Genie Z40 Manual de Servicio Abril 2016 PDF

Service Manual
Serial Number Range
Z-40/23N from Z4007-100 to

Z40N13-1901
Z-40/23N RJ
Part No. 119817

Rev B1
April 2016
Service Manual April 2016
Introduction
Intr oducti on Intr oducti on
Important Inform ati 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.
maintenance procedure. Therefore, product specifications are subject to
change without notice.
This manual provides detailed scheduled
maintenance information for the machine owner Readers are encouraged to notify Genie of errors
and user. It also provides troubleshooting and and send in suggestions for improvement. All
repair procedures for qualified service communications will be carefully considered for
professionals. future printings of this and all other manuals.
Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However, Contact Us:
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these Internet: www.genielift.com
instances, we strongly recommend that E-mail: [email protected]
maintenance and repair be performed at an
authorized Genie dealer service center. Find a Manual for this Model
Go to http://www.genielift.com
Compliance Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Machine Classification Manuals, Parts Manuals and Operator's Manuals.
Group B/Type 3 as defined by ISO 16368
Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2011 by Terex Corporation

119817 Rev B, April 2016
First Edition, Third Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“Z” is a trademark of Terex South Dakota, Inc.
ii Z-40/23N, Z-40/23N RJ Part No. 119817

April 2016 Service Manual
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A4 12/2014 Repair Procedures Added 2-4, Platform Overload Recovery
B 9/2015 Added ending serial break to front cover.
B1 3/2016 Repair Procedures Updated 1-1, How to Calibrate a Joystick
B1 3/2016 Repair Procedures Updated 9-1, How to Calibrate the Steer Angle Sensor
B1 3/2016 Fault Codes Updated Control System Fault Codes Chart
B1 3/2016 Schematics Updated Chassis Schematic - Beacon option, charger
interlock
B1 3/2016 Schematics Updated Hydraulic Schematic - Orifice size, Secondary
Boom circuit.
B1 3/2016 Specifications Updated Performance Specifications - Boom function
speeds
Reference Examples:
Section – Maintenance, B-3
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. 119817 Z-40/23N, Z-40/23N RJ iii

Introduction
Revision History
Revision Date Section Procedure / Page / Description
Reference Examples:
Section – Maintenance, B-3
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
iv Z-40/23N, Z-40/23N RJ Part No. 119817

Introduction
Serial Number Legend
1 Model
2 Model year
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)
Part No. 119817 Z-40/23N, Z-40/23N RJ v

Safety Rules
Gener al Safety R ules
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.
vi Z-40/23N, Z-40/23N RJ Part No. 119817

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.
Part No. 119817 Z-40/23N, Z-40/23N RJ vii

April 2016
Table of Contents
Introduction Introduction .......................................................................................................... ii

Important Information ..............................................................................................ii
Find a Manual for this Model...................................................................................ii
Revision History ..................................................................................................... iii
Serial Number Legend ........................................................................................... v
Section 1 Safety Rules......................................................................................................... vi

General Safety Rules .............................................................................................vi
Section 2 Specifications ....................................................................................................... 1

Machine Specifications .......................................................................................... 1
Performance Specifications ................................................................................... 2
Hydraulic Specification ........................................................................................... 3
Hydraulic Component Specifications ..................................................................... 5
Manifold Component Specifications....................................................................... 5
Machine Torque Specifications .............................................................................. 6
Hydraulic Hose and Fitting Torque Specifications ................................................. 7
Torque Procedure .................................................................................................. 8
SAE and Metric Fasteners Torque Charts ........................................................... 10
viii Z-40/23N, Z-40/23N RJ Part No. 119817

April 2016
Table of Contents
Section 3 Scheduled Maintenance Procedures ............................................................... 11

Introduction ........................................................................................................... 11
Pre-Delivery Preparation Report .......................................................................... 14
Maintenance Inspection Report............................................................................ 16
Checklist A Procedures ..................................................................................... 17

A-1 Inspect the Manuals and Decals.................................................................... 17
A-2 Perform Pre-operation Inspection .................................................................. 18
A-3 Perform Function Tests ................................................................................. 18
A-4 Perform 30 Day Service................................................................................. 19
A-5 Grease the Turntable Rotation Bearing and Worm Drive Gear ..................... 19
Checklist B Procedures ..................................................................................... 20

B-1 Inspect the Battery ......................................................................................... 20
B-2 Inspect the Electrical Wiring .......................................................................... 21
B-3 Inspect the Tires, Wheels and Lug Nut Torque ............................................. 23
B-4 Confirm the Proper Brake Configuration ....................................................... 23
B-5 Check the Oil Level in the Drive Hubs ........................................................... 24
B-6 Test the Ground Control Override ................................................................. 25
B-7 Test the Platform Self-leveling ....................................................................... 25
B-8 Test the Drive Brakes .................................................................................... 26
B-9 Test the Drive Speed - Stowed Position ........................................................ 26
B-10 Test the Drive Speed - Raised or Extended Position .................................. 27
B-11 Test the Alarm Package (if equipped) ......................................................... 28
B-12 Inspect the Electrical Contactor ................................................................... 28
B-13 Perform Hydraulic Oil Analysis .................................................................... 29
B-14 Test the Emergency Power System ............................................................ 29
Part No. 119817 Z-40/23N, Z-40/23N RJ ix

April 2016
Table of Contents
Checklist C Procedures ..................................................................................... 31

C-1 Grease the Platform Overload Mechanism (if equipped) .............................. 31
C-2 Test the Platform Overload System (if equipped) ......................................... 31
Checklist D Procedures ..................................................................................... 34

D-1 Check the Boom Wear Pads ......................................................................... 34
D-2 Check the Turntable Rotation Bearing Bolts ................................................. 34
D-3 Check the Axle Mounting Bolts ..................................................................... 36
D-4 Check the Platform Rotation Mounting Bolts ................................................ 36
D-5 Check the Free-wheel Configuration ............................................................ 37
D-6 Replace the Drive Hub Oil............................................................................. 38
D-7 Replace the High Pressure Hydraulic Filter Element .................................... 38
D-8 Inspect for Turntable Bearing Wear .............................................................. 39
Checklist E Procedures ..................................................................................... 41

E-1 Test or Replace the Hydraulic Oil.................................................................. 41
E-2 Grease the Steer Axle Wheel Bearings ........................................................ 43
x Z-40/23N, Z-40/23N RJ Part No. 119817

April 2016
Table of Contents
Section 4 Repair Procedures ............................................................................................. 45

Introduction ........................................................................................................... 45
Platform Controls ............................................................................................... 47

1-1 Joysticks ......................................................................................................... 47
How to Adjust the Joystick Threshold Setting ................................................. 48
How to Adjust the Maximum Speed Setting .................................................... 49
How to Adjust the Function Ramp Up Time Setting........................................ 51
How to Adjust the Function Ramp Down Time Setting ................................... 53
How to Adjust the Max Speed Drive Settings ................................................. 54
Platform Components ........................................................................................ 56

2-1 Platform Leveling Slave Cylinder ................................................................... 56
2-2 Platform Rotator ............................................................................................. 57
2-3 Platform Overload System ............................................................................. 58
2-4 Platform Recovery Overload .......................................................................... 60
Jib Boom Components ...................................................................................... 61

3-1 Jib Boom ........................................................................................................ 61
3-2 Jib Boom Bell Crank (models without rotating jib boom) ............................... 62
3-3 Jib Boom Rotator (models with rotating jib boom) ......................................... 63
How to Bleed the Jib Boom Rotator ................................................................ 64
3-4 Jib Boom Lift Cylinder .................................................................................... 65
Primary Boom Components .............................................................................. 66

4-1 Cable Track .................................................................................................... 66
How to Remove the Cable Track .................................................................... 66
How to Repair the Primary Boom Cable Track ............................................... 68
4-2 Primary Boom................................................................................................. 68
How to Remove the Primary Boom ................................................................. 69
How to Disassemble the Primary Boom ......................................................... 71
4-3 Primary Boom Lift Cylinder ............................................................................ 72
4-4 Primary Boom Extension Cylinder ................................................................. 74
4-5 Platform Leveling Master Cylinder ................................................................. 75
Secondary Boom Components ......................................................................... 77

5-1 Secondary Boom ............................................................................................ 78
5-2 Secondary Boom Lift Cylinders ...................................................................... 82
Part No. 119817 Z-40/23N, Z-40/23N RJ xi

April 2016
Table of Contents
Hydraulic Pump .................................................................................................. 84

6-1 Auxiliary and Function Pump ......................................................................... 84
6-2 How to Remove the Function Pump .............................................................. 85
Manifolds ............................................................................................................ 88
7-1 Function Manifold Components ..................................................................... 88
7-2 Valve Adjustments - Function Manifold ......................................................... 90
7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components ................ 94
7-4 Jib Boom and Platform / Jib Rotate Manifold Components ........................... 95
7-5 Valve Coils ..................................................................................................... 96
Turntable Rotation Components ...................................................................... 97

8-1 Turntable Rotation Hydraulic Motor ............................................................... 97
Steer Axle Components .................................................................................... 99

9-1 Hub and Bearings .......................................................................................... 99
How to Calibrate the Steer Angle Sensor .......................................................... 100
Non-steer Axle Components........................................................................... 102

10-1 Drive Motors............................................................................................... 102
10-2 Drive Brake ................................................................................................ 103
Motor Controllers ............................................................................................. 104

11-1 Motor Controllers ....................................................................................... 104
xii Z-40/23N, Z-40/23N RJ Part No. 119817

April 2016
Table of Contents
Section 5 Fault Codes ....................................................................................................... 105

Introduction ......................................................................................................... 105
Control System Fault Codes ........................................................................... 106

How to Retrieve Control System Fault Codes - Platform Controls .................... 106
How to Retrieve Control System Fault Codes - Ground Controls ...................... 107
Control System Fault Codes .............................................................................. 108
Motor Controller Fault Codes.......................................................................... 116

Motor Controller Fault Codes ............................................................................. 116
Drive Motor Thermal Sensor .............................................................................. 119
Section 6 Schematics........................................................................................................ 121

Introduction ......................................................................................................... 121
Wire Circuit Legend ............................................................................................ 122
Wiring Coloring and Legend ............................................................................... 126
Power Cable Diagram ........................................................................................ 131
Motor Contoller Pin Legend ................................................................................ 132
Ground Control Box Pin Legend ........................................................................ 133
Platform Control Box Pin Legend ....................................................................... 134
Turntable and Platform Controller Pin Legend ................................................... 135
Electrical Symbol Legend ................................................................................... 136
Hydraulic Symbols Legend ................................................................................. 137
Electrical Schematics ...................................................................................... 139

Electrical Schematic - Chassis ........................................................................... 140
Electrical Schematic - Ground Controls ............................................................. 141
Electrical Schematic - Platform Controls ............................................................ 144
Ground Control Box Wiring Diagram .................................................................. 145
Platform Control Box Wiring Diagram ................................................................ 148
Platform Control Box Wiring Diagram - Options ................................................. 149
Hydraulic Schematics ...................................................................................... 151

Hydraulic Schematic ........................................................................................... 152
Part No. 119817 Z-40/23N, Z-40/23N RJ xiii

Specifications
Section 2 Specific ati ons
Machi ne Specific ations
Machine Specifications Fluid capacities
Tires and wheels Front Rear Hydraulic tank 8 gallons

Tire size 22 x 7 x 17.75 in 25.6 x 7 x 22 in 30.3 liters
(solid rubber) 56 x 17.8 x 45 cm 56 x 17.8 x Hydraulic system 10 gallons
45 cm (including tank) 37.9 liters
Overall tire diameter 22in 25.6in Drive hubs 23 fl oz
55.9 cm 65 cm 680 cc
Wheel diameter 18.4 in 22 in Drive hub oil type: EP 80-90W gear oil
46.7 cm 56 cm API service classification GL5
Wheel width 7 in 7 in Batteries
Wheel lugs 8 @ 5/8 - 18 9 @ 5/8 - 18
Type 6V DC
Lug nut torque
Group size L16GH
(lubricated) 94 ft-lbs 94 ft-lbs
Quantity 8
127.5 Nm 127.5 Nm
Capacity 350 AH
(dry) 125 ft-lbs 125 ft-lbs
Reserve capacity @ 25A 750 minutes
169.5 Nm 169.5 Nm rate
For operational specifications, refer to the Weight, each 106 lb

48 kgs
Operator's Manual.
Part No. 119817 Z-40/23N, Z-40/23N RJ 1

Specifications
Performanc e Specific ati ons
Performance Specifications Boom function speeds, maximum from platform

controls (with rated load secured to platform)
Z-40/23N and Z-40/23N RJ Jib boom up 16 to 20 seconds
Drive speed, maximum Jib boom down 16 to 20 seconds
Drive speed, stowed 4.5 mph Jib boom rotate, 180°, Z40/23N 16 to 20 seconds
7.24 km/h RJ
40 ft / 6.0 sec
Primary boom up 26 to 30 seconds
12.2 m / 6.0 sec
Primary boom down 26 to 30 seconds
Drive speed, stowed (CE 3.75 mph
models) 6 km/h Primary boom extend 18 to 22 seconds
40 ft / 7.3 sec Primary boom retract 18 to 22 seconds
12.2 m / 7.3 sec
Secondary boom up 32 to 36 seconds
Drive speed, boom raised or 0.68 mph
extended, all models 1.09 km/h Secondary boom down° 32 to 36 seconds
40 ft/40 sec Turntable rotate, 355° 62 to 68 seconds
12.2 m/40 sec
Platform rotate, 180° 10 to 14 seconds
Braking distance
On paved surface 5 to 7 ft
1.5 to 2m
Gradeability See Operator's
Manual
2 Z-40/23N, Z-40/23N RJ Part No. 119817

Specifications
Hydraulic Specific ati on
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
1 Chevron hydraulic oil 5606A
Product Support before use.
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.
Part No. 119817 Z-40/23N, Z-40/23N RJ 3

Specifications
Chevron Rando HD Premium Oil Petro-Canada Environ MV 46

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 46
Viscosity index 200 Viscosity index 154
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 8.0
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 44.4
Brookfield Viscosity Flash point 482°F / 250°C
cP @ -4°F / -20°C 1040 Pour point -49°F / -45°C
cP @ -22°F / -30°C 3310
Maximum continuous operating 180°F / 82°C
Flash point 375°F / 190°C temperature
Pour point -58°F / -50°C
Maximum continuous operating 171°F / 77°C Shell Tellus S4 VX Fluid
temperature
Note: A hydraulic oil heating system is
Properties
recommended when the ambient temperature is ISO Grade 32
consistently below 0°F / -18°C.
Viscosity index 300
Note: Do not operate the machine when the Kinematic Viscosity
ambient temperature is below -20°F / -29°C with cSt @ 200°F / 100°C 9
Rando HD Premium MV. cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
Chevron 5606A Hydraulic Oil cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
Fluid Properties cSt @ -40°F / -40°C 2624
ISO Grade 15 Flash point >100
Viscosity index 300 Pour point -76°F / -60°C
Kinematic Viscosity Maximum continuous operating 103°F / 75°C
cSt @ 200°F / 100°C 5.5 temperature
cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Flash point 180°F / 82°C
UCON Hydrolube HP-5046 Fluid
Pour point -81°F / -63°C Properties
Maximum continuous operating 124°F / 51°C ISO Grade 46
temperature
Viscosity index 192
Note: Use of Chevron 5606A hydraulic fluid, or
Kinematic Viscosity
equivalent, is required when ambient temperatures cSt @ 149°F / 65°C 22
are consistently below 0°F / -17°C unless an oil cSt @ 104°F / 40°C 46
heating system is used. cSt @ 0°F / -18°C 1300
Flash point None
Continued use of Chevron 5606A
hydraulic fluid, or equivalent, Pour point -81°F / -63°C
when ambient temperatures are Maximum continuous operating 189°F / 87°C
consistently above 32°F / 0°C temperature
may result in component damage
4 Z-40/23N, Z-40/23N RJ Part No. 119817

Specifications
Hydraulic C omponent Speci fications Manifold Com ponent Specific ati ons
Hydraulic Component Manifold Component

Specifications Specifications
Function pump Plug torque
Type: Fixed displacement gear pump SAE No. 2 36 in-lbs / 4 Nm
Displacement 0.244 cu in SAE No. 4 10 ft-lbs / 13 Nm
4 cc
SAE No. 6 14 ft-lbs / 19 Nm
High pressure filter Beta 3≥200 with 101 psi
/ 7 bar bypass
Function manifold
Proportional relief pressure, variable 50 to 3000 psi
3.4 to 207 bar Valve Coil Resistance
Primary boom down relief valve 2100 psi Note: The following coil resistance specifications are at
pressure 145 bar an ambient temperature of 68°F / 20°C. As valve coil
resistance is sensitive to changes in air temperature, the
Platform level relief valve pressure 2500 psi
coil resistance will typically increase or decrease by 4%
172 bar
for each 18°F / 10°C that your air temperature increases
Platform level flow regulator 1800 psi or decreases from 68°F / 20°C.
124 bar
Valve Coil Resistance Specification
Turntable rotate relief pressure 0.6 gpm
Description Specification
2.27 L/min
Solenoid valve, 3 position 4 way, 20V DC 24 Ω
Auxiliary pump
(schematic item BG)
Type: Fixed
Proportional solenoid valve, 3 position 24 Ω
displacement
4 way, 20V DC (schematic items AA, AB,
gear pump
AC, BC, BG, BK, BN, BS, and BU)
Displacement 0.5 gpm
Proportional solenoid relief valve, 20V DC 22 Ω
1.9 L/min
(schematic item BW)
Part No. 119817 Z-40/23N, Z-40/23N RJ 5

Specifications
Machi ne T orque Specifications
Machine Torque Specifications

Platform rotator
3/4 -10 center bolt, GR 8 (dry) 380 ft-lbs
515 Nm
3/4 - 10 center bolt, GR 8 (lubricated) 280 ft-lbs

379 Nm
3/8 -16 bolts, GR 8, (dry) 44 ft-lbs
60 Nm
3/8 -16 bolts, GR 8, (lubricated) 33 ft-lbs
45 Nm
Jib boom rotator, Z-40/23N RJ
1 -8 center bolt, GR 5, (dry) 640 ft-lbs
868 Nm
1 -8 center bolt, GR 5, (dry) 480 ft-lbs
650 Nm
1/2 - 13 bolts, GR 5, (dry) 75 ft-lbs
102 Nm
1/2 - 13 bolts, GR 5, (lubricated) 57 ft-lbs
77Nm
Axles
5/8 -11 mounting bolt, GR 5 (dry) 150 ft-lbs
203 Nm
5/8 11 mounting bolt, GR 5 (lubricated) 101 ft-lbs
149 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 180 ft-lbs
244 Nm
Rotate bearing motor/brake mounting bolts, 93 ft-lbs
lubricated 126 Nm
Drive motor and hubs
Drive hub mounting bolts, lubricated 180 ft-lbs
244 Nm
Drive motor mounting bolts, lubricated 5 ft-lbs
6.8 Nm
6 Z-40/23N, Z-40/23N RJ Part No. 119817

Specifications
Hydraulic H ose and Fitting T orque Specific ations
Hydraulic Hose and Fitting

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

(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
-4 7/16-20 2
SAE O-ring Boss Port
(tube fitting - installed into Steel)
-6 9/16-18 1¼
SAE Dash Size Torque
-8 3/4-16 1
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-10 7/8-14 1 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
-12 1 1/16-12 1 37° (Non-adj) 22 ft-lbs / 30 Nm
-16 1 5/16-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-20 1 5/8-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-24 1 7/8-12 1
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 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. 119817 Z-40/23N, Z-40/23N RJ 7

Specifications
Torque Pr ocedure
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.
8 Z-40/23N, Z-40/23N RJ Part No. 119817

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. 119817 Z-40/23N, Z-40/23N RJ 9

Specifications
SAE and M etric F asteners Tor que C harts
10 Z-40/23N, Z-40/23N RJ Part No. 119817

Scheduled Maintenance Procedures

Section 3 Schedul ed Mai ntenance Pr ocedures
Intr oducti on
Machine Configuration:
 Unless otherwise specified, perform each
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
 Maintenance inspections shall be completed • The red Emergency Stop button in the off
by a person trained and qualified on the position at both the ground and platform
maintenance of this machine. controls
 Scheduled maintenance inspections shall be • Wheels chocked
completed daily, quarterly, semi-annually,
• All external AC power supply disconnected
annually and every 2 years as specified of the
from the machine
Maintenance inspection Report. The frequency
and extent of periodic examinations and tests • Boom in the stowed position
may also depend on national regulations.
• Turntable secured with the turntable rotation
Failure to perform each lock
procedure as presented and
scheduled may cause death,
serious injury or substantial
damage.
 Immediately tag and remove from service a

damaged or malfunctioning machine.
 Repair any machine damage or malfunction
before operating the machine.
 Use only Genie approved replacement parts.
 Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Part No. 119817 Z-40/23N, Z-40/23N RJ 11

About This Section Maintenance Symbols Legend

This section contains detailed procedures for each Note: The following symbols have been used in this
scheduled maintenance inspection. manual to help communicate the intent of the
instructions. When one or more of the symbols
Each procedure includes a description, safety appear at the beginning of a maintenance
warnings and step-by-step instructions. procedure, it conveys the meaning below.
Symbols Legend Indicates that tools will be required to

perform this procedure.
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety Indicates that new parts will be required to
messages that follow this symbol perform this procedure.
to avoid possible injury or death.
Indicates a imminently hazardous Indicates that dealer service will be

situation which, if not avoided, will required to perform this procedure.
Indicates a potentially hazardous Indicates that a cold motor or pump will be

situation which, if not avoided, required to perform this procedure.
could result in death or serious
injury.

situation which, if not avoided,
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
12 Z-40/23N, Z-40/23N RJ Part No. 119817

Pre-delivery Preparation Report

The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies for each inspection. Store completed
forms as required.
Maintenance Schedule
The Scheduled Maintenance Procedures section
and the Maintenance Inspection Report have been
divided into subsections. Use the following chart to
determine which group(s) of procedures are
required to perform a scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C
Annually or every 1000 hours A+B+C+D
Two-year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report

The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.
Part No. 119817 Z-40/23N, Z-40/23N RJ 13

Pre-Delivery Preparation Report

Pre-Deliv ery Prepar ati on Repor t
Fundamentals Instructions
It is the responsibility of the owner or dealer to Use the operator’s manual on your machine.
perform the Pre-delivery Preparation.
The Pre-delivery Preparation consists of
The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the
each delivery. The inspection is designed to Maintenance items and the Function Tests.
discover if anything is apparently wrong with a
machine before it is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be Follow the instructions in the operator’s manual.
used. If damage or any variation from factory
delivered condition is discovered, the machine If any inspection receives an N, remove the
must be tagged and removed from service. machine from service, repair and re-inspect it. After
repair, place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, acceptable
N = no, remove from service
Scheduled maintenance inspections shall be R = repaired
performed by qualified service technicians, Comments
according to the manufacturer's specifications and
the requirements listed in the responsibilities
manual.
Pre-delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
This page intentionally left blank.
Part No. 119817 Z-40/23N, Z-40/23N RJ 15

Maintenance Inspection Report

Maintenanc e Ins pection R eport
Model Checklist A Y N R Checklist C Y N R

Serial number A-1 Inspect the manuals C-1 Grease platform
Date and decals overload (if equipped)
Hour meter A-2 Pre-operation C-2 Test platform

inspection overload (if equipped)
Machine owner
A-3 Function tests Checklist D Y N R
Inspected by (print)
Perform after 40 hours: D-1 Boom wear pads
Inspector signature
A-4 30-day service D-2 Turntable bearing
Inspector title bolts
Inspector company Perform every 100 hours:
D-3 Axle mounting bolts
A-5 Grease rotation
bearing D-4 Platform rotation bolts
Instructions
Checklist B Y N R D-5 Free-wheel
• Make copies of this report to use for configuration
each inspection. B-1 Battery
D-6 Drive hub oil
• Select the appropriate checklist(s) for B-2 Electrical wiring
the type of inspection(s) to perform. D-7 Hydraulic filters
B-3 Tires and wheels
Daily or every 8 hours A D-8 Turntable bearing
Quarterly or every A+B B-4 Drive hub bolts wear
250 hours B-5 Drive hub oil Checklist E Y N R
Semi-annually or A+B+C
B-6 Ground control E-1 Hydraulic oil
every 500 hours override
Annually or A+B+C+D E-2 Wheel bearings
B-7 Platform leveling
every Comments
1000 hours B-8 Drive brakes
Two-year or A+B+C+D+E B-9 Drive speed - stowed
every
2000 hours B-10 Drive speed - raised
• Place a check in the appropriate box B-11 Alarm package
after each inspection procedure is
completed. B-12 Electrical contactors
• Use the step-by-step procedures in B-13 Hydraulic oil analysis
this section to learn how to perform
these inspections. B-14 Test the Emergency
Power System
• If any inspection receives an "N," tag
and remove the machine from service,
repair and re-inspect it. After repair,
place a check in the "R" box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
16 Z-40/23N, Z-40/23N RJ Part No. 119817

Checklist A Procedures
Checklist A Pr ocedur es
A-1 Ins pect the M anuals and D ec als
A-1 3 Open the operator's manual to the decals

inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed every 8 hours or daily, whichever comes Result: The machine is equipped with all
first. required decals, and all decals are legible and
Maintaining the operator’s and safety manuals in in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each required decals, or one or more decals are
machine and should be stored in the container illegible or in poor condition. Remove the
provided in the platform. An illegible or missing machine from service until the decals are
manual will not provide safety and operational replaced.
information necessary for a safe operating
condition. 4 Always return the manuals to the storage
container after use.
In addition, maintaining all of the safety and
Note: Contact your authorized Genie distributor or
instructional decals in good condition is mandatory
Genie if replacement manuals or decals are
for safe machine operation. Decals alert operators
needed.
and personnel to the many possible hazards
associated with using this machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
1 Check to make sure that the operator's and
safety manuals are present and complete in
the storage container on the platform.
2 Examine the pages of each manual to be sure
that they are legible and in good condition.
Result: The operator's manual is appropriate
for the machine and all manuals are legible
and in good condition.
Result: The operator's manual is not
appropriate for the machine or all manuals are
not in good condition or is illegible. Remove
the machine from service until the manual is
replaced.
Part No. 119817 Z-40/23N, Z-40/23N RJ 17

A-2 Per form Pre- operation Ins pection A-3 Per form F uncti on Tes ts
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes
first. first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
18 Z-40/23N, Z-40/23N RJ Part No. 119817

A-4 Per form 30 Day Servic e A-5 Greas e the T urntable R otati on Beari ng and Worm Driv e Gear
A-4 A-5
Perform 30-Day Service Grease the Turntable Rotation
Bearing and Worm Drive Gear
The 30-day maintenance procedure is a one time

procedure to be performed after the first 30 days or
Genie specifications require that this procedure be
40 hours of usage. After this interval, refer to the
performed every 100 hours of operation. Perform
maintenance tables for continued scheduled
this procedure more often if dusty conditions exist.
maintenance.
Frequent application of lubrication to the turntable
1 Perform the following maintenance
bearing and rotate gear is essential to good
procedures:
machine performance and service life. Continued
All Models: use of an improperly greased bearing and gear will
result in component damage.
• B-3 Inspect the Tires, Wheels and Lug
Nut Torque 1 Open the ground controls side turntable cover.
• B-4 Check the Drive Hub Mounting 2 Locate the grease fitting for the turntable
Bolts rotate bearing.
• D-2 Check the Turntable Rotation 3 Pump grease into the turntable rotation
Bearing Bolts bearing. Rotate the turntable in increments of
4 to 5 inches / 10 to 13 cm at a time and
• D-3 Check the Axle Mounting Bolts repeat this step until the entire bearing has
been greased.
• D-4 Check the Platform Rotation
Mounting Bolts 4 Apply grease to each tooth of the drive gear,
located under the turntable.
• D-7 Replace the Hydraulic Filters
Grease Specification
Chevron Ultra-duty grease, EP NLGI 1 (lithium based)
or equivalent
Part No. 119817 Z-40/23N, Z-40/23N RJ 19

Checklist B Procedures
Checklist B Pr ocedur es
B-1 Ins pect the Battery
B-1 4 Be sure that the battery cable connections are

free of corrosion.
Inspect the Battery
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion
on the battery terminals and cables.
Genie specifications require that this procedure be 5 Be sure that the battery retainers and cable
performed every 250 hours or quarterly, whichever connections are tight.
comes first.
6 Fully charge the batteries. Allow the batteries
Proper battery condition is essential to good engine to rest 24 hours before continuing this
and machine performance and operational safety. procedure to allow the battery cells to
Improper fluid levels or damaged cables and equalize.
connections can result in engine and component
damage and hazardous conditions. 7 Put on protective clothing and eye wear.
8 Remove the battery vent caps and check the
Electrocution/burn hazard.
specific gravity of each battery cell with a
Contact with electrically charged
hydrometer. Note the results.
circuits could result in death or
serious injury. Remove all rings, 9 Check the ambient air temperature and adjust
watches and other jewelry. the specific gravity reading for each cell as
follows:
Bodily injury hazard. Batteries • Add 0.004 to the reading of each cell for
contain acid. Avoid spilling or every 10° / 5.5° C above 80° F / 26.7° C.
contacting battery acid.
Neutralize battery acid spills with • Subtract 0.004 from the reading of each cell
baking soda and water. for every 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjusted
1 Disconnect each battery pack from the
specific gravity of 1.277 or higher. The battery
machine.
is fully charged. Proceed to step 13.
2 Release the battery pack latch and rotate the
Result: One or more battery cells display a
battery pack out and away from the chassis.
specific gravity of 1.217 or below. Proceed to
3 Remove the cover from each battery box. step 10.
10 Perform an equalizing charge OR fully charge
the batteries and allow the batteries to rest at
least 6 hours.
11 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
20 Z-40/23N, Z-40/23N RJ Part No. 119817

B-2 Ins pect the Electrical Wiring
12 Check the ambient air temperature and adjust B-2

the specific gravity reading for each cell as
follows:
Inspect the Electrical Wiring
• Add 0.004 to the reading of each cell for every 10°
/ 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell for
performed every 250 hours or quarterly, whichever
every 10° / 5.5° C below 80° F / 26.7° C.
comes first.
Result: All battery cells display a specific
Maintaining electrical wiring in good condition is
gravity of 1.277 or greater. The battery is fully
essential to safe operation and good machine
charged. Proceed to step 13.
performance. Failure to find and replace burnt,
Result: The difference in specific gravity chafed, corroded or pinched wires could result in
readings between cells is greater than 0.1 OR unsafe operating conditions and may cause
the specific gravity of one or more cells is less component damage.
than 1.217. Replace the battery.
13 Check the battery acid level. If needed, Contact with electrically charged
replenish with distilled water to 1/8 inch / 3 mm circuits could result in death or
below the bottom of the battery fill tube. Do not serious injury. Remove all rings,
overfill. watches and other jewelry.
14 Install the vent caps and neutralize any
electrolyte that may have spilled. 1 Open both turntable covers.
2 Inspect the following areas for burnt, chafed,
corroded and loose wires:
• Hydraulic power unit
• High pressure filter
• Inside of the ground control box
• Turntable manifold wiring
3 Inspect for a lite, even coating of dielectric
grease in the following locations:
• All wire harness connectors to the ground
control box.
• All wire harness connectors to the turntable
control module (TCON) (located under the
ground control box).
Note: Do not apply excessive amounts of dielectric
grease to harness connectors, pins or sockets.
Part No. 119817 Z-40/23N, Z-40/23N RJ 21

4 Remove the drive chassis cover from the 14 Install the center turntable cover.
nonsteer end of the machine.
15 Lower the boom to the stowed position and
5 Inspect the following areas for burnt, chafed, turn the machine off.
corroded, pinched and loose wires:
16 Inspect the following areas for burnt, chafed,
• Drive motors corroded, pinched and loose wires:
• Motor controllers • Cable track on the primary, jib and
secondary booms
• Electrical contactor
• Jib boom to platform cable harness
6 Inspect for a lite, even coating of dielectric
grease in the following locations: • Inside of the platform control box
• Motor controller wire harness connectors 17 Inspect for a lite, even coating of dielectric
grease in the following locations:
grease to harness connectors, pins or sockets. • All wire harness connectors to the platform
control box
7 Remove the drive chassis cover from the steer
end of the machine. • All wire harness connectors to the platform
control module (PCON) (located inside of
8 Remove the cover from the fuse box located the platform control box)
above the steer axle.
9 Inspect the following areas for burnt, chafed, grease to harness connectors, pins or sockets.
corroded, pinched and loose wires:
• Fuses
• Steer sensor and harness
10 Install the fuse box cover and both drive
chassis covers.
11 Raise the secondary boom until the mid-pivot
is approximately 10 feet / 3 m off the ground.
12 Remove the center turntable cover.
13 Inspect the following areas for burnt, chafed
and pinched cables:
• Turntable area
• Auxiliary power unit
22 Z-40/23N, Z-40/23N RJ Part No. 119817

B-3 Ins pect the Tir es, Wheels and Lug N ut T orque B-4 C onfirm the Pr oper Brak e C onfigurati on
B-3 B-4
Inspect the Tires, Wheels and Check the Drive Hub Mounting
Lug Nut Torque Bolts
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
Maintaining the tires and wheels, including proper Maintaining proper torque of the drive hub
wheel fastener torque, is essential to safe mounting bolts is essential to safe machine
operation and good performance. Tire and/or operation. Improper bolt torque could result in an
wheel failure could result in a machine tip-over. unsafe operating condition and component
Component damage may also result if problems damage.
are not discovered and repaired in a timely fashion.
1 Remove the axle covers from the non-steer
Bodily injury hazard. An axle.
over-inflated tire can explode 2 Check the torque of the drive hub bolts. Refer
and could cause death or serious to Specifications, Machine Specifications.
injury.
Tip-over hazard. Do not use

temporary flat tire repair
products.
Note: The tires on some machines are foam-filled

and do not need air added to them.
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear.
2 Check each wheel for damage, bends and
cracked welds.
3 Check each lug nut for proper torque. Refer to
Specifications, Machine Specifications.
4 Check the pressure in each air-filled tire.
Part No. 119817 Z-40/23N, Z-40/23N RJ 23

3 If necessary, remove the top plug and add oil
B-5 C heck the Oil Lev el in the Drive H ubs
B-5 until the oil level is even with the bottom of the
Check the Drive Hub Oil Level side plug hole.
and Fastener Torque 4 Install the plug(s) into the drive hub.
5 Check the torque of the drive hub mounting
bolts. Refer to Specifications, Machine
Specifications.
performed every 250 hours or quarterly, whichever 6 Repeat this procedure for each drive hub.
comes first.
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and continued
use may cause component damage.
1 Drive the machine to rotate the hub until the
plugs are located one on top and the other at
90 degrees.
1 drive hub plugs
2 Remove the plug located at 90 degrees and

check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
24 Z-40/23N, Z-40/23N RJ Part No. 119817

B-6 T est the Gr ound Contr ol Override B-7 T est the Pl atform Self-l eveli ng
B-6 B-7
Test the Ground Control Override Test the Platform Self-leveling
comes first.
Note: Genie specifications require that this
A properly functioning ground control override is procedure be performed every 250 hours or
essential to safe machine operation. The ground quarterly, whichever comes first.
control override function is intended to allow
Automatic platform self-leveling throughout the full
ground personnel to operate the machine from the
cycle of boom raising and lowering is essential for
ground controls whether or not the Emergency
safe machine operation. The platform is maintained
Stop button on the platform controls is in the on or
level by the platform leveling slave cylinder which is
off position. This function is particularly useful if the
controlled by the platform leveling master cylinder
operator at the platform controls cannot return the
located at the base of the primary boom. A platform
boom to the stowed position.
self-leveling failure creates an unsafe working
1 Push in the red Emergency Stop button at the condition for platform and ground personnel.
platform controls to the off position.
1 Turn the key switch to ground controls and pull
2 Turn the key switch to ground controls and pull out the red Emergency Stop button to the 'ON'
out the red Emergency Stop button to the 'ON' position at both the ground and platform
position. controls.
3 Operate each boom function through a partial 2 Lower the boom to the stowed position.
cycle at the ground controls.
3 Hold the function enable toggle switch to
Result: All boom functions should operate. either side and adjust the platform to a level
position using the platform level toggle switch.
4 Raise and lower the primary boom through a
full cycle.
Result: The platform should remain level at all
times to within ±5 degrees.
Part No. 119817 Z-40/23N, Z-40/23N RJ 25

B-8 T est the Drive Brakes B-9 T est the Drive Speed - Stow ed Posi tion
B-8 B-9
Test the Drive Brakes Test the Drive Speed – Stowed
Position

comes first.
Proper brake action is essential to safe machine comes first.
operation. The drive brake function should operate
Proper drive function is essential to safe machine
smoothly, free of hesitation, jerking and unusual
operation. The drive function should respond
noise. Hydraulically-released individual wheel
quickly and smoothly to operator control. Drive
brakes can appear to operate normally when they
performance should also be free of hesitation,
are actually not fully operational.
jerking and unusual noise over the entire
Collision hazard. Be sure that the proportionally controlled speed range.Note: Select
machine is not in free-wheel or a test area that is firm, level and free of
partial free-wheel configuration. obstructions.
Refer to maintenance procedure, 1 Create start and finish lines by marking two
Confirm the Proper Brake lines on the ground 40 feet / 12.2 m apart.
Configuration.
2 Turn the key switch to platform control and pull
Note: Select a test area that is firm, level and free out the red Emergency Stop button to the on
of obstructions. position at both the ground and platform
controls.
1 Mark a test line on the ground for reference.
3 Lower the boom to the stowed position.
2 Lower the boom to the stowed position.
4 Choose a point on the machine (i.e., contact
3 Turn the key switch to platform controls. patch of a tire) as a visual reference for use
4 Choose a point on the machine (i.e., contact when crossing the start and finish lines.
patch of a tire) as a visual reference for use 5 Bring the machine to top drive speed before
when crossing the test line. reaching the start line. Begin timing when your
5 Bring the machine to top drive speed before reference point on the machine crosses the
reaching the test line. Release the drive start line.
joystick when your reference point on the 6 Continue at full speed and note the time when
machine crosses the test line. the machine reference point crosses the finish
6 Measure the distance between the test line line. Refer to Specifications, Performance
and your machine reference point. Refer to Specifications.
Specifications, Performance Specifications.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
26 Z-40/23N, Z-40/23N RJ Part No. 119817

B-10 T est the Driv e Speed - Rais ed or Ex tended Posi tion
B-10 5 Lower the boom to the stowed position and

extend the boom 1 foot / 30 cm.
Test the Drive Speed – Raised or
Extended Position patch of a tire) as a visual reference for use
when crossing the start and finish lines.
7 Bring the machine to top drive speed before
Genie specifications require that this procedure be reaching the start line. Begin timing when your
performed every 250 hours or quarterly, whichever reference point on the machine crosses the
comes first. start line.
Proper drive function is essential to safe machine 8 Continue at full speed and note the time when
operation. The drive function should respond the machine reference point crosses the finish
quickly and smoothly to operator control. Drive line. Refer to Specifications, Performance
performance should also be free of hesitation, Specifications.
jerking and unusual noise over the entire
proportionally controlled speed range.
Note: Select a test area that is firm, level and free
of obstructions.
1 Create start and finish lines by marking two
lines on the ground 40 feet / 12.2 m apart.
patch of a tire) as a visual reference for use
3 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
4 Continue at full speed and note the time when
the machine reference point crosses the finish
line. Refer to Specifications, Performance
Specifications.
Part No. 119817 Z-40/23N, Z-40/23N RJ 27

B-11 T est the Alarm Pack age (if equi pped) B-12 Ins pec t the Elec trical C ontac tor
B-11 B-12
Test the Alarm Package (if Inspect the Electrical Contactor
equipped)
performed every 250 hours or quarterly, whichever Genie requires that this procedure be performed
comes first. every 250 hours or quarterly, whichever comes
first.
The alarm package includes:
Maintaining the electrical contactor in good
• Travel alarm condition is essential to safe machine performance.
• Descent alarm Failure to locate a worn or damaged contactor
could result in unsafe operating conditions and may
• Flashing beacon cause component damage.
Alarms and a beacon are installed to alert 1 Remove the drive chassis cover from the
operators and ground personnel of machine non-steer end of the machine and locate the
proximity and motion. The alarm package is electrical contactor mounted to the inside of
installed on the turntable covers. the non-steer axle.
1 Turn the key switch to ground control and pull 2 Locate the electrical contactor mounted on the
out the red Emergency Stop button to the 'ON' fuse bracket.
position at both the ground and platform
controls. 3 Visually inspect the contact points of the
contactor for the following items:
Result: The flashing beacon should be on and
flashing. • Excessive burns
2 Turn the key switch to platform control. • Excessive arcs
Result: The flashing beacon should be on and • Excessive pitting
flashing.
3 Press down the foot switch. Move the drive Contact with electrically charged
control handle off center, hold for a moment circuits could result in death or
and then release it. Move the drive control serious injury. Remove all rings,
handle off center in the opposite direction, watches and other jewelry.
hold for a moment and then release it.
Note: Replace the contactor if any damage is
Result: The travel alarm should sound when found.
the drive control handle is moved off center in
either direction.
28 Z-40/23N, Z-40/23N RJ Part No. 119817

B-13 Perform Hy draulic Oil Analysis B-14 T est the Emer gency Pow er Sy stem
B-13 Perform Hydraulic Oil B-14

Analysis Test the Emergency Power
System

comes first.
Replacement or testing of the hydraulic oil is comes first.
essential for good machine performance and
Testing the emergency power system regularly is
service life. Dirty oil and a clogged suction strainer
essential to safe machine operation if the primary
may cause the machine to perform poorly and
power source fails.
continued use may cause component damage.
Extremely dirty conditions may require oil changes 1 Turn the key switch to ground control and pull
to be performed more often. For hydraulic oil out the red Emergency Stop button to the on
specifications, Refer to Specifications, Hydraulic position at both the ground and platform
Specifications. controls.
Note: Before replacing the hydraulic oil, the oil may 2 At the ground controls, break the security tie
be tested by an oil distributor for specific levels of and lift the emergency power switch cover (if
contamination to verify that changing the oil is equipped).
necessary. If the hydraulic oil is not replaced at the
3 Simultaneously hold the emergency power
two year inspection, test the oil quarterly. Replace
switch on and activate each boom function
the oil when it fails the test. Refer to Maintenance
toggle switch.
Procedure, Test or Replace the Hydraulic Oil.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom functions operate.
4 Close the emergency power switch cover and
secure the cover with a security tie (if
equipped).
Part No. 119817 Z-40/23N, Z-40/23N RJ 29

5 Turn the key switch to platform controls.

6 At the platform controls, break the security tie
and lift the emergency power switch cover (if
equipped).
7 Press down on the foot switch and
simultaneously hold the emergency power
switch on and activate each boom function.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom functions operate.
8 Close the emergency power switch cover and
secure the cover with a security tie (if
equipped).
30 Z-40/23N, Z-40/23N RJ Part No. 119817

Checklist C Procedures
Checklist C Pr ocedur es C-2 Test the Platform Ov erload Sy stem (if equipped)
C-1 Gr eas e the Platform Ov erload Mec hanism (if equipped)
C-1 C-2
Grease the Platform Overload Test the Platform Overload
Mechanism (if equipped) System (if equipped)
performed every 500 hours or six months, performed every 500 hours or six months,
whichever comes first. whichever comes first OR when the machine fails
to lift the maximum rated load.
Perform this procedure more often if dusty
conditions exist. Testing the platform overload system regularly is
essential to safe machine operation. Continued use
Application of lubrication to the platform overload of an improperly operating platform overload
mechanism is essential to safe machine operation. system could result in the system not sensing an
Continued use of an improperly greased platform overloaded platform condition. Machine stability
overload mechanism could result in the system not could be compromised resulting in the machine
sensing an overloaded platform condition and will tipping over.
result in component damage.
The platform overload system is designed to detect
1 Locate the grease fittings on each pivot pin of an overloaded platform and prevent machine
the platform overload assembly. operation anytime the machine is turned on. When
2 Thoroughly pump grease into each grease activated, the system halts all normal boom
fitting. operation, giving visual and audible warning to the
operator.
Grease Specification
Models equipped with the platform overload option
Chevron Ultra-duty grease, EP NLGI 1 (lithium based) are provided with additional machine components:
or equivalent
an adjustable spring-loaded platform support
subassembly, a limit switch, an electronic module
which receives the overload signal and interrupts
power, and an audio/visual warning indication to
alert the operator of the overload.
Part No. 119817 Z-40/23N, Z-40/23N RJ 31

The platform support subassembly utilizes two load 5 Carefully move the test weights to each
support arms that are opposed in a full remaining location on the platform. Refer to
parallelogram link. This isolates platform loads into Illustration 1.
a shear or vertical state, which translates into a
compressive load. A spring in the parallelogram Result: The platform overload indicator lights
link supports this purely compressive load should be off at both the ground and platform
regardless of where the load is placed in the controls and the alarm should not sound.
platform. Result: The platform overload indicator lights
are on and the alarm is sounding. Calibrate
As weight is added to the platform, the spring will
the platform overload system. Refer to Repair
compress until, when the platform is overloaded,
Procedure, How to Calibrate the Platform
the lower arm contacts a limit switch and thereby
Overload System (if equipped).
activating the overload signal. When adjusted
correctly, the platform overload system will
deactivate normal boom operation at platform
capacity.
Note: Perform this procedure with the machine on
a firm, level surface.
1 Turn the key switch to platform control. Start
the engine and level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate. Illustration 1
3 Remove all weight, tools, accessories and 6 Using a suitable lifting device, place an
equipment from the platform. additional 10 lbs / 23 kg of weight onto the
platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an Result: The alarm should sound. The platform
inaccurate test. overload indicator lights should be flashing at
both the ground and platform controls.
4 Using a suitable lifting device, place a test
weight equal to that of the available capacity in Result: The alarm does not sound and the
one of the locations shown. Refer to platform overload indicator lights are not
Illustration 1. flashing. Calibrate the platform overload
system. Refer to Repair Procedure, How to
Result: The platform overload indicator lights Calibrate the Platform Overload System (if
should be off at both the ground and platform equipped).
controls and the alarm should not sound.
Note: There may be a 2 second delay before the
Result: The platform overload indicator lights overload indicator lights flash and the alarm
are on and the alarm is sounding. Calibrate sounds.
the platform overload system. Refer to Repair
Procedure, How to Calibrate the Platform
Overload System (if equipped).
32 Z-40/23N, Z-40/23N RJ Part No. 119817

7 Carefully move the test weights to each 12 Using a suitable lifting device, remove all test
remaining location on the platform. Refer to weights from the platform.
Illustration 1.
Result: The alarm does not sound and the
Result: The platform overload indicator lights platform overload indicator lights are not
should be flashing at both the ground and flashing.
platform controls and the alarm should sound.
13 Test all machine functions from the ground
Result: The alarm does not sound and the controls.
platform overload indicator lights are not
Result: All ground control functions should
flashing. Calibrate the platform overload
operate normally.
system. Refer to Repair Procedure, How to
Calibrate the Platform Overload System (if 14 Turn the key switch to platform control.
equipped).
15 Test all machine functions from the platform
Note: There may be a 2 second delay before the controls.
overload indicator lights flash and the alarm
sounds. Result: All platform control functions should
operate.
8 Test all machine functions from the platform Note: If the platform overload system is not
controls. operating properly, Refer to Repair Procedure 2-3,
Result: All platform control functions should How to Calibrate the Platform Overload System (if
not operate. equipped).
9 Turn the key switch to ground control. 16 Using a suitable lifting device, remove the
remaining test weights from the platform.
controls.
Result: All ground control functions should not
operate.
11 Using auxiliary power, test all machine
functions from the ground controls.
Result: All ground control functions should
operate normally.
Note: OVERLOAD RECOVERY will be displayed
at the platform control box LCD display.
Part No. 119817 Z-40/23N, Z-40/23N RJ 33

Checklist D Procedures
Checklist D Pr ocedur es D-2 Check the Tur ntabl e R otation Beari ng Bolts
D-1 Check the Boom Wear Pads
D-1 D-2
Check the Boom Wear Pads Check the Turntable Rotation
Bearing Bolts

performed every 1000 hours or annually, Genie specifications require that this procedure be
whichever comes first. performed every 1000 hours or annually,
Maintaining the boom wear pads in good condition whichever comes first.
is essential to safe machine operation. Wear pads Maintaining proper torque on the turntable bearing
are placed on boom tube surfaces to provide a low bolts is essential to safe machine operation.
friction, replaceable wear pad between moving Improper bolt torque could result in an unsafe
parts. Improperly shimmed wear pads or continued operating condition and component damage
use of extremely worn wear pads may result in
component damage and unsafe operating 1 Raise the secondary boom and place a safety
conditions. chock on the lift cylinder rods. Carefully lower
the boom onto the lift cylinder safety chock.
1 Measure each wear pad. Replace the wear
pad once it reaches the minimum allowable Crushing hazard. Keep hands
thickness. If the wear pad is still within away from the cylinder and all
specification, shim as necessary to obtain moving parts when lowering the
minimum clearance with zero binding. boom.
2 Extend and retract the boom through the Note: The lift cylinder safety chock is available
entire range of motion to check for tight spots through Genie Parts Department. (Genie part
that may cause binding or scraping of the number 33484).
boom.
2 Remove the center turntable cover fasteners.
Note: Always maintain squareness between the
Remove the cover from the machine.
outer and inner boom tubes.
Primary boom wear pad specifications Minimum

Top and side wear pads 5/8 inch
(platform end of boom) 15.9 mm
Bottom wear pad 3/8 inch

(platform end of boom) 9.5 mm
Top bottom and side wear pads 3/8 inch

(pivot end of boom) 9.5 mm
34 Z-40/23N, Z-40/23N RJ Part No. 119817

3 Confirm that each turntable mounting bolt is 7 Check to be sure that each bearing mounting
torqued in sequence to specification. Refer to bolt under the drive chassis is torqued in
Specifications, Machine Torque sequence to specification. Refer to
Specifications. Specifications, Machine Torque
Specifications.
Bolt torque sequence

Bolt torque sequence
4 Install the center turntable cover.
5 Remove the lift cylinder safety chock and
lower the boom to the stowed position.
6 Remove the drive chassis covers from both
ends of the machine.
Part No. 119817 Z-40/23N, Z-40/23N RJ 35

D-3 Check the Axl e M ounti ng Bolts D-4 Check the Pl atform R otation M ounti ng Bolts
D-3 D-4
Check the Axle Mounting Bolts Check the Platform Rotation
Mounting Bolts

performed every 1000 hours or annually,
whichever comes first.
Maintaining proper torque of the steer axle whichever comes first.
mounting bolts is essential to safe machine
Maintaining proper torque of the platform rotation
operation. Improper bolt torque could result in an
mounting bolts and jib boom rotation mounting
unsafe operating condition and component
bolts (Z-40/23N RJ) is essential to safe machine
damage.
operation. Improper bolt torque could result in an
1 Remove the drive chassis covers from both unsafe operating condition and component
ends of the drive chassis. damage.
2 Locate the eight axle mounting bolts on each 1 Check the torque of the fasteners at the
axle. Torque the bolts to specification. Refer to platform rotator. Refer to Specifications,
Specifications, Machine Torque Machine Torque Specifications.
Specifications.
2 Z-40/23N RJ: Check the torque of the
fasteners at the jib boom rotator. Refer to
Specifications, Machine Torque
Specifications.
36 Z-40/23N, Z-40/23N RJ Part No. 119817

D-5 Check the Free-wheel Confi gur ation
D-5 4 Disengage the drive hubs by turning over the

drive hub disconnect caps on each non-steer
Check the Free-wheel wheel hub.
Configuration

Proper use of the free-wheel configuration is 1 Hub Disengaged Position
essential to safe machine operation. The 2 Hub Engaged Position
free-wheel configuration is used primarily for
towing. A machine configured to free-wheel without 5 Manually rotate each non-steer wheel.
operator knowledge could result in death or serious Result: Each non-steer wheel should rotate
injury and property damage. with minimum effort.
Collision hazard. Select a work 6 Re-engage the drive hubs by turning over the
site that is firm and level. hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and
Component damage hazard. If remove the jack stands.
the machine must be towed, do
not exceed 2 mph / 3.2 km/h. Collision hazard. Failure to
re-engage the drive hubs could
1 Chock the steer wheels to prevent the result in death or serious injury
machine from rolling. and property damage.
2 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive
chassis between the non-steer tires.
3 Lift the wheels off the ground and place jack
stands under the drive chassis for support.
Part No. 119817 Z-40/23N, Z-40/23N RJ 37

D-6 Repl ace the Drive H ub Oil D-7 Repl ace the High Press ure Hydr aulic Filter El ement
D-6 D-7
Replace the Drive Hub Oil Replace the High Pressure
Hydraulic Filter Element

Replacing the drive hub oil is essential for good whichever comes first.
machine performance and service life. Failure to
Replacement of the high pressure hydraulic filter is
replace the drive hub oil at yearly intervals may
cause the machine to perform poorly and continued
service life. A dirty or clogged filter may cause the
use may result in component damage
machine to perform poorly and continued use may
1 Select the drive hub to be serviced. Drive the cause component damage. Extremely dirty
machine until one of the two plugs is at the conditions may require that the filters be replaced
lowest point. more often.
2 Remove both plugs and drain the oil. The high pressure hydraulic filter is equipped with a
sensor that will detect a clogged filter. If the filter
3 Drive the machine to rotate the hub until one becomes clogged, a warning or fault message will
of the plugs is located on top and the other be shown on the LCD display screen at the
one is at 90 degrees. platform controls. The sensor and its
accompanying fault should not be used as an
indication of when to perform machine
maintenance.
Bodily injury hazard. Beware of

hot oil. Contact with hot oil may
cause severe burns.
1 Open the power unit side turntable cover and

locate the high pressure hydraulic filter above
the power unit.
1 Plugs
2 Place a suitable container under the hydraulic
4 Fill the hub with oil from the top hole until the filter.
oil level is even with the bottom of the side
plug hole. Refer to Specifications, Machine
Specifications.
5 Install the plugs into the drive hub.
6 Repeat steps 1 through 5 for the other drive
hub.
38 Z-40/23N, Z-40/23N RJ Part No. 119817

D-8 Inspec t for T urntable Beari ng W ear
3 Remove the filter housing by using a wrench D-8

on the nut provided on the bottom of the
housing.
Inspect for Turntable Bearing
4 Remove the filter element from the housing.
Wear
5 Inspect the housing seal and replace it if
necessary.
6 Install the new filter element into the housing Genie specifications require that this procedure be
and tighten securely.
7 Clean up any oil that may have spilled during
the installation procedure. Periodic inspection of turntable bearing wear is
essential to safe machine operation, good machine
8 Turn the key switch to ground controls and pull performance and service life. Continued use of a
the red Emergency Stop button out to the on worn turntable bearing could create an unsafe
position at both the ground and platform operating condition, resulting in death or serious
controls. injury and component damage.
9 Activate any boom function and inspect the Note: Perform this procedure with the machine on
filter and related components to be sure that a firm, level surface with the boom in the stowed
there are no leaks. position.
10 Use a permanent ink marker to write the date
1 Grease the turntable bearing. Refer to
and number of hours from the hour meter on
Maintenance Procedure, Grease the
the oil filter.
Turntable Bearing and Rotate Gear.
2 Torque the turntable bearing bolts to
specification. Refer to Maintenance
Procedure, Check the Turntable Rotation
Bearing Bolts.
3 Start the machine from the ground controls
and raise the primary and secondary booms to
full height. Do not extend the primary boom.
Part No. 119817 Z-40/23N, Z-40/23N RJ 39

4 Place a dial indicator between the drive 7 Note the reading on the dial indicator.
chassis and the turntable at a point that is
Result: The measurement is less than
directly under, or inline with, the boom and no
0.055 inch / 1.4 mm. The bearing is good.
more than 1 inch / 2.5 cm from the bearing.
Result: The measurement is more than
Note: To obtain an accurate measurement, place
0.055 inch / 1.4 mm. The bearing is worn and
the dial indicator no more than 1 inch / 2.5 cm from
needs to be replaced.
the turntable rotation bearing.
8 Fully retract the primary boom. Raise the
primary and secondary booms to full height.
Visually inspect the dial indicator to be sure
the needle returns to the "zero" position.
9 Remove the dial indicator and rotate the

turntable 90°.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four
equally spaced areas 90° apart.
11 Lower the primary and secondary booms to
the stowed position and turn the machine off.
12 Remove the dial indicator from the machine.
1 turntable
2 dial indicator
3 drive chassis
4 turntable rotation bearing
5 Adjust the dial indicator needle to the "zero"

position.
6 Lower the secondary boom to the stowed
position and lower the primary boom to a
horizontal position. Fully extend the primary
boom.
40 Z-40/23N, Z-40/23N RJ Part No. 119817

Checklist E Procedures
Checklist E Pro ced ures
E-1 T est or Replac e the Hy dr aulic Oil
E-1 1 Close the two hydraulic tank shut-off valves at

the hydraulic tank.
Test or Replace the Hydraulic Oil
Component damage hazard.
The engine must not be started
with the hydraulic tank shut-off
Genie specifications require that this procedure be valves in the closed position or
performed every 2000 hours or every two years, component damage will occur. If
whichever comes first. the tank valves are closed,
remove the key from the key
Perform this procedure more often if dusty switch and tag the machine to
conditions exist. inform personnel of the
condition.
Replacement or testing of the hydraulic oil is
2 Remove the drain plug from the hydraulic tank
service life. Dirty oil and a clogged suction strainer
and completely drain the tank into a container
or hydraulic filters may cause the machine to
of suitable capacity. Refer to Specifications,
perform poorly and continued use may cause
Machine Specifications.
component damage. Extremely dirty conditions
may require oil changes to be performed more 3 Tag, disconnect and plug the two suction
frequently. hoses from the hydraulic tank.
Note: Before replacing the hydraulic oil, the oil may 4 Tag, disconnect and plug the two supply
be tested by an oil distributor for specific levels of hoses for the auxiliary power units. Cap the
contamination to verify that changing the oil is fittings on the hydraulic tank.
necessary. If the hydraulic oil is not replaced at the 5 Tag, disconnect and plug the hydraulic hose
two year inspection, test the oil quarterly. Replace from the drive motor case drain filter at the
the oil when it fails the test. hydraulic tank. Cap the fitting on the hydraulic
Note: When removing a hose assembly or fitting, tank.
the O-ring (if equipped) on the fitting and/or hose 6 Tag, disconnect and plug the hydraulic hose at
end must be replaced. All connections must be the return filter. Cap the fitting on the return
torqued to specification during installation. Refer to filter housing.
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Note: Perform this procedure with the boom in the
stowed position.
Part No. 119817 Z-40/23N, Z-40/23N RJ 41

7 Remove the turntable cover using a suitable 12 Attach an overhead crane or similar lifting
lifting device. device to the battery box for the auxiliary
power unit batteries.
Crushing hazard. The turntable
cover may become unbalanced 13 Remove the battery box retaining fasteners
and fall if not properly supported and carefully remove the battery box from the
and secured to a suitable lifting machine.
device.
Crushing hazard. The battery
8 Remove the ground control box mounting box could become unbalanced
and fall when removed from the
fasteners. Move the ground control box out of
the way. machine if not properly
supported.
9 Remove the cover from the auxiliary power
unit batteries. Bodily injury hazard. Batteries
10 Tag and disconnect the cables from the contain acid. Avoid spilling or
auxiliary power unit batteries. contacting battery acid.
Neutralize battery acid spills with
Electrocution/burn hazard. baking soda and water.
circuits could result in death or 14 Remove the hydraulic tank retaining fasteners.
serious injury. Remove all rings,
15 Support the hydraulic tank with 2 lifting straps.
watches and other jewelry.
Place one lifting strap at each end of the tank
and attach the lifting straps to an appropriate
11 Tag and disconnect the cables from the
lifting device.
engine starting battery located on the engine
side of the machine. 16 Remove the hydraulic tank from the machine.
Electrocution/burn hazard. Crushing hazard. The hydraulic
Contact with electrically charged tank could become unbalanced
circuits could result in death or and fall if not properly supported
serious injury. Remove all rings, when removed from the
watches and other jewelry. machine.
17 Remove the suction strainers from the tank

and clean them using a mild solvent.
42 Z-40/23N, Z-40/23N RJ Part No. 119817

E-2 Greas e the Steer Axle Wheel Beari ngs
18 Rinse out the inside of the tank using a mild E-2

solvent.
Grease the Steer Axle Wheel
19 Install the suction strainers using pipe thread
sealant on the threads.
Bearings
20 Install the drain plug using pipe thread sealant
on the threads.
21 Install the hydraulic tank onto the machine. Genie specifications require that this procedure be
performed every 2000 hours or every two years,
22 Install the ground control box and mounting whichever comes first.
fasteners.
Perform this procedure more often if dusty
23 Install the two suction hoses, return filter hose, conditions exist.
drive motor case drain filter hose and the
supply hoses for the auxiliary power units. Maintaining the steer axle wheel bearings is
essential for safe machine operation and service
24 Install the turntable cover. life. Operating the machine with loose or worn
25 Fill the tank with hydraulic oil until the level is wheel bearings may cause an unsafe operating
within the top 2 inches / 5 cm of the sight condition and continued use may result in
gauge. Do not overfill. Refer to Specifications, component damage. Extremely wet or dirty
Machine Specifications. conditions or regular steam cleaning and pressure
washing of the machine may require that this
26 Open the two hydraulic tank shut-off valves at procedure be performed more often.
the hydraulic tank.
1 Loosen the wheel lug nuts. Do not remove
27 Clean up any oil that may have spilled during
them.
the installation procedure.
2 Block the non-steer wheels, then center a
28 Start the engine and check for leaks.
lifting jack under the steer axle.
3 Raise the machine 6 inches / 15 cm and place
blocks under the drive chassis for support.
4 Remove the lug nuts. Remove the tire and
wheel assembly.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and
down.
Result: There should be no side to side or up
and down movement.
Skip to step 10 if there is no movement.
Part No. 119817 Z-40/23N, Z-40/23N RJ 43

6 Remove the dust cap from the hub. Remove 14 Pack both bearings with clean, fresh grease.
the cotter pin from the castle nut.
15 Place the large inner bearing into the rear of
7 Tighten the castle nut to 158 ft-lbs / 214 Nm to the hub.
seat the bearings.
16 Install a new bearing grease seal into the hub
Note: Rotate the hub by hand while torquing the by pressing it evenly into the hub until it is
castle nut to make sure the bearings seat properly. flush.
8 Loosen the castle nut one full turn and then 17 Slide the hub onto the yoke spindle.
re-tighten to 35 ft-lbs / 47 Nm.
Component damage hazard. Do
9 Check for wheel bearing wear by attempting to not apply excessive force or
move the wheel hub side to side, then up and damage to the lip of the seal may
down. occur.
Result: If there is no side to side or up and
18 Fill the hub cavity with clean, fresh grease.
down movement, continue with step 11 and
grease the wheel bearings. 19 Place the outer bearing into the hub.
Result: If there is side to side or up and down 20 Install the washer and castle nut.
movement, continue to step 11 and replace
21 Tighten the slotted nut to 158 ft-lbs / 214 Nm
the wheel bearings with new ones.
to seat the bearings.
Note: When replacing a wheel bearing, both the
22 Loosen the castle nut and re-tighten to
inner and outer bearings, including the pressed-in
35 ft-lbs / 47 Nm.
races, must be replaced.
23 Install a new cotter pin. Bend the cotter pin to
10 Remove the dust cap from the hub. Remove lock it in.
the cotter pin from the castle nut.
Note: Always use a new cotter pin when installing a
11 Remove the castle nut. castle nut.
12 Pull the hub off of the spindle. The washer and
24 Install the dust cap, then the tire and wheel
outer bearing should fall loose from the hub.
assembly. Torque the wheel lug nuts to
13 Place the hub on a flat surface and gently pry specification. Refer to Specifications, Machine
the bearing seal out of the hub. Remove the Specifications.
rear bearing.
44 Z-40/23N, Z-40/23N RJ Part No. 119817

Repair Procedures
Section 4 Repair Pr oc edures
Intr oducti on
Machine Configuration:
 Unless otherwise specified, perform each
repair procedure with the machine in the
following configuration:
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.
 Repair any machine damage or malfunction from the machine
• Boom in the stowed position
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. 119817 Z-40/23N, Z-40/23N RJ 45

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

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

Indicates that an incorrect result has occurred
46 Z-40/23N, Z-40/23N RJ Part No. 119817

Platform Controls
Platform Contro ls
1-1 Joys ticks
1-1 7 Move the joystick full stroke and hold for

5 seconds in each direction.
Joysticks
Result: The alarm should sound a short beep
indicating successful joystick calibration in
How to Calibrate a Joystick each direction.
The joysticks on this machine utilize digital Hall 8 Joysticks with a thumb rocker switch:
Effect technology for proportional control. If a Press down and hold the thumb rocker switch
joystick is disconnected or replaced, it must be in each direction.
calibrated before that particular machine function
Result: The alarm should sound a short beep
will operate.
indicating successful joystick calibration in
Note: The joystick must be calibrated before the each direction.
threshold, max-out or ramp rate can be set. 9 Repeat this procedure for each joystick
Note: For units with revision D software or higher, controlled machine function.
the control system continuously monitors and Note: No machine function should operate while
updates joystick calibration, therefore it is not performing the joystick calibration procedure.
necessary perform this procedure.
1 Turn the key switch to platform control.
2 Pull out the red Emergency Stop button to the
'ON' position at both the ground and platform
controls.
3 Open the platform control box.
4 Select a joystick to calibrate. Do not press
down on the foot switch.
5 Disconnect the wire harness connector from
the joystick for approximately 10 seconds or
until the alarm sounds.
Result: The alarm should sound a long beep
indicating the joystick has lost calibration.
After 3 seconds the alarm should sound a
short beep to enter calibration mode.
6 Connect the wire harness connector to the
joystick.
Result: The alarm should sound a long beep
setting the neutral calibration point.
Part No. 119817 Z-40/23N, Z-40/23N RJ 47

Platform Controls
How to Adj ust the Joystick Thr eshol d Setting
How to Adjust the Joystick Toggle switch controlled functions:

Threshold Setting Note: Begin this procedure with the rotary speed
control at the plaform controls turned fully in the
The threshold setting of a joystick is the minimum
counterclockwise direction.
output at which a function proportional valve can
open and allow the function to operate. 10 Press down on the foot switch and activate the
function in the direction to be corrected. Slowly
turn the rotary speed control in the clockwise
stowed position.
direction just until the function begins to move.
1 Turn the key switch to platform control. Do not Momentarily activate the drive enable toggle
start the engine. switch in the right direction.
2 Pull out the red Emergency Stop button to the Result: The alarm should sound indicating the
'ON' position at both the ground and platform setting has been saved.
controls. Joystick controlled functions:
3 Do not press down the foot switch.
Note: Begin this procedure with the rotary speed
4 Move and hold the drive enable toggle switch control at the plaform controls turned fully in the
in the right direction while holding the steer clockwise direction.
rocker switch in the right direction.
11 Press down on the foot switch and slowly
5 When the display leaves SYSTEM READY move the joystick in the direction to be
mode, release the drive enable toggle switch corrected until the function begins to move.
and the steer rocker switch. Momentarily activate the drive enable toggle
Result:The display will show FAULTS. switch in the right direction.
6 Momentarily activate the steer rocker switch in Result: The alarm should sound indicating the
the right direction until SETTINGS is shown on setting has been saved. To exit programming
the display. mode:
7 Momentarily activate the drive enable toggle 12 Move and hold the drive enable toggle switch
switch in the right direction until VALVE AND in the left direction until the display screen
PUMP SETTINGS is shown on the display. returns to SYSTEM READY.
8 Momentarily activate the drive enable toggle

switch in the right direction until THRESHOLD
CURRENT is shown on the display.
switch in the right direction to enter the
threshold calibration mode.
48 Z-40/23N, Z-40/23N RJ Part No. 119817

Platform Controls
How to Adj ust the Maxim um Speed Setti ng
How to Adjust the Maximum 5 When the display leaves SYSTEM READY
mode, release the drive enable toggle switch
Speed Setting and the steer rocker switch.
The maximum speed setting of a joystick and Result: The display will show FAULTS.
toggle switch controls the maximum speed of a
machine function. Whenever a hydraulic cylinder, 6 Momentarily activate the steer rocker switch in
drive motor or hydraulic pump is replaced, the the right direction until SETTINGS is shown on
maximum speed setting should be adjusted to the display.
maintain optimum performance. The maximum 7 Momentarily activate the drive enable toggle
speed settings can be changed to compensate for
switch in the right direction until VALVE AND
hydraulic pump wear and to maintain peak
PUMP SETTINGS is shown on the display.
performance from the machine.
Note: There are two types of max speed settings. switch in the right direction until THRESHOLD
is shown on the display.
High flow functions: Primary up / down,
secondary up / down and extend / retract. 9 Momentarily activate the steer rocker switch in
the right direction until VALVE MAXIMUM
Low flow functions: Platform rotate, jib rotate, jib CURRENT is shown on the display.
up / down and turntable rotate.
Note: Begin this procedure with the rotary speed switch in the right direction to enter VALVE
control at the platform turned fully in the clockwise MAXIMUM CURRENT calibration mode.
direction.
High flow functions:
11 Momentarily activate one of the high flow
2 Pull out the red Emergency Stop button to the functions full stroke.
controls. Result: The display will show the function,
direction and milliamps.
12 Press down on the foot switch and activate the
4 Move and hold the drive enable toggle switch same function in the same direction again.
in the right direction while holding the steer
rocker switch in the right direction. Result: Alarm sounds, continue to step 15.
Result: Alarm does not sound, continue to
step 13.
Part No. 119817 Z-40/23N, Z-40/23N RJ 49

Platform Controls
13 Release the footswitch. Momentarily activate Low flow functions:

the steer rocker in the left direction to
decrease the value shown on the display in 19 Momentarily activate one of the low flow
small increments. Continue to step 14. functions full stroke.
14 Press down on the foot switch and activate the Result: The display will show the function,
same function in the same direction. Repeat direction and milliamps.
step 13 until the alarm sounds while function is 20 Start a timer, press down on the foot switch
in motion. Then release the foot switch and and activate the same function in the same
momentarily activate the steer rocker switch in direction again.. Record the time it takes for
the right direction 3 times. Continue to step 17. that function to complete a full cycle; i.e., jib
15 Release the footswitch. Momentarily activate up.
the steer rocker in the right direction to 21 Compare the machine function time with the
increase the value shown on the display in function times listed. Refer to Specifications,
small increments. Continue to step 16. Performance Specifications. Determine
16 Press down on the foot switch and activate the whether the function time needs to increase or
same function in the same direction. Repeat decrease.
step 15 until the alarm no longer sounds while 22 To adjust a function speed, release the foot
function is in motion. Then momentarily switch. Momentarily move the steer rocker
activate the steer rocker switch in the right switch in the right direction to increase or
direction 2 times. Continue to step 17. momentarily in the left direction to decrease.
17 Momentarily activate the drive enable toggle Note: Each time the steer rocker switch is
switch in the right direction to save the new momentarily pressed, the time will change in 5mA
setting. to 10mA increments.
Result: The alarm should sound indicating the 23 When function times have been achieved,
setting has been saved. activate the drive enable toggle switch to the
18 Repeat steps 11 through 17 as needed for right to save your changes.
high flow functions. Result: The alarm should sound indicating the
setting has been saved.
24 Repeat steps 19 through 23 as needed for low
flow functions.
To exit programming mode:
25 Move and hold the drive enable toggle switch
in the left direction until the display screen
returns to SYSTEM READY.
50 Z-40/23N, Z-40/23N RJ Part No. 119817

Platform Controls
How to Adj ust the Functi on R amp U p Tim e Setti ng
How to Adjust the Function Ramp 9 Momentarily activate the steer rocker switch in
the right direction until RAMP UP TIME is
Up Time Setting shown on the display.
The ramp up time setting of a function controls the 10 Momentarily activate the drive enable toggle
time at which it takes for the function to reach switch in the right direction to enter RAMP UP
maximum output, when moved out of the neutral TIME calibration mode.
position. The ramp up time of a function can be
changed to compensate for hydraulic pump wear to 11 Press down on the foot switch and
maintain peak performance from the machine. momentarily activate the function to be
corrected.
control at the platform turned fully in the clockwise Result: The display will show the function,
direction. direction and milliamps.
12 Press down on the foot switch, start a timer
and activate the same function in the same
2 Pull out the red Emergency Stop button to the direction.
Note how long it takes the function to reach
controls.
maximum speed. This is the ramp up time.
3 Do not press down on the foot switch.
13 Compare the function ramp up time with the
4 Move and hold the drive enable toggle switch table on the next page and determine whether
in the right direction while holding the steer the ramp up time needs to increase or
rocker switch in the right direction. decrease.
5 When the display leaves SYSTEM READY
and the steer rocker switch.
Result: The display will show FAULTS.
6 Momentarily activate the steer rocker switch in
the right direction until SETTINGS is shown on
the display.
Part No. 119817 Z-40/23N, Z-40/23N RJ 51

Platform Controls
14 To adjust the ramp up time setting, release the To exit programming mode:
foot switch. Momentarily move the steer
rocker switch in the right direction to increase 17 Move and hold the drive enable toggle switch
or momentarily in the left direction to in the left direction until the display screen
decrease. returns to SYSTEM READY.
Note: Each time the steer rocker switch is Ramp rate (factory settings)
momentarily pressed, the time will change in Primary boom up/down 1 second
0.1 second increments.
Secondary boom up/down
Note: Changing the ramp up time setting in one accelerate 1 second
direction will also change the opposite direction. Turntable rotate
15 When ramp time has been achieved, activate accelerate 1 second
the drive enable toggle switch to the right to Extend/Retract
save your changes.
accelerate 0.5 second
Result: The alarm should sound indicating the Jib up/down
accelerate 2.5 seconds
16 Repeat steps 11 through 13 for each machine Platform Rotate
function.
accelerate 2 seconds
Jib rotate (if equipped)
accelerate 2 seconds
52 Z-40/23N, Z-40/23N RJ Part No. 119817

Platform Controls
How to Adj ust the Functi on R amp D ow n Tim e Setting
How to Adjust the Function Ramp 9 Momentarily activate the steer rocker switch in
the right direction until RAMP DOWN TIME is
Down Time Setting shown on the display.
The ramp down time setting of a function controls 10 Momentarily activate the drive enable toggle
the time at which it takes for the function to come to switch in the right direction to enter RAMP
a complete stop, when returned to the neutral DOWN TIME calibration mode.
position. The ramp down time of a function can be
changed to compensate for hydraulic pump wear to 11 Press down on the foot switch and
maintain peak performance from the machine. momentarily activate the function to be
corrected.
control at the platform turned fully in the clockwise Result: The display will show the function,
direction. direction and milliamps.
12 Press down on the foot switch, start a timer
and activate the same function in the same
2 Pull out the red Emergency Stop button to the direction. Note how long it takes the function to
'ON' position at both the ground and platform reach maximum speed. This is the ramp down
controls. time.
3 Do not press down the foot switch. 13 Compare the function ramp down time with the
table on the next page and determine whether
the ramp down time needs to increase or
in the right direction while holding the steer
decrease.
14 To adjust the ramp down time setting, release
5 When the display leaves SYSTEM READY
the foot switch. Momentarily move the steer
rocker switch in the right direction to increase
or momentarily in the left direction to
Result: The display will show FAULTS. decrease.
6 Momentarily activate the steer rocker switch in Note: Each time the steer rocker switch is
the right direction until SETTINGS is shown on momentarily pressed, the time will change in
the display. 0.1 second increments.
7 Momentarily activate the drive enable toggle Note: Changing the ramp down time setting in one
switch in the right direction until VALVE AND direction will also change the opposite direction.
Part No. 119817 Z-40/23N, Z-40/23N RJ 53

Platform Controls
How to Adj ust the Max Speed Driv e Settings
15 When ramp time has been achieved, activate How to Adjust the Max Speed
the drive enable toggle switch to the right to
save your changes.
Drive Settings
Result: The alarm should sound indicating the Adjusting the max speed setting will only affect the
setting has been saved. stowed drive speed. Elevated drive speed is not
adjustable.
16 Repeat steps 11 through 13 for each machine
function. Note: Begin this procedure with the machine in the
stowed position.
in the left direction until the display screen 2 Pull out the red Emergency Stop button to the
returns to SYSTEM READY. 'ON' position at both the ground and platform
controls.
Ramp down time (factory settings)
Primary boom up/down in the right direction while holding the steer
decelerate 1.5 second rocker switch in the right direction.
Secondary boom up/down 4 When the display leaves SYSTEM READY
decelerate 0.65 second mode, release the drive enable toggle switch
Turntable rotate and the steer rocker switch.
decelerate 0.25 second Result: The display will show FAULTS.
Extend/Retract 5 Momentarily activate the steer rocker switch in
decelerate 0.5 seconds the right direction until SETTINGS is shown on
Jib up/down
the display.
decelerate 0.25 second 6 Momentarily activate the drive enable toggle
Platform rotate
decelerate 0.15 second
Jib rotate (if equipped)
the right direction until you see the
decelerate 0.25 seconds AUTHORIZATION screen.
switch in the right direction to enter the
authorization screen.
54 Z-40/23N, Z-40/23N RJ Part No. 119817

Platform Controls
9 Using the rocker switch on the drive joystick, 16 Bring the machine to maximum drive speed
momentarily activate steer left, left, right, and before reaching the start line. Begin timing
left. when your reference point on the machine
crosses the start line.
Result: The alarm will sound.
17 Continue at full speed and note the time when
the machine reference point passes over the
the right direction until you see the DRIVE
finish line. Release the foot switch. Refer to
SETTINGS screen.
Specifications, Performance Specifications.
Result: The drive speed meets specification.
switch in the right direction to enter the DRIVE
Continue to step 19.
SETTINGS menu.
Result: The drive speed does not meet
Result: The display will show ACCEL RAMP.
specification. Continue to step 18 to adjust the
12 Momentarily activate the steer rocker switch in drive speed.
the right direction until you see the MAX
18 Momentarily move the steer rocker switch in
SPEED screen.
the right direction to increase or momentarily
13 Momentarily activate the drive enable toggle in the left direction to decrease. Repeat steps
switch in the right direction to enter the MAX 16 and 17.
SPEED menu.
Note: Adjusting this setting will affect the stowed
14 Create start and finish lines by marking two drive speed in forward and reverse.
lines on the ground 40 feet / 12.2 m apart.
15 Choose a point on the machine; i.e., contact switch to the right direction to save your
patch of a tire, as a visual reference for use changes.
Result: The alarm should sound indicating the
in the left direction until the display screen
returns to SYSTEM READY.
Part No. 119817 Z-40/23N, Z-40/23N RJ 55

Platform Components
Platform Co mpon ents
2-1 Platform Lev eling Slav e Cyli nder
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.
The slave cylinder and the rotator pivot are the two Bodily injury hazard. Spraying
primary supports for the platform. The slave hydraulic oil can penetrate and
cylinder keeps the platform level through the entire burn skin. Loosen hydraulic
range of boom motion. It operates in a connections very slowly to allow
closed-circuit hydraulic loop with the master the oil pressure to dissipate
cylinder. The slave cylinder is equipped with gradually. Do not allow oil to
counterbalance valves to prevent movement in the squirt or spray.
event of a hydraulic line failure.
5 Remove the pin retaining fastener from the
slave cylinder rod-end pivot pin. Do not
How to Remove the Platform remove the pin. Do not remove the pin.
Leveling Slave Cylinder 6 Remove the external snap rings from the slave
Note: Before cylinder removal is considered, bleed cylinder barrel-end pivot pin. Do not remove
the slave cylinder to be sure there is no air in the the pin.
closed loop. 7 Place a block of wood under the barrel of the
Note: When removing a hose assembly or fitting, slave cylinder for support. Protect the cylinder
the O-ring (if equipped) on the fitting and/or hose rod from damage.
end must be replaced. All connections must be 8 Use a soft metal drift to remove the rod-end
torqued to specification during installation. Refer to pivot pin.
Specifications. Crushing hazard. The platform
could fall if not properly
1 Extend the boom until the slave cylinder supported.
barrel-end pivot pin is accessible.
2 Raise the boom slightly and place blocks
The slave cylinder rod may
under the platform for support.
become damaged if it is allowed
3 Lower the primary boom until the platform is to fall if not properly supported
resting on the blocks just enough to support by the lifting device.
the platform. Do not rest the entire weight of
the boom on the blocks. 9 Use a soft metal drift to remove the barrel-end
pivot pin.
10 Carefully pull the cylinder, with hydraulic
hoses, out of the boom.
56 Z-40/23N, Z-40/23N RJ Part No. 119817

Platform Components
2-2 Platform Rotator
How to Bleed the Slave Cylinder 2-2

1 Raise the primary boom to a horizontal Platform Rotator
position.
2 Move the platform level toggle switch up and How to Bleed the Platform
down through two platform leveling cycles to
remove any air that might be in the system. Rotator
Note: This procedure will require two people.
1 Move the function enable toggle switch to
either side and activate the platform rotate
toggle switch to the right and then to 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.
4 Move the function enable toggle switch to

either side and hold the platform rotate toggle
switch to the left position until the platform is
fully rotated to the left. Continue holding the
toggle switch until air stops coming out of the
bleed screw. Close the bleed screw.
Crushing hazard. Keep clear of
the platform during rotation.
Part No. 119817 Z-40/23N, Z-40/23N RJ 57

Platform Components
2-3 Platform Ov erload System
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
connections very slowly to allow 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
Note: Perform this procedure with the machine on
toggle switch until air stops coming out of the
a firm, level surface.
bleed screw. Close the bleed screw.
Crushing hazard. Keep clear of
the platform during rotation. 2 Determine the maximum platform
capacity.Refer to the machine serial plate.
7 Clean up any hydraulic oil that may have
spilled. 3 Remove all weight, tools and accessories from
the platform.
8 Rotate the platform fully in both directions and
inspect the bleed screws for leaks. Note: Failure to remove all weight, tools and
accessories from the platform will result in an
incorrect calibration.
4 Using a suitable lifting device, place a test
weight equal to the maximum platform
capacity at the center of the platform floor.
58 Z-40/23N, Z-40/23N RJ Part No. 119817

Platform Components
Determine the limit switch trigger point: Confirm the setting:

5 Gently move the platform up and down by 6 Turn the key switch to platform control.
hand, so it bounces approximately 1 to
7 Lift the test weight off the platform floor using a
2 inches / 2.5 to 5 cm. Allow the platform to
suitable lifting device.
settle.
8 Place the test weight back onto the center of
Result: The overload indicator light and the
the platform floor using a suitable lifting
alarm is on. Slowly tighten the load spring
device.
adjustment nut by turning it clockwise just until
the overload indicator light and alarm turns off. Result: The alarm should be off. The platform
overload indicator light should be off at both
Note: The platform will need to be moved up and
the ground and platform controls.
down and allowed to settle between adjustments.
Note: There may be an approximate 2 second
Note: There may be an approximate 2 second delay before the overload indicator light and alarm
delay before the overload indicator light turns on turn off.
and the alarm sounds.
9 Add an additional 10 lb / 4.5 kg test weight to
Result: The overload indicator light and the original test weight to overload the
alarm is off. Slowly loosen the load spring platform.
adjustment nut by turning it counterclockwise
just until the overload indicator light and alarm Result: The alarm should sound. The platform
turn on. overload indicator light should be flashing at both
the ground and platform controls.
Note: There may be an approximate 2 second
delay before the overload indicator light turns on Note: There may be an approximate 2 second
and the alarm sounds. delay before the overload indicator light turns on
and the alarm sounds.
Note: The platform will need to be moved up and
down and allowed to settle between adjustments. 10 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
11 Turn the key switch to ground control.
controls.
Result: All ground control functions should not
operate.
Note: If the platform overload system is not
operating properly, repeat steps 1 through 4.
Part No. 119817 Z-40/23N, Z-40/23N RJ 59

Platform Components
2-4 Platform Recov ery Overl oad
2-4 5 When the display leaves SYSTEM READY

Platform Overload Recovery and the steer rocker switch.
Message (software 1256908A and Result: The display will show FAULTS.
later)
If the platform controls LCD screen displays switch in the right direction.
OVERLOAD RECOVERY, the emergency lowering Result: The display will show ACTIVE
system has been used while the platform was FAULTS.
overloaded.
the right direction until RESET OVERLOAD
How to Clear the Platform MSG is shown on the display.
Overload Recovery Message 8 Momentarily activate the drive enable toggle
switch in the right direction.
Note: This message shall be cleared by a person
trained and qualified on the troubleshooting and Result: The display will show ENTER
repair of this machine. PASSWORD.
Note: Use the following chart to identify the 9 Momentarily active the steer rocker switch in
description of each LCD screen control button used the following order.
in this procedure. Steer right, steer right, steer right, steer left.
1 Turn the key switch to platform control. Result: A one second audible alarm pulse
2 Pull out the red Emergency Stop button to the verifies the message has been reset.
on position at both the ground and platform Result: The alarm does not sound. Repeat this
controls. procedure starting with step 8.
3 Do not press down on the foot switch. 10 Push in the red Emergency Stop button to the
4 Move and hold the drive enable toggle switch off position.
in the right direction while holding the steer 11 Pull out the red Emergency Stop button to the
rocker switch in the right direction. on position.
OVERLOAD RECOVERY is not shown on the
display.
60 Z-40/23N, Z-40/23N RJ Part No. 119817

Jib Boom Components

Jib Bo om Co mpon ents
3-1 Jib Boom
3-1 5 Remove the pin retaining fasteners from the

jib boom leveling arm pivot pin at the platform
Jib Boom rotator.
6 Use a soft metal drift to remove the leveling
How to Remove the Jib Boom arm pivot pin. Let the leveling arms and jib
boom lift cylinder hang down.
hydraulic oil can penetrate and 7 Remove the pin retaining fastener from the jib
burn skin. Loosen hydraulic boom lift cylinder barrel-end pivot pin.
connections very slowly to allow 8 Use a soft metal drift to remove the platform
the oil pressure to dissipate rotator pivot pin and remove the platform
gradually. Do not allow oil to rotator from the machine.
squirt or spray.
Crushing hazard. The jib boom
Note: When removing a hose assembly or fitting, could fall when the pin is
the O-ring (if equipped) on the fitting and/or hose removed if not properly
end must be replaced. All connections must be supported by the overhead
torqued to specification during installation. Refer to crane.
Specifications. 9 Remove the pin retaining fasteners from the
jib boom lift cylinder rod-end pivot pin. Do not
1 Remove the platform and the platform remove the pin.
mounting weldment.
10 Slide both of the jib boom leveling arms off of
2 Support the platform rotator with a suitable the jib boom cylinder rod-end pivot pin.
lifting device.
11 Remove all hose and cable clamps from the jib
3 Tag, disconnect and plug the platform rotator boom.
hydraulic hoses. Cap the fittings on the
rotator.Remove the platform. Remove the 12 Tag, disconnect and plug the jib boom lift
platform mounting weldment and the platform cylinder hydraulic hoses. Cap the fittings on
rotator. Refer to Repair Procedure, How to the jib boom lift cylinder.
Remove the Platform Rotator
4 Attach a lifting strap from an overhead crane hydraulic oil can penetrate and
to the jib boom for support. burn skin. Loosen hydraulic
Component damage hazard. the oil pressure to dissipate
Hoses and cables can be gradually. Do not allow oil to
damaged if they are kinked or squirt or spray.
pinched.
Part No. 119817 Z-40/23N, Z-40/23N RJ 61

Jib Boom Components

3-2 Jib Boom Bell Crank (models without rotati ng jib boom)
13 Remove the mounting fasteners from the jib 3-2

boom/platform rotate manifold and lay the
manifold to the side. Do not remove the hoses
Jib Boom Bell Crank (models
or disconnect the wiring. without rotating jib boom)
Hoses and cables can be How to Remove the Jib Boom
damaged if they are kinked or
pinched. Bell Crank
14 Attach a lifting strap from an overhead crane stowed position.
to the rod end of the jib boom lift cylinder.
Note: When removing a hose assembly or fitting,
15 Use a soft metal drift to remove the jib boom the O-ring (if equipped) on the fitting and/or hose
rod-end pivot pin. Remove the jib boom lift end must be replaced. All connections must be
cylinder from the machine. torqued to specification during installation. Refer to
Crushing hazard. The jib boom Specifications, Hydraulic Hose and Fitting Torque
could fall when the pin is Specifications.
removed if not properly 1 Remove the jib boom. Refer to Repair
supported by the overhead Procedure, How to Remove the Jib Boom.
crane.
2 Support and secure the jib boom bell crank to
16 Remove the pin retaining fastener from the jib an appropriate lifting device.
boom pivot pin. Do not remove the pin.
3 Remove the pin retaining fasteners from the
17 Attach a lifting strap from an overhead crane slave cylinder rod-end pivot pin. Do not
to the jib boom. remove the pin.
18 Use a soft metal drift to remove the jib boom 4 Place a block of wood under the platform
pivot pin. Carefully remove the jib boom from leveling slave cylinder for support. Protect the
the machine. cylinder rod from damage.
Crushing hazard. The jib boom 5 Remove the pin retaining fasteners from the
could fall when the pin is removed jib boom bell crank at the extension boom.
if not properly supported by the Use a soft metal drift to remove the pin.
overhead crane. 6 Use a soft metal drift to remove the slave
cylinder rod-end pivot pin.
7 Remove the jib boom bell crank from the
extension boom.
bellcrank may become
unbalanced and fall if it is not
properly supported when it is
removed from the machine.
62 Z-40/23N, Z-40/23N RJ Part No. 119817

Jib Boom Components

3-3 Jib Boom R otator (models with r otating ji b boom)
3-3 5 Support and secure the jib boom bell crank to

an appropriate lifting device.
Jib Boom Rotator (models with
rotating jib boom) slave cylinder rod-end pivot pin. Do not
The platform rotator is a hydraulically activated remove the pin.
helical gear assembly used to rotate the jib boom 7 Place a block of wood under the platform
180 degrees. leveling slave cylinder for support. Protect the
cylinder rod from damage.
How to Remove the Jib Boom 8 Remove the pin retaining fasteners from the
jib boom bell crank at the extension boom.
Rotator Use a soft metal drift to remove the pin.
Note: When removing a hose assembly or fitting, 9 Use a soft metal drift to remove the slave
the O-ring (if equipped) on the fitting and/or hose cylinder rod-end pivot pin.
end must be replaced. All connections must be
torqued to specification during installation. Refer to 10 Remove the jib boom bell crank from the
Specifications, Hydraulic Hose and Fitting Torque extension boom.
Specifications.
1 Remove the jib boom. Refer to Repair bellcrank may become
Procedure, How to Remove the Jib Boom. unbalanced and fall if it is not
properly supported when it is
2 Support and secure the jib boom rotator to an removed from the machine.
appropriate lifting device.
3 Remove the eight mounting bolts from the jib
boom rotator mount.
4 Remove the center bolt. Carefully remove the
jib boom rotator from the machine.
rotator could become
unbalanced and fall when
removed from the machine if not
properly supported and secured
to the lifting device.
Note: When installing the jib boom rotator, be sure

to torque the fasteners to specification. Refer to
Specifications, Machine Torque Specifications.
Part No. 119817 Z-40/23N, Z-40/23N RJ 63

Jib Boom Components

How to Bleed the Jib Boom Rotator
How to Bleed the Jib Boom 4 Move and hold the function enable switch to
either side and move and hold the jib boom
Rotator rotate toggle switch to the left for
Note: This procedure will require two people. approximately 5 seconds, then release it.
Repeat three times.
1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the on 5 Fully rotate the jib boom to the left and
position at both the ground and platform continue holding the jib boom rotate toggle
controls. switch until air stops coming out of the bleed
screw.
2 Connect a clear hose to the top bleed valve.
Place the other end of the hose in a container Crushing hazard. Keep hands
to collect any drainage. Open the top bleed and head clear of the jib boom
valve, but do not remove it. during rotation.
6 Rotate the jib boom to the right until the jib

boom is centered.
7 Open the bottom bleed screw.
8 Rotate the jib boom to the right and continue
holding the platform rotate toggle switch until
air stops coming out of the bleed screw.
Crushing hazard. Keep hands
and head clear of the jib boom
during rotation.
9 Close the bleed screw.

10 Rotate the jib boom full left and right and
1 top bleed valve
inspect the bleed screws for leaks.
2 clear hose
3 container Crushing hazard. Keep hands
4 bottom bleed valve and head clear of the jib boom
during rotation.
3 Move and hold the function enable toggle
switch to either side and move and hold the jib 11 Turn the key switch to the off position and
boom rotate toggle switch to the right for clean up any hydraulic oil that may have
approximately 5 seconds, then release it. spilled.
Repeat three times.
Crushing hazard. Keep hands
and head clear of the jib boom
during rotation.
64 Z-40/23N, Z-40/23N RJ Part No. 119817

Jib Boom Components

3-4 Jib Boom Lift Cylinder
3-4 4 Use a soft metal drift to tap the rod-end pivot

pin half way out and lower one of the leveling
Jib Boom Lift Cylinder links to the ground. Tap the pin the other
direction and lower the opposite leveling link.
How to Remove the Jib Boom Lift Do not remove the pin.
Cylinder 5 Support the jib boom with a suitable lifting

device.
the O-ring (if equipped) on the fitting and/or hose 6 Remove the pin retaining fasteners from the
end must be replaced. All connections must be jib boom lift cylinder barrel-end pivot pin. Use
torqued to specification during installation. Refer to a soft metal drift to remove the barrel-end pivot
Specifications, Hydraulic Hose and Fitting Torque pin.Let the cylinder hang down.
Specifications. Crushing hazard. The jib boom
1 Raise the jib boom slightly and place blocks lift cylinder may become
under the platform mounting weldment. Then unbalanced and fall when it is
lower the jib boom until the platform is resting removed from the machine if it is
on the blocks just enough to support the not properly supported by the
platform. overhead crane.
Note: Do not rest the entire weight of the boom on 7 Attach a lifting strap from an overhead crane
the blocks. to the lug on the rod end of the jib boom lift
cylinder.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on 8 Use a soft metal drift to remove the jib boom
the cylinder. lift cylinder rod-end pin. Remove the jib boom
lift cylinder from the machine.
hydraulic oil can penetrate and Crushing hazard. The jib boom
burn skin. Loosen hydraulic lift cylinder may become
connections very slowly to allow unbalanced and fall when it is
the oil pressure to dissipate removed from the machine if it is
gradually. Do not allow oil to not properly supported by the
squirt or spray. overhead crane.

jib boom lift cylinder rod-end pivot pin. Do not
remove the pin.
Part No. 119817 Z-40/23N, Z-40/23N RJ 65

Primary Boom Components

Primar y Bo om Co mpon ents
4-1 C able Track

from ports P and T at the jib boom/platform
Cable Track rotate manifold. Cap the fittings on the
manifold.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
How to R emove the C able Track
squirt or spray.
7 Tag and disconnect the hydraulic hoses from

How to Remove the Cable Track the platform leveling slave cylinder at the
Note: When removing a hose assembly or fitting, union and connect them together using a
the O-ring (if equipped) on the fitting and/or hose connector. Connect the hoses from the
end must be replaced. All connections must be cylinder together using a connector.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque Bodily injury hazard. Spraying
Specifications. hydraulic oil can penetrate and
1 Tag and disconnect each electrical connector connections very slowly to allow
from the platform control box. the oil pressure to dissipate
2 Remove the hose and cable clamp from the jib
squirt or spray.
boom bellcrank pivot pin.
3 Remove all of the hose and cable clamps from 8 Remove the hose and cable clamp from the
the jib boom and platform support. platform end of the cable track tube.
4 Remove the power to platform electrical box 9 Pull all of the electrical cables out of the plastic
mounting fasteners. Remove the electrical box cable track. Do not pull out the hydraulic
from the platform. Do not disconnect the hoses.
wiring. 10 Remove all hose and cable clamps from the
5 Remove the jib boom/platform rotate manifold underside of the primary boom.
cover.
66 Z-40/23N, Z-40/23N RJ Part No. 119817

11 Tag, disconnect and plug the jib 15 Place blocks between the cable track tube and
boom/platform rotator hydraulic hoses at the the lower cable track. Secure the cable track
union located above the primary boom lift tube and lower cable track together.
cylinder. Cap the fittings on the unions.
Crushing hazard. If the upper
Bodily injury hazard. Spraying and lower cable tracks are not
hydraulic oil can penetrate and properly secured together, the
burn skin. Loosen hydraulic cable track could become
connections very slowly to allow unbalanced and fall when
the oil pressure to dissipate removed from the machine.
squirt or spray. 16 Support and secure the cable track to an
overhead crane or other similar lifting device.
12 Pull the jib boom/platform rotator hydraulic
17 Remove the cable track tube retaining
hoses, disconnected at the union, through the
fasteners from the platform end of the
mounting ears of the rod end of the primary
extension tube.
boom lift cylinder, towards the platform.
18 Remove the cable track mounting fasteners
Component damage that attach the lower cable track tray to the
hazard.Cables and hoses can be primary boom.
pinched. 19 Remove the cable track from the machine and
place it on a structure capable of supporting it.
13 Remove the cover from the bottom of the
cable track. Crushing hazard. If the upper
and lower cable tracks are not
14 Pull all of the cables through the mounting properly secured together, the
ears of the rod end of the primary boom lift cable track could become
cylinder, towards the counterweight end of the unbalanced and fall when
machine. removed from the machine.
Part No. 119817 Z-40/23N, Z-40/23N RJ 67


How to R epair the Primary Boom C abl e Tr ack 4-2 Primary Boom
How to Repair the Primary Boom How to Shim the Primary Boom
Cable Track 1 Extend the boom until the wear pads are
accessible.
The boom cable track can be 2 Loosen the wear pad mounting fasteners.
damaged if it is twisted.
3 Install the new shims under the wear pad to
Note: A 7 link repair section of cable track is obtain zero clearance and zero drag.
available through the Genie Service Parts 4 Tighten the mounting fasteners.
Department.
5 Extend and retract the boom through an entire
cycle. Check for tight spots that could cause
scraping or binding.
Note: Always maintain squareness between the
outer and inner boom tubes.
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.
68 Z-40/23N, Z-40/23N RJ Part No. 119817


How to R emove the Primary Boom
How to Remove the Primary 3 Remove the cable track. Refer to Repair
Procedure, How to Remove the Cable Track.
Boom
4 Remove the hose and cable guard from the
Bodily injury hazard. This upper pivot.
procedure requires specific repair
skills, lifting equipment and a Bodily injury hazard. Spraying
suitable workshop. Attempting hydraulic oil can penetrate and
this procedure without these skills burn skin. Loosen hydraulic
and tools could result in death or connections very slowly to allow
serious injury and significant the oil pressure to dissipate
component damage. Dealer gradually. Do not allow oil to
service is strongly recommended. squirt or spray.
Note: Perform this procedure with the boom in the 5 Raise the primary boom until the master
stowed position. cylinder barrel-end pivot pin is accessible.
Note: When removing a hose assembly or fitting, 6 Remove the pin retaining fastener from the
the O-ring (if equipped) on the fitting and/or hose master cylinder barrel-end pivot pin. Use a soft
end must be replaced. All connections must be metal drift to remove the pin. Lower the
torqued to specification during installation. Refer to cylinder and let it hang down.
Specifications.
When lowering the master
1 Remove the jib boom. Refer to Repair cylinder down, be sure not to
Procedure, How to Remove the Jib Boom. damage the master cylinder
hoses or fittings.
2 Models without rotating jib boom: Remove
the jib boom bellcrank. Refer to Repair 7 Locate the primary boom drive speed limit
Procedure, How to Remove the Jib Boom switch inside the upper pivot.
Bellcrank.
Models with rotating jib boom: Remove the
jib boom rotator. Refer to Repair Procedure,
How to Remove the Jib Boom Rotator.
Part No. 119817 Z-40/23N, Z-40/23N RJ 69

8 Remove the primary boom drive speed limit 16 Place support blocks under the primary boom
switch mounting fasteners and move the limit lift cylinder.
switch out of the way. Do not disconnect the
wiring.
primary boom lift cylinder rod-end pivot pin.
9 Locate the primary extension boom drive Use a soft metal drift to remove the pin.
speed limit switch inside the extension boom.
Crushing hazard. The boom lift
10 Remove the primary extension boom drive cylinder and primary boom will
speed limit switch mounting fasteners. Do not fall if not properly supported.
disconnect the wiring.
11 Pull the limit switch and the wiring out of the 18 Lower the rod end of the primary boom lift
extension tube and move it out of the way. cylinder onto support blocks. Protect the
12 Tag, disconnect and plug the primary boom
extension cylinder hydraulic hoses. Cap the 19 Remove the pin retaining fasteners from the
fittings on the cylinder. primary boom pivot pin.
20 Remove the primary boom pivot pin with a soft
metal drift. Carefully remove the primary boom
from the machine and place it on a structure
burn skin. Loosen hydraulic capable of supporting it.
the oil pressure to dissipate Bodily injury hazard. Spraying
gradually. Do not allow oil to hydraulic oil can penetrate and
squirt or spray. burn skin. Loosen hydraulic
13 Lower the primary boom to a horizontal the oil pressure to dissipate
14 Attach a 5 ton / 5,000 kg overhead crane to gradually. Do not allow oil to
the center point of the primary boom. squirt or spray.
15 Attach a similar lifting device to the primary 21 Attach a lifting strap from an overhead crane
boom lift cylinder. to the primary boom lift cylinder.
70 Z-40/23N, Z-40/23N RJ Part No. 119817


How to Dis ass embl e the Primary Boom
22 Place 2 x 4 x 18 inch / 5 x 10 x 46 cm support How to Disassemble the Primary

blocks under the cylinder, across the
secondary boom.
Boom
23 Remove the pin retaining fastener from the Note: Complete disassembly of the boom is only
primary boom lift cylinder rod-end pivot pin. necessary if the outer or inner boom tubes must be
Use a soft metal drift to remove the pin. replaced. The extension cylinder can be removed
without completely disassembling the boom. Refer
Crushing hazard. The primary to Repair Procedure, How to Remove the
boom lift cylinder could become Extension Cylinder.
unbalanced and fall if not
properly supported by the lifting 1 Remove the primary boom. Refer to Repair
device. Procedure, How to Remove the Primary
Boom.
24 Lower the rod end of the primary boom lift 2 Place blocks under the extension cylinder for
cylinder onto support blocks. Protect the support.
3 Remove the retaining fasteners from the
25 Remove the pin retaining fastener from the extension cylinder barrel-end pivot pin. Use a
primary boom pivot pin. soft metal drift to remove the pin.
26 Remove the primary boom pivot pin with a soft 4 Remove and label the location of the wear
metal drift. Carefully remove the primary boom pads from the top side of the boom tube at the
assembly from the machine. platform end of the boom.
Crushing hazard. The primary Note: Pay careful attention to the location and
boom could become unbalanced amount of shims used with each wear pad.
machine if not properly attached
to the overhead crane.
Part No. 119817 Z-40/23N, Z-40/23N RJ 71


4-3 Primary Boom Lift Cylinder
5 Support and slide the extension tube and 4-3

extension cylinder assembly out of the boom
tube.
Primary Boom Lift Cylinder
Crushing hazard. The boom The primary boom lift cylinder raises and lowers
extension tube could fall when the primary boom. The primary boom lift cylinder is
removed from the boom if not equipped with a counterbalance valve to prevent
properly supported. movement in the event of a hydraulic line failure.
Note: During removal, the overhead crane strap will

need to be adjusted for proper balancing. How to Remove the Primary
Boom Lift Cylinder
6 Remove the external snap rings from the
extension cylinder rod-end pivot pin at the Bodily injury hazard. This
platform end of the extension tube. Use a soft procedure requires specific repair
metal drift to remove the pin. skills, lifting equipment and a
7 Support and slide the extension cylinder out of suitable workshop. Attempting
the base end of the extension tube. Place the this procedure without these skills
extension cylinder on blocks for support. and tools could result in death or
serious injury and significant
Crushing hazard. The extension component damage. Dealer
cylinder could become service is strongly recommended.
removed from primary boom Note: When removing a hose assembly or fitting,
extension tube if not properly the O-ring (if equipped) on the fitting and/or hose
supported. end must be replaced. All connections must be
Note: During removal, the overhead crane strap will Specifications, Hydraulic Hose and Fitting Torque
need to be adjusted for proper balancing. 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 Using the overhead crane, raise the primary
boom slightly to take the pressure off the
primary boom lift cylinder pivot pins.
72 Z-40/23N, Z-40/23N RJ Part No. 119817

5 Support both ends of the primary boom lift 9 Lower the rod end of the lift cylinder onto the
cylinder with a second overhead crane or block. Protect the cylinder rod from damage.
similar lifting device. Crushing hazard. The primary
6 Tag, disconnect and plug the primary boom lift boom could become unbalanced
cylinder hydraulic hoses. Cap the fittings on and fall when removed from the
the cylinder. machine if not properly attached
hydraulic oil can penetrate and 10 Remove the primary boom lift cylinder
burn skin. Loosen hydraulic barrelend pivot pin retaining fasteners. Use a
connections very slowly to allow slide hammer to remove the barrel-end pivot
the oil pressure to dissipate pin. Carefully remove the primary boom lift
gradually. Do not allow oil to cylinder from the machine.
squirt or spray.
Crushing hazard. The lift cylinder
7 Place a support block across both turntable could become unbalanced and
covers under the primary boom lift cylinder. fall if not properly supported and
secured to the lifting device.
primary boom lift cylinder rod-end pivot pin. Crushing hazard. The primary
Use a soft metal drift to remove the pin. boom could become unbalanced
Crushing hazard. The primary
boom could become unbalanced
Part No. 119817 Z-40/23N, Z-40/23N RJ 73


4-4 Primary Boom Extension C ylinder
4-4 3 Remove the hose and cable guard from the

upper pivot.
Primary Boom Extension
4 Tag, disconnect and plug the primary boom
Cylinder extension cylinder hydraulic hoses. Cap the
The primary boom extension cylinder extends and fittings on the cylinder.
retracts the primary boom extension tube. The Bodily injury hazard. Spraying
primary boom extension cylinder is equipped with hydraulic oil can penetrate and
counterbalance valves to prevent movement in the burn skin. Loosen hydraulic
event of a hydraulic line failure. connections very slowly to allow
How to Remove the Primary gradually. Do not allow oil to
squirt or spray.
Boom Extension Cylinder
5 Locate the primary extension boom drive
Bodily injury hazard. This speed limit switch inside the extension boom
procedure requires specific repair at the pivot end.
skills, lifting equipment and a
suitable workshop. Attempting 6 Remove the primary extension boom drive
this procedure without these skills speed limit switch mounting fasteners. Do not
and tools could result in death or disconnect the wiring.
serious injury and significant 7 Pull the limit switch and the wiring out of the
component damage. Dealer extension tube and move it out of the way.
service is strongly recommended.
8 At the platform end of the boom, remove the
Note: When removing a hose assembly or fitting, external snap rings from the extension
the O-ring (if equipped) on the fitting and/or hose cylinder rod-end pivot pin. Use a soft metal
end must be replaced. All connections must be drift to remove the pin.
9 Remove the barrel-end pivot pin retaining
fasteners.
Specifications.
10 Place a support block under the barrel end of
1 Raise the primary boom to a horizontal the primary boom extension cylinder.
position.
11 Use a slide hammer to remove the pin.
2 Extend the primary boom until the primary
boom extension cylinder rod-end pivot pin is
accessible in the primary boom extension
tube.
74 Z-40/23N, Z-40/23N RJ Part No. 119817


4-5 Platform Lev eling M aster Cylinder
12 Support and slide the extension cylinder out of 4-5

the upper pivot.
Platform Leveling Master
Crushing hazard. The extension Cylinder
cylinder could fall when removed
from the extension boom if not The platform leveling master cylinder acts as a
properly supported. pump for the slave cylinder. It is part of the
closed-loop hydraulic circuit that keeps the platform
Component damage hazard. Be level through the entire range of primary boom
careful not to damage the motion. The platform leveling master cylinder is
counterbalance valves on the located inside the upper mid-pivot at the pivot end
primary boom extension cylinder of the primary boom.
when removing the cylinder from
the primary boom.
How to Remove the Platform
Component damage hazard. Leveling Master Cylinder
Hoses and cables can be
damaged if the primary boom Bodily injury hazard. This
extension cylinder is dragged procedure requires specific repair
across them. skills, lifting equipment and a
suitable workshop. Attempting
Note: Note the length of the cylinder after removal. this procedure without these skills
The cylinder must be at the same length for and tools could result in death or
installation. serious injury and significant
component damage. Dealer

the O-ring (if equipped) on the fitting and/or hose
Specifications.
1 Raise the secondary boom until both the
rodend and barrel-end pivot pins of the master
cylinder are accessible.
Part No. 119817 Z-40/23N, Z-40/23N RJ 75

2 Tag, disconnect and plug the master cylinder

hydraulic hoses. Cap the fittings on the
cylinder.
squirt or spray.
3 Attach an overhead crane or similar lifting

device to the master cylinder.
master cylinder barrel-end pivot pin. Use a soft
metal drift to remove the pin.
Crushing hazard. The master
cylinder could become
properly attached to the
overhead crane.
5 Remove the pin retaining fastener from the

rodend pivot pin.
6 Place a rod through the rod-end pivot pin and
twist to remove the pin.
7 Remove the master cylinder from the
machine.
Crushing hazard. The master
cylinder could become
properly attached to the
overhead crane.
76 Z-40/23N, Z-40/23N RJ Part No. 119817

Secondary Boom Components

Second ar y Boo m Comp onent s
Secondary Boom components 6 lower compression arm

1 upper pivot 7 turntable pivot
2 upper compression arm 8 counterweight (Z-30N / Z-30N RJ)
3 mid-pivot 9 upper secondary boom
4 compression link
5 lower secondary boom
Part No. 119817 Z-40/23N, Z-40/23N RJ 77


5-1 Secondary Boom

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 5 Remove the pin retaining fastener from the
and tools could result in death or primary boom lift cylinder barrel-end pivot pin.
serious injury and significant
6 Use a slide hammer to remove the pin.
component damage. Dealer
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 boom lift cylinder could become
secondary boom by following the disassembly unbalanced and fall if not
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 7 Lower the secondary boom to the stowed
torqued to specification during installation. Refer to position.
Specifications, Hydraulic Hose and Fitting Torque 8 Tag, disconnect and plug the hydraulic hoses
Specifications. on both of the secondary boom lift cylinders.
Cap the fittings on the cylinders.
1 Remove the primary boom. Refer to Repair
Procedure, How to Remove the Primary Bodily injury hazard. Spraying
Boom. hydraulic oil can penetrate and
2 Remove the master cylinder. Refer to Repair burn skin. Loosen hydraulic
Procedure, How to Remove the Platform connections very slowly to allow
Leveling Master Cylinder. the oil pressure to dissipate
3 Attach a lifting strap from an overhead crane squirt or spray.
to the lug on the rod end of the primary boom
lift cylinder. Using the overhead crane, raise
the primary boom lift cylinder to a vertical
position.
78 Z-40/23N, Z-40/23N RJ Part No. 119817


9 Remove the pin retaining fasteners from both 16 Attach a lifting strap from a second overhead
sides of the secondary boom lift cylinder rod crane to the number 1 arm at the mid-point
end pivot pin and barrel-end pivot pin. Do not between the upper pivot and mid-pivot.
remove the pins.
10 Attach a strap from an overhead crane to the number 1 arm pivot pins at the mid-pivot and
lug on the rod end of one of the secondary the upper pivot. Do not remove the pins.
boom lift cylinders for support. Do not apply 18 Use a soft metal drift to drive both pins out.
any lifting pressure.
19 Remove the number 1 arm from the machine.
11 Use a soft metal drift to drive the barrel-end
pivot pin half way out. Lower the barrel end of Crushing hazard. The number
the secondary boom lift cylinder and let it hang 1 arm could become unbalanced
down. and fall when removed from the
12 Use a soft metal drift to drive the rod-end pivot to the overhead crane.
pin half way out.
13 Remove the secondary boom lift cylinder from Crushing hazard. The upper
the machine. pivot could fall when the number
1 arm is removed from the
Crushing hazard. The secondary machine if not properly
boom lift cylinder could become supported by the overhead
unbalanced and fall when crane.
properly attached to the 20 Attach a lifting strap from an overhead crane
overhead crane. to the upper pivot.
Component damage hazard. 21 Using the overhead crane attached to the

When removing a secondary upper pivot, raise the secondary boom
boom lift cylinder from the assembly approximately 30 inches / 76 cm.
machine, be careful not to 22 Insert a 4 x 4 x 11 inch / 10 x 10 x 28 cm block
damage the counterbalance between the number 2 arm and the boom rest.
valve at the barrel end of the Lower the secondary boom assembly onto the
cylinder. block.
14 Repeat steps 12 through 15 for the other Crushing hazard. The secondary
secondary boom lift cylinder. boom assembly could fall if not
properly supported by the4 x 4 x
15 Attach a lifting strap from an overhead crane
11 inch / 10 x 10 x 28 cm block.
to the upper pivot for support. Do not lift it.
Part No. 119817 Z-40/23N, Z-40/23N RJ 79


23 Pull all of the cables and hoses out through 30 Lower the number 2 arm onto the boom rest
the upper pivot. pad.
Component damage hazard. 31 Insert a 4 x 4 x 81/2 inch / 10 x 10 x 22 cm
Cables and hoses can be block between the number 3 arm and the
damaged if they are kinked or number 4 arm at the mid-pivot end.
pinched. 32 Attach a lifting strap from the overhead crane
to the mid-pivot for support. Do not apply any
24 Remove the hose and cable cover and clamps lifting pressure.
from the top of the number 2 arm.
25 Pull all of the hoses and cables out of the number 2, 3 and 4 arm pivot pins at the
upper pivot and out through the mid-pivot. mid-pivot. Do not remove the pins.
Lay the hoses and cables on the ground.
34 Use a soft metal drift to drive each pin out.
Component damage hazard. Remove the mid-pivot from the secondary
Cables and hoses can be boom assembly.
pinched. Crushing hazard. The mid-pivot
could become unbalanced and
26 Remove the pin retaining fastener from the fall when removed from the
number 2 arm pivot pin at the upper pivot. Use secondary boom assembly if not
a soft metal drift to remove the pin. properly supported by the
overhead crane.
27 Remove the upper pivot from the machine.
Crushing hazard. The upper 35 Attach the lifting strap from an overhead crane
pivot could become unbalanced to the center point of the number 2 arm for
and fall when removed from the support. Do not apply any lifting pressure.
28 Attach the lifting strap from an overhead crane

to the number 2 arm at the upper pivot end.
29 Raise the number 2 arm slightly and remove
the 4 x 4 x 11 inch / 10 x 10 x 28 cm block.
80 Z-40/23N, Z-40/23N RJ Part No. 119817


36 Remove the pin retaining fasteners from both 40 Remove the number 2 arm from the machine.
compression link pivot pins. Do not remove
the pins. Crushing hazard. The number
2 arm could become
37 Use a soft metal drift to remove the lower
compression link pivot pin at the number
removed from the secondary
3 arm.
boom assembly if not properly
38 Support the compression link with an supported by the overhead
appropriate lifting device. crane.
39 Use a soft metal drift to remove the upper 41 Remove the hose and cable cover and clamps
compression link pivot pin from the number from the number 3 arm.
2 arm. Remove the compression link from the
machine. 42 Remove the secondary boom drive speed limit
switch mounting fasteners from the number
Crushing hazard. The number 4 arm at the mid-pivot end. Do not disconnect
2 arm could fall when the the wiring.
compression link is disconnected
from the number 2 arm if not 43 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.
Crushing hazard. The Component damage hazard.

compression link may fall if not Cables and hoses can be
properly supported when damaged if they are kinked or
removed from the secondary pinched.
boom assembly.
44 Remove the mounting fasteners from the
cover located in the boom storage area to
access the number 3 and number 4 arm pivot
pin retaining fasteners at the turntable pivot.
Part No. 119817 Z-40/23N, Z-40/23N RJ 81


5-2 Secondary Boom Lift Cyli nders
45 Attach the lifting strap from the overhead 5-2

crane to the centerpoint of the number 3 arm
for support. Do not apply any lifting pressure.
Secondary Boom Lift Cylinder
46 Remove the pin retaining fasteners from the The secondary boom lift cylinder raises and lowers
number 3 arm at the turntable pivot. Do not the secondary boom. The secondary boom lift
remove the pin. cylinder is equipped with counterbalance valves to
prevent movement in the event of a hydraulic line
47 Use a slide hammer to remove the number failure.
3 arm pivot pin from the turntable pivot
through the access hole in the counterweight.
48 Remove the number 3 arm from the machine. How to Remove the Secondary
Boom Lift Cylinder
Crushing hazard. The number
3 arm could become unbalanced Bodily injury hazard. This
and fall when removed from the procedure requires specific repair
machine if not properly skills, lifting equipment and a
supported by the overhead suitable workshop. Attempting
crane. this procedure without these skills
and tools could result in death or
49 Remove the pin retaining fasteners from the serious injury and significant
number 4 arm at the turntable pivot. Do not component damage. Dealer
remove the pin. service is strongly recommended.
50 Attach a lifting strap from the overhead crane
to the center point of the number 4 arm. Do
not apply any lifting pressure.
51 Use a slide hammer to remove the number torqued to specification during installation. Refer to
4 arm from the turntable pivot through the Specifications, Hydraulic Hose and Fitting Torque
access hole in the counterweight. Specifications.
52 Remove the number 4 arm from the machine. 1 With the secondary boom in the stowed
postion, raise the primary boom until it is
Crushing hazard. The number
above the secondary boom lift cylinder
4 arm could become unbalanced
rod-end pivot pin.
machine if not properly
supported by the overhead
crane.
82 Z-40/23N, Z-40/23N RJ Part No. 119817

2 Tag, disconnect and plug the hydraulic hoses 7 Remove the secondary boom lift cylinder from
on the secondary boom lift cylinder. Cap the the machine.
fittings on the cylinder.
Crushing hazard. The secondary
Bodily injury hazard. Spraying boom lift cylinder could become
hydraulic oil can penetrate and unbalanced and fall when
burn skin. Loosen hydraulic removed from the machine if not
connections very slowly to allow properly attached to the
the oil pressure to dissipate overhead crane.
squirt or spray. Component damage hazard.
When removing a secondary
3 Remove the pin retaining fasteners from the boom lift cylinder from the
secondary boom lift cylinder rod-end pivot pin machine, be careful not to
and barrel-end pivot pin. Do not remove the damage the counterbalance
pins. valve at the barrel end of the
cylinder.
4 Attach a strap from an overhead crane to the
lug on the rod end of the secondary boom lift
cylinder for support. Do not apply any lifting
pressure.
5 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.
6 Use a soft metal drift to drive the rod-end pivot
pin half way out.
Part No. 119817 Z-40/23N, Z-40/23N RJ 83

Hydraulic Pump
4 Remove the center turntable cover fasteners.
Hydr aulic Pump
6-1 Auxiliary and F uncti on Pump
6-1 Remove the cover from the machine.

How to Remove the Auxiliary 5 Tag, disconnect and plug the hydraulic hoses
Pump from the auxiliary pump. Cap the fittings on the
pump.
How to Remove the Auxiliary Bodily injury hazard. Spraying

Pump burn skin. Loosen hydraulic
Note: When removing a hose assembly or fitting, connections very slowly to allow
the O-ring (if equipped) on the fitting and/or hose the oil pressure to dissipate
end must be replaced. All connections must be gradually. Do not allow oil to
torqued to specification during installation. Refer to squirt or spray.
Specifications. 6 Remove the auxiliary pump mounting bolts.
Carefully remove the pump.
1 Raise the secondary boom approximately 6 ft /
2 m. Turn the machine off.
tank. Refer to Specifications, Machine
Specifications.
3 Remove the drain plug from the hydraulic
tank. Completely drain the hydraulic tank into
a container of suitable capacity.
cause severe burns.
84 Z-40/23N, Z-40/23N RJ Part No. 119817

Hydraulic Pump
3 Tag, disconnect and plug the hydraulic hoses
6-2 H ow to Rem ov e the F unc tion Pum p
6-2 from the pump. Cap the fittings on the pump.

How to Remove the Function
Pump hydraulic oil can penetrate and
The function pump motor operates at various
speeds, depending on the flow and pressure
required for the machine function selected. A
speed sensor, built into the pump motor, enables
squirt or spray.
the control system to monitor and control the speed
of the pump motor, which controls the flow output 4 Remove the pump mounting bolts. Carefully
of the pump. remove the pump.
Note: When removing a hose assembly or fitting, Note: When replacing the function pump, it will
the O-ring (if equipped) on the fitting and/or hose need to be calibrated. Refer to Repair Procedure,
end must be replaced. All connections must be How to Calibrate the Function Pump.
Specifications.
tank. Refer to Section 2, Specifications.
2 Remove the drain plug from the hydraulic
tank. Completely drain the hydraulic tank into
a container of suitable capacity..
cause severe burns.
Part No. 119817 Z-40/23N, Z-40/23N RJ 85

Hydraulic Pump
How to Calibrate the Function 6 When the display leaves SYSTEM READY
Pump and the steer rocker switch.
Calibration of the function pump is essential to Result: The display will show FAULTS.
good machine performance and service life.
Continued use of an uncalibrated or improperly 7 Momentarily activate the steer rocker switch in
calibrated function pump could result in reduced the right direction until SETTINGS is shown on
machine performance. The function pump must be the display.
calibrated before machine functions are calibrated 8 Momentarily activate the drive enable toggle
or before adjusting boom function speeds. switch in the right direction to enter the
SETTINGS menu.
Note: This procedure must be performed with the
rotary speed controller turned to the full clockwise Result: The display will show VALVE AND
position. PUMP SETTINGS.
1 Calibrate the proportional relief valve.Refer to 9 Momentarily activate the drive enable toggle
Repair Procedure, How to Calibrate the switch in the right direction to enter the VALVE
Proportional Relief Valve. AND PUMP SETTINGS menu.
2 Turn the key switch to platform control. Result: The display will show THRESHOLD
CURRENT.
3 Pull out the red Emergency Stop buttons to
the on position at both the ground and 10 Momentarily activate the steer rocker switch in
platform controls. the right direction until START PUMP GPM is
shown on the display.
5 Move and hold the drive enable toggle switch switch in the right direction to begin pump
in the right direction while holding the steer calibration.
86 Z-40/23N, Z-40/23N RJ Part No. 119817

Hydraulic Pump
12 Press down on the foot switch. Move and hold

the primary boom rocker switch in the extend
direction until the boom is fully extended and
an audible alarm has sounded.
Result: The alarm sounds. Continue to step
13.
Result: The alarm does not sound. Fully
retract the primary boom and repeat steps
11 and 12.
13 Move and hold the drive enable toggle in the
left position until the display returns to
SYSTEM READY mode.
Part No. 119817 Z-40/23N, Z-40/23N RJ 87

Manifolds
Manifold s
7-1 F uncti on Manifold C om ponents
7-1 Function Manifold Components

The function manifold is located behind the ground controls turntable cover.
Index Schematic
Description Function Torque
No. Item
— Coil nut 4-5 ft-lbs / 5-7 Nm
1 Proportional solenoid valve, BU Primary boom extend/retract 16-20 ft-lbs / 24-27 Nm
3 position 4 way
2 Orifice, 0.046 inch / 1.17 mm BM Secondary boom down
3 Proportional solenoid valve, BS Primary boom up/down 16-20 ft-lbs / 24-27 Nm
3 position 4 way
4 Proportional solenoid valve, BC Steer left/right 16-20 ft-lbs / 24-27 Nm
3 position 4 way
5 Proportional solenoid valve, BN Secondary boom up/down 18-20 ft-lbs / 25-27 Nm
3 position 4 way
6 Relief valve, 2100 psi / 145 bar BP Secondary boom down 18-20 ft-lbs / 25-27 Nm
7 Pressure compensator valve,80 psi / BL Turntable rotate circuit 25-25 ft-lbs / 34-36.7 Nm
5.5 bar
8 Proportional solenoid BK Turntable rotate left/right 18-20 ft-lbs / 25-27 Nm
valve,3 position 4 way
9 Shuttle valve BJ Turntable rotate circuit 4-5 ft-lbs / 5-7 Nm
10 Counterbalance valve,1000 psi / BT Primary boom down 44-52 ft-lbs / 60-70 Nm
70 bar
11 Proportional relief valve,50 to BW System relief 18-20 ft-lbs / 25-27 Nm
3000 psi / 3 to 207 bar
12 Needle valve BH Primary level up/down 18-20 ft-lbs / 25-27 Nm
13 Check valve, 4 psi / 0.3 bar BA Prevents oil from draining from 20 ft-lbs / 27 Nm
turntable rotate circuit back to tank
14 Check valve, 25 psi / 1.7 bar BX System relief valve circuit 18-20 ft-lbs / 25-27 Nm
15 Check valve, 4 psi / 0.3 bar BY Prevents oil from draining out of 18-20 ft-lbs / 25-27 Nm
jib/rotate manifold back to tank
16 Shuttle valve BF Platform level 18-20 ft-lbs / 25-27 Nm
17 Check valve, dual pilot BE Platform level 20 ft-lbs / 27 Nm
18 Check valve, 25 psi / 1.7 bar BB Prevents oil from draining out of 18-20 ft-lbs / 25-27 Nm
manifold
19 Relief valve, 2500 psi / 172 bar BD Platform level relief 18-20 ft-lbs / 25-27 Nm
20 Solenoid valve, 3 position 4 way BG Platform level up/down 16-20 ft-lbs / 24-27 Nm
88 Z-40/23N, Z-40/23N RJ Part No. 119817

Manifolds
Part No. 119817 Z-40/23N, Z-40/23N RJ 89

Manifolds
7-2 Valve Adjus tments - Func tion M anifol d
7-2 Valve Adjustments - Function Note: The function enable toggle switch must be
activated within 2 seconds of the audible tone.
Manifold
Result: The green LED on the TCON should
change from a slow blinking light to a rapid
How to Calibrate the Proprotional blinking light.
Relief Valve Result: The green LED on the TCON does not
Note: This procedure must be performed at the blink rapidly. Push in the red Emergency Stop
ground controls with the jib boom in the fully button to the off position and repeat this
elevated position. procedure beginning with step 3.
1 Turn the key switch to the off position, and

push in the red Emergency Stop button to the
off position.
2 Connect a 0 to 3000 psi / 0 to 207 bar
pressure gauge to test port TP1 on the
function manifold.
3 Turn the key switch to the ground control
position. Pull out the red Emergency Stop
button to the on position and immediately
activate the function enable toggle switch in
either direction 3 times after the alarm sounds.
1 green LED
2 red LED
3 turntable control module (TCON)
90 Z-40/23N, Z-40/23N RJ Part No. 119817

Manifolds
4 Move and hold the secondary boom toggle 7 Move and hold the jib boom toggle switch in
switch in the down direction. the up direction. Momentarily activate the
platform level toggle switch in the up direction
Result: The pressure gauge shows 1100 psi
to increase the relief pressure or in the down
/76 bar. Continue to step 6.
direction to decrease the relief pressure.
Result: The pressure gauge does not show Repeat this procedure beginning with step 6.
1100 psi / 76 bar. Continue to step 5.
Note: Momentarily activating the platform level
Note: Do not activate the function enable toggle toggle switch will increase or decrease the relief
switch while making this adjustment. pressure in increments of approximately 50 psi /
3 bar.
5 Move and hold the secondary boom toggle
switch in the down direction. Momentarily 8 Move and hold the primary boom toggle switch
activate the platform level toggle switch in the in the retract direction.
up direction to increase the relief pressure or
in the down direction to decrease the relief
pressure. Repeat this procedure beginning
with step 4. Result: The pressure gauge does not show
2500 psi / 172 bar continue to step 9.
toggle switch will increase or decrease the relief Note: Do not activate the function enable toggle
pressure in increments of approximately 50 psi / switch while making this adjustment.
3 bar.
9 Move and hold the primary boom toggle switch
6 Move and hold the jib boom toggle switch in in the retract direction. Momentarily activate
the up direction. the platform level toggle switch in the up
direction to increase the relief pressure or in
the down direction to decrease the relief
pressure. Repeat this procedure beginning
Result: The pressure does not show 2100 psi with step 6.
Note: Do not activate the function enable toggle toggle switch will increase or decrease the relief
switch while making this adjustment. pressure in increments of approximately 50 psi /
3 bar. To exit programming mode:
in the left direction until the display returns to
SYSTEM READY mode.
Part No. 119817 Z-40/23N, Z-40/23N RJ 91

Manifolds
How to Adjust the Secondary 6 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
Boom Down Relief Valve counterclockwise to decrease the pressure.
1 Turn the machine off. Locate the proportional Install the relief valve cap.
relief valve (item BW) on the function manifold.
Result: The relief pressure meets specification.
Remove the coil nut and remove the coil from
Continue to step 7.
the valve cartridge and set aside. Do not
disconnect the coil electrical connector. Result: The relief pressure does not meet
specification. Repeat this procedure beginning
with step 3.
pressure gauge to the test port TP1 on the
function manifold. Tip-over hazard. Do not adjust
3 Turn the key switch to ground controls. the relief valve higher than
specified.
4 With the secondary boom fully lowered, move
and hold the function enable toggle switch to 7 Turn the machine off. Remove the pressure
either side and hold the secondary boom gauge and install the proportional relief valve
up/down toggle switch in the down direction. coil.
Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
Component Specifications.
5 Turn the machine off. Hold the secondary
boom down relief valve with a wrench and
remove the cap (item BP).
92 Z-40/23N, Z-40/23N RJ Part No. 119817

Manifolds
How to Adjust the Platform Level 6 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
Relief Valve counterclockwise to decrease the pressure.
1 Turn the machine off. Locate the proportional Install the relief valve cap.
relief valve (item BW) on the function manifold.
Result: The relief pressure meets specification.
Remove the coil nut and remove the coil from
Continue to step 7.
the valve cartridge and set aside. Do not
disconnect the coil electrical connector. Result: The relief pressure does not meet
specification. Repeat this procedure beginning
with step 3.
pressure gauge to the test port TP2 on the
function manifold. Tip-over hazard. Do not adjust
3 Turn the key switch to ground controls. the relief valve higher than
specified.
4 Move and hold the function enable toggle
switch to either side and hold the platform 7 Turn the machine off. Remove the pressure
level up/down toggle switch in the up gauge and install the proportional relief valve
direction. Observe the pressure reading on the coil.
pressure gauge. Refer to Specifications,
Hydraulic Component Specifications.
5 Turn the machine off. Hold the platform level
relief valve with a wrench and remove the cap
(item BD).
Part No. 119817 Z-40/23N, Z-40/23N RJ 93

Manifolds
7-3 Jib Boom and Pl atform / Jib Boom Rotate M anifol d C om ponents
7-3
Jib Boom / Platform Rotate Manifold Components, Z-40/23N
The jib boom/platform rotate manifold is mounted to the jib boom.
Index Schematic
No. Item
1 Proportional solenoid valve, AA Jib boom up / down 18-20 ft-lbs / 25-27 Nm
3 position 4 way
2 Proportional solenoid valve, AB Platform rotate 18-20 ft-lbs / 25-27 Nm
3 position 4 way
94 Z-40/23N, Z-40/23N RJ Part No. 119817

Manifolds
7-4 Jib Boom and Pl atform / Jib Rotate M anifol d C omponents
7-4
Jib Boom and Platform / Jib Rotate Manifold Components, Z-40/23N
RJ
The jib boom/platform rotate manifold is mounted to the jib boom.
Index Schematic
No. Item
1 Proportional solenoid valve, AA Jib boom up/down 18-20 ft-lbs / 25-27 Nm
3 position 4 way
2 Proportional solenoid valve, AB Platform rotate left/right 18-20 ft-lbs / 25-27 Nm
3 position 4 way
3 Proportional solenoid valve, AC Jib boom rotate left/right 18-20 ft-lbs / 25-27 Nm
3 position 4 way
Part No. 119817 Z-40/23N, Z-40/23N RJ 95

Manifolds
7-5 Valve Coils
7-5 2 Test the coil resistance using a multimeter set

to resistance (Ω). Refer to the Valve Coil
Valve Coils Resistance Specification table.
Result: If the resistance is not within the
How to Test a Coil adjusted specification, plus or minus 10%,
replace the coil.
A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity Valve Coil Resistance
within the coil. Zero resistance or infinite resistance
indicates the coil has failed. Specification
Since coil resistance is sensitive to temperature, Note: The following coil resistance specifications
resistance values outside specification can are at an ambient temperature of 68°F / 20°C. As
produce erratic operation. When coil resistance valve coil resistance is sensitive to changes in air
decreases below specification, amperage temperature, the coil resistance will typically
increases. As resistance rises above specification, increase or decrease by 4% for each 18°F / 10°C
voltage increases. that your air temperature increases or decreases
from 68°F / 20°C.
While valves may operate when coil resistance is
outside specification, maintaining coils within Valve Coil Resistance Specification
specification will help ensure proper valve function Description Specification
over a wide range of operating temperatures. Proportional solenoid valve, 3 position 24 Ω
4 way, 20V DC
Note: If the machine has been in operation, allow
(schematic items AA, AB, AC, BC, BG,
the coil to cool at least 3 hours before performing BK, BN, BS, BU)
this test.
Solenoid valve, 20V DC 24 Ω
1 Tag and disconnect the wiring from the coil to (schematic item BG)
be tested. Proportional solenoid relief valve, 22 Ω
20V DC (schematic item BW)
96 Z-40/23N, Z-40/23N RJ Part No. 119817

Turntable Rotation Components

Turntable Rot ation Co mpon ents
8-1 T urntabl e R otation Hy draulic M otor
8-1
Turntable Rotation Assembly
How to Remove the Turntable

Rotation Assembly
Specifications.
1 Raise the secondary boom until the upper
pivot is above the turntable covers. Turn the
machine off.
3 Remove the retaining fasteners from the
2 Secure the turntable from rotating with the
center turntable cover. Remove the cover from
turntable rotation lock pin.
the machine.
Crushing hazard. The turntable 4 Disconnect the battery packs from the
rotation assembly could become machine.
removed from the machine if not Electrocution/burn hazard.
properly supported by the Contact with electrically charged
overhead crane. circuits could result in death or
Part No. 119817 Z-40/23N, Z-40/23N RJ 97

Turntable Rotation Components

5 Tag, disconnect and plug the hydraulic hoses
from the turntable rotation motor manifold.
Cap the fittings on the manifold.
squirt or spray.
6 Attach a lifting strap from an overhead crane

or other suitable lifting device to the turntable
rotation assembly.
7 Remove the turntable rotation assembly
mounting fasteners.
8 Carefully remove the turntable rotation
assembly from the machine.
Crushing Hazard. The machine
could tip over when the turntable
rotation assembly is removed if
the turntable rotation lock is not
in the locked position.
Crushing hazard. The turntable

rotation assembly could become
properly supported by the
overhead crane.
98 Z-40/23N, Z-40/23N RJ Part No. 119817

Steer Axle Components

7 Remove the steer sensor cover retaining
Steer A xle Co mponents
9-1 H ub and Bearings
9-1 Steer Angle Sensor fasteners. Remove the steer sensor assembly
from the machine.
How to Replace the Steer Angle Note: Inspect the sensor activator pin to make sure
Sensor it is not broken or twisted.
The steer angle sensor, installed on the steer yoke Note: If the sensor activator pin needs to be
pivot pin, is monitored by the control system to replaced, note the mounting orientation to be sure
determine steer angle. The control system uses the the new one is installed correctly.
steer angle input, along with pre-programmed
8 Install the new steer sensor assembly to the
parameters, to vary the speed of each drive motor
yoke pivot pin. Loosely install the cover
while steering to minimize tire scrub and to help
retaining fasteners.
minimize turning radius. Drive speed is also
reduced proportionately depending on the steer Note: Be sure the sensor activator pin is engaged
angle to minimize lateral platform acceleration. into the sensor.
1 Adjust the steer tires so they are in a straight Note: The arrow on the steer sensor cover should
driving position. point towards the front of the machine.
2 Turn the key switch to the off position. 9 Connect the steer sensor harness to the main
3 Push in the red Emergency Stop buttons to harness.
the off position at both the ground and 10 Set a voltmeter to read DC voltage. Probe the
platform controls. back of the electrical connector at the orange
4 Remove the drive chassis cover at the steer wire using the positive lead of the voltmeter.
end of the machine. Probe the back of the electrical connector at
the black wire using the negative lead of the
5 Remove the cable clamp securing the steer voltmeter.
sensor cable to the chassis.
6 Tag and disconnect the steer sensor harness
from the main harness. 12 Pull out the red Emergency Stop buttons to
the on position at both the ground and
platform controls.
Part No. 119817 Z-40/23N, Z-40/23N RJ 99


13 Adjust the steer sensor cover so that the volt Calibrate Steer Center
meter reads 2.5V DC.
14 Tighten steer sensor cover fasteners. switch in the right direction.
15 Install the cable clamp to secure the steer Result: The Display will show NO and
sensor cable to the drive chassis. ENABLE will appear at the bottom of the
16 Install the drive chassis cover. screen.
17 Calibrate the steer sensor. See How to 10 Momentarily activate the steer rocker switch
Calibrate the Steer Angle Sensor. in the right direction to activate calibrate
How to C alibr ate the Steer Angle Sensor
steer center.
How to Calibrate the Steer Angle Result: ENABLE will appear at the bottom of
Sensor the screen.
1 Turn the key switch to platform control. 11 Momentarily activate the drive enable toggle
switch in the right direction.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform Result: The display will show YES. Proceed to
controls. step 12.
3 Using the thumb rocker switch on the drive Result: System does not allow YES to appear.
joystick, adjust the steer wheels so they are Press in the red Emergency stop button and
pointing straight ahead, in line with the return to step one. Check steer angle sensor
nonsteer wheels. Release the foot switch. wiring is correct and steer tires are pointing
straight ahead.
in the right direction while holding the steer 12 Momentarily activate the drive enable toggle
rocker switch in the right direction. switch in the right direction to save the setting.
5 When the display leaves SYSTEM READY Result: The alarm will sound indicating the
mode, release the drive enable toggle switch setting has been saved.
and the steer rocker switch on the drive steer Calibrate Steer Right
joystick.
Result: The display will show FAULTS. the right direction until you see the
6 Momentarily activate the steer rocker switch in CALIBRATE RIGHT screen and press the
the right direction until SETTINGS is shown on drive enable toggle switch once to the right.
the display. Result: The display will show NO and
7 Momentarily activate the steer rocker switch in ENABLE will appear at the bottom of the
the right direction until you see the DRIVE screen.
SETTINGS screen. 14 Adjust the steer wheels fully in the right
8 Momentarily activate the drive enable toggle direction.
switch in the right direction until you see the
CALIBRATE CENTER screen.
Note: Authorization is not required for steer
calibrations.
100 Z-40/23N, Z-40/23N RJ Part No. 119817


15 Momentarily activate the drive enable toggle 20 Momentarily activate the drive enable toggle
switch in the right direction to activate calibrate switch in the right direction.
steer right.
Result: ENABLE will appear at the bottom of
Result: ENABLE will appear at the bottom of the screen.
the screen.
16 Momentarily activate the steer rocker switch in the right direction.
the right direction.
Result: The display will show YES.
Result: The display will show YES.
17 Momentarily activate the drive enable toggle switch in the right direction to save the setting.
switch in the right direction to save the setting.
Result: The alarm will sound indicating the
Result: The alarm should sound indicating the setting has been saved.
Note: After all three calibrations have been
Calibrate Steer Left accepted, an alarm sounds to indicate the
calibration procedure is successful and
18 Momentarily activate the steer rocker switch in CALIBRATION OK will appear on the display.
the right direction until you see the
CALIBRATE LEFT screen and press the drive To exit programming mode:
enable toggle switch once to the right.
1 Move and hold the drive enable toggle in the
Result: The display will show NO and left position until the display returns to
ENABLE will appear at the bottom of the SYSTEM READY mode.
screen.
19 Adjust the steer wheels fully in the left
direction
Part No. 119817 Z-40/23N, Z-40/23N RJ 101

Non-steer Axle Components

Non-steer A xle Co mpon ents
10- 1 Drive Motors
10-1 4 Tag and disconnect the power cables from the

drive motor.
Drive Motors
5 Tag and disconnect the electrical connectors
for the brake, speed and temperature sensors
How to Remove a Drive Motor at the drive motor.
The drive motors are AC powered and are a 6 Remove the drive motor fasteners.
brushless design requiring very little maintenance.
7 Support and slide the drive motor shaft out of
They have built-in speed and temperature sensors
the drive hub. Remove the drive motor from
which are monitored by the turntable controller
the machine.
(TCON) and the platform controller (PCON). The
speed sensor is a Hall-effect type and is part of the
rear motor shaft bearing. The temperature switch
will shut down the drive motor if it becomes
excessively hot.
1 Disconnect the battery packs from the
machine.
2 Remove the chassis cover fasteners from the

non-steer end of the chassis. Remove the
cover.
3 Remove the axle covers fasteners from the
the non-steer axle. Remove the covers.
102 Z-40/23N, Z-40/23N RJ Part No. 119817

Non-steer Axle Components

10- 2 Drive Br ak e
10-2 Drive Brake
How to Remove a Drive Brake

Proper brake action is essential to safe machine
operation. The machine uses drive motor
regenerative braking to slow and stop the machine.
Spring applied electrically released individual
wheel brakes hold the machine once it has stopped.
The drive motor regenerative braking should
operate smoothly, free of hesitation and jerking.
1 Block the steer wheels to prevent the machine
from rolling.
machine.
cover.
4 Tag and disconnect the electrical connector
from the brake.
5 Loosen the brake mounting fasteners in an
even pattern until all spring tension has been
relieved. Remove the fasteners.
6 Remove the brake from the drive motor.
Note: Some parts may fall loose from the brake
assembly during removal. Refer to the following
illustrations to be sure the spring pattern is correct
and that the rest of the brake components are
assembled properly prior to installing the brake
onto the drive motor.
Note: When installing the brake, torque the brake
mounting fasteners to 7.4 ft-lbs / 10 Nm.
1 brake disk
2 brake plate
3 spacer
4 brake body
5 spring
6 screw
Part No. 119817 Z-40/23N, Z-40/23N RJ 103

Motor Controllers
Motor Controller s
11- 1 M otor Contr ollers
11-1 Motor Controllers The motor controllers also control the valve outputs
and machine options such as flashing beacon,
There are two drive motor controllers located inside travel alarm, etc. Refer to Fault Codes section, for
the non-steer axle, one for each drive motor. When a list of fault codes and additional information. For
viewed from the non-steer end of the machine, the further information or assistance, consult the Genie
right side motor controller is the "master" and the Product Support.
left side motor controller is the "slave." The master
motor controller controls the right drive motor and
the function pump. The slave motor controller
controls the left side drive motor and auxiliary
power unit. The motor controllers are also AC
voltage inverters which take the DC voltage from
the system batteries and convert the voltage to AC
power for the drive motors. The motor controllers
are in communication with the turntable controller
(TCON) and the platform controller (PCON) which
are able to communicate operating or fault
information to the LCD display at the platform
controls.
VCON Visual
Controller (LCD
Display)
 Right (Master) Motor Left (Slave) Motor
 Controller Controller
TCON System *NODE 2* Outputs/Lift *NODE 5*
Controller (Master)  Pump (Net Master)  Outputs/AUX Pump
  
 
PCON Drive/Steer *NODE 3* Right Drive *NODE 4* Left Drive
Inputs Motor Motor
104 Z-40/23N, Z-40/23N RJ Part No. 119817

Fault Codes
Section 5 Faul t Codes
Intr oducti on
Before Troubleshooting:
 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
Attempting short cuts may produce hazardous
 Troubleshooting and repair procedures shall conditions.
be completed by a person trained and qualified
on the repair of this machine  Be aware of the following hazards and follow
generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction 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.
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
from the machine
• Boom in the stowed position
lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)
Part No. 119817 Z-40/23N, Z-40/23N RJ 105

Control System Fault Codes

Control System F ault Cod es
How to R etrieve Contr ol Sy stem F ault Codes - Platform Contr ols
Control System Fault Codes To access motor controller faults:

switch in the right direction until ACTIVE
How to Retrieve Control System FAULTS is shown on the display.
Fault Codes from the Platform
10 Activate the steer rocker switch in the right
Controls direction until MOTOR CONTROLLER
At least one fault code is present when the alarm at FAULTS is shown on the display.
the platform controls produces two short beeps 11 Momentarily activate the drive enable toggle
every 30 seconds for 10 minutes. switch in the right direction to access the
motor controller fault codes.
2 Pull out the red Emergency Stop button to the direction to scroll through the fault codes.
on position at both the ground and platform
controls. 13 Refer to the fault code table on the following
pages to aid in troubleshooting the machine by
3 Do not press down the foot switch. pinpointing the area or component affected.
4 Move and hold the drive enable toggle switch 14 To exit the fault code screen, momentarily
in the right direction and hold the steer rocker activate the drive enable toggle switch to the
switch in the right direction. left direction until FAULTS is shown on the
5 When the display leaves SYSTEM READY display.
Result:The display will show FAULTS. 15 Push in the red Emergency Stop button at the
platform controls. Wait approximately
To access active faults: 5 seconds and then pull out the red
Emergency Stop button out to the on position.
switch in the right direction until ACTIVE
FAULTS is shown on the display.
switch in the right direction to access the
active fault codes.
direction to scroll through the fault codes.
106 Z-40/23N, Z-40/23N RJ Part No. 119817


How to R etrieve Contr ol Sy stem F ault Codes - Ground C ontrols
How to Retrieve Control System 8 Use the fault code table on the following
pages to aid in troubleshooting the machine by
Fault Codes from the Ground pinpointing the area or component affected.
Controls Note: Only control system fault codes can be
1 Turn the key switch to platform control. retrieved from TCON. Motor controller fault codes
can only be retrieved by following the procedure
2 Pull out the red Emergency Stop button to the using the platform controls. Refer to Control
on position at both the ground and platform System Fault Codes, How to Retrieve Control
controls. System Fault Codes from the Platform Controls.
3 Open the ground controls side turntable cover.
4 Locate the turntable control module (TCON)
underneath the ground control box.
5 Visually inspect the flashing green and red
LEDs on the controller.
Note: The red LED indicates the source of the error
and the green LED indicates the error type.
6 Determine the error source: The flashing red
LED, when combined with short or long
pauses between the flash, tells the service
technician the specific source of the error.
Error source code 32, for example, would
appear as three quick red flashes followed by
a short pause of almost two seconds, then two
more quick red flashes. Error source code
33 would appear as three quick red flashes
followed by a short pause, then three more
quick red flashes followed by a long pause.
7 Determine the error type: The flashing green
LED, when combined with short or long 1 green LED
pauses between the flash, tells the service 2 red LED
technician the specific error type. Error type 3 turntable control module (TCON)
code 12, for example, would appear as one
quick green flash followed by a short pause of
almost two seconds, then two more quick
green flashes followed by a long pause. Error
type code 15 would appear as one quick
green flash followed by a short pause, then
five more quick green flashes followed by a
long pause.
Part No. 119817 Z-40/23N, Z-40/23N RJ 107


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

Do not operate machine with
batteries charging. Batteries
Main contactor open or overcharged, exceeds 65V DC with
12 Out of range will not close. All excessive braking. Batteries
11 BATTERY_PWR functions disabled. undercharged, may occur under
load. Replace right (master) AC
motor controller.
Slow functions. Battery
15 Value too low Charge or replace batteries.
charge less than 10%.
PR5_COIL Value too low Check for short to main contactor.
Main contactor coil. Coil shorted Check diode on main contactor.
12 15 All functions disabled.
Replace main contactor. Replace
right (master) motor controller.
Check for voltage at main contactor
coil with machine in the on position.
Value too high
12 All functions disabled. (24V DC on red wire. 48V DC on
Contacts stuck closed
orange wire). Replace main
PR5_CONTACT contactor.
13
Main contactor. Check for voltage at main contactor
coil with machine in the on position.
Value too low
15 All functions disabled. (24V DC on red wire. 48V DC on
Contacts stuck open
orange wire). Replace main
contactor.
Value too high Check for open at proportional relief
No primary or secondary valve.(wh/rd wire). Replace coil.
12 Open circuit
(unplugged or failed up
14 RELIEF_VALVE valve coil)
Check for short to proportional relief
Value at 0V No primary or secondary
16 valve. Check coil resistance (22
output shorted to B- up.
Ohms). Replace coil.
108 Z-40/23N, Z-40/23N RJ Part No. 119817


Fault Release foot switch and recycle
power. Check for power to PCON at
21 Foot switch on within All functions disabled.
15 FOOTSWITCH 200 milliseconds of C28-6 with foot switch not pressed.
power-up Replace foot switch
24 Time out All functions disabled. Release foot switch and press again.
SPEED_DIAL Check for 5V DC (orange wire).
Value too high Function speeds Check output. 0-4.7V DC (wh/rd).
16 Rotary Speed 12
controller > 5.2 volts reduced. Check input at VCON at C35-3.
Replace rotary controller.
12 Value too high Check for 48V DC to main function
Pump motor output pump. Check for current leakage
too high with repsect from motor or cables to B-. Replace
to PWM applied right (master) AC motor controller.
Lift pump disabled batteries charging. Check for 48V
17 LIFT_PUMP 15 Value too low
Auxiliary functions only. DC to main function pump. Replace
right (master) AC motor controller.
Allow main pump to cool down.
Check for air restriction to electric
21 Fault
motor. Check relief valve settings at
main manifold.
TACH_LIFTPUMP Check 3 wire plug on encoder at pump
No primary up or motor. Check 5V DC (red wire).
18 Lift pump motor 21 Fault
secondary up. Replace lift pump encoder and wiring.
encoder.
Check fuse F1 (200A). Check for
Auxiliary functions 24V DC to Aux pump. Replace Aux.
12 Value too high
disabled. pump. Replace left (slave) AC motor
AUX_PUMP controller.
19
Auxiliary pump.
Check for 24V DC to Aux pump.
Main lift pump and drive
15 Value too low Replace Aux. pump. Replace left
disabled.
(slave) AC motor controller.
Part No. 119817 Z-40/23N, Z-40/23N RJ 109


11 Shorted to supply Inspect and repair joystick wiring.
PRI_UD_JYSTK 16 Value at 0V Replace joystick.
Primary up/down function
21 Primary up/down Not calibrated Check neutral output range is within
disabled.
joystick. 17 Neutral out if range 2000 to 3000 mV. Calibrate joystick.
Replace joystick.
22 PRI_UP_VALVE 12 Value too high Primary up function Check for open or short from
Primary boom up 15 Value too low disabled. TCON(C14-5) to the up coil.
valve. Replace coil.
23 PRI_DN_VALVE 12 Value too high Check for open or short from
Primary down function TCON(C14-6) to the down coil.
Primary boom down 15 Value too low disabled.
valve. Replace coil.
PRI_ER_JYSTK Replace joystick.
16 Value at 0V
Primary extend/retract
25 Primary boom Not calibrated Check neutral output range is within
extend/retract function disabled.
joystick. 17 Neutral out if range 2000 to 3000 mV. Calibrate joystick.
Replace joystick.
PRI_EX_VALVE 12 Value too high Check for open or short from
Primary extend function TCON(C14-3) to the extend coil.
26 Primary boom 15 Value too low disabled. Replace coil.
extend valve.
PRI_RT_VALVE 12 Value too high Check for open or short from TCON
Primary retract function (C14-4) to the retract coil. Replace
27 Primary boom 15 Value too low disabled. coil.
retract valve.
SEC_UP_VALVE 12 Value too high Check for open or short from TCON
Secondary up function (C14-7) to the secondary up coil.
32 Secondary boom up 15 Value too low
disabled. Replace coil.
valve.
110 Z-40/23N, Z-40/23N RJ Part No. 119817


SEC_DN_VALVE 12 Value too high Check for open or short from TCON
Secondary down function (C14-8) to the secondary down coil.
33 Secondary boom 15 Value too low disabled. Replace coil.
down valve.
JIB_UP_VALVE 12 Value too high Check for open or short from PCON
36 Jib boom up valve. 15 Value too low Jib up function disabled. (C29-5) to the jib up coil. Replace
coil.
37 JIB_DN_VALVE 12 Value too high Check for open or short from PCON
Jib down function (C29-6) to the jib down coil. Replace
Jib boom down 15 Value too low disabled.
valve. coil.
11 Shorted to supply Turntable rotate Inspect and repair joystick wiring.
TT_ROT_JYSTK 16 Value at 0V functions disabled. Replace joystick.
41 Turntable rotate Not calibrated Check neutral output range is within
joystick. Turntable rotate
17 Neutral out of range 2000 to 3000 mV. Calibrate joystick.
functions disabled.
Replace joystick.
42 TT_CW_VALVE 12 Value too high Turntable rotate Check for open or short from TCON
Turntable rotate 15 Value too low clockwise function (C29-8) to the turntable CW coil.
clockwise valve. disabled. Replace coil.
43 TT_CCW_VALVE 12 Value too high Turntable rotate Check for open or short from TCON
Turntable rotate 15 Value too low counterclockwise (C29-7) to the turntable CCW coil.
counter clockwise function disabled. Replace coil.
46 PROT_CW_VALV 12 Value too high Platform rotate clockwise Check for open or short from PCON
Platform rotate 15 Value too low function disabled. (C29-3) to the platform rotate CW
clockwise valve. coil. Replace coil.
47 PROT_CCW_VLV 12 Value too high Platform rotate Check for open or short from PCON
Platform rotate 15 Value too low counterclockwise (C29-4) to the platform rotate CCW
counter clockwise function disabled. coil. Replace coil.
16 Value at 0V Replace joystick.
DRIVE_JYSTK
51 Not calibrated Drive functions disabled. Check neutral output range is within
Drive joystick.
17 Neutral out of range 2000 to 3000 mV. Calibrate joystick.
Replace joystick.
Part No. 119817 Z-40/23N, Z-40/23N RJ 111


batteries charging. Check cable
connections. Check for 33V AC
12 Value too high across any two legs on drive motor
at full stick. Replace right drive
motor. Replace right (master) AC
AC_R_MOTOR motor controller.
52 Right side drive Drive function disabled. Check cable connections. Check for
motor. 33V AC across any two legs on drive
15 Value too low motor at full stick. Replace right drive
motor controller.
Check wires to thermal sensor at
21 Fault 6 wire deutsch plug on motor. Check
resistance on thermal sensor.
batteries charging. Check cable
connections. Check for 33V AC
12 Value too high across any two legs on drive motor
at full stick. Replace right drive
motor. Replace right (master) drive
controller.
AC_L_MOTOR
53 Drive function disabled. Check cable connections. Check for
Left side drive motor. 33V AC across any two legs on drive
15 Value too low motor at full stick. Replace right drive
motor controller.
Check wires to thermal sensor at
21 Fault 6 wire connector on motor. Check
resistance on thermal sensor.
BRAKE_RIGHT Check for 48V DC to brake

Value too low (WH/RD). Check for 48V DC at
54 Brake AC motor right 15 Drive function disabled.
Coil shorted C16-4. (48V is brake set, 0V is
side. released). Replace brake
112 Z-40/23N, Z-40/23N RJ Part No. 119817

BRAKE_LEFT Check for 48V DC to brake

Value too low (WH/RD). Check for 48V DC at
55 Brake AC motor left 15 Drive function disabled.
Coil shorted C23-4. (48V is brake set, 0V is
side. released). Replace brake
Check wiring at the 6 wire connector
TACH_R_MOTOR at the drive motor. Check for 12V DC
56 Right side AC drive 21 Fault Drive function disabled. on pins 1 and 2. Replace motor.
motor encoder. Replace right (master) AC motor
controller.
Check wiring at the 6 wire connector
TACH_L_MOTOR at the drive motor. Check for 12V DC
57 Left side AC drive 21 Fault Drive function disabled. on pins 1 and 2. Replace motor.
motor encoder. Replace left (slave) AC motor
controller.
Check can bus circuit for open.
Check can bus resistor. Isolate all
13 No response All functions disabled.
other modules simultaneously.
AC_R_CTRLR Replace right AC motor controller.
58 Right side AC motor
controller. Refer to MOTOR CONTROLLER
All functions disabled or FAULT CODES screen at platform.
21 Fault
limited. See Motor Controller Fault Codes
chart.
59 AC_L_CTRLR 21 Fault All functions disabled or Refer to MOTOR CONTROLLER
Left side AC motor limited. FAULT CODES screen at platform.
controller. See Motor Controller Fault Codes
chart.
11 Shorted to supply Repair joystick wire connections or
STEER_JYSTK
16 Value at 0V Steering function replace joystick.
61
Joystick steer. disabled.
17 Not calibrated Calibrate joystick. Replace joystick.
Steering and platform Check wiring and coil for function
Value too low level functions disabled. causing fault. Fault at power up,
15
Coil shorted Flashing beacon replace right AC motor controller.
AC_R_OUTPUT disabled
62 Right side AC motor
controller output. Steering and platform Check wiring and coil for function
Value at 0V level functions disabled. causing fault. Fault at power up,
16
Output shorted to B- Flashing beacon replace right (Master) AC motor
disabled controller.
Part No. 119817 Z-40/23N, Z-40/23N RJ 113


Check for 5V DC (GR/WH) at steer
11 Shorted high (5V) sensor. Check for 0-5V DC (orange)
12 Value too high output at steer sensor. Check for
Wheel speed correction 0-5V DC (orange) at C16-30 on right
STEER_SENSOR 15 Value too low AC motor controller. Replace steer
63 is disabled. Drive speed
Steer angle sensor. 16 Value at 0V sensor.
reduced.
17 Not calibrated
Replace steer sensor. Re-calibrate
21 Fault steer sensor.
Verify wiring. Replace steer sensor
Hour meter, brake relay
and tilt sensor alarm Check wiring and coil for function
15 Value too low disabled. Platform causing fault. Fault at power up,
overload alarm disabled replace left AC motor controller.
AC_L_OUTPUT (option).
66 Left side AC motor
Value at 0V Hour meter, brake relay
controller output. Check wiring and coil for function
Output shorted to and tilt sensor alarm
disabled. Platform causing fault. Look for short to B- in
16 B- (only detected
overload alarm disabled wire from faulted function to left AC
with key switch motor controller
turned to platform) (option).
DENA_SW_PBOX 12 Value too high Check for voltage output at drive

Drive function disabled in enable toggle switch. (Blue) C35-4.
67 Platform control box 19 Out of Range
drive disable zone. Check for voltage output when not
drive enable switch. 21 Fault activated.
Check for 24V DC at function enable
FUNC_SW_GBOX
toggle switch. Check for 24V DC
68 Ground box function 21 Fault Auxiliary functions only.
input at TCON at C14-2. Check for
enable switch.
voltage output when not activated.
With Red Emergency Stop pulled
out at ground control, CR62 should
ESTOP_RELAY
close. Check for 24V DC on 30 and
71 Emergency Stop 11 Shorted to supply All functions disabled.
87 of CR62. Replace relay. Replace
relay.
red Emergency Stop button
contacts.
114 Z-40/23N, Z-40/23N RJ Part No. 119817


72 JROT_CW_VALV 12 Value too high Jib rotate clockwise Check for open or short from PCON
Jib rotate clockwise 15 Value too low function disabled. (C29-8) to the platform rotate CW
valve. coil. Replace coil.
74 JROT_CCW_VLV 12 Value too high Jib rotate Check for open or short from PCON
Jib boom rotate 15 Value too low counterclockwise (C29-7) to the platform rotate CCW
counterclockwise function disabled. coil. Replace coil.
valve.
Do not exceed maximum platform
weight. Check for 24V DC input to
Platform functions limited
load sensor (black.) Check for 24V
to recovery only. Primary
DC output from load sensor when
OVERLOAD_SW 12 Value too high lift pump functions at
not overloaded to PCON pin C28-7
76 Platform overload ground controls disabled.
21 Fault (black at switch, WH/BK at module).
switch (option). Auxiliary functions at
Check for 0V DC output from load
ground control only.
sensor when not overloaded to right
Extend disabled.
AC motor controller pin C16-19
(white at switch, BL/WH at module).
Check can bus circuit for open.
VCON_PBOX Platform functions
Check can bus resistor (120 Ω).
77 Platform display 13 No response disabled. Ground
Isolate all other modules
screen. controls operative.
simultaneously.
PCON_PBOX Platform functions Check can bus circuit for open.
78 Platform controller 13 No response disabled. Ground Check can bus resistor. Isolate all
screen. controls operative. other modules simultaneously.
System was overloaded
LOAD SENSE
82 21 Fault and moved under AUX For reporting purposes only.
RECOVERY
power.
DISABLED BY
83 21 Fault Functions disabled. Contact machine owner
OWNER
Part No. 119817 Z-40/23N, Z-40/23N RJ 115

Motor Controller Fault Codes

Motor Controller Fau lt Cod es
Motor Contr oller F aul t C odes
AC Motor Error Type Condition Solution

controller code
24592 Watchdog No functions or drive. Replace the AC motor controller.
65297 Logic failure #3 No functions or drive. Replace the AC motor controller.
65298 Logic failure #2 No functions or drive. Replace the AC motor controller.
8977 S TB Y I HIGH No functions or drive. Replace the AC motor controller.
12592 Capacitor charge No functions or drive. Check for 48V DC on B + , using B
- for ground.
Replace the AC motor controller.
12833 Contactor driver No functions or drive. Replace the AC motor controller.
65503 Safety feedback No functions or drive. Replace the AC motor controller.
12835 P OS AUX Shorted No functions or drive. Check for 48V DC on the WH/RD
wire going to the right brake coil.
Replace the AC motor controller.
8785 Hardware c oil s hort No functions or drive. Replace the AC motor controller.
tim e out
65512 Wrong set point No functions or drive. Replace the AC motor controller.
6513 Power M OS shorted No functions or drive. Replace the AC motor controller.
65515 Tiller error No functions or drive. Check for 48V DC R-1, OR/RD on
master motor controller.
Check for 24V DC on R-29, Blue
on master motor controller.
Replace AC motor controller.
116 Z-40/23N, Z-40/23N RJ Part No. 119817


controller code
65517 Analog input No functions or drive. If problem is c ons is tant, replac e
the AC controller.
65520 Hardware fault No functions or drive. Replace the AC motor controller.
65531 Wrong set battery Cut out valves, function pump, Replace the AC motor controller.
propel stopped, MC opened, EB
applied.
21808 EEPROM time out Functions and drive will revert to Cycle power off and back on.
factory default settings. If the fault disappears, all valve
settings will have to be readjusted.
If fault is maintained, replace the
AC motor controller.
13912 High temperature Functions and drive start to Let the AC motor controllers cool
degrade and quit. One or both off.
motor controllers have exceeded If fault persist with AC motor
85°C/185°F. controllers cooled, replace faulty
65516 Current gain Functions and drive will revert to Readjust the max current Setting.
factory default settings.
16913 Thermic sensor time Function and drive speeds will Replace the AC motor controller.
out slow down.
65512 Slip profile No drive. Replace the AC motor controller.
65360 Forward/Reverse Propel is stopped (node 2 only). Replace the right (master) AC
motor controller.
65508 Plat-Gnd switch open Node 2 only. Replace the right (master) AC
motor controller.
65521 Check up needed Continuous normal operation Perform scheduled maintenance
(node 2 only).
Part No. 119817 Z-40/23N, Z-40/23N RJ 117


controller code
24592 Watchdog No functions or drive. Replace the AC motor controller.
65509 Wrong zero No functions or drive. Replace the AC motor controller.
65510 Output mismatch No functions or drive. Replace the AC motor controller.
65530 Input mismatch No functions or drive. Replace the AC motor controller.
65511 Safety feedback No functions or drive. Replace the AC motor controller.
65512 Wrong setpoint No functions or drive. Replace the AC motor controller.
65513 Wrong config. No functions or drive. Replace the AC motor controller.
65532 Hardware fault No functions or drive. Replace the AC motor controller.
65528 Analog input No functions or drive. Replace the AC motor controller.
21808 EEPROM time out No functions or drive. Replace the AC motor controller.
9233 I=0 ever No functions or drive. Replace the AC motor controller.
8977 STBY I HIGH No functions or drive. Replace the AC motor controller.
16912 High temperature Function pump chopper maximum Let the AC motor controllers cool
current reduced proportionally to off.
temperature increase. If fault persist with AC motor
controllers cooled, replace faulty
65515 Hardware fault valve No functions or drive. Replace the AC motor controller.
65280 Tiller mismatch No functions or drive. Replace the AC motor controller.
16913 Current sensor time No functions or drive. Replace the AC motor controller.
out
21776 EEPROM warning No functions or drive. Replace the AC motor controller.
118 Z-40/23N, Z-40/23N RJ Part No. 119817


Drive Motor T hermal Sens or
Drive Motor Thermal Sensor 3 Remove the fasteners from the axle covers
from the non-steer axle. Remove the covers.
The thermal sensor is monitored by the motor
4 Tag and disconnect the six pin Deutsch
controllers to maintain optimum performance and
electrical connector for the speed and
as a thermal shutdown protection device.
temperature sensor at the drive motor.asure
Normal safe operating range is between -40°F / the drive motor case temperature using a
-40°C and 131°F / 55°C at an 85% duty cycle. thermometer.
Thermal faults will occur when the temperature 5 Measure the drive motor case temperature
exceeds its threshold of 302°F / 150°C. Then drive using a thermometer.
speeds will be reduced by 50%. 6 Measure the resistance between pins 5 and
6 on the Deutsch connector going into the
Thermal shut down occurs at 392°F / 200°C.
motor housing. Compare value to chart on
right.
How to Test the Thermal Sensor
machine.

cover.
Part No. 119817 Z-40/23N, Z-40/23N RJ 119

Temperature Resistance Temperature Resistance

°F / °C Ohm °F / °C Ohm
-40 / -40 355 320 / 160 1415
-22 / -30 386 338 / 170 1493
-4 / -20 419 347 / 180 1572
14 / -10 455 374 / 190 1654
32 / 0 493 392 / 200 1739
50 / 10 533 410 / 210 1825
68 /20 576 428 / 220 1914
77 / 25 598 446 / 230 2006
86 / 30 621 464 / 240 2099
104 / 40 668 482 / 250 2195
122 / 50 718 500 / 260 2293
140 / 60 769 518 / 270 2392
158 / 70 824 536 / 280 2490
176 / 80 880 554 / 290 2584
194 / 90 939 572 / 300 2668
212 / 100 1000
230 / 110 1063
248 / 120 1129
266 / 130 1197
284 / 140 1268
302 / 150 1340
120 Z-40/23N, Z-40/23N RJ Part No. 119817

Schematics
Section 6 Schem atics
Intr oducti on
About This Section

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
damaged or malfunctioning machine. Bodily injury hazard. Spraying
 Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine. connections very slowly to allow
Before Troubleshooting: gradually. Do not allow oil to
squirt or spray.
 Be sure that all necessary tools and test
equipment are available and ready for use.
Part No. 119817 Z-40/23N, Z-40/23N RJ 121

Schematics
Wire Circuit Legend
Circuit numbering
1 Circuit numbers consist of three parts: the Circuit prefix
circuit prefix, circuit number and circuit suffix.
C Control
The circuit prefix indicates the type of circuit.
The circuit number describes the function of D Data
the circuit. The circuit suffix provides an E Engine
abbreviation for the number or may be used to G Gauges
further define the function of this portion of the
N Neutral
circuit. It also may be used to indicate the final
end of the circuit, i.e., LS or limit sw. P Power
R Relay Output
2 The circuit number may be used more than
once in a circuit. S Safety
V Valve
For Example:
C 74 PL – This is the circuit for the lockout valve #1.
C stands for control, 74 is the number of the circuit
for the primary #1 lock out valve. PL stands for
Primary Lockout.
S 62 BST – This is the circuit that communicates to
the onboard computers of the machine that the
boom is fully stowed. S stands for safety, 62 is the
number of the circuit for boom stowed and BST
stands for Boom Stowed.
P 48 LP – P stands for power. 48 is the circuit
number for work lamps and LP stands for Lamp.
R 48 LP – R stands for relay. In this case it is the
wire that feeds the relay coil for the work lamp. All
other numbers remain the same.
V61AXR – V stands for valve power. Number
61 stands for axle retracted circuit; AXR stands for
Axle retracted.
R46HRN – R stands for Relay output, supplying
power to the horn (HRN). Number 46 is the circuit
number for the horn.
122 Z-40/23N, Z-40/23N RJ Part No. 119817

Schematics
Suffix Definition Suffix Definition

GEN AC Generator EDC Electrical Displacement Control
AF Alternator Field ENV Envelope Light
ANG Angle ESP Engine Speed Select
ABV Auxiliary Boom Valve ESL Engine Status Lamp
AFV Auxiliary Forward Valve ENL Envelope Lockout
AH Auxiliary Hydraulic Pump FLR Filter Restricted
APV Auxiliary Platform Valve FLT Filter Switch
ARV Auxiliary Reverse Valve FB Flashing Beacon
ASV Auxiliary Steer/Drive Valve FS Float Switch
AXE Axle Extend Valve FTS Foot switch Signal
AXO Axle Oscillate FWD Forward
AXR Axle Retract Valve FP Fuel Pump
AFP Axle Front Position FL Fuel Select (gas/LP)
RAP Axle Rear Position FSL Fuel Solenoid
BAT Battery FE Function Enable
BEX Boom Extended TCN Ground Control
BST Boom Stowed GND Ground
BRK Brake HRN Horn
BV Bypass Valves HS High RPM
CAL Calibrate HG Hydraulic Generator
CAN CAN Signal IGN Ignition
SHD CAN Shield JBD Jib Bellcrank Down
CAT CATS Module JBU Jib Bellcrank Up
CNK Chain Break JBS Jib Sensor
DTH Data High JUD Jib Up/Down Control
DTL Data Low JD Jib Down
DCN Drive Chassis Controller JFC Jib Up/Down Flow Control
DE Drive Enable JSV Jib Select Valve
DEL Drive Enable Left JU Jib Up
DER Drive Enable Right JER Jib Extend/Retract Control
Part No. 119817 Z-40/23N, Z-40/23N RJ 123

Schematics
Suffix Definition Suffix Definition

JBE Jib Extend PS Pressure Switches
JBR Jib Retract PBS Primary Boom Angle Sensor
JRL Jib Rotate Left (CCW) PBD Primary Boom Down
JRR Jib Rotate Right (CW) PBL Primary Boom Extend/Retract Lockout
JPW Joystick 5V DC Power Valve
LPS Lamps PBE Primary Boom Extend
LF Left Front PER Primary Boom Extend/Retract Flow

Control
LFS Left Front Steer Sensor
PBR Primary Boom Retract
LR Left Rear
PBU Primary Boom Up
LRS Left Rear Steer Sensor
PBF Primary Boom Up/Down Flow Control
LS Limit Switch
PLS Primary Boom Extend/Retract Signal
LSR Lift Speed Reduction
PES Primary Boom Up/Down Signal
LDS Load Sensor
PEL Primary Extend/Retract Lockout
LO Lockout
PSL Primary Length Sensor
LS Low RPM
PL Primary Lockout
LOF Low fuel
PWR Power
MS Motor Shift (Speed)
PSL Power to Length Sensor
MFV Multi Function Valve
PSE Program Set up Enable
PCN Platform Control
JPL Propel Signal
PLD Platform Level Down
PLL Propel Lockout
PLF Platform Level Flow Control
PRV Proportional Valve
PLU Platform Level Up
PXS Proximity Sensor
PRF Platform Rotate Flow Control
REC Receptacle
PRC Platform Rotate Control
RCV Recovery
PRL Platform Rotate Left (CCW)
RL Retract Lockout
PRR Platform Rotate Right (CW)
RET Return
PTA Platform Tilt Alarm
REV Reverse
PTS Platform Tilt Sensor
RF Right Front
PCE Pressure Comp Enable
RFS Right Front Steer Sensor
PSR Pressure Sender
RR Right Rear
RRS Right Rear Steer Sensor
124 Z-40/23N, Z-40/23N RJ Part No. 119817

Schematics
Suffix Definition
RPM RPM
SBS Sec Boom Angle Sensor
SBL Sec Boom Elevated
SBD Sec Boom Down
SBE Sec Boom Extend
SER Sec Boom Extend/Retract Flow Control
SBR Sec Boom Retract
SBU Sec Boom Up
SUD Sec Boom Up/Down Flow Control
SB Secondary Boom
SLE Secondary Boom Lockout Valve
(extend)
SLD Secondary Boom Lockout Valve (riser
down)
SP Spare
SS Speed Sensor
SA Start Aid (Glow Plug or choke)
STR Starter
STC Steer Control Signal
SCW Steering Valve (CW)
SCC Steering Valve (CCW)
TSR Temp Sender
TS Temp Switches
TET Tether
TAX Tilt Alarm X axis
TAY Tilt Alarm Y axis
TCN Ground Control Panel
TRF Turntable Rotate Flow Control
TRR Turntable Rotate Right (CW)
TTA Turntable Tilt Alarm
TTS Turntable Tilt Sensor
TSW Test Switch
Part No. 119817 Z-40/23N, Z-40/23N RJ 125

Schematics
Wiring C oloring and Legend
Wire Coloring
1 All cylinder extension colors are solid and all Power Circuits
retract functions are striped black. When using
P10 Primary boom extend valve
black wire, the stripe shall be white.
P11 Primary boom up valve
2 All rotations that are LEFT or CW are solid,
P30 Secondary boom down and
RIGHT or CCW are striped and black. When extend valves
the wire is black, the stripe is white.
P38 Propel (drive) valves
3 All proportional valve wiring is striped. P39 Turntable rotate flow
control valve
Wire Color Legend
BL Blue
BL/BK Blue/Black
BL/RD Blue/Red
BL/WH Blue/White
BK Black
BK/RD Black/Red
BK/WH Black/White
BR Brown
GR Green
GR/BK Green/Black
GR/WH Green/White
RD Red
RD/BK Red/Black
RD/WH Red/White
OR Orange
OR/BL Orange/Blue
OR/BK Orange/Black
OR/RD Orange/Red
WH White
WH/BK White/Black
WH/RD White/Red
YL Yellow
126 Z-40/23N, Z-40/23N RJ Part No. 119817

Schematics
Color Circuit # Primary Function Color Circuit # Primary Function

RD 1 Primary boom up driver RD 24 Power to warning senders
RD/BK 2 Primary boom down driver WH/BK 25 Power to oil pressure sender
RD/WH 3 Primary boom up/down flow WH/RD 26 Power to temp sender
control proportional valve driver RD 27 Auxiliary Power
WH 4 Turntable rotate left valve driver RD/BK 28 Platform level alarm
WH/BK 5 Turntable rotate right valve RD/WH 29 Drive Motor shift (speed)
driver
WH 30 Forward/EDC-A
WH/RD 6 Turntable rotate flow control
proportional valve driver WH/BK 31 Reverse/EDC-B
BK 7 Primary boom extend WH/RD 32 Brake
BK/WH 8 Primary boom retract BK 33 Start
BK/RD 9 Primary boom Extend/Retract BK/WH 34 Start Aid (glow plug or choke)
proportional valve driver BK/RD 35 High Engine speed select
BL 10 Secondary boom up valve driver BL 36 Steer clockwise
BL/BK 11 Secondary boom down valve BL/BK 37 Steer counterclockwise
driver
BL/WH 38 Gasoline
BL/WH 12 Secondary boom up/down flow
BL/RD 39 LPG
control proportional valve driver
OR 40 Limit switch signal stowed
BL/RD 13 Drive enable
OR/BK 41 RPM signal
OR 14 Platform level up valve
OR/RD 42 Boom retracted signal
OR/BK 15 Platform level down valve
GR 43 Jib Up
OR/RD 16 Platform up/down flow control
proportional valve driver GR/BK 44 Jib Down
GR 17 Platform rotate left valve driver GR/WH 45 AC Generator
GR/BK 18 Platform rotate right valve driver WH 46 Horn
GR/WH 19 Jib select valve driver circuit WH/BK 47 Output Power Enable
RD 20 12V DC battery supply WH/RD 48 Work Lamp
WH 21 12V DC ignition supply WH/BK 49 Motion Lamp
BK 22 Key switch power to platform BL 50 Auxiliary Boom
WH 23 Power to platform BL/WH 51 Auxiliary Steer
BL/RD 52 Auxiliary Platform
Part No. 119817 Z-40/23N, Z-40/23N RJ 127

Schematics

WH/BK 53 Boom envelope safety valve N/A 80 Can 2.0/J1939 Shield
cutoff GR 81 Can 2.0/J1939 Low
BK/WH 54 Power to safety interlock YL 82 Can 2.0/J1939 High
switches
(engine) GR/WH 83 Tilt signal X axis
GR/BK 55 Axle oscillation GR/BK 84 Tilt signal Y axis
RD 56 Foot switch/TCON estop power GR 85 Tilt sensor power
RD/WH 57 Boom down safety interlock OR 86 Hydraulic Filter restricted
RD/BK 58 Safety interlock to engine RD 87 Platform Level Safety Power
GR/WH 59 Chain break circuit RD/BK 88 Platform Level Safety Output
GR/WH 60 Axle extend BR 89 Platform Level Safety Ground
GR 61 Axle retract RD/BK 90 Proximity Kill
OR 62 Boom stowed (safety) RD/WH 91 Gate Interlock
OR/RD 63 Power to boom envelope safety WH/BK 92 Motor Speed (LO/HI)
switch WH/RD 93 Motor Bypass
OR/BK 64 Power for operational switches WH 94 Load Sensor
BL/WH 65 Low fuel indication OR 95 Tether ESTOP return
BL 66 Drive Enable RD 96 Tether Power
BL 67 Secondary boom not stowed BK 97 Tether ESTOP Power
RD 68 Primary Boom lowered WH 98 J1708 + (high)
(operational)
BK 99 J1708- (low)
BK 69 Primary boom #1 extended
WH/RD 100 Outrigger lowered
BL/WH 70 Primary boom #2 retracted
WH/BK 101 Outrigger raised
BL/BK 71 Primary boom #2 extended
OR 102 Pothole protector up
GR 72 Secondary boom extend
OR/RD 103 Pothole protector down
GR/BK 73 Secondary boom retract
BK/WH 104 Proprietary Data buss -(I.e. ITT
RD 74 Primary #1 Lockout or AP)
RD/WH 75 Primary #2 Lockout BK/RD 105 Proprietary Data buss + (I.e. ITT
BL 76 Primary boom #3 extended or AP)
WH 77 Lower Angle #1 operational
WH/BK 78 Upper Angle #2 operational
BK 79 Power from TCON ESTOP
128 Z-40/23N, Z-40/23N RJ Part No. 119817

Schematics

GR 106 Spare BL 131 Motion Alarm
RD 107 Alternator Field GR 132 Platform Load Input
BL/WH 108 Engine Status GR/WH 133 Platform Load Alarm
GR/WH 109 Sensor Power GR/BK 134 Key Switch power
BK 110 Sensor Return BL/WH 135 Fuel Pump
OR 111 Steer Signal RD 136 Power to Safety Module
RD 112 Steer Signal to Solenoid Valve RD/WH 137 Propel Power (P_38)
OR/RD 113 Multi-function Valve RD/BK 138 Primary Boom Up/Secondary
BK/RD 114 Load Moment Overweight Boom Down-Extend (P_11/30)
RD/BK 115 Load Moment Underweight WH/RD 139 Turntable Rotate Flow Control
Safety (P_39)
OR 116 Hydraulic Oil Cooler
OR/RD 140 Boom Envelope Safety
RD 117 Flashing Beacon
RD 141 Primary Boom Angle Signal
OR 118 Lift Speed Reduction Safety
BL 119 Hydraulic Pressure Sensor OR 142 Secondary Boom Angle Signal
Output Safety
OR 120 Oil Cooler Fan BL/RD 143 Drive Enable Left
GR 121 Axle Oscillate Left BL/WH 144 Drive Enable Right
GR/BK 122 Axle Oscillate Right RD/WH 145 Calibrate
RD/BK 123 Primary Boom Angle Signal BL 146 Jib Bellcrank Up Flow Control
Operational
BL/BK 147 Jib Bellcrank Down Flow Control
RD/WH 124 Secondary Boom Angle Signal
Operational BL/WH 148 Jib Bellcrank Sensor
WH/RD 125 Secondary Boom Lockout GR/WH 149 Jib Up/Down Flow Control
(Extend Enable) GR/BK 150 Hydraulic Generator Bypass
WH/BK 126 Secondary Boom Lockout (Riser GR 151 Hydraulic EDC Output
Down Enable) BK 152 Injector Retard
GR 127 ECU Test Switch BK 153 Jib Extend
OR/RD 128 Low Engine Speed BK/WH 154 Jib Retract
RD/BK 129 Descent Alarm
WH/RD 130 Travel Alarm
Part No. 119817 Z-40/23N, Z-40/23N RJ 129

Schematics

OR/RD 155 Pressure Comp. Enable GR/WH 176 Secondary Extend/Retract Flow
GN/WH 156 Jib Up/Down Control
BK/RD 157 Jib Extend/Retract BL/RD 177 Extend/Retract Lockout
BL/RD 158 Steer Signal Rocker BK 178 Control Module Status Light
BL/WH 159 Steer Joystick Signal GR 179 Drive Power Relay
WH/RD 160 Propel Joystick Signal BK 180 Lift Power Relay
WH/BK 161 Secondary Boom Joystick OR 181 48 volt Alternator Field (or
Signal battery)
OR 162 Joystick 5V DC power RD 182 24 volt battery
BL/WH 163 Primary Extend/Retract Signal BL 183 Envelope or Load Sense

Recovery
RD/WH 164 Primary Up/Down Signal
WH 184 Program Set up Enable
WH/RD 165 TT Rotate Signal
WH 185 Encode A
OR 166 Boom Length Signal Safety
BL 186 Encode B
OR/BK 167 Boom Length Signal
Operational BL 187 Bootstrap or Program Enable
BL/RD 168 Primary Boom Hydraulic GR 188 Safety Cross Check

Lockout BK 189 Data Receive
GN 169 Envelope Active LED BK/WH 190 Data Transmit
WH/RD 170 Load Sense Relay Source WH/RD 191 Multi-function Pressure Relief
WH/BK 171 Load Sense Relay Sink WH/BK 192 Jib Rotate Left
BL 172 Up/Down Flow Control Ground WH/RD 193 Jib Rotate Right
BK 173 Extend/Retract Flow Control WH/RD 194 Speed Select Input
Ground OR/RD 195 Electric Brake Source
WH 174 Key switch Power, Ground YL 196 2.5 volt Sensor Power
Position
BR N/A Ground or Return
WH/BK 175 Load Sensor Signal,
Operational
130 Z-40/23N, Z-40/23N RJ Part No. 119817

Power Cable Diagram

Pow er C abl e Di agr am
Part No. 119817 Z-40/23N, Z-40/23N RJ 131

Motor Contoller Pin Legend

Motor Contoller Pin Legend
Pin Numbering for 35 Pin Motor Controller Connector

Left Motor Controller (Slave) Right Motor Controller (Master)
1 R195PWR - OR/RD 1 R195PWR - OR/RD

2 C32BRK - WH/RD 2 C32BRK - WH/RD
3 R181PWR - OR 3 R181PWR - OR
4 R32RET - BK 4 R32RET - BK
5 P110RET - BK 5 P110RET - BK
6 PERSONALIZE R 6 C184PSE - OR
7 SPARE DIG IN 7 C28TTS RD/BK
8 SPARE OUT 8 V14PLUA - OR
9 C130TA - WH/RD 9 C117FB - RD
10 R181PWR - OR 10 R181PWR - OR
11 C197RET - WH 11 SPARE DIG OUT
12 SPARE DIG OUT 12 C181RET - OR
13 D185SEN - WH 13 D185SEN - WH
14 D186SEN - BL 14 D186SEN - BL
15 C16PLF - OR/RD 15 C192JR - WH/BK
16 TXD- SERIAL 16 TXD - SERIAL
17 C27AUX - RD 17 C199TS - WH/RD
18 D187PSE - BL 18 D187PSE - BL
19 SPARE DIG IN 19 SL32LDS - BL/WH
20 SPARE DIG IN 20 C22PWR - BK
21 RXD- SERIAL 21 RXD - SERIAL
22 C26TSR - WH/RD 22 C26TSR - WH/RD
23 C133PLA - GR/WH 23 V15PLDA - OR/BK
24 SPARE PROP OUT 24 V191PCEA - WH/RD
25 P198SEN - RD 25 P198SEN - RD
26 TXD+ SERIAL 26 TXD+ SERIAL
27 D81CAN "-" - GR 27 D81CAN "-" - GR
28 D82CAN "+" - YL 28 D82CAN "+" - YL
29 R174PWR - WH 29 C66LS - BL
30 C156JUD - GR/WH 30 C111LFS - OR
31 C17PRL - GR 31 SPARE DIG IN
32 C18PRR - GR/BK 32 C47FE - WH/BK
33 SPARE OUT 33 V36SCWA - BL
34 C32RET - WH/RD 34 V37SCCA - BL/BK
35 SPARE DIG IN 35 C86FLR - OR
132 Z-40/23N, Z-40/23N RJ Part No. 119817

Ground Control Box Pin Legend

Ground C ontrol Box Pin Legend
Harness Legend
1 C4
2 C3
3 C2
4 C1
5 C5
Pin Numbering for 12 pin connectors
C1 Ground Control C2 Ground Control C3 Ground Control Box C4 Ground Control C5 Ground Control
Box Harness Box Harness Harness Box Harness Box Harness
1 R195PWR - 1 C18PRR - GR/BK 1 C41RPM - OR 1 P23BAT - RD 1 C28TTS - RD/BK
OR/RD
2 C17PRL - GR 2 C134PWR - RD 2 P22BAT - RD/BK 2 V191PCEA -
2 R181PWR - OR WH/RD
3 C27AUX - RD 3 C47FE - WH/BK 3 GND - RD/WH
3 S132LDS - 3 V36SCWA - BL
BL/WH 4 C133PLA - GR/BK 4 C165TRS - WH/RD 4 C134PWR -
WH/BK 4 V37SCCA -
4 C22PWR - BK 5 C32RET - WH/RD 5 C163PLS - BL/WH
BL/BK
6 C156JUD - 6 R46HRN - WH 5 D82CAN(+) - YL
5 D82CAN(+) - 5 V14PLUA - OR
YL GR/WH 7 SPARE 6 D81CAN(-) - GR
7 C16PLF - OR/RD 7 C27AUX - 6 V15PLDA -
6 D81CAN(-) - 8 P109PWR - OR/BK
WH/RD
GR 8 C197RET - WH GR/WH
8 C46HRN - BK 7 V15PLDB -
7 C192JR - 9 D82CAN(+) - YL 9 D82CAN(+) - YL OR/BK
WH/BK 9 S132LDS -
10 D81CAN(-) - GR 10 D81CAN(-) - GR 8 V14PLUB - OR
BK/WH
8 P109PWR - 11 R174PWR - WH 11 C164PES - RD/WH
GR/WH 9 V37SCCB -
10 R181PWR - BL
12 C130TA - WH/RD 12 C161SB - WH/BK BL/BK
9 C184PSE - OR 11 GND - BL/BK
10 V36SCWB - BL
10 P181BAT - OR 12 SPARE
11 V191PCEB -
11 P182BAT - RD WH/RD
12 C47FE - WH/BK 12 C134PWR - RD
Part No. 119817 Z-40/23N, Z-40/23N RJ 133

Platform Control Box Pin Legend

Platform C ontrol Box Pin Legend
C27
C25
C31
Pin Numbering for 4 Pin Numbering for 12 Pin Connector (C27) Pin Numbering for 24 Pin
Pin Connector (C31) Connector (C25)
1 P23BAT - WH 1 SPARE 1 P23BAT - WH

2 C56FTS - RD 2 SPARE 2 P22BAT - BKD
3 V17PRL - GR 3 GND - BR
4 V18PRR - GR/BK 4 C134PWR - RD
5 V43JU - GR 5 D82CAN(+) - YL
6 V44JD - GR/BK 6 D81CAN(-) - GR
7 V193JRR - WH/RD 7 C27AUX - RD
8 V192JRL - WH/BK 8 C46HRN - WH
9 GND - BR 9 S132LDS - BL/WH
10 C134PWR - RD 10 R181PWR - OR
11 S132LDS - BL/WH 11 SPARE
12 C175LDS - WH/BK 12 SPARE
13 P49LPS - WH/BK
14 C49GEN - GR/WH
15 GND - BR
16 SPARE
17 SPARE
18 SPARE
19 C48LPS - WH/RD
20 GND - BR
21 C48LPS - WH/RD
22 GND - BR
23 SPARE
24 SPARE
134 Z-40/23N, Z-40/23N RJ Part No. 119817

Turntable and Platform Controller Pin Legend

Turntable and Pl atform C ontroller Pi n Legend
Pin Numbering for

12 Pin Connectors
PCON Platform Controller PCON Platform Controller TCON Turntable Controller TCON Turntable Controller
(C28) (C29) (C13) (C14)
1 GND - BR 1 C156JUD - GR/WH 1 GROUND - BR 1 C41RPM - OR
2 C134PWR - RD 2 C160JPL - WH/RD 2 C134PWR - RD 2 C47FE - WH/BK
3 D82CAN(+) - YL 3 V17PRL - GR 3 D82CAN(+) - YL 3 V07PBE - BK
4 D81CAN(-) - GR 4 V18PRR - GR/BK 4 D81CAN(-) - GR 4 V08PBR - BK/WH
5 C163PLS - BL/WH 5 V43JU - GR 5 C163PLS - BL/WH 5 V01PBU - RD
6 C56FTS - RD 6 V44JD - GR/BK 6 C68PBD - RD 6 V02PBD - RD/BK
7 C175LDS - WH/BK 7 V193JRR - WH/RD 7 C40SBD - OR 7 V10SBU - BL
8 P162JPW - OR 8 V192JRL - WH/BK 8 P109PWR - GR/WH 8 V11SBD - BL/BK
9 GND - BR 9 C130TA - WH/RD 9 R110RET - BR 9 V04TRL - WH
10 C164PES - RD/WH 10 SPARE 10 C165TRS - WH/RD 10 V05TRR - WH/BK
11 C159STC - BL/WH 11 C134PWR - RD 11 C165PES - RD/WH 11 C134PWR - RD
12 C165TRS - WH/RD 12 C134PWR - RD 12 C161SB - WH/BK 12 C134PWR - RD
Part No. 119817 Z-40/23N, Z-40/23N RJ 135

Electrical Symbol Legend

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

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

Resistor with ohm value Battery seperator Gauge sending unit
open normally closed
Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow
normally open switch - normally open normally closed normally open plug or flame ignitor
136 Z-40/23N, Z-40/23N RJ Part No. 119817

Hydraulic Symbols Legend

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,

Double acting cylinder Differential sensing valve
or motor) 3 way
Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator valve
valve setting proportional valve
Solenoid operated
Directional valve Pilot operated 3 position,
Flow divider/combiner valve 2 position, 3 way directional
(mechanically activated) 3 way shuttle valve
valve
Solenoid operated
Solenoid operated
Counterbalance valve with 3 position, 4 way 2 position, 2 way solenoid
3 position, 4 way directional
pressure and pilot ratio proportional directional valve
valve
valve
Part No. 119817 Z-40/23N, Z-40/23N RJ 137

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138 Z-40/23N, Z-40/23N RJ Part No. 119817

Electrical Schematics
Electrical Schematic - Chassis
139
Elec trical Schem atic - C hassis
Electrical Schematic - Chassis
140 Z-40/23N, Z-40/23N RJ Part No. 119817

Elec trical Schem atic - Ground Contr ols
Electrical Schematic - Ground Controls
Part No. 119817 Z-40/23N, Z-40/23N RJ 141

Electrical Schematic - Ground Controls
142
Electrical Schematic - Platform Controls
143
Elec trical Schem atic - Platform Contr ols
Electrical Schematic - Platform Controls
144 Z-40/23N, Z-40/23N RJ Part No. 119817

Ground C ontrol Box Wiring Diagram
Ground Control Box Wiring Diagram
Part No. 119817 Z-40/23N, Z-40/23N RJ 145

Ground Control Box Wiring Diagram
146
Platform Control Box Wiring Diagram
147
Platform C ontrol Box Wiring Di agr am
Platform Control Box Wiring Diagram
148 Z-40/23N, Z-40/23N RJ Part No. 119817

Platform C ontrol Box Wiring Di agr am - Opti ons
Platform Control Box Wiring Diagram - Options
Part No. 119817 Z-40/23N, Z-40/23N RJ 149

Platform Control Box Wiring Diagram - Options
150
Hydr aulic Schematics
Hydraulic Schematic
151
Hydraulic Schem atic
Hydraulic Schematic
Z-40/23N, Z- 40/23N R J Part No. 119817 Servic e M anual April 2016
152 Z-40/23N, Z-40/23N RJ Part No. 119817

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Service Manual

Serial Number Range

Z-40/23N from Z4007-100 to

Part No. 119817

Important Technical Publications

Basic mechanical, hydraulic and electrical skills are

Machine Design Life

Copyright © 2011 by Terex Corporation

ii Z-40/23N, Z-40/23N RJ Part No. 119817

Part No. 119817 Z-40/23N, Z-40/23N RJ iii

iv Z-40/23N, Z-40/23N RJ Part No. 119817

Serial Number Legend

Part No. 119817 Z-40/23N, Z-40/23N RJ v

Do Not Perform Maintenance

vi Z-40/23N, Z-40/23N RJ Part No. 119817

Personal Safety Workplace Safety

Be aware of potential crushing hazards

Part No. 119817 Z-40/23N, Z-40/23N RJ vii

Introduction Introduction .......................................................................................................... ii

Section 1 Safety Rules......................................................................................................... vi

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

viii Z-40/23N, Z-40/23N RJ Part No. 119817

Section 3 Scheduled Maintenance Procedures ............................................................... 11

Checklist A Procedures ..................................................................................... 17

Checklist B Procedures ..................................................................................... 20

Part No. 119817 Z-40/23N, Z-40/23N RJ ix

Checklist C Procedures ..................................................................................... 31

Checklist D Procedures ..................................................................................... 34

Checklist E Procedures ..................................................................................... 41

x Z-40/23N, Z-40/23N RJ Part No. 119817

Section 4 Repair Procedures ............................................................................................. 45

Platform Controls ............................................................................................... 47

Platform Components ........................................................................................ 56

Jib Boom Components ...................................................................................... 61

Primary Boom Components .............................................................................. 66

Secondary Boom Components ......................................................................... 77

Part No. 119817 Z-40/23N, Z-40/23N RJ xi

Hydraulic Pump .................................................................................................. 84

Turntable Rotation Components ...................................................................... 97

Steer Axle Components .................................................................................... 99

Non-steer Axle Components........................................................................... 102

Motor Controllers ............................................................................................. 104

xii Z-40/23N, Z-40/23N RJ Part No. 119817

Section 5 Fault Codes ....................................................................................................... 105

Control System Fault Codes ........................................................................... 106

Motor Controller Fault Codes.......................................................................... 116

Section 6 Schematics........................................................................................................ 121

Electrical Schematics ...................................................................................... 139

Hydraulic Schematics ...................................................................................... 151

Part No. 119817 Z-40/23N, Z-40/23N RJ xiii

Machine Specifications Fluid capacities

Tires and wheels Front Rear Hydraulic tank 8 gallons

For operational specifications, refer to the Weight, each 106 lb

Part No. 119817 Z-40/23N, Z-40/23N RJ 1

Performance Specifications Boom function speeds, maximum from platform

2 Z-40/23N, Z-40/23N RJ Part No. 119817

Hydraulic Oil Specifications Do not top off with incompatible