Genie Z-40/23N Service And Repair Manual
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Genie Z-40/23N Service And Repair Manual

Genie Z-40/23N Service And Repair Manual

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

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Questions and answers

Mohammed Alhaj
February 15, 2025

LCD screen displays overload recovery

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1 comments:
Mr. Anderson
February 15, 2025

To resolve the overload recovery issue on the Genie Z-40/23N LCD screen, follow these steps:

1. Ensure the platform is not overloaded. Remove excess weight until the overload indicator light turns off.
2. If the LCD screen displays OVERLOAD RECOVERY, the emergency lowering system has been activated while overloaded.
3. To clear the message:
- Momentarily activate the drive enable toggle switch in the right direction.
- The display will show FAULTS.
- Momentarily activate the steer rocker switch in the right direction until RESET OVERLOAD MSG appears on the display.
- Momentarily activate the drive enable toggle switch in the right direction.
- The display will show ENTER PASSWORD.
- Enter the reset sequence: Steer right, steer right, steer right, steer left.
4. Only trained and qualified personnel should perform this procedure.

If the issue persists, refer to the Genie service manual for further troubleshooting.

This answer is automatically generated

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Greg
May 3, 2025

Working on a Genie Z-40/23N RJ s/n Z40N13-2342 I'm getting system fault code 1912 upon startup. 200A fuse is good, has a new aux motor/pump. Swapped left and right controllers and no change. Getting a single beep every 30 seconds while powered up. Motor controller fault code is aux_pump 12560. Can't find code 12560 in manual

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Summary of Contents for Genie Z-40/23N

  • Page 1 Service and Repair Manual Serial Number Range Z-40/23N from Z40N13-1902 to This manual includes: Z40N16N-4499 Repair procedures Fault Codes Z-40/23N RJ from Z40NN-4500 Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Find A Manual For This Model

    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.
  • Page 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. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 4: Serial Number Legend

    5 Serial number (stamped on chassis) 3 Facility code 6 Serial label (located under cover) From September 1, 2016 1 Model 4 Serial number (stamped on chassis) 2 Facility code 5 Serial label (located under cover) 3 Sequence number Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 5: Safety Rules

    You read, understand and obey: • manufacturer's instructions and safety rules • employer's safety rules and worksite regulations • applicable governmental regulations  You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 6 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. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 7: Table Of Contents

    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 Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 8 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 viii Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 9 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 Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 10 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 Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 11: Specifications

    127.5 Nm Capacity 390 AH (dry) 125 ft-lbs 125 ft-lbs Reserve capacity @ 25A 789 minutes 169.5 Nm 169.5 Nm rate Weight, each 101 lb For operational specifications, refer to the 46 kgs Operator's Manual. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 12: Performance Specifications

    Service and Repair Manual September 2016 Specifications 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 Jib boom down 16 to 20 seconds Drive speed, maximum Drive speed, stowed 4.5 mph...

  • Page 13: Hydraulic Specification

    Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 14 Continued use of Chevron 5606A Flash point None 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 Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 15: Hydraulic Component Specifications

    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. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 16: Machine Torque Specifications

    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...

  • Page 17: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed 23 ft-lbs / 31.2 Nm...

  • Page 18: Torque Procedure

    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). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly.
  • Page 19 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting. Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 20: Sae And Metric Fasteners Torque Charts

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

  • Page 21: Repair Procedures

     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.
  • Page 22 Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 23: Platform Controls

    After 3 seconds the alarm should sound a short beep to enter calibration mode. Connect the wire harness connector to the joystick. Result: The alarm should sound a long beep setting the neutral calibration point. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 24: How To Adjust The Joystick Threshold Setting

    Momentarily activate the drive enable toggle switch in the right direction until THRESHOLD CURRENT is shown on the display. Momentarily activate the drive enable toggle switch in the right direction to enter the threshold calibration mode. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 25: How To Adjust The Maximum Speed Setting

    Result: Alarm sounds, continue to step 15. rocker switch in the right direction. Result: Alarm does not sound, continue to step 13. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 26 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. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 27: How To Adjust The Function Ramp Up Time Setting

    Momentarily activate the drive enable toggle switch in the right direction until VALVE AND PUMP SETTINGS is shown on the display. Momentarily activate the drive enable toggle switch in the right direction until THRESHOLD is shown on the display. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 28 Result: The alarm should sound indicating the Jib up/down setting has been saved. 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 Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 29: How To Adjust The Function Ramp Down Time Setting

    VALVE AND direction will also change the opposite direction. PUMP SETTINGS is shown on the display. Momentarily activate the drive enable toggle switch in the right direction until THRESHOLD is shown on the display. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 30: How To Adjust The Max Speed Drive Settings

    Momentarily activate the steer rocker switch in Jib rotate (if equipped) the right direction until you see the decelerate 0.25 seconds AUTHORIZATION screen. Momentarily activate the drive enable toggle switch in the right direction to enter the authorization screen. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 31: September

    Result: The alarm should sound indicating the setting has been saved. To exit programming mode: 20 Move and hold the drive enable toggle switch in the left direction until the display screen returns to SYSTEM READY. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 32: Platform Components

    Do not rest the entire weight of the boom on the blocks. Use a soft metal drift to remove the barrel-end pivot pin. 10 Carefully pull the cylinder, with hydraulic hoses, out of the boom. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 33: Platform Rotator

    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. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 34: Platform Overload System

    Using a suitable lifting device, place a test weight equal to the maximum platform capacity at the center of the platform floor. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 35 11 Turn the key switch to ground control. 12 Test all machine functions from the ground 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. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 36: Platform Recovery Overload

    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. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 37: Jib Boom Components

    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. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 38: Jib Boom Bell Crank (Models Without Rotating Jib Boom)

    Remove the jib boom bell crank from the extension boom. Crushing hazard. The jib boom bellcrank may become unbalanced and fall if it is not properly supported when it is removed from the machine. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 39: Jib Boom Rotator (Models With Rotating Jib Boom)

    Note: When installing the jib boom rotator, be sure to torque the fasteners to specification. Refer to Specifications, Machine Torque Specifications. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 40: How To Bleed The Jib Boom Rotator

    5 seconds, then release it. Repeat three times. Crushing hazard. Keep hands and head clear of the jib boom during rotation. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 41: Jib Boom Lift Cylinder

    Do not allow oil to not properly supported by the overhead crane. squirt or spray. Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 42: Primary Boom Components

    Do not pull out the hydraulic from the platform. Do not disconnect the hoses. wiring. 10 Remove all hose and cable clamps from the Remove the jib boom/platform rotate manifold underside of the primary boom. cover. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 43 Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 44: How To Repair The Primary Boom Cable Track

    Install the new shims under the wear pad to obtain zero clearance and zero drag. Note: A 7 link repair section of cable track is available through the Genie Service Parts Tighten the mounting fasteners. Department. Extend and retract the boom through an entire cycle.

  • Page 45: How To Remove The Primary Boom

    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. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 46 15 Attach a similar lifting device to the primary 21 Attach a lifting strap from an overhead crane to the primary boom lift cylinder. boom lift cylinder. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 47: How To Disassemble The Primary Boom

    Note: Pay careful attention to the location and Crushing hazard. The primary amount of shims used with each wear pad. boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 48: Primary Boom Lift Cylinder

    Attach a 5 ton / 5000 kg overhead crane to the primary boom for support. Using the overhead crane, raise the primary boom slightly to take the pressure off the primary boom lift cylinder pivot pins. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 49 Lower the rod end of the lift cylinder onto the block. Protect the cylinder rod from damage. Crushing hazard. The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 50: Primary Boom Extension Cylinder

    11 Use a slide hammer to remove the pin. Extend the primary boom until the primary boom extension cylinder rod-end pivot pin is accessible in the primary boom extension tube. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 51: Platform Leveling Master Cylinder

    All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Raise the secondary boom until both the rodend and barrel-end pivot pins of the master cylinder are accessible. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 52 Place a rod through the rod-end pivot pin and twist to remove the pin. Remove the master cylinder from the machine. Crushing hazard. The master cylinder could become unbalanced and fall if not properly attached to the overhead crane. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 53: Secondary Boom Components

    6 lower compression arm Secondary Boom components 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. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 54: Secondary Boom

    Remove the pin retaining fasteners from both the primary boom lift cylinder to a vertical sides of the secondary boom lift cylinder rod position. end pivot pin and barrel-end pivot pin. Do not remove the pins. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 55 1 arm pivot pins at the mid-pivot and 24 Remove the hose and cable cover and clamps the upper pivot. Do not remove the pins. from the top of the number 2 arm. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 56 Crushing hazard. The number 2, 3 and 4 arm pivot pins at the compression link may fall if not mid-pivot. Do not remove the pins. properly supported when removed from the secondary boom assembly. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 57 52 Remove the number 4 arm from the machine. Crushing hazard. The number 4 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 58: Secondary Boom Lift Cylinders

    Component damage hazard. When removing a secondary boom lift cylinder from the machine, be careful not to damage the counterbalance valve at the barrel end of the cylinder. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 59: Hydraulic Pump

    Completely drain the hydraulic tank into a container of suitable capacity. Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns. Remove the center turntable cover fasteners. Remove the cover from the machine. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 60: How To Remove The Function Pump

    Remove the pump mounting bolts. Carefully remove the pump. Note: When replacing the function pump, it will need to be calibrated. Refer to Repair Procedure, How to Calibrate the Function Pump. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 61: September

    10 Momentarily activate the steer rocker switch in the right direction until START PUMP GPM is shown on the display. 11 Momentarily activate the drive enable toggle switch in the right direction to begin pump calibration. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 62: Manifolds

    Prevents oil from draining out of 18-20 ft-lbs / 25-27 manifold Relief valve, 2500 psi / 172 bar Platform level relief 18-20 ft-lbs / 25-27 Solenoid valve, 3 position 4 way Platform level up/down 16-20 ft-lbs / 24-27 Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 63 September 2016 Service and Repair Manual Manifolds Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 64: Valve Adjustments - Function Manifold

    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) Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 65 50 psi / switch while making this adjustment. 3 bar. To exit programming mode: 10 Move and hold the drive enable toggle switch in the left direction until the display returns to SYSTEM READY mode. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 66 Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specifications. Turn the machine off. Hold the secondary boom down relief valve with a wrench and remove the cap (item BP). Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 67 Observe the pressure reading on the pressure coil. gauge. Refer to Specifications, Hydraulic Component Specifications. Turn the machine off. Hold the platform level relief valve with a wrench and remove the cap (item BD). Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 68: Jib Boom And Platform / Jib Boom Rotate Manifold Components

    Service and Repair Manual September 2016 Manifolds Jib Boom / Platform Rotate Manifold Components, Z-40/23N The jib boom/platform rotate manifold is mounted to the jib boom. Index Schematic Description Function Torque Item — Coil nut 4-5 ft-lbs / 5-7 Nm...

  • Page 69: Jib Boom And Platform / Jib Rotate Manifold Components

    September 2016 Service and Repair Manual Manifolds Jib Boom and Platform / Jib Rotate Manifold Components, Z-40/23N The jib boom/platform rotate manifold is mounted to the jib boom. Index Schematic Description Function Torque Item — Coil nut 4-5 ft-lbs / 5-7 Nm...

  • Page 70: Valve Coils

    BK, BN, BS, BU) this test. Solenoid valve, 20V DC (schematic item 24 Ω Tag and disconnect the wiring from the coil to be tested. Proportional solenoid relief valve, 22 Ω 20V DC (schematic item BW) Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 71: Turntable Rotation Components

    Remove the retaining fasteners from the center turntable cover. Remove the cover from the machine. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 72: Steer Axle Components

    Note: Inspect the sensor activator pin to make sure it is not broken or twisted. Note: If the sensor activator pin needs to be replaced, note the mounting orientation to be sure the new one is installed correctly. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 73: How To Calibrate The Steer Angle Sensor

    CALIBRATE LEFT screen and press the drive Result: ENABLE will appear at the bottom of enable toggle switch once to the right. the screen. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 74 CALIBRATION OK will appear on the display. To exit programming mode: Move and hold the drive enable toggle in the left position until the display returns to SYSTEM READY mode. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 75: Non-Steer Axle Components

    Remove all rings, watches and other jewelry. Remove the chassis cover fasteners from the non-steer end of the chassis. Remove the cover. Remove the axle covers fasteners from the the non-steer axle. Remove the covers. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 76: 10-2 Drive Brake

    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 Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 77: Motor Controllers

    There are two drive motor controllers located inside a list of fault codes and additional information. For the non-steer axle, one for each drive motor. When further information or assistance, consult the Genie viewed from the non-steer end of the machine, the Product Support.

  • Page 78: Fault Codes

    • All external AC power supply disconnected from the machine • Boom in the stowed position • Turntable secured with the turntable rotation lock • Welder disconnected from the machine (if equipped with the weld cable to platform option) Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 79: Control System Fault Codes

    FAULTS is shown on the display. Momentarily activate the drive enable toggle switch in the right direction to access the active fault codes. Activate the steer rocker switch in the right direction to scroll through the fault codes. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 80: How To Retrieve Control System Fault Codes - Ground Controls

    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. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 81: Control System Fault Codes

    Open circuit (unplugged or failed valve coil) 14 RELIEF_VALVE Check for short to proportional relief Value at 0V No primary or secondary valve. Check coil resistance (22 output shorted to B- Ohms). Replace coil. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 82 Replace left (slave) AC motor AUX_PUMP controller. 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. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 83 Value too high Check for open or short from TCON SEC_UP_VALVE Secondary up function (C14-7) to the secondary up coil. Value too low Secondary boom up disabled. Replace coil. valve. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 84 Inspect and repair joystick wiring. Replace joystick. Value at 0V DRIVE_JYSTK Drive functions disabled. Not calibrated Check neutral output range is within Drive joystick. 2000 to 3000 mV. Calibrate joystick. Neutral out of range Replace joystick. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 85 Check for 48V DC to brake BRAKE_RIGHT Value too low (WH/RD). Check for 48V DC at Drive function disabled. Brake AC motor right C16-4. (48V is brake set, 0V is Coil shorted side. released). Replace brake Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 86 Steering and platform Check wiring and coil for function controller output. Value at 0V level functions disabled. causing fault. Fault at power up, Flashing beacon replace right (Master) AC motor Output shorted to B- disabled controller. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 87 CR62 should ESTOP_RELAY close. Check for 24V DC on 30 and 11 Shorted to supply All functions disabled. Emergency Stop 87 of CR62. Replace relay. Replace relay. red Emergency Stop button contacts. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 88 Check can bus resistor. Isolate all controls operative. other modules simultaneously. screen. System was overloaded LOAD SENSE 21 Fault and moved under AUX For reporting purposes only. RECOVERY power. DISABLED BY 21 Fault Functions disabled. Contact machine owner OWNER Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 89: Motor Controller Fault Codes

    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. Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 90 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). Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 91 No functions or drive. Replace the AC motor controller. 16913 Current sensor time No functions or drive. Replace the AC motor controller. 21776 EEPROM warning No functions or drive. Replace the AC motor controller. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 92: Drive Motor Thermal Sensor

    6 on the Deutsch connector going into the 482 / 250 2195 motor housing. Compare value to chart on 500 / 260 2293 right. 518 / 270 2392 536 / 280 2490 554 / 290 2584 572 / 300 2668 Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 93: Schematics

    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 test equipment are available and ready for use. Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 94: Wire Circuit Legend

    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. Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 95 Jib Sensor Data High Jib Up/Down Control Data Low Jib Down Drive Chassis Controller Jib Up/Down Flow Control Drive Enable Jib Select Valve Drive Enable Left Jib Up Drive Enable Right Jib Extend/Retract Control Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 96 Platform Rotate Left (CCW) Retract Lockout Platform Rotate Right (CW) Return Platform Tilt Alarm Reverse Platform Tilt Sensor Right Front Pressure Comp Enable Right Front Steer Sensor Pressure Sender Right Rear Right Rear Steer Sensor Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 97 Steering Valve (CCW) Temp Sender Temp Switches Tether Tilt Alarm X axis Tilt Alarm Y axis Ground Control Panel Turntable Rotate Flow Control Turntable Rotate Right (CW) Turntable Tilt Alarm Turntable Tilt Sensor Test Switch Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 98: Wiring Coloring And Legend

    BL/BK Blue/Black BL/RD Blue/Red BL/WH Blue/White Black BK/RD Black/Red BK/WH Black/White Brown Green GR/BK Green/Black GR/WH Green/White RD/BK Red/Black RD/WH Red/White Orange OR/BL Orange/Blue OR/BK Orange/Black OR/RD Orange/Red White WH/BK White/Black WH/RD White/Red Yellow Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 99 Jib select valve driver circuit WH/RD Work Lamp 12V DC battery supply WH/BK Motion Lamp 12V DC ignition supply Auxiliary Boom Key switch power to platform BL/WH Auxiliary Steer Power to platform BL/RD Auxiliary Platform Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 100 Primary #1 Lockout or AP) RD/WH Primary #2 Lockout BK/RD Proprietary Data buss + (I.e. ITT or AP) Primary boom #3 extended Lower Angle #1 operational WH/BK Upper Angle #2 operational Power from TCON ESTOP Z-40/23N, Z-40/23N RJ Part No. 1268528...
  • Page 101 GR/BK Hydraulic Generator Bypass WH/BK Secondary Boom Lockout (Riser Hydraulic EDC Output Down Enable) Injector Retard ECU Test Switch Jib Extend OR/RD Low Engine Speed BK/WH Jib Retract RD/BK Descent Alarm WH/RD Travel Alarm Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 102 Up/Down Flow Control Ground WH/RD Jib Rotate Right Extend/Retract Flow Control WH/RD Speed Select Input Ground OR/RD Electric Brake Source Key switch Power, Ground 2.5 volt Sensor Power Position Ground or Return WH/BK Load Sensor Signal, Operational Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 103: Power Cable Diagram

    September 2016 Service and Repair Manual Power Cable Diagram Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 104: Motor Contoller Pin Legend

    C156JUD - GR/WH C111LFS - OR C17PRL - GR SPARE DIG IN C18PRR - GR/BK C47FE - WH/BK SPARE OUT V36SCWA - BL C32RET - WH/RD V37SCCA - BL/BK SPARE DIG IN C86FLR - OR Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 105: Ground Control Box Pin Legend

    C130TA - WH/RD C161SB - WH/BK C184PSE - OR 11 GND - BL/BK V36SCWB - BL 10 P181BAT - OR 12 SPARE V191PCEB - 11 P182BAT - RD WH/RD 12 C47FE - WH/BK C134PWR - RD Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 106: Platform Control Box Pin Legend

    S132LDS - BL/WH SPARE C175LDS - WH/BK SPARE P49LPS - WH/BK C49GEN - GR/WH GND - BR SPARE SPARE SPARE C48LPS - WH/RD GND - BR C48LPS - WH/RD GND - BR SPARE SPARE Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 107: Turntable And Platform Controller Pin Legend

    C164PES - RD/WH SPARE C165TRS - WH/RD V05TRR - WH/BK C159STC - BL/WH C134PWR - RD C165PES - RD/WH C134PWR - RD C165TRS - WH/RD C134PWR - RD C161SB - WH/BK C134PWR - RD Part No. 1268528 Z-40/23N, Z-40/23N RJ...

  • Page 108: Electrical Symbol Legend

    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 Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 109: Hydraulic Symbols Legend

    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. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 110 Service and Repair Manual September 2016 This page intentionally left blank. Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 111: Electrical Schematics

    September 2016 Service and Repair Manual Electrical Schematic - Chassis...

  • Page 112: Electrical Schematic - Chassis

    Service and Repair Manual September 2016 Electrical Schematic - Chassis Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 113: Electrical Schematic - Ground Controls

    September 2016 Service and Repair Manual Electrical Schematic - Ground Controls Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 114 Service and Repair Manual September 2016 Electrical Schematic - Ground Controls...
  • Page 115 September 2016 Service and Repair Manual Electrical Schematic - Platform Controls...

  • Page 116: Electrical Schematic - Platform Controls

    Service and Repair Manual September 2016 Electrical Schematic - Platform Controls Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 117: Ground Control Box Wiring Diagram

    September 2016 Service and Repair Manual Ground Control Box Wiring Diagram Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 118 Service and Repair Manual September 2016 Ground Control Box Wiring Diagram...
  • Page 119 September 2016 Service and Repair Manual Platform Control Box Wiring Diagram...

  • Page 120: Platform Control Box Wiring Diagram

    Service and Repair Manual September 2016 Platform Control Box Wiring Diagram Z-40/23N, Z-40/23N RJ Part No. 1268528...

  • Page 121: Platform Control Box Wiring Diagram - Options

    September 2016 Service and Repair Manual Platform Control Box Wiring Diagram - Options Part No. 1268528 Z-40/23N, Z-40/23N RJ...
  • Page 122 Service and Repair Manual September 2016 Platform Control Box Wiring Diagram - Options...

  • Page 123: Hydraulic Schematics

    September 2016 Service and Repair Manual Hydraulic Schematic...

  • Page 124: Hydraulic Schematic

    Service and Repair Manual September 2016 Hydraulic Schematic Z-40/23N, Z- 40/23N R J Part No. 1268528 Servic e and R epair M anual September 2016 Z-40/23N, Z-40/23N RJ Part No. 1268528...

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