Terex Genie Z-40/23N Page 21 Service And Repair Manual Download

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September 2016

Service and Repair Manual

Repair Procedures

Part No. 1268528

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

Section 3

Repair Pr ocedures

Observe and Obey:



Repair procedures shall be completed by a

person trained and qualified on the repair of

this machine.



Immediately tag and remove from service a

damaged or malfunctioning machine.



Repair any machine damage or malfunction

before operating the machine.

Before Repairs Start:



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.

Machine Configuration:



Unless otherwise specified, perform each

repair procedure with the machine in the

following configuration:

•

Machine parked on a firm, level surface

•

Key switch in the off position with the key

removed

•

The red Emergency Stop button in the off

position at both the ground and platform

controls

•

Wheels chocked

•

All external AC power supply disconnected

from the machine

•

Boom in the stowed position

•

Turntable secured with the turntable rotation

lock

Summary of Contents for Genie Z-40/23N

Page 1: ...902 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 ...

Page 2: ...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 improveme...

Page 3: ...cedures 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 procedur...

Page 4: ...erial 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 ...

Page 5: ... 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 regulatio...

Page 6: ...tial 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 fro...

Page 7: ...ication 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 ...

Page 8: ...9 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...

Page 9: ...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 Syst...

Page 10: ...atform 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 Option...

Page 11: ...m Wheel width 7 in 7 in Wheel lugs 8 5 8 18 9 5 8 18 Lug nut torque lubricated 94 ft lbs 94 ft lbs 127 5 Nm 127 5 Nm dry 125 ft lbs 125 ft lbs 169 5 Nm 169 5 Nm For operational specifications refer to the Operator s Manual Fluid capacities Hydraulic tank 8 gallons 30 3 liters Hydraulic system 10 gallons including tank 37 9 liters Drive hubs 23 fl oz 680 cc Drive hub oil type EP 80 90W gear oil API...

Page 12: ...12 2 m 40 sec Braking distance On paved surface 5 to 7 ft 1 5 to 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 seconds Jib boom down 16 to 20 seconds Jib boom rotate 180 Z40 23N RJ 16 to 20 seconds Primary boom up 26 to 30 seconds Primary boom down 26 to 30 seconds Primary boom extend 18 to 22 seco...

Page 13: ...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 I...

Page 14: ... 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 Viscosit...

Page 15: ...gpm 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 co...

Page 16: ... 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 bolt...

Page 17: ... 16 18 1 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...

Page 18: ...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 he...

Page 19: ...rrect 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...

Page 20: ...Service and Repair Manual September 2016 Specifications 10 Z 40 23N Z 40 23N RJ Part No 1268528 ...

Page 21: ...nual 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 Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a...

Page 22: ...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 result in death or serious injury Indicates a potentially hazardous situation which if ...

Page 23: ...stick 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 al...

Page 24: ...splay 8 Momentarily activate the drive enable toggle switch in the right direction until THRESHOLD CURRENT is shown on the display 9 Momentarily activate the drive enable toggle switch in the right direction to enter the threshold calibration mode Toggle switch controlled functions Note Begin this procedure with the rotary speed control at the plaform controls turned fully in the counterclockwise ...

Page 25: ... down the foot switch 4 Move and hold the drive enable toggle switch in the right direction while holding the steer rocker switch in the right direction 5 When the display leaves SYSTEM READY mode release the drive enable toggle switch 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...

Page 26: ... sound indicating the setting has been saved 18 Repeat steps 11 through 17 as needed for high flow functions Low flow functions 19 Momentarily activate one of the low flow functions full stroke Result The display will show the function direction and milliamps 20 Start a timer press down on the foot switch and activate the same function in the same direction again Record the time it takes for that ...

Page 27: ...ase the drive enable toggle switch 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 7 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND PUMP SETTINGS is shown on the display 8 Momentarily activate the drive enable toggle switch in the ...

Page 28: ...e direction 15 When ramp time has been achieved activate the drive enable toggle switch to the right to save your changes Result The alarm should sound indicating the setting has been saved 16 Repeat steps 11 through 13 for each machine function To exit programming mode 17 Move and hold the drive enable toggle switch in the left direction until the display screen returns to SYSTEM READY Ramp rate ...

Page 29: ... display 7 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND PUMP SETTINGS is shown on the display 8 Momentarily activate the drive enable toggle switch in the right direction until THRESHOLD is shown on the display 9 Momentarily activate the steer rocker switch in the right direction until RAMP DOWN TIME is shown on the display 10 Momentarily activate the ...

Page 30: ...rive Settings Adjusting the max speed setting will only affect the stowed drive speed Elevated drive speed is not adjustable Note Begin this procedure with the machine in the stowed position 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 Move and hold the drive enable toggle switch in the right direct...

Page 31: ... when crossing the start and finish lines 16 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 17 Continue at full speed and note the time when the machine reference point passes over the finish line Release the foot switch Refer to Specifications Performance Specifications Result The drive speed mee...

Page 32: ...ks under the platform for support 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Do not rest the entire weight of the boom on the blocks 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the unions and connect them together using a connector Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loose...

Page 33: ...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 gradual...

Page 34: ...spilled 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks 2 3 Platform Overload System How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability ...

Page 35: ... and down and allowed to settle between adjustments Confirm the setting 6 Turn the key switch to platform control 7 Lift the test weight off the platform floor using a suitable lifting device 8 Place the test weight back onto the center of the platform floor using a suitable lifting device Result The alarm should be off The platform overload indicator light should be off at both the ground and pla...

Page 36: ...in the right direction while holding the steer rocker switch in the right direction 5 When the display leaves SYSTEM READY mode release the drive enable toggle switch and the steer rocker switch Result The display will show FAULTS 6 Momentarily activate the drive enable toggle switch in the right direction Result The display will show ACTIVE FAULTS 7 Momentarily activate the steer rocker switch in...

Page 37: ...ib boom for support Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 5 Remove the pin retaining fasteners from the jib boom leveling arm pivot pin at the platform rotator 6 Use a soft metal drift to remove the leveling arm pivot pin Let the leveling arms and jib boom lift cylinder hang down 7 Remove the pin retaining fastener from the jib boom lift cylinder bar...

Page 38: ...orted by the overhead crane 3 2 Jib Boom Bell Crank models without rotating jib boom How to Remove the Jib Boom Bell Crank Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hy...

Page 39: ...boom rotator from the machine Crushing hazard The jib boom 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 5 Support and secure the jib boom bell crank to an appropriate li...

Page 40: ...ear of the jib boom during rotation 4 Move and hold the function enable switch to either side and move and hold the jib boom rotate toggle switch to the left for approximately 5 seconds then release it Repeat three times 5 Fully rotate the jib boom to the left and continue holding the jib boom rotate toggle switch until air stops coming out of the bleed screw Crushing hazard Keep hands and head cl...

Page 41: ...y Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the rod end pivot pin half way out and lower one of the leveling links to the ground Tap the pin the other direction and lower the opposite leveling link Do not remove the pin 5 Support the jib boom with a suitable liftin...

Page 42: ...e the power to platform electrical box mounting fasteners Remove the electrical box from the platform Do not disconnect the wiring 5 Remove the jib boom platform rotate manifold cover 6 Tag disconnect and plug the hydraulic hoses from ports P and T at the jib boom platform rotate manifold Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loose...

Page 43: ...ull all of the cables through the mounting ears of the rod end of the primary boom lift cylinder towards the counterweight end of the machine 15 Place blocks between the cable track tube and the lower cable track Secure the cable track tube and lower cable track together Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced an...

Page 44: ...e 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 How to Shim the Primary Boom 1 Extend the boom until the wear pads are accessible 2 Loosen the wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 ...

Page 45: ...e Jib Boom 2 Models without rotating jib boom Remove the jib boom bellcrank Refer to Repair Procedure How to Remove the Jib Boom Bellcrank Models with rotating jib boom Remove the jib boom rotator Refer to Repair Procedure How to Remove the Jib Boom Rotator 3 Remove the cable track Refer to Repair Procedure How to Remove the Cable Track 4 Remove the hose and cable guard from the upper pivot Bodily...

Page 46: ... horizontal 14 Attach a 5 ton 5 000 kg overhead crane to the center point of the primary boom 15 Attach a similar lifting device to the primary boom lift cylinder 16 Place support blocks under the primary boom lift cylinder 17 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The boom lift cylinder and ...

Page 47: ...ly from the machine Crushing hazard The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane How to Disassembl e the Primary Boom How to Disassemble the Primary Boom Note Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely d...

Page 48: ...linder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these ...

Page 49: ...t pin Use a soft metal drift to remove the pin Crushing hazard The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane 9 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 attac...

Page 50: ...imary boom to a horizontal position 2 Extend the primary boom until the primary boom extension cylinder rod end pivot pin is accessible in the primary boom extension tube 3 Remove the hose and cable guard from the upper pivot 4 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and b...

Page 51: ... for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of primary boom motion The platform leveling master cylinder is located inside the upper mid pivot at the pivot end of the primary boom How to Remove the Platform Leveling Master Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment...

Page 52: ...ch an overhead crane or similar lifting device to the master cylinder 4 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin Use a soft metal drift to remove the pin Crushing hazard The master cylinder could become unbalanced and fall if not properly attached to the overhead crane 5 Remove the pin retaining fastener from the rodend pivot pin 6 Place a rod through the ro...

Page 53: ...ponents Part No 1268528 Z 40 23N Z 40 23N RJ 43 Secondary Boom components 1 upper pivot 2 upper compression arm 3 mid pivot 4 compression link 5 lower secondary boom 6 lower compression arm 7 turntable pivot 8 counterweight Z 30N Z 30N RJ 9 upper secondary boom ...

Page 54: ...ne 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 4 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure ...

Page 55: ... overhead crane to the number 1 arm at the mid point between the upper pivot and mid pivot 17 Remove the pin retaining fasteners from the number 1 arm pivot pins at the mid pivot and the upper pivot Do not remove the pins 18 Use a soft metal drift to drive both pins out 19 Remove the number 1 arm from the machine Crushing hazard The number 1 arm could become unbalanced and fall when removed from t...

Page 56: ...mid pivot for support Do not apply any lifting pressure 33 Remove the pin retaining fasteners from the number 2 3 and 4 arm pivot pins at the mid pivot Do not remove the pins 34 Use a soft metal drift to drive each pin out Remove the mid pivot from the secondary boom assembly Crushing hazard The mid pivot could become unbalanced and fall when removed from the secondary boom assembly if not properl...

Page 57: ... Attach the lifting strap from the overhead crane to the centerpoint of the number 3 arm for support Do not apply any lifting pressure 46 Remove the pin retaining fasteners from the number 3 arm at the turntable pivot Do not remove the pin 47 Use a slide hammer to remove the number 3 arm pivot pin from the turntable pivot through the access hole in the counterweight 48 Remove the number 3 arm from...

Page 58: ...ift cylinder rod end pivot pin 2 Tag disconnect and plug the hydraulic hoses on the secondary boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the secondary ...

Page 59: ...r under the hydraulic 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 Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 4 Remove the center turntable cover fasteners Remove the cover from the machine 5 Tag disconnect and plug the hydraulic h...

Page 60: ...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 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 How to Calibrate the ...

Page 61: ...n the right direction to enter the VALVE AND PUMP SETTINGS menu Result The display will show THRESHOLD CURRENT 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 12 Press down on the foot switch Move and hold the primary boom rocke...

Page 62: ...onal solenoid valve 3 position 4 way BK Turntable rotate left right 18 20 ft lbs 25 27 Nm 9 Shuttle valve BJ Turntable rotate circuit 4 5 ft lbs 5 7 Nm 10 Counterbalance valve 1000 psi 70 bar BT Primary boom down 44 52 ft lbs 60 70 Nm 11 Proportional relief valve 50 to 3000 psi 3 to 207 bar BW System relief 18 20 ft lbs 25 27 Nm 12 Needle valve BH Primary level up down 18 20 ft lbs 25 27 Nm 13 Che...

Page 63: ...September 2016 Service and Repair Manual Manifolds Part No 1268528 Z 40 23N Z 40 23N RJ 53 ...

Page 64: ... 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 Note The function enable toggle switch must be activated within 2 seconds of the audible tone Result The green LED on the TCON should change from a s...

Page 65: ...ment 7 Move and hold the jib boom toggle switch in the up direction Momentarily activate 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 with step 6 Note Momentarily activating the platform level toggle switch will increase or decrease the relief pressure in increments of a...

Page 66: ...itch to either side and hold the secondary boom up down toggle switch in the down direction 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 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockw...

Page 67: ...e and hold the platform level up down toggle switch in the up direction Observe the pressure reading on the 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 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the press...

Page 68: ...nents Z 40 23N The jib boom platform rotate manifold is mounted to the jib boom Index No Description Schematic Item Function Torque Coil nut 4 5 ft lbs 5 7 Nm 1 Proportional solenoid valve 3 position 4 way AA Jib boom up down 18 20 ft lbs 25 27 Nm 2 Proportional solenoid valve 3 position 4 way AB Platform rotate 18 20 ft lbs 25 27 Nm ...

Page 69: ...old is mounted to the jib boom Index No Description Schematic Item Function Torque Coil nut 4 5 ft lbs 5 7 Nm 1 Proportional solenoid valve 3 position 4 way AA Jib boom up down 18 20 ft lbs 25 27 Nm 2 Proportional solenoid valve 3 position 4 way AB Platform rotate left right 18 20 ft lbs 25 27 Nm 3 Proportional solenoid valve 3 position 4 way AC Jib boom rotate left right 18 20 ft lbs 25 27 Nm ...

Page 70: ...If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Ω Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Valve Coil Resi...

Page 71: ...ine 4 Disconnect the battery packs from the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 5 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor manifold Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Lo...

Page 72: ...s Remove the steer sensor assembly from the machine 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 8 Install the new steer sensor assembly to the yoke pivot pin Loosely install the cover retaining fasteners Note Be sure the sensor activat...

Page 73: ...eer rocker switch in the right direction to activate calibrate steer center Result ENABLE will appear at the bottom of the screen 11 Momentarily activate the drive enable toggle switch in the right direction Result The display will show YES Proceed to step 12 Result System does not allow YES to appear Press in the red Emergency stop button and return to step one Check steer angle sensor wiring is ...

Page 74: ...een 21 Momentarily activate the steer rocker switch in the right direction Result The display will show YES 22 Momentarily activate the drive enable toggle switch in the right direction to save the setting Result The alarm will sound indicating the setting has been saved Note After all three calibrations have been accepted an alarm sounds to indicate the calibration procedure is successful and CAL...

Page 75: ...otor if it becomes excessively hot 1 Disconnect the battery packs from the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 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...

Page 76: ...attery packs from the machine 3 Remove the chassis cover fasteners from the non steer end of the chassis Remove the 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 d...

Page 77: ...he 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 The motor controllers also control the valve outputs and machine options such as flashing beacon travel ala...

Page 78: ...s chocked 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 Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all ne...

Page 79: ...ly activate the drive enable toggle switch in the right direction to access the active fault codes 8 Activate the steer rocker switch in the right direction to scroll through the fault codes To access motor controller faults 9 Momentarily activate the drive enable toggle switch in the right direction until ACTIVE FAULTS is shown on the display 10 Activate the steer rocker switch in the right direc...

Page 80: ...onds 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 pauses between the flash tells the service technician the specific error type Error type code 12 for example would appear as one quick...

Page 81: ...contactor Check diode on main contactor Replace main contactor Replace right master motor controller 13 PR5_CONTACT Main contactor 12 Value too high Contacts stuck closed All functions disabled Check for voltage at main contactor coil with machine in the on position 24V DC on red wire 48V DC on orange wire Replace main contactor 15 Value too low Contacts stuck open All functions disabled Check for...

Page 82: ...d Lift pump disabled Auxiliary functions only Check for 48V DC to main function pump Check for current leakage from motor or cables to B Replace right master AC motor controller 15 Value too low Do not operate machine with batteries charging Check for 48V DC to main function pump Replace right master AC motor controller 22 Fault Allow main pump to cool down Check for air restriction to electric mo...

Page 83: ...ed Check for open or short from TCON C14 6 to the down coil Replace coil 25 PRI_ER_JYSTK Primary boom extend retract joystick 11 16 Shorted to supply Value at 0V Primary extend retract function disabled Inspect and repair joystick wiring Replace joystick 17 Not calibrated Neutral out if range Check neutral output range is within 2000 to 3000 mV Calibrate joystick Replace joystick 26 PRI_EX_VALVE P...

Page 84: ...000 to 3000 mV Calibrate joystick Replace joystick 42 TT_CW_VALVE Turntable rotate clockwise valve 12 15 Value too high Value too low Turntable rotate clockwise function disabled Check for open or short from TCON C29 8 to the turntable CW coil Replace coil 43 TT_CCW_VALVE Turntable rotate counter clockwise 12 15 Value too high Value too low Turntable rotate counterclockwise function disabled Check...

Page 85: ...res to thermal sensor at 6 wire deutsch plug on motor Check resistance on thermal sensor 53 AC_L_MOTOR Left side drive motor 12 Value too high Drive function disabled Do not operate machine with batteries charging Check cable connections Check for 33V AC across any two legs on drive motor at full stick Replace right drive motor Replace right master drive controller 15 Value too low Check cable con...

Page 86: ...us circuit for open Check can bus resistor Isolate all other modules simultaneously Replace right AC motor controller 22 Fault All functions disabled or limited Refer to MOTOR CONTROLLER FAULT CODES screen at platform See Motor Controller Fault Codes chart 59 AC_L_CTRLR Left side AC motor controller 22 Fault All functions disabled or limited Refer to MOTOR CONTROLLER FAULT CODES screen at platform...

Page 87: ...ft AC motor controller 16 Value at 0V Output shorted to B only detected with key switch turned to platform Hour meter brake relay and tilt sensor alarm disabled Platform overload alarm disabled option Check wiring and coil for function causing fault Look for short to B in wire from faulted function to left AC motor controller 67 DENA_SW_PBOX Platform control box drive enable switch 12 19 22 Value ...

Page 88: ...liary functions at ground control only Extend disabled Do not exceed maximum platform weight Check for 24V DC input to load sensor black Check for 24V DC output from load sensor when not overloaded to PCON pin C28 7 black at switch WH BK at module Check for 0V DC output from load sensor when not overloaded to right AC motor controller pin C16 19 white at switch BL WH at module 77 VCON_PBOX Platfor...

Page 89: ...place 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 tim e out No functions or drive Replace the AC m...

Page 90: ...ult is maintained replace the AC motor controller 13912 High temperature Functions and drive start to degrade and quit One or both motor controllers have exceeded 85 C 185 F Let the AC motor controllers cool off If fault persist with AC motor controllers cooled replace faulty AC motor controller 65516 Current gain Functions and drive will revert to factory default settings Readjust the max current...

Page 91: ... 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 maximu...

Page 92: ...asteners from the non steer end of the chassis Remove the cover 3 Remove the fasteners from the axle covers from the non steer axle Remove the covers 4 Tag and disconnect the six pin Deutsch electrical connector for the speed and temperature sensor at the drive motor asure the drive motor case temperature using a thermometer 5 Measure the drive motor case temperature using a thermometer 6 Measure ...

Page 93: ...y 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 About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings...

Page 94: ...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 sta...

Page 95: ...hield CAT CATS Module CNK Chain Break DTH Data High DTL Data Low DCN Drive Chassis Controller DE Drive Enable DEL Drive Enable Left DER Drive Enable Right Suffix Definition EDC Electrical Displacement Control ENV Envelope Light ESP Engine Speed Select ESL Engine Status Lamp ENL Envelope Lockout FLR Filter Restricted FLT Filter Switch FB Flashing Beacon FS Float Switch FTS Foot switch Signal FWD Fo...

Page 96: ...otate Right CW PTA Platform Tilt Alarm PTS Platform Tilt Sensor PCE Pressure Comp Enable PSR Pressure Sender Suffix Definition PS Pressure Switches PBS Primary Boom Angle Sensor PBD Primary Boom Down PBL Primary Boom Extend Retract Lockout Valve PBE Primary Boom Extend PER Primary Boom Extend Retract Flow Control PBR Primary Boom Retract PBU Primary Boom Up PBF Primary Boom Up Down Flow Control PL...

Page 97: ...own 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 Con...

Page 98: ...is white 3 All proportional valve wiring is striped 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 Power Circuits P10 P...

Page 99: ...portional valve driver GR 17 Platform rotate left valve driver GR BK 18 Platform rotate right valve driver GR WH 19 Jib select valve driver circuit RD 20 12V DC battery supply WH 21 12V DC ignition supply BK 22 Key switch power to platform WH 23 Power to platform Color Circuit Primary Function RD 24 Power to warning senders WH BK 25 Power to oil pressure sender WH RD 26 Power to temp sender RD 27 ...

Page 100: ...xtend GR BK 73 Secondary boom retract RD 74 Primary 1 Lockout RD WH 75 Primary 2 Lockout BL 76 Primary boom 3 extended WH 77 Lower Angle 1 operational WH BK 78 Upper Angle 2 operational BK 79 Power from TCON ESTOP Color Circuit Primary Function N A 80 Can 2 0 J1939 Shield GR 81 Can 2 0 J1939 Low Y L 82 Can 2 0 J1939 High GR WH 83 Tilt signal X axis GR BK 84 Tilt signal Y axis GR 85 Tilt sensor pow...

Page 101: ...BK 126 Secondary Boom Lockout Riser Down Enable GR 127 ECU Test Switch OR RD 128 Low Engine Speed RD BK 129 Descent Alarm WH RD 130 Travel Alarm Color Circuit Primary Function BL 131 Motion Alarm GR 132 Platform Load Input GR WH 133 Platform Load Alarm GR BK 134 Key Switch power BL WH 135 Fuel Pump RD 136 Power to Safety Module RD WH 137 Propel Power P_38 RD BK 138 Primary Boom Up Secondary Boom D...

Page 102: ... Load Sense Relay Sink BL 172 Up Down Flow Control Ground BK 173 Extend Retract Flow Control Ground WH 174 Key switch Power Ground Position WH BK 175 Load Sensor Signal Operational Color Circuit Primary Function GR WH 176 Secondary Extend Retract Flow Control BL RD 177 Extend Retract Lockout BK 178 Control Module Status Light GR 179 Drive Power Relay BK 180 Lift Power Relay OR 181 48 volt Alternat...

Page 103: ...September 2016 Service and Repair Manual Power Cable Diagram Part No 1268528 Z 40 23N Z 40 23N RJ 93 ...

Page 104: ... 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 W...

Page 105: ...D 12 C47FE WH BK 1 C18PRR GR BK 2 C17PRL GR 3 C27AUX RD 4 C133PLA GR BK 5 C32RET WH RD 6 C156JUD GR WH 7 C16PLF OR RD 8 C197RET WH 9 D82CAN YL 10 D81CAN GR 11 R174PWR WH 12 C130TA WH RD 1 C41RPM OR 2 C134PWR RD 3 C47FE WH BK 4 C165TRS WH RD 5 C163PLS BL WH 6 R46HRN WH 7 SPARE 8 P109PWR GR WH 9 D82CAN YL 10 D81CAN GR 11 C164PES RD WH 12 C161SB WH BK 1 P23BAT RD 2 P22BAT RD BK 3 GND RD WH 4 C134PWR ...

Page 106: ...H 2 C56FTS RD 1 SPARE 2 SPARE 3 V17PRL GR 4 V18PRR GR BK 5 V43JU GR 6 V44JD GR BK 7 V193JRR WH RD 8 V192JRL WH BK 9 GND BR 10 C134PWR RD 11 S132LDS BL WH 12 C175LDS WH BK 1 P23BAT WH 2 P22BAT BKD 3 GND BR 4 C134PWR RD 5 D82CAN YL 6 D81CAN GR 7 C27AUX RD 8 C46HRN WH 9 S132LDS BL WH 10 R181PWR OR 11 SPARE 12 SPARE 13 P49LPS WH BK 14 C49GEN GR WH 15 GND BR 16 SPARE 17 SPARE 18 SPARE 19 C48LPS WH RD 2...

Page 107: ...8 P162JPW OR 9 GND BR 10 C164PES RD WH 11 C159STC BL WH 12 C165TRS WH RD 1 C156JUD GR WH 2 C160JPL WH RD 3 V17PRL GR 4 V18PRR GR BK 5 V43JU GR 6 V44JD GR BK 7 V193JRR WH RD 8 V192JRL WH BK 9 C130TA WH RD 10 SPARE 11 C134PWR RD 12 C134PWR RD 1 GROUND BR 2 C134PWR RD 3 D82CAN YL 4 D81CAN GR 5 C163PLS BL WH 6 C68PBD RD 7 C40SBD OR 8 P109PWR GR WH 9 R110RET BR 10 C165TRS WH RD 11 C165PES RD WH 12 C161...

Page 108: ...o terminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency stop button normally closed Resistor with ohm value Battery seperator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normal...

Page 109: ... position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Sole...

Page 110: ...Service and Repair Manual September 2016 100 Z 40 23N Z 40 23N RJ Part No 1268528 This page intentionally left blank ...

Page 111: ...September 2016 Service and Repair Manual 101 Electrical Schematic Chassis ...

Page 112: ...Service and Repair Manual September 2016 102 Z 40 23N Z 40 23N RJ Part No 1268528 Electrical Schematic Chassis ...

Page 113: ...September 2016 Service and Repair Manual Part No 1268528 Z 40 23N Z 40 23N RJ 103 Electrical Schematic Ground Controls ...

Page 114: ...Service and Repair Manual September 2016 104 Electrical Schematic Ground Controls ...

Page 115: ...September 2016 Service and Repair Manual 105 Electrical Schematic Platform Controls ...

Page 116: ...Service and Repair Manual September 2016 106 Z 40 23N Z 40 23N RJ Part No 1268528 Electrical Schematic Platform Controls ...

Page 117: ...September 2016 Service and Repair Manual Part No 1268528 Z 40 23N Z 40 23N RJ 107 Ground Control Box Wiring Diagram ...

Page 118: ...Service and Repair Manual September 2016 108 Ground Control Box Wiring Diagram ...

Page 119: ...September 2016 Service and Repair Manual 109 Platform Control Box Wiring Diagram ...

Page 120: ...Service and Repair Manual September 2016 110 Z 40 23N Z 40 23N RJ Part No 1268528 Platform Control Box Wiring Diagram ...

Page 121: ...September 2016 Service and Repair Manual Part No 1268528 Z 40 23N Z 40 23N RJ 111 Platform Control Box Wiring Diagram Options ...

Page 122: ...Service and Repair Manual September 2016 112 Platform Control Box Wiring Diagram Options ...

Page 123: ...September 2016 Service and Repair Manual 113 Hydraulic Schematic ...

Page 124: ...Service and Repair Manual September 2016 114 Z 40 23N Z 40 23N RJ Part No 1268528 Hydraulic Schematic Z 40 23N Z 40 23N R J Part No 1268528 Service and R epair M anual September 2016 ...

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