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

September 2016 Service and Repair Manual
Specifications
Part No. 1268528 Z-40/23N, Z-40/23N RJ 1
Section 2 Speci fic ati ons
Machine Specifications
Tires and wheels
Front
Rear
Tire size
2
2 x 7 x 17.75 in
25.
6 x 7 x 22 in
(solid rubber)
5
6 x 17.8 x 45 cm
5
6 x 17.8 x
4
5 cm
Overall tire diameter
22in
25.6in
55.
9 cm
6
5 cm
Wheel diameter
18.
4 in
2
2 in
46.
7 cm
5
6 cm
Wheel width
7
in
7
in
Wheel lugs
8 @ 5/8
- 18
9 @ 5/8
- 18
Lug nut torque
(lubricated)
9
4 ft-lbs
9
4 ft-lbs
127.5 Nm
127.5 Nm
(dry)
12
5 ft-lbs
12
5 ft-lbs
169.5 Nm
169.5 Nm
For operational specifications, refer to the
Operator's Manual.
Fluid capacities
Hydraulic tank
8 g
allons
30.3 l
iters
Hydraulic system
10 g
allons
(including tank)
37.9 l
iters
Drive hubs
23 f
l oz
680 c
c
Drive hub oil type:
EP 80-
90W gear oil
API
service classification GL5
Batteries
Type
6V DC
Group size
L16GH
Quantity
8
Capacity
390 AH
Reserve capacity @ 25A
rate
789 minutes
Weight, each
101 lb
46 kgs

Service and Repair Manual September 2016
Specifications
2 Z-40/23N, Z-40/23N RJ Part No. 1268528
Performance Specifications
Z-40/23N and Z-40/23N RJ
Drive speed, maximum
Drive speed, stowed
4.5 m
ph
7.24 k
m/h
40 ft / 6.0 s
ec
12.2 m / 6.0 s
ec
Drive speed, stowed (CE
models)
3.75 m
ph
6 k
m/h
40 ft / 7.3 s
ec
12.2 m / 7.3 s
ec
Drive speed, boom raised or
extended, all models
0.68 m
ph
1.09 k
m/h
40 ft/40 s
ec
12.2 m/40 s
ec
Braking distance
On paved surface
5 to 7 f
t
1.5 t
o 2m
Gradeability
See Operator's
Manual
Boom function speeds, maximum from platform
controls (with rated load secured to platform)
Jib boom up
16 to 20 s
econds
Jib boom down
16 to 20 s
econds
Jib boom rotate, 180°, Z40/23N
RJ
16 to 20 s
econds
Primary boom up
26 to 30 s
econds
Primary boom down
26 to 30 s
econds
Primary boom extend
18 to 22 s
econds
Primary boom retract
18 to 22 s
econds
Secondary boom up
32 to 36 s
econds
Secondary
boom down° 32 to 36 s
econds
Turntable rotate, 355° 62 to 68 seconds
Platform rotate, 180° 10 to 14 seconds

September 2016 Service and Repair Manual
Specifications
Part No. 1268528 Z-40/23N, Z-40/23N RJ 3
Hydraulic Oil Specifications
Hydraulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditi
oning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
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
the approved optional fluids. Consult Genie
Product Support before use.
Optional fluids may not have
the same hydraulic lifespan and
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.
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydraulic lines, filters,
control valve
s and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

Service and Repair Manual September 2016
Specifications
4 Z-40/23N, Z-40/23N RJ Part No. 1268528
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron 5606A
hydraulic fluid, or equivalent,
when ambient temperatures are
consistently above 32°F / 0°C
may result in component damage
Petro-Canada Environ MV 46
Fluid Properties
ISO
Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F / 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash point
>100
Pour point
-76°F / -
60°C
Maximum continuous
operating
temperature
103°F / 75°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum
continuous operating
temperature
189°F / 87°C

September 2016 Service and Repair Manual
Specifications
Part No. 1268528 Z-40/23N, Z-40/23N RJ 5
Hydraulic Component
Specifications
Function pump
Type: Fixed displacement gear pump
Displacement
0.244 c
u in
4 c
c
High pressure filter
Beta 3≥200 with 101 p
si
/ 7 b
ar bypass
Function manifold
Proportional relief pressure, variable
50 to 3000 p
si
3.4 to 207 b
ar
Primary boom down relief valve
pressure
2100 p
si
145 b
ar
Platform level relief valve pressure
2500 p
si
172 b
ar
Platform level flow regulator
1800 p
si
124 b
ar
Turntable rotate relief pressure
0.6 g
pm
2.27 L/min
Auxiliary pump
Type:
Fixed
displacement
gear pump
Displacement
0.5 g
pm
1.9 L/min
Manifold Component
Specifications
Plug torque
SAE No. 2
36 in-
lbs / 4 Nm
SAE No. 4
10 ft-
lbs / 13 Nm
SAE No. 6
14 ft-
lbs / 19 Nm
SAE No. 8
38 ft-
lbs / 51 Nm
SAE No. 10
41 ft-
lbs / 55 Nm
SAE No. 12
56 ft-
lbs / 76 Nm
Valve Coil Resistance
Note: The following coil resistance specifications are at
an ambient temperature of
68°F / 20°C. As valve coil
resistance is sensitive to changes in air temperature, the
coil resistance will typically increase or decrease by 4%
for each 18°F / 10°C that your air temperature increases
or decreases from 68°F / 20°C.
Valve Coil Resistance S
pecification
Description
Specification
Solenoid valve,
3 position 4 way, 20V DC
(schematic item BG)
24
Ω
Proportional solenoid valve,
3 position
4
way, 20V DC (schematic items AA, AB,
AC, BC, BG, BK, BN, BS, and BU)
24
Ω
Proportional solenoid relief
valve, 20V DC
(schematic item BW)
22
Ω

Service and Repair Manual September 2016
Specifications
6 Z-40/23N, Z-40/23N RJ Part No. 1268528
Machine Torque Specifications
Platform rotator
3/4
-10 center bolt, GR 8 (dry)
38
0 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 1
1 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,
lubricated
93 ft-
lbs
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

September 2016 Service and Repair Manual
Specifications
Part No. 1268528 Z-40/23N, Z-40/23N RJ 7
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be
torqued to specification when they are removed
and installed or when new hoses or fittings are
installed.
Seal-Lok™ Fittings
(hose end - ORFS)
SAE Dash Size Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 ¼
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash Size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
Adjustable Fitting Non-adjustable fitting
1 jam nut
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash Size Torque
-4 ORFS / 37° (Adj)
ORFS (Non-adj)
37° (Non-adj)
15 ft-lbs / 20.3 Nm
26 ft-lbs / 35.3 Nm
22 ft-lbs / 30 Nm
-6 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
35 ft-lbs / 47.5 Nm
29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
60 ft-lbs / 81.3 Nm
52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)
100 ft-lbs / 135.6 Nm
85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm

Service and Repair Manual September 2016
Specifications
8 Z-40/23N, Z-40/23N RJ Part No. 1268528
Torque Procedure
Seal-Lok™ fittings
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
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.
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in
this section.
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
approximately 30 in-lbs / 3.4 Nm.
2 Using a permanent ink marker, make a
reference mark on one the flats of the hex nut
and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
Illustration 1
1 hex nut
2 reference mark
3 body hex fitting

September 2016 Service and Repair Manual
Specifications
Part No. 1268528 Z-40/23N, Z-40/23N RJ 9
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.

Service and Repair Manual September 2016
Specifications
10 Z-40/23N, Z-40/23N RJ Part No. 1268528