Terex Genie Z-40/23N Installation and operating manual

Service and Repair Manual
Serial Number Range
Z-40/23N
from Z40N13-1902 to
Z40N16N-
4499
This manual includes:
Repair
procedures
Fault Codes
Electrical and
Hydraulic Schematics
Z-40/23N RJ
from Z40NN-4500
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268528
Rev A2
September 2016

Service and Repair Manual September 2016
Introduction
ii Z-40/23N, Z-40/23N RJ Part No. 1268528
Intr od ucti o n Intr od uct i o n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2015 by Terex Corporation
1268528 Rev A, September 2016
First Edition, First 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.

September 2016 Service and Repair Manual
Introduction
Part No. 1268528 Z-40/23N, Z-40/23N RJ iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Release
A1 3/2016 Specifications Updated Performance Specifications, Boom function speeds
A1 3/2016 Repair Procedures Updated 1-1, How to Calibrate Joystick
A1 3/2016 Repair Procedures Updated 9-1, How to Calibrate Steer angle sensor.
A1 3/2016 Fault Codes Updated Control Systems Fault Codes Chart
A1 3/3016 Schematics
Updated Chassis Schematic, Ground Control Schematic and
Wiring Diagram.
A1 3/2016 Schematics Updated Hydraulic - Orifice size, Secondary boom circuit.
A2 9/2016 Introduction Serial Number Legend
Reference Examples: Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual September 2016
Introduction
iv Z-40/23N, Z-40/23N RJ Part No. 1268528
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label (located under cover)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1268528 Z-40/23N, Z-40/23N RJ v
Section 1 Safet y 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.

Service and Repair Manual September 2016
Safety Rules
vi Z-40/23N, Z-40/23N RJ Part No. 1268528
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could re
sult in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Be sure to
wear protective eye wear and
other protective clothing if the situation
warrants it.
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.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are
in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

September 2016
Table of Contents
Part No. 1268528 Z-40/23N, Z-40/23N RJ vii
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules..........................................................................................................v
General Safety Rules ............................................................................................. v
Section 2 Specifications.......................................................................................................1
Machine Specifications ........................................................................................... 1
Performance Specifications .................................................................................... 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
Section 3 Repair Procedures .............................................................................................11
Introduction ........................................................................................................... 11
Platform Controls...............................................................................................13
1-1 Joysticks ......................................................................................................... 13
How to Adjust the Joystick Threshold Setting ................................................. 14
How to Adjust the Maximum Speed Setting .................................................... 15
How to Adjust the Function Ramp Up Time Setting........................................ 17
How to Adjust the Function Ramp Down Time Setting ................................... 19
How to Adjust the Max Speed Drive Settings ................................................. 20

September 2016
Table of Contents
viii Z-40/23N, Z-40/23N RJ Part No. 1268528
Platform Components .......................................................................................22
2-1 Platform Leveling Slave Cylinder ................................................................... 22
2-2 Platform Rotator ............................................................................................. 23
2-3 Platform Overload System ............................................................................. 24
2-4 Platform Recovery Overload .......................................................................... 26
Jib Boom Components......................................................................................27
3-1 Jib Boom ........................................................................................................ 27
3-2 Jib Boom Bell Crank (models without rotating jib boom) ............................... 28
3-3 Jib Boom Rotator (models with rotating jib boom) ......................................... 29
How to Bleed the Jib Boom Rotator................................................................ 30
3-4 Jib Boom Lift Cylinder .................................................................................... 31
Primary Boom Components .............................................................................32
4-1 Cable Track.................................................................................................... 32
How to Remove the Cable Track .................................................................... 32
How to Repair the Primary Boom Cable Track ............................................... 34
4-2 Primary Boom ................................................................................................ 34
How to Remove the Primary Boom ................................................................ 35
How to Disassemble the Primary Boom ......................................................... 37
4-3 Primary Boom Lift Cylinder ............................................................................ 38
4-4 Primary Boom Extension Cylinder ................................................................. 40
4-5 Platform Leveling Master Cylinder ................................................................. 41
Secondary Boom Components ........................................................................43
5-1 Secondary Boom ........................................................................................... 44
5-2 Secondary Boom Lift Cylinders ..................................................................... 48
Hydraulic Pump.................................................................................................. 49
6-1 Auxiliary and Function Pump ......................................................................... 49
6-2 How to Remove the Function Pump .............................................................. 50

September 2016
Table of Contents
Part No. 1268528 Z-40/23N, Z-40/23N RJ ix
Manifolds.............................................................................................................52
7-1 Function Manifold Components ..................................................................... 52
7-2 Valve Adjustments - Function Manifold .......................................................... 54
7-3 Jib Boom and Platform / Jib Boom Rotate Manifold Components ................. 58
7-4 Jib Boom and Platform / Jib Rotate Manifold Components ........................... 59
7-5 Valve Coils ..................................................................................................... 60
Turntable Rotation Components ......................................................................61
8-1 Turntable Rotation Hydraulic Motor ............................................................... 61
Steer Axle Components.....................................................................................62
9-1 Hub and Bearings .......................................................................................... 62
How to Calibrate the Steer Angle Sensor ............................................................ 63
Non-steer Axle Components.............................................................................65
10-1 Drive Motors ................................................................................................. 65
10-2 Drive Brake................................................................................................... 66
Motor Controllers ...............................................................................................67
11-1 Motor Controllers .......................................................................................... 67
Section 4 Fault Codes.........................................................................................................68
Introduction ........................................................................................................... 68
Control System Fault Codes.............................................................................69
How to Retrieve Control System Fault Codes - Platform Controls ...................... 69
How to Retrieve Control System Fault Codes - Ground Controls ........................ 70
Control System Fault Codes ................................................................................ 71
Motor Controller Fault Codes............................................................................79
Motor Controller Fault Codes ............................................................................... 79
Drive Motor Thermal Sensor ................................................................................ 82

September 2016
Table of Contents
x Z-40/23N, Z-40/23N RJ Part No. 1268528
Section 5 Schematics.........................................................................................................83
Introduction .......................................................................................................... 83
Wire Circuit Legend ............................................................................................. 84
Wiring Coloring and Legend ................................................................................ 88
Power Cable Diagram .......................................................................................... 93
Motor Contoller Pin Legend ................................................................................. 94
Ground Control Box Pin Legend .......................................................................... 95
Platform Control Box Pin Legend......................................................................... 96
Turntable and Platform Controller Pin Legend .................................................... 97
Electrical Symbol Legend .................................................................................... 98
Hydraulic Symbols Legend .................................................................................. 99
Electrical Schematics......................................................................................101
Electrical Schematic - Chassis ........................................................................... 102
Electrical Schematic - Ground Controls ............................................................. 103
Electrical Schematic - Platform Controls ........................................................... 106
Ground Control Box Wiring Diagram ................................................................. 107
Platform Control Box Wiring Diagram ................................................................ 110
Platform Control Box Wiring Diagram - Options ................................................ 111
Hydraulic Schematics......................................................................................113
Hydraulic Schematic .......................................................................................... 114