the display.

2 Refer to the fault code tables on the following pages.
Part No. 1268197GT Z®-45 XC™ 71


Platform Ov erload Sys tem Fault C odes

ID Name ID Name
34 Ext. Ret. Limit 36 Cross check fault Alarm sounds indicating a fault. Check primary boom
Switch retracted operational
Overload LED is on. (LS1) and safety (LS5)
limit switches.
Functions disabled, engine shutdown. Boom retracted:
Auxiliary functions enabled except 0 volts at C42LS of LS1.
extend. 12 volts at C166LS of
LS5.
75 SCON - Safety 34 Software Alarm sounds indicating a fault. Install correct software part
controller mismatch Overload LED is on. number and version in
Primary and Functions disabled, engine secondary micro-controller.
secondary shutdown.
micro-controllers Auxiliary functions enabled except
software do not extend.
match.
76 Platform load cell 12 Value Too High Platform overloaded. Reduce weight in platform.
13 No Response No communication to load cell. Check CAN bus circuit for
open or short.
Check for cable damage to
load cell.
Check for power at load cell.
15 Value Too Low Output from load cell lower than Confirm the platform load cell
expected while primary up is is properly pre-loaded and is
active. free of obstructions.
17 Not calibrated Zero load not calibrated: Calibrate the load cell.
Alarm sounds indicating a fault.
Overload LED is on.
Functions disabled, engine
shutdown.
Auxiliary functions enabled except
extend.
Zero load calibrated, gain is
not:
Unit operates with reduced load
capacity.
21 Internal load cell Alarm sounds indicating a fault. Inspect load cell for damage.
status Overload LED is on. Cycle power off then back on.
Functions disabled, engine If fault persist, replace load
shutdown. cell.
extend.
31 Invalid setup Calibrate load cell with proper.
load or replace
36 Cross check fault Inspect load cell for damage.
Cycle power off then back on.
If fault persist, replace load
cell.
72 Z®-45 XC™ Part No. 1268197GT


ID Name ID Name
79 Hour meter 13 No Response Loss of communication to hour Check power and ground to
meter. hour meter.
Machine functions normal. Check CAN bus circuit for
open or short.
Check CAN bus resistance
between CAN high and CAN
low. 60 ohms.
82 Overload recovery 21 Fault Platform overloaded and machine Refer to Repair Procedure,
operated using auxiliary power. Platform Overload Recovery
Fault remains active until reset is Fault.
performed.
102 Overload function 12 Value Too High SCON detects 12VDC from CR54 Check for 12VDC at SCON
cutout relay or CR55 terminal 87 when C41-6. Should be 0VDC.
terminals 85 and 86 are not Replace CR54 or CR55.
activated. Check for short to 12VDC in
Alarm sounds indicating a fault. harness to SCON C41-6.
Overload LED is on.
shutdown.
extend.
15 Value Too Low SCON detects 0VDC from CR54 or Check for 0VDC at SCON
CR55 terminal 87 when terminals C41-6. Should be 12VDC.
85 and 86 are activated. Replace CR54 or CR55.
Alarm sounds indicating a fault. Check for open in harness to
Overload LED is on. SCON C41-6.
shutdown.
extend.
103 Overload engine 12 Value Too High SCON detects input from TB21 Replace CR56.
cutout relay when CR56 terminals 85 and 86 Check for short from TB21 in
are not activated. harness to SCON C42-2.
Alarm sounds indicating a fault.
Overload LED is on.
shutdown.
extend.
Part No. 1268197GT Z®-45 XC™ 73

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 hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
 Read, understand and obey the safety rules squirt or spray.
 Be sure that all necessary tools and test
equipment are available and ready for use.
74 Z®-45 XC™ Part No. 1268197GT

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 separator 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
Part No. 1268197GT Z®-45 XC™ 75

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

Cylinder, double acting 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 Solenoid valve, 2 position 2
position 4 way directional position, 4 way proportional
pressure and pilot ratio way
valve directional valve
76 Z®-45 XC™ Part No. 1268197GT

Electrical Component and Wire Color Legends
Item Description Item Description

B Battery H Horn or Alarm
B1 Engine Start - 12V DC H1 Tilt/load sense alarm
C Connector H4 Descent (ground)
C7 Power to platform, 12v cable connector H6 Load sense (ground)
C9 Foot switch input connector JC Joystick
C54 Options connector JC1 Boom proportional joystick: secondary
boom up/down
CB Circuit Breaker
JC2 Boom proportional joystick: primary
CB1 Circuit breaker, engine, 15a
up/down, turntable rotate
CB2 Circuit breaker, controls, 15a
JC3 Drive proportional joystick
CB7 Circuit breaker, controls, 10a Engine throttle
solenoid KS Key switch
KS1 Key switch
CR Control Relay
CR1 Start relay L LED or Light
CR2 Ignition power relay L1 Drive enable led
CR4 High idle relay L2 Check engine led
CR5 Horn relay L4 Platform overload led (ce only)
CR13 Jib relay (jib option) L29 Drive lights
CR14 Jib relay (jib option) L48 Tilt alarm led (ansi/csa only)
CR17 Hydraulic oil cooling fan (option) LS Limit Switch

CR23 Drive light enable LS1 Primary boom extend
CR27 Brake circuit relay (lift/drive option) LS2 Primary boom up
CR30 Limit switch relay (lift/drive option) LS3 Drive enable
CR76 Load sense aux recovery (AS models) LS4 Secondary boom up
CR51 Aircraft package (option) LS18 CE limit switch
G Gauge
G1 Battery Charge Indicator
G2 Engine oil pressure
G3 Engine coolant temp.
G4 Engine oil temp.
G6 Hour meter
Part No. 1268197GT Z®-45 XC™ 77

Item Description Item Description

M Motor TS Toggle Switch
M2 Auxiliary pump TS1 Auxiliary pump switch
M3 Engine starter TS2 Start engine switch
M4 Fuel pump TS3 Fuel select switch (ford efi only)
P Button TS4 Hi/low rpm switch
P1 Red emergency stop button TS6 Glow plug switch
P2 Emergency stop button TS7 Platform rotate switch
P3 Horn Button TS8 Jib rotate switch (jib option)
P4 Function enable button TS9 Platform level switch
PR Power Relay TS13 Primary boom extend/retract switch
PR1 Auxiliary pump (m2) TS14 Drive speed switch
PR2 Engine starter (m3) TS15 Drive enable switch
PR3 Starting aid / glow plugs TS43 Heater switch (option)
PR4 Function pump (m5) TS46 Proximity kill switch (option)
R Resistor TS47 Generator switch (option)
R4 Speed limiting variable resistor 20 ohms TS51 Auxiliary pump toggle switch
R14 Up/down speed resister 7.5 ohms TS52 Engine start toggle switch
TS53 Fuel select toggle switch
SW Switch
TS54 Rpm select toggle switch
SW2 Engine oil pressure
TS56 Glow plug toggle switch
SW3 Engine oil temperature
TS57 Platform rotate toggle switch
TS58 Jib boom up/down toggle switch (option)
TS59 Platform level up/down toggle switch
TS60 Secondary boom up/down toggle switch
TS61 Primary boom up/down toggle switch
TS62 Turntable rotate toggle switch
TS63 Primary boom extend/retract toggle switch
TS64 Run/test toggle switch (Ford)
TS74 Run/test toggle switch (Deutz)
78 Z®-45 XC™ Part No. 1268197GT

Item Description Wire Color Legend

U Module Item Description
U1 Ignition start module BL Blue
U4 EDC - drive pump BK Black
U13 Alc 500 joystick controller card BR Brown
U18 Control module GN Green
U33 Load sense module OR Orange
U34 Time delay relay - 2 seconds, 10A PP Purple
U35 Time delay relay RD Red
U38 Time delay relay WH White
U39 J1939 Ground Control Box Display YL Yellow
X ALC500 connectors BL/RD Blue/Red
X101 ALC500 power connector BL/WH Blue/White
X101 ALC500 input/out connectors BK/RD Black/Red
X102 ALC500 input/out connectors
OR/WH Orange/White
RD/BK Red/Black
RD/WH Red/White
WH/BL White/Blue
WH/BK White/Black
WH/RD White/Red
WH/YL White/Yellow
YL/BK Yellow/Black
X1-4 Circuit splice
Part No. 1268197GT Z®-45 XC™ 79

Hour Meter Legend
The hour meter (HCON) displays the SCON 8 Pin Connector

software version upon startup for 5 seconds. Pin number Circuit Wire color
Under normal operation the display will sequence 1 CAN High Yellow
between engine hours and battery voltage every 5 2 CAN Low Green
seconds.
3 12V (B+) Heater Red
Active platform overload fault codes are also 4 Not Used
displayed. 5 12V (B+) Red
6 Not Used
7 Not Used
8 Ground (B-) Brown
1 LCD display
2 red LED - fault indicator
3 yellow LED - battery indicator
4 green LED - engine hours indicator
5 8 pin connector
80 Z®-45 XC™ Part No. 1268197GT

Hydraulic Schematic
81
Hydraulic Schematic
82 Z®-45 XC™ Part No. 1268197GT

Options Wiring Diagram
83
Options Wiring Diagram
84 Z®-45 XC™ Part No. 1268197GT

Electrical Schematic, Deutz D2011 L03i
85
86 Z®-45 XC™ Part No. 1268197GT

Part No. 1268197GT Z®-45 XC™ 87

88
Ground Control Box Switch Panel Wiring Diagram
89
Ground Control Box Switch Panel Wiring Diagram
90 Z®-45 XC™ Part No. 1268197GT

Ground Control Box Terminal Strip Wiring Diagram
Part No. 1268197GT Z®-45 XC™ 91

Ground Control Box Terminal Strip Wiring Diagram
92
Platform Control Box Switch Panel Wiring Diagram
93
Platform Control Box Switch Panel Wiring Diagram
94 Z®-45 XC™ Part No. 1268197GT

Platform Control Box Terminal Strip Wiring Diagram
Part No. 1268197GT Z®-45 XC™ 95

Platform Control Box Terminal Strip Wiring Diagram
96
Platform Control Box Relay Wiring Diagram
97
Platform Control Box Relay Wiring Diagram
98 Z®-45 XC™ Part No. 1268197GT

Electrical Schematic, Platform Overload
Part No. 1268197GT Z®-45 XC™ 99

Electrical Schematic, Platform Overload

Z®-45 XC
™
Part No. 1268197GT Servic e and R epair M anual June 2018
100 Z®-45 XC™ Part No. 1268197GT

This Manual Includes: Repair Procedures Fault Codes Electrical and Hydraulic Schematics

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Service and Repair Manual

Serial Number Range

For detailed maintenance

Part No. 1268197GT

Important Technical Publications

Compliance Find a Manual for this Model

ii Z®-45 XC™ Part No. 1268197GT

B2 6/2018 Schematics GCON Terminal Strip Wiring Diagram

Part No. 1268197GT Z®-45 XC™ iii

Serial Number Legend

iv Z®-45 XC™ Part No. 1268197GT

Do Not Perform Maintenance

Part No. 1268197GT Z®-45 XC™ v

Personal Safety Workplace Safety

vi Z®-45 XC™ Part No. 1268197GT

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

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

Part No. 1268197GT Z®-45 XC™ vii

Section 3 Repair Procedures ............................................................................................. 13

Platform Controls ............................................................................................... 15

Platform Components ....................................................................................... 20

Jib Boom Components ...................................................................................... 25

Primary Boom Components ............................................................................. 28

viii Z®-45 XC™ Part No. 1268197GT

Secondary Boom Components ......................................................................... 37

Hydraulic Pumps ................................................................................................ 45

Turntable Rotation Components ...................................................................... 64

Axle Components ............................................................................................... 65

Part No. 1268197GT Z®-45 XC™ ix

Section 4 Fault Codes......................................................................................................... 66

Control System Fault Codes ............................................................................. 67

Section 5 Schematics ......................................................................................................... 74

Hydraulic Schematics ........................................................................................ 81

Electrical Schematics – Options ...................................................................... 83

Electrical Schematics – CE Models ................................................................. 85

x Z®-45 XC™ Part No. 1268197GT

Machine Specifications Performance Specifications

Part No. 1268197GT Z®-45 XC™ 1

Hydraulic Oil Specifications Do not top off with incompatible

Note: Extended machine operation can cause the

2 Z®-45 XC™ Part No. 1268197GT

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

Part No. 1268197GT Z®-45 XC™ 3

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

Shell Tellus S4 VX Fluid

4 Z®-45 XC™ Part No. 1268197GT

Hydraulic Component Function manifold

Specifications System relief valve pressure,

Charge Pump Boom extend flow regulator 2 gpm

Function pump Displacement per revolution 0.54 to 1.53 cu in

Auxiliary Pump High pressure filter: Beta 3 ˆ 200

Type gear, fixed High pressure filter bypass 102 psi

Displacement per revolution 0.067 cu in Medium pressure filter Beta 3 ˆ 200

Part No. 1268197GT Z®-45 XC™ 5

Manifold Component Specifications

6 Z®-45 XC™ Part No. 1268197GT

Deutz D2011 L03i Engine Lubrication system