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Z-40/23N RJ

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1. A B C D E F G H J K L JIB BOOM UP DOWN oc ee COUNTERBALANCE VALVES 1 PLATFORM ROTATE JIB BOOM ROTATE VALVE RATIO PRESSURE l X X 0 8 GPM 0 4 GPM CR 31 750 PSI Burr An zab a ass mops GA GB co BT 81 1000 PSI I p T M Id 7 7 I GB 151 3000 PSI Io i 1 o M cc cD cE cF 31 3800PSI pt OR dub uu ddl 451 3000PSI 2 21 I I cL 451 3500 PSI PR2 PRI JR2 JAI GJ GK 451 3600 PSI SECONDARY BOOM LIP DOWN PRIMARY BOOM UP DOWN 34 3800PSI TURNTABLE ROTATE 2 1 1 0 GPM 2 2 1 1 GPM r 71 71 71 je elm m SE C z E Ak M AB PRIMARY BOOM WHI m
2. unlocked position locked position Remove the retaining fasteners from the center turntable cover Remove the cover from the machine Disconnect the battery packs from the machine removed from the machine if not AWARNING Electrocution burn hazard properly supported by the overhead crane Genie BRAND Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Part No 119817 Z 40 23N Z 40 23N RJ 97 Service Manual September 2015 Turntable Rotation Components 5 disconnect and plug the hydraulic hoses from the turntable rotation motor manifold Cap the fittings on the manifold AWARNING 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 6 Attach a lifting strap from an overhead crane or other suitable lifting device to the turntable rotation assembly 7 Remove the turntable rotation assembly mounting fasteners 8 Carefully remove the turntable rotation assembly from the machine A WARNING Crushing Hazard The machine could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not
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4. 39 Checklist E 5 rennen 41 E 1 Test or Replace the Hydraulic 41 E 2 Grease the Steer Axle Wheel Bearings 43 Genie X Z 40 23N Z 40 23N RJ Part No 119817 September 2015 No Ewy e A ZN e SSS Table of Contents Section 4 Repair 5 dA Za Ad 45 MOGUCOM 45 Platform Controls 47 iza 47 Platform trn nente nnne nnn 56 2 1 Platform Leveling Slave Cylinder 56 2 2 Platform Rotator ses ar 57 2 3 Platform Overload 58 2 4 Platform Recovery Overload 60 Jib Boom AAA 61 3 1 Jib BOOM OE 61 3 2 Jib Boom Bell Crank models without rotating jib boom 62 3 3 Jib Boom Rotator models with rotating jib 63 3 4 Jib Boom Litt CylIMdEr ocio ete e 65 Primary Boom 2 1 66 4 1 Cable Pr e ee eis 66 4 2 ud 111 10 21 1000 11 POOR
5. Non adjustable fitting SAE O ring Boss Port SAE Dash Size Thread Size Flats tube fitting installed into Steel 4 7116 20 2 SAE Dash Size Torque 6 9 16 18 1 4 5 37 Adj 15 ft lbs 20 3 Nm 8 3 4 16 1 ORFS Non adj 26 ft lbs 35 3 Nm ey 37 Non adj 22 ft lbs 30 Nm s mim saa 2522 16 1 5 16 12 1 8 5 Adj Non adj 60 ft lbs 81 3 Nm 20 1 5 8 12 1 37 Adj Non adj 52 ft lbs 70 5 Nm 24 1 7 8 12 1 10 ORFS Non adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft Ibs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft lbs 413 5 Nm Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ Service Manual ARE A LD LSLSoLJGLoLLoJL L2D UCCA Specifications Torque Procedure Seal Lok fittings 1 Note The O ring in Parker Seal Lok fittings and Replace the O ring The O ring must be replaced anytime the seal has been broken JIC 37 fittings September 2015 1 Align the tube flare hex nut against the nose of the fitting body body approximately 30 in lbs hex fitting and tighten the hex nut to the body hex fitting to hand tight 3 4 Nm The O ring cannot be re used if the fitting or 2 Using a permanent ink marker make a hos
6. POWER UNIT SIDE BATTERY PACK RD LEFT INVERTER vO v LEFT SIDE DRIVE MOTOR Part No 119817 RD BK BK BK O 2 LIFT PUMP PRIMARY LIFT PUMP 5 AUXILIARY OL RD BK FUSE BOX ASSEMBLY Genie BRAND Z 40 23N Z 40 23N RJ Power Cable Diagram BK RD 1 Service Manual TANK SIDE BATTERY PACK RD O Di MAIN CONTACTOR A2 OP O Be DB RIGHT INVERTER 2 v RIGHT SIDE DRIVE MOTOR Service Manual September 2015 Motor Contoller Pin Legend 136 QOOCO OOCO OU Pin Numbering for 35 Pin Motor Controller Connector Left Motor Controller Slave O O R w M R195PWR OR RD C32BRK WH RD R181PWR OR R32RET BK P110RET BK PERSONALIZE R SPARE DIG IN SPARE OUT C130TA WH RD R181PWR OR C197RET WH SPARE DIG OUT D185SEN WH D186SEN BL C16PLF OR RD TXD SERIAL C27AUX RD D187PSE BL SPARE DIG IN SPARE DIG IN RXD SERIAL C26TSR WH RD C133PLA GR WH SPARE PROP OUT P198SEN RD TXD SERIAL D81CAN GR D82CAN YL R174PWR WH
7. le IN jo IND IND Ko r c w m 2 lt T w 2 w m U 2 lt Nm Nm 6 2 125 81 mo 108 147 313 202 274 269 365 610 394 535 525 715 970 83 791 778 1055 682 925 909 Ofe w e fs 09 2 Gr Co foo gt fo 66 lt ajojv 25 2 2 Y w o a AIN S IB gt 5 olol ojojo aj u 420 570 762 Genie BRAND 10 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Scheduled Maintenance Procedures Observe and Obey AWARNING NAN WH M Part No 119817 Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified of the Maintenance inspection Report The frequency and extent of periodic examinations and tests may also depend on national regulations Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage Imme
8. Rnnmm Hera Checklist D Procedures Note To obtain an accurate measurement place Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing the dial indicator more than 1 inch 2 5 cm from the turntable rotation bearing 40 1 turntable 2 dial indicator 3 drive chassis 4 turntable rotation bearing Adjust the dial indicator needle to the Zero position Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom Z 40 23N Z 40 23N RJ 9 11 12 Genie September 2015 Note the reading on the dial indicator Result The measurement is less than 0 055 inch 1 4 mm The bearing is good Result The measurement is more than 0 055 inch 1 4 mm The bearing is worn and needs to be replaced Fully retract the primary boom Raise the primary and secondary booms to full height Visually inspect the dial indicator to be sure the needle returns to the zero position Remove the dial indicator and rotate the turntable 90 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart Lower the primary and secondary booms to the stowed position and turn the machine of
9. 27 B 11 Test the Alarm Package if 28 B 12 Inspect the Electrical 0 12100 aaa aaa nenene 28 B 13 Perform Hydraulic Oil 29 B 14 Test the Emergency Power System 29 Genie Part No 119817 Z 40 23N Z 40 23N RJ ix September 2015 BZ gt gt EE en d Table of Contents Checklist 4 21 31 C 1 Grease the Platform Overload Mechanism if equipped 31 C 2 Test the Platform Overload System if 31 Checklist D Procedures yo zaa zza Poda dada cise 34 0 1 Check the Boom Wear 34 0 2 Check the Turntable Rotation Bearing 34 D 3 Check the Axle Mounting 36 0 4 Check the Platform Rotation Mounting Bolts 36 0 5 Check the Free wheel Configuration 2 37 D 6 Replace the Drive Hub 38 D 7 Replace the High Pressure Hydraulic Filter 38 D 8 Inspect for Turntable Bearing Wear
10. GROUND GONTROL BOX WARD EPE Se s m eem _ _ ___________ _ _ _ _____ ___ _ _ _ __ 2 az i EM 3 88 88 15 ees 2 TO C25 AT PLATFORM GONTROL BOX Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 145 Service Manual September 2015 Electrical Schematic Ground Controls 146 September 2015 Service Manual lll Electrical Schematic Platform Controls 147 Service Manual September 2015 Electrical Schematic Platform Controls A B D E F 6 H J K L R2 EMERGENCY STOP 1 Seren a 7 CEA AG RAA PRIMARY BOOM UP DOWN 9 4 AUXILIARY BOOM EXTEND BBTRAGT m Tss 1819 7815 POWER z 8 B B B AN
11. 120 Genie Z 40 23N Z 40 23N RJ AC Motor Error Type Condition Solution controller code 24592 Watchdog No functions or drive Replace the AC motor controller 65297 Logic failure 3 No functions or drive Replace the AC motor controller 65298 Logic failure 2 No functions or drive Replace the AC motor controller 8977 TB Y HIGH No functions or drive Replace the AC motor controller 12592 Capacitor charge No functions or drive Check for 48V DC on using for ground Replace the AC motor controller 12833 Contactor driver No functions or drive Replace the AC motor controller 65503 Safety feedback No functions or drive Replace the AC motor controller 12835 P OS AUX Shorted No functions or drive Check for 48V DC on the WH RD wire going to the right brake coil Replace the AC motor controller 8785 Hardware short No functions or drive Replace the AC motor controller tim e out 65512 Wrong set point No functions or drive Replace the AC motor controller 6513 Power OS shorted No functions or drive Replace the AC motor controller 65515 Tiller error No functions or drive Check for 48V DC R 1 OR RD on master motor controller Check for 24V DC on R 29 Blue on master motor controller Replace AC motor controller Part No 119817 September 2015 Service Manual Motor Controller Fault Codes AC Motor Error Type Condition Solut
12. BRAND Z 40 23N Z 40 23N RJ 31 Part No 119817 Service Manual ja 2 a J Checklist Procedures The platform support subassembly utilizes two load support arms that are opposed in a full parallelogram link This isolates platform loads into a shear or vertical state which translates into a compressive load A spring in the parallelogram link supports this purely compressive load regardless of where the load is placed in the platform As weight is added to the platform the spring will compress until when the platform is overloaded the lower arm contacts a limit switch and thereby activating the overload signal When adjusted correctly the platform overload system will deactivate normal boom operation at platform capacity Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to platform control Start the engine and level the platform Determine the maximum platform capacity Refer to the machine serial plate Remove all weight tools and equipment from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test 4 32 Using a suitable lifting device place a test weight equal to that of the available capacity in one of the locations shown Refer to Illustration 1 Result The platform overl
13. C2BTTS RD BK J2 10 VIBIPCEA WH RD J1 4 J2 4 BK P22BAT V368CWA BL Ji 5 V37SCCA BL K J1 7 N14PLUA OR 1 9 C4 8 C46HRN WH 10000000F visPLD c5 130099QG7 visPLDB OR BK J1 12 Vi4PLUB OR Ji 10 7 BL K 418 RISSPWR OR RD C82RET WH RD P181PWROR V368CWB BL J1 6 V191PCEB WHRD 1 3 Ri81PWR OR CA34PWR RD TS1 G134PWR RD C8 GR G2 3 G27AUX RD C32 C5 12 J2 8 C134PWR RD C27AUX RD 225 P22BAT BK Tasi 02 11 R174PWR WH AUXILIARY OO RD KEY SWITCH FD 01 4 G22PWR BK Pi EMERGENCY STOP 635 1 BLWH 3212 PI00PWR GR WH C24 8 HOUR METER PLATFORM OVERLOAD LED T 61 PRIMARY C197RET WH HEROTATE A PRIMARY p o 2 gy EXTEND RETRACT Ci C192JR 03 11 164 RD WH CSA PIO
14. BRAND Z 40 23N Z 40 23N RJ 139 Service Manual September 2015 Electrical Symbol Legend Connection no terminal T circuits connect at terminal Circuits crossing no connection 1 H1 F Battery Coil solenoid or relay Horn or alarm Flashing beacon Gauge F1 FS1 w L3 co Xe BK 25 Diode Hour meter LED Fuse with amperage Foot switch A A LS3 zjo PRi i aig 9 T circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid 21 r I 15A Quick disconnect terminal Circuit breaker with amperage PLATFORM m GROUND KS1 Es Key switch H P3 Horn button normally open dn 8 2 m lt m WHOHdLY ld Toggle switch DPDT 1 d Emergency stop button normally closed 4 2 1515 3NION3 Toggle switch SPDT 5100 Resistor with ohm value AUX MAIN Battery seperator Tilt sensor Gauge sending unit 5 Oil temperature switch normally open Coolant temperature switch normally open Oil pressure switch normally closed n N O Control relay contact normally open Diode starting aid
15. 3 sz GIBDELBLIRO_ 5 e CIHPWR RD 23 GQ sa w si remo 288 7 zi a E E CHMFCWHRD GI7PRLGA __ P29BAT WH OR PZ3BAT WH GND BR CIGPLFORIRD gg aie 5 O46DRE BL WH 5 5 TS ae enc 2 WH VIBSURR WH RD Gi 3 G134PWA RD 025 7 O27AUX AD Vi82JRL con ac CIB2IALWHBK aras P23BAT WH CI34PWR RD Fey CIS4PWn RD G124BWR RD rape evan CI888LAGRK_ oas n C SZIEL WHEK a GZATTARDIEK E Tener wk WH RD 2 C201 fe lo P23BAT WH alle 5 C1880BRWHIRD _ me 19 5 5 5 2 YLDGZCAN PORO DSICAN GR 88 TS eoo 595 B OR DEZCAN YL 55 M qs B Ie BE 4 dA Del 5852 ED gl casa CURL GR AZaogac zj C134PWA FD 2 Awl 9 gc CISPAR AREK WAJD al al gl 0299 GR VASUU O Q a 59 GRIBKVISPAR 9 GRVI7PRL e E C293 m O 8 EM FE 69 9 E 5 EE zl T 5 z 5 5 mec E 9 Q e RD CIMFWA d CIS6PWA YL BE BR GND RE 5354 OR OtG2JPW WH BK Vi 2JAL E P182JPW OR o tone CIBPLF 5 NHRD 5 Os Os 9 9 9 e 59 co O189PLSBLWH _ 5 ra GND BR ae PI62JPW OR 5 2 oo
16. Ganie Part No 119817 BRAND Z 40 23N Z 40 23N RJ 149 Service Manual September 2015 gt gt gt gt E Ground Control Box Wiring Diagram 150 September 2015 Service Manual Z ZZOZ LC DC CC LOLO Platform Control Box Wiring Diagram 151 September 2015 PLUS 1 MODULE B C22 p cen g zl T 8 E C252 _P22BAT BK anomew Ej 8 sa Rol z lt E wih 85 zag C1580D GRWH E P28BATWH 2 5 gh PIMBATWH Vi7PALGA Sa 8 V18PAR 9 9 NABIU GR cms E SET cna a 5 Z GNDBR a ES gl Pi84PWR RD H rr DAZGAN YL 5 D amp 1CAN GR G183PLSBL WH mw AD cate
17. RDWH 2910 BD G124PWR NEJ ka WHAD_ z a HD CIS4PWA 58 G134PWR 232 BR GND E SE PZZBAT BK O BR GND 2 BR GND YLC198PWA C58 2 WH O OA PlGiPW A Platform Control Box Wiring Diagram Service Manual Part No 119817 Genie Z 40 23N Z 40 23N RJ 152 September 2015 Service Manual Platform Control Box Wiring Diagram Options G H J K L M e 000000 4 n R 8 1100000000000 1 i zk 000000 4 9 12 8 8 8 Lob i 8 E g Tm T815 20 11 Li m M m pAVEENABLE 9 DEF DRIVE ENABLE jo jo x Celera LED JCZ 5 8 5 3 H 6 1 10 1 PRIMARY UP DOWN 3 E PRIMARY EXTEND RETRACT a a d m AND TURNTABLE ROTATE DRIVE STEER PLATFO Ao oB CONTROL DISPLAY CON e OQ GR BK CI38PLA 9 0 c32 1 OR 1 1 Lp
18. 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 Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Use only Genie approved replacement parts Repair Procedures Machine Configuration V Unless otherwise specified perform each repair procedure with the machine in the following configuration e Machine parked on a firm level surface e Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked e All external AC power supply disconnected from the machine e Boom in the stowed position e Turntable secured with the turntable rotation lock Z 40 23N Z 40 23N RJ 45 Part No 119817 Service Manual September 2015 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop Select the appropriate repair procedure afte
19. Crushing hazard The extension cylinder could become unbalanced and fall when removed from primary boom extension tube if not properly supported Note During removal the overhead crane strap will need to be adjusted for proper balancing 4 3 Primary Boom Lift Cylinder 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 AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 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 Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom to a horizontal position 2 Raise the secondary boom until the primary boom lift cylinder barrel end pivot pin is above the turntable covers 3 Attach a 5 ton 5000 kg overhead crane to the primary boom for support 4 Using the overhead crane raise the primary boom slightly to take the pressure off the primary boom lift cylinde
20. EXTENDIRETRACT 3 A 1 5 1 0 GPM 3 2 2 4 GPM 4 4 o gt GG LET eS 1 e GM GN ol 71 on aj da swn A Loe I J FL M c9 4 11 i FI WM o OLX I C JIB BOOM AND PLATFORM JIB ROTATE MANIFOLD Z 40 23N RJ e nas oP it 9 STEER CYLINDER l 1 Bcsaba eel 4 PRESSURE 2 8 GPM E R VI R E R E R SWITCH NO PLATFORM LEVEL MASTER HIGH PRESSURE NE COE FILTER E AP L Z AG 1 5 e lt GII gt skl S W w Do l E p ee AUXILIARY Bal 88 4 PUMP ee 1 ae 1 1 esa a ap a BC Ba BN BS BU 1 E 1 O 6 SHEDOES 1 E f 1 4 7 71 2500 PSI I X BENE Ln T AE BP BL LIFT PUMP 4GOJREV PRESS 7 pec MNT e Ld e 5 60 3000 PSI m 03 e e 1 BY TANK Ex HYDRAULIC TANK L 1 FUNCTION MANIFOLD 8 ZSEE cL
21. Momentarily activate the drive enable toggle switch in the right direction to enter the CALIBRATE LEFT screen Result The display will show NO 101 Service Manual September 2015 Steer Axle Components 25 Momentarily activate the steer rocker switch in the right direction Result The display will show YES 26 Momentarily activate the drive enable toggle switch in the right direction to save the setting Result The alarm should sound indicating the setting has been saved To exit programming mode 27 Move hold the drive enable toggle in the left position until the display returns to SYSTEM READY mode 1 1 hA 102 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 10 1 Drive Motors How to Remove a Drive Motor The drive motors are AC powered and are a brushless design requiring very little maintenance They have built in speed and temperature sensors which are monitored by the turntable controller TCON and the platform controller PCON The speed sensor is a Hall effect type and is part of the rear motor shaft bearing The temperature switch will shut down the drive motor if it becomes excessively hot 1 Disconnect the battery packs from the machine A WARNING 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
22. 121 Service Manual September 2015 Motor Controller Fault Codes AC Motor Error Type Condition Solution controller code 24592 Watchdog No functions or drive Replace the AC motor controller 65509 Wrong zero No functions or drive Replace the AC motor controller 65510 Output mismatch No functions or drive Replace the AC motor controller 65530 Input mismatch No functions or drive Replace the AC motor controller 65511 Safety feedback No functions or drive Replace the AC motor controller 65512 Wrong setpoint No functions or drive Replace the AC motor controller 65513 Wrong config No functions or drive Replace the AC motor controller 65532 Hardware fault No functions or drive Replace the AC motor controller 65528 Analog input No functions or drive Replace the AC motor controller 21808 EEPROM time out No functions or drive Replace the AC motor controller 9233 0 ever No functions or drive Replace the AC motor controller 8977 STBY I HIGH No functions or drive Replace the AC motor controller 16912 High temperature Function pump chopper maximum Let the AC motor controllers cool current reduced proportionally to off temperature increase If fault persist with AC motor controllers cooled replace faulty AC motor controller 65515 Hardware fault valve No functions or drive Replace the AC motor controller 65280 Tiller mismatch No functions or drive Replace the AC m
23. CAN Shield CATS Module Chain Break Data High Data Low Drive Chassis Controller Drive Enable Drive Enable Left Drive Enable Right Part No 119817 Suffix EDC ENV ESP ESL ENL FLR FLT FB FS FTS FWD FP FL FSL FE TCN GND HRN HS HG IGN JBD JBU JBS JUD JD JFC JSV JU JER Genie BRAND Z 40 23N Z 40 23N RJ Service Manual Schematics Definition Electrical Displacement Control Envelope Light Engine Speed Select Engine Status Lamp Envelope Lockout Filter Restricted Filter Switch Flashing Beacon Float Switch Foot switch Signal Forward Fuel Pump Fuel Select gas LP Fuel Solenoid Function Enable Ground Control Ground Horn High RPM Hydraulic Generator Ignition Jib Bellcrank Down Jib Bellcrank Up Jib Sensor Jib Up Down Control Jib Down Jib Up Down Flow Control Jib Select Valve Jib Up Jib Extend Retract Control 127 Service Manual x gt ma gt gt gt gt a S S S Schematics Suffix Definition JBE Jib Extend JBR Jib Retract JRL Jib Rotate Left CCW JRR Jib Rotate Right CW JPW Joystick 5V DC Power LPS Lamps LF Left Front LFS Left Front Steer Sensor LR Left Rear LRS Left Rear Steer Sensor LS Limit Switch LSR Lift Speed Reduction LDS Load Sensor LO Lockout LS Low RPM LOF Low fuel MS Motor Shift Speed MFV Multi Function Valve PCN Platform Control PLD Platform Level Down PLF Platform Level Flow Control PLU
24. Check wiring and coil for function and tilt sensor alarm causing fault Fault at power up disabled Platform replace left slave AC motor overload alarm disabled controller option 67 DENA SW PBOX 12 Value too high Drive Function disabled Check for voltage output at drive Platform control box 19 Out of Range in drive disable zone enable toggle switch Blue drive enable switch 22 FAULT Check for voltage input at VCON at V1 4 Replace VCON 68 FUNC SW 22 Fault Auxiliary functions only Check for 24V DC at function enable Ground box function toggle switch enable switch Check for 24V DC input at TCON at P2 2 Check for 24V DC input at right Master AC motor controller at R 32 Replace TCON Replace right master AC motor controller 71 ESTOP RELAY 11 Shorted High 24V All functions disabled With Red Emergency Stop pulled Emergency Stop out at ground control CR62 should relay close Check for 24V DC on 30 and 87 of CR62 Replace relay Replace red Emergency Stop button contacts 118 Genie Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Control System Fault Codes counterclockwise valve function disabled Error Source Error Type ID ID Condition Solution 72 JROT_CW_VALV 12 Value too high Jib rotate clockwise Check for open or short from PCON Jib rotate clockwise 15 Value too low function disabled
25. 1 Tag and disconnect each electrical connector burn skin Loosen hydraulic from the platform control box connections very slowly to allow the oil pressure to dissipate 2 Remove the hose and cable clamp from the jib gradually Do not allow oil to boom bellcrank pivot pin squirt or spray 3 Remove all of the hose and cable clamps from ii 8 Remove the hose and cable clamp from the the jib boom and platform support ie platform end of the cable track tube 4 Remove the power to platform electrical box mounting 55 the electrical box 9 Pull all of the electrical cables out of the plastic from the platform Do not disconnect the cable track Do not pull out the hydraulic wiring hoses 5 Remove the jib boom platform rotate manifold 10 Remove all hose and cable clamps from the cover underside of the primary boom Genie 66 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Primary Boom Components 11 Tag disconnect and plug the jib 15 Place blocks between the cable track tube and boom platform rotator hydraulic hoses at the the lower cable track Secure the cable track union located above the primary boom lift tube and lower cable track together cylinder Cap the fittings on the unions AWARNING Crushing hazard If the upper AWARNING Bodily injury hazard Spraying and lower cable tracks are not hydraulic oil can penetrate and properly secured together the burn skin Loosen hydraulic c
26. A I Table of Contents 11 Pre Delivery Preparation 14 Maintenance Inspection 16 Checklist Procedures 4 2 4 4 17 1 Inspect the Manuals 17 2 Perform Pre operation 00011 18 A 3 Perom FUNCION Tests yz 18 4 Perform 30 Day aaa 19 5 Grease the Turntable Rotation Bearing and Worm Drive 19 Checklist Procedures 20 B 1 Inspect the 20 B 2 Inspect the Electrical Wiring 2 2 22 21 B 3 Inspect the Tires Wheels and Lug Nut Torque 23 B 4 Confirm the Proper Brake Configuration 23 B 5 Check the Oil Level the Drive 24 B 6 Test the Ground Control Override aaa aaa 25 B 7 Test the Platform 25 B 8 Test the Drive 26 B 9 Test the Drive Speed Stowed 26 B 10 Test the Drive Speed Raised or Extended Position
27. Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 15 Service Manual September 2015 ON AY Maintenance Inspection Report Model Checklist A YNR Checklist YNR A 1 Inspect the manuals C 1 Grease platform Serial number and decals overload if equipped 2 Pre operation 2 Test platform Date inspection overload if equipped A 3 Function tests Checklist D YNR Hour meter Perform after 40 hours 0 1 Boom wear pads Machi A 4 30 day service D 2 Turntable bearing achine owner bolts Perform every 100 hours D 3 Axle mounting bolts Inspected by print A 5 Grease rotation Inspector signature bearing D 4 Platform rotation bolts Inspector title Checklist B YNR D 5 Free wheel configuration Inspector company B 1 Battery D 6 Drive hub oil Bec 0 7 Hydraulic filters B 3 Tires and wheels Instructions D 8 Turntable bearing B 4 Drive hub bolts wear Make copies of this report to use for each inspection B 5 Drive hub oil Checklist E YNR Select the appropriate checklist s for B 6 Ground control the type of inspection s to perform E 1 Hydraulic oil override Daily or every 8 hours A B 7 Platform leveling E 2 Wheel bearings Quarterly or every PAR B 8 Drive brakes Comments 250 hours Semi annually or A B C B 9 Drive speed stowed every 500
28. 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 Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib boom Refer to Repair Procedure How to Remove the Jib Boom 2 Support and secure the jib boom bell crank to an appropriate lifting device 3 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin 4 Place a block of wood under the platform leveling slave cylinder for support Protect the cylinder rod from damage 5 Remove the pin retaining fasteners from the jib boom bell crank at the extension boom Use a soft metal drift to remove the pin 6 Use a soft metal drift to remove the slave cylinder rod end pivot pin 7 Remove the jib boom bell crank from the extension boom A WARNING Crushing hazard The jib boom bellcrank may become unbalanced and fall if it is not properly supported when it is removed from the machine Genie 62 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 aa asa TT RAZIE A EE Service Manual Jib Boom Components 3 3 5 Support and secure the jib boom bell crank to Jib Boom Rotator
29. P2 8 to the platform rotate CW coil valve Replace coil 74 JROT_CCW_VLV 12 Value too high Jib rotate Check for open or short from PCON Jib boom rotate 15 Value too low counterclockwise P2 7 to the platform rotate CCW coil Replace coil 76 OVERLOAD_SW Platform overload switch option 77 VCON_PBOX Platform display screen 12 22 13 Value too high Fault No response Platform functions limited to recovery only Primary lift pump functions at ground controls disabled Auxiliary functions at ground control only Extend disabled Platform functions disabled Ground controls operative Do not exceed maximum platform weight Check for 24V DC black input to load sensor Check for 24V DC red output from load sensor Check for OV DC on right master AC motor controller on R 19 Replace load sensor Check can bus circuit for open Check can bus resistor Isolate all other modules simultaneously Replace right master motor controller 78 PCON_PBOX Platform controller screen 13 No response Platform functions disabled Ground controls operative Check can bus circuit for open Check can bus resistor Isolate all other modules simultaneously Replace right master motor controller Part No 119817 Genie BRAND Z 40 23N Z 40 23N RJ 119 Service Manual September 2015 Motor Controller Fault Codes
30. V Repair any machine damage or malfunction Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine V Be sure that all necessary tools and test equipment are available and ready for use Part No 119817 Genie BRAND Z 40 23N Z 40 23N RJ Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics 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 125 Service Manual September 2015 Schematics Circuit numbering 1 Circuit numbers consist of three parts the circuit prefix circuit number and circuit suffix The circuit prefix indicates the type of circuit The circuit number describes the function of the circuit The circuit suffix provides an abbreviation for the number or may be used to further define the function of this portion of the circuit It also may be used to indicate the final end of the circuit i e LS or limit sw 2 Thecircuit number may be used more than once in a circuit For Example C 74 PL This is the circuit for the lockout valve 1 C stands for control 74 is the number of the circuit for the primary 1 lock out valve PL
31. aa asa gt OB 21 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The platform overload indicator lights should be flashing at both the ground and platform controls and the alarm should sound Result The alarm does not sound and the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 8 10 11 Test all machine functions from the platform controls Result All platform control functions should not operate Turn the key switch to ground control Test all machine functions from the ground controls 12 13 14 15 Service Manual Checklist C Procedures Using a suitable lifting device remove all test weights from the platform Result The alarm does not sound and the platform overload indicator lights are not flashing Test all machine functions from the ground controls Result All ground control functions should operate normally Turn the key switch to platform control Test all machine functions from the platform controls Result All platform control functions should operate Note If the platform overload system is not operating properly Refer to Repair
32. ccc Ll MED MD c f LaL LC LONE Genie BRAND 156 Z 40 23N Z 40 23N RJ Part No 119817 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Scandinavia Phone 0046 3157 5154 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 935 725 090 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 4221 491 820 Genie Australia Pty Ltd Phone 61 7 3456 4444 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Sinapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
33. drive valves Turntable rotate flow control valve Part No 119817 September 2015 jaaa gt gt gt AA BE Color RD RD BK RD WH WH WH BK WH RD BK BK WH BK RD BL BL BK BL WH BL RD OR OR BK OR RD GR GR BK GR WH RD WH BK WH Circuit Primary Function Color 1 Primary boom up driver RD 2 Primary boom down driver WH BK 3 Primary boom up down flow WH RD control proportional valve driver RD 4 Turntable rotate left valve driver RD BK 5 Turntable rotate right valve RD WH driver 6 Turntable rotate flow control proportional valve driver WH BK 7 WH RD 8 Primary boom retract BK 9 Primary boom Extend Retract BK WH proportional valve driver BK RD 10 Secondary boom up valve driver BL 11 Secondary boom down valve driver BL WH 12 Secondary boom up down flow BL RD control proportional valve driver 13 Drive enable SR 14 Platform level up valve OR BK 15 Platform level down valve 16 Platform up down flow control GB proportional valve driver GR BK 17 Platform rotate left valve driver GR WH 18 Platform rotate right valve driver WH 19 Jib select valve driver circuit WH BK 20 12V DC battery supply WH RD 21 12V DC ignition supply WH BK 22 Key switch power to platform BL 23 Power to platform BL WH BL RD Gania Part No 119817 BRAND Z 40 23N Z 40 23N RJ Service Manual Schematics Circuit Primary Function 24 25 26 27 28
34. glow plug or flame ignitor 140 Z 40 23N Z 40 23N RJ Genie BRAND Part No 119817 September 2015 Service Manual Hydraulic Symbols Legend 0 037 0 94 mm Nazi 4778 Orifice with size a Check valve Shut off valve Pump fixed displacement 7 Pump bi directional variable displacement Motor bi directional Motor 2 speed bi directional Double acting cylinder Pump prime mover engine KOM Shuttle valve 2 position Differential sensing valve Filter with bypass relief Relief valve with pressure or motor 3 way NA A ie kr Priority flow regulator valve Solenoid operated valve setting proportional valve MELDE TZM Directional valve mechanically activated Counterbalance valve with pressure and pilot ratio Flow divider combiner valve A Solenoid operated 3 position 4 way directional valve Pilot operated 3 position 3 way shuttle valve si d DAS Solenoid operated 3 position 4 way proportional directional valve Solenoid operated 2 position 3 way directio
35. 23N Z 40 23N RJ 77 Service Manual September 2015 Secondary Boom Components 5 1 Secondary Boom How to Disassemble the Secondary Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order 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 Hydraulic Hose and Fitting Torque Specifications 1 Remove the primary boom Refer to Repair 4 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder Cap the fittings on the cylinder AWARNING 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 5 Remove the pin retaining fastener from the primary boom lift cylinder barrel end pivot pin 6 Useaslide hammer to remove the pin Remove the primary boom lift cylinder from the machine AWARN
36. 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Power to warning senders Power to oil pressure sender Power to temp sender Auxiliary Power Platform level alarm Drive Motor shift speed Forward EDC A Reverse EDC B Brake Start Start Aid glow plug or choke High Engine speed select Steer clockwise Steer counterclockwise Gasoline LPG Limit switch signal stowed RPM signal Boom retracted signal Jib Up Jib Down AC Generator Horn Output Power Enable Work Lamp Motion Lamp Auxiliary Boom Auxiliary Steer Auxiliary Platform 131 Service Manual a Schematics Color Circuit Primary Function Color WH BK 53 Boom envelope safety valve N A cutoff GR BK WH 54 Power to safety interlock YL switches engine GR WH GR BK 55 Axle oscillation GR BK RD 56 Foot switch TCON estop power GR RD WH 57 Boom down safety interlock OR RD BK 58 Safety interlock to engine RD GR WH 59 Chain break circuit RD BK GR WH 60 Axle extend BR GR 61 Axle retract RD BK OR 62 Boom stowed safety RD WH OR RD 63 Power to boom envelope safety WH BK switch WH RD OR BK 64 Power for operational switches WH BL WH 65 Low fuel indication OR BL 66 Drive Enable RD BL 67 Secondary boom not stowed BK RD 68 Primary Boom lowered WH operational BK BK 69 Primary boom 1 extended WH RD BL WH 70 Primary boom 2 retracted WH BK BL BK 71 Primary boom 2 extended OR GR 72 Secondary boom extend O
37. 4 When the display leaves SYSTEM READY mode release the drive enable toggle switch and the steer rocker switch Result The display will show FAULTS 5 Momentarily activate the steer rocker switch in the right direction until SETTINGS is shown on the display 6 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND PUMP SETTINGS is shown on the display 7 Momentarily activate the steer rocker switch in the right direction until you see the AUTHORIZATION screen 8 activate the drive enable toggle switch in the right direction to enter the authorization screen Genie 54 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 aa asa FE 10 11 12 13 14 15 Part No 119817 Using the rocker switch on the drive joystick momentarily activate steer left left right and left Result The alarm will sound Momentarily activate the steer rocker switch in the right direction until you see the DRIVE SETTINGS screen Momentarily activate the drive enable toggle switch in the right direction to enter the DRIVE SETTINGS menu Result The display will show ACCEL RAMP Momentarily activate the steer rocker switch in the right direction until you see the MAX SPEED screen Momentarily activate the drive enable toggle switch in the right direction to enter the MAX SPEED menu Create start and finish lines by marking two
38. 68 4 3 Primary Boom Lift Cylinder 2 72 4 4 Primary Boom Extension 2 T 4 5 Platform Leveling Master 2 75 Secondary Boom Components eese ennt nennen nn nnns 77 5 1 Secondary 78 5 2 Secondary Boom Lift 82 Gania BRAND Part No 119817 Z 40 23N Z 40 23N RJ xi September 2015 BZ gt gt EE FI Table of Contents Hydraulic 84 6 1 Auxiliary and Function 84 6 2 How to Remove the Function 2 2 2 42 40 0400 85 Manifolds TJE 88 7 1 Function Manifold Components s esse ee ea aaa aaa aaa aaa 88 7 2 Valve Adjustments Function Manifold 90 7 3 Jib Boom and Platform Jib Boom Rotate Manifold Components 94 7 4 Jib Boom and Platform Jib Rotate Manifold Components 95 7 5 Valve 96 Turntable Rotation 440 4 4 4 4 11313 97 8 1 Turntable Rotation Hydraulic 97 Steer Axle Components 4000 99 9 1 UD and Bearlngs ubt 99 Non steer Axle 0
39. BK 114 Load Moment Overweight 115 Load Moment Underweight WH RD 116 Hydraulic Oil Cooler OR RD 117 Flashing Beacon RD 118 Lift Speed Reduction 119 Hydraulic Pressure Sensor OR Output 120 Oil Cooler Fan BL RD 121 Axle Oscillate Left BL WH 122 Axle Oscillate Right RD WH 123 Primary Boom Angle Signal BL 124 2 Angle Signal oa Sos pp 125 Secondary Boom Lockout GR WH Extend Enable GR BK 126 Secondary Boom Lockout Riser GR Down Enable BK 127 ECU Test Switch BK 128 Low Engine Speed BK WH 129 Descent Alarm 130 Travel Alarm Gania Part No 119817 BRAND Z 40 23N Z 40 23N RJ Service Manual Schematics Circuit Primary Function 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 Motion Alarm Platform Load Input Platform Load Alarm Key Switch power Fuel Pump Power to Safety Module Propel Power P_38 Primary Boom Up Secondary Boom Down Extend P_11 30 Turntable Rotate Flow Control Safety P_39 Boom Envelope Safety Primary Boom Angle Signal Safety Secondary Boom Angle Signal Safety Drive Enable Left Drive Enable Right Calibrate Jib Bellcrank Up Flow Control Jib Bellcrank Down Flow Control Jib Bellcrank Sensor Jib Up Down Flow Control Hydraulic Generator Bypass Hydraulic EDC Output Injector Retard Jib Extend Jib Retract 133 Service Manual September 2015 a aa gt SSS EE Schematic
40. C2 10 4 Ss 5 2 4 187 WH 1 027 G16PLF OR RD FUNCTION O158JUD GR WH 3 CZE NC I I C133PLAGRAK E wi C27AUX RD 3 E CI7PRLGR ca Ci8PRR GREK pes METER cra C1615B WHAK PLATFORM orn C164PES su Cai 4 I TT L RD e AUXILIARY HIE POWER 2 OI8PRR AREK is C95 0168PLS 0 PLATFORM 4 WH RD an RIGHT PORTE P22BAT G134PWR RD Powa e LEFT RIGHT I GI86PWRYL NE JIB ROTATE O51 85 95 i 1 4 5 5 3 e TS58 I PLATFORM 2 2 C16PLF OR RD LEVEL 2658 4 cia DOWN C57 4 1 LE pi 4 JIB BOOM CE Eu Cis6JUD GRAWH e 253 4 26510 s 4 CR5 DOWN UP CSE 6 ns 5 T580 T Tr H 87 yy SECONDARY 1 6 7 8 1818 t 55 86 per DOWN UP Tos 8 GR62 1 3 R4 79 7 PRIMARY BOOM 2 1 CIE4PES RDWH 1 Re m E RETRACT EXTEND 9 2 DIODE BOARD z PRIMARY BOOM E tl eda C163PLS EXTEND RETRACT 7 5 eee LEFT I aot E 4 ele
41. Emergency Stop button in the off position at both ground and platform controls e Wheels chocked All external AC power supply disconnected from the machine e Boom in the stowed position Turntable secured with the turntable rotation lock e Welder disconnected from the machine if equipped with the weld cable to platform option Fault Codes 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 necessary tools and test equipment are available and ready for use Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Two persons will be required to safely perform some troubleshooting procedures Genie BRAND Z 40 23N Z 40 23N RJ 107 Service Manual September 2015 Control System Fault Codes Control System Fault Codes How to Retrieve Control System Fault Codes from the Platform Controls At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes 1 the key switch to platf
42. Emergency Stop button out to the on position at both the ground and platform controls 9 Activate any boom function and inspect the filter and related components to be sure that there are no leaks 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter Checklist D Procedures D 8 Inspect for Turntable Bearing Wear Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine on a firm level surface with the boom in the stowed position 1 Grease the turntable bearing Refer to Maintenance Procedure Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification Refer to Maintenance Procedure Check the Turntable Rotation Bearing Bolts 3 Startthe machine from the ground controls and raise the primary and secondary booms to full height Do not extend the primary boom Genie BRAND Z 40 23N Z 40 23N RJ 39 Part No 119817 Service Manual A NN O7
43. Manual September 2015 Checklist A Procedures A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie 18 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual A 4 Pe
44. Manual A M ZZ PO DAM Control System Fault Codes September 2015 Error Source Error Type ID Name ID Name Condition Solution 21 PRI UD JYSTK 11 Shorted high 5V Primary up down function Inspect and repair joystick wiring Primary up down 12 Value too high disabled Replace joystick Joystick 15 Value too low 16 Value at OV 17 Not calibrated Primary up down function Calibrate joystick Replace joystick disabled 22 PRI UP VALVE 12 Value too high Primary up function Check for open or short from TCON Primary boom up 15 Value too low disabled P2 5 to the up coil Replace coil valve 23 PRI DN VALVE 12 Value too high Primary down function Check for open or short from TCON Primary boom down 15 Value too low disabled P2 6 to the down coil Replace coil valve 25 PRILER_JYSTK 11 Shorted high 5V Primary extend retract Inspect and repair joystick wiring Primary boom 12 Value too high function disabled Replace joystick extend retract 15 Value too low RENE 16 Value at OV 17 Not calibrated Primary extend retract Calibrate joystick Replace joystick function disabled 26 PRI_EX_VALVE 12 Value too high Primary extend function Check for open or short from TCON Primary boom 15 Value too low disabled P2 3 to the extend coil Replace extend valve coil 27 PRI_RT_VALVE 12 Value too high Primary retract function Check for open o
45. Platform Level Up Platform Rotate Flow Control PRC Platform Rotate Control PRL Platform Rotate Left CCW PRR Platform Rotate Right CW PTA Platform Tilt Alarm PTS Platform Tilt Sensor PCE Pressure Comp Enable PSR Pressure Sender 128 Suffix PS PBS PBD PBL PBE PER PBR PBU PBF PLS PES PEL PSL PL PWR PSL PSE JPL PLL PRV PXS REC RCV RL RET REV RF RFS RR RRS Genie Z 40 23N Z 40 23N RJ September 2015 Definition Pressure Switches Primary Boom Angle Sensor Primary Boom Down Primary Boom Extend Retract Lockout Valve Primary Boom Extend Primary Boom Extend Retract Flow Control Primary Boom Retract Primary Boom Up Primary Boom Up Down Flow Control Primary Boom Extend Retract Signal Primary Boom Up Down Signal Primary Extend Retract Lockout Primary Length Sensor Primary Lockout Power Power to Length Sensor Program Set up Enable Propel Signal Propel Lockout Proportional Valve Proximity Sensor Receptacle Recovery Retract Lockout Return Reverse Right Front Right Front Steer Sensor Right Rear Right Rear Steer Sensor Part No 119817 September 2015 Service Manual a Schematics Suffix Definition RPM RPM SBS Sec Boom Angle Sensor SBL Sec Boom Elevated SBD Sec Boom Down SBE Sec Boom Extend SER Sec Boom Extend Retract Flow Control SBR Sec Boom Retract SBU Sec Boom Up SUD Sec Boom Up Down Flow Control SB Secondary Boom SLE Secondary
46. Procedure How to Calibrate the Platform Overload System if equipped 16 Result All ground control functions should not operate Using auxiliary power test all machine functions from the ground controls Result All ground control functions should operate normally Note OVERLOAD RECOVERY will be displayed at the platform control box LCD display Part No 119817 Genie BRAND Z 40 23N Z 40 23N RJ Using a suitable lifting device remove the remaining test weights from the platform 33 Service Manual September 2015 Checklist D Procedures D 1 Check the Boom Wear Pads Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions 1 Measure each wear pad Replace the wear pad once it reaches the minimum allowable thickness If the wear pad is still within specification shim as necessary to obtain minimum clearance with zero binding 2 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Note Always
47. September 2015 Service Manual Checklist E Procedures 18 Rinse out the inside of the tank using a mild E 2 SPIEL Grease the Steer Axle Wheel 19 Install the suction strainers using pipe thread Bearings sealant on the threads 20 Install the drain plug using pipe thread sealant on the threads Genie specifications require that this procedure be 21 Install the hydraulic tank onto the machine performed every 2000 hours or every two years 22 Install the ground control box and mounting whichever comes first fasteners Perform this procedure more often if dusty 23 Install the two suction hoses return filter hose conditions exist drive motor case drain filter hose and the ER supply hoses for the auxiliary power units Maintaining the steer axle wheel bearings is essential for safe machine operation and service 24 Install the turntable cover life Operating the machine with loose or worn 25 Fill the tank with hydraulic until the level is Wheel bearings may cause an unsafe operating within the top 2 inches 5 cm of the sight condition and continued use may result in gauge Do not overfill Refer to Specifications component damage Extremely Wet or dirty Machine Specifications conditions or regular steam cleaning and pressure washing of the machine may require that this 26 Open the two hydraulic tank shut off valves at procedure be performed more often the hydraulic tank Loosen the wheel lug nuts Do not remove 27 Clean any oi
48. Symbol Legand ee 140 Hydraulic Symbols 141 Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ xiii September 2015 BZ gt gt EE FI Table of Contents Electrical Schematics 143 Electrical Schematic 144 Electrical Schematic Ground 145 Electrical Schematic Platform Controls 148 Ground Control Box Wiring Diagram 149 Platform Control Box Wiring 152 Platform Control Box Wiring Diagram Options 153 Hydraulic ARERR ESY 155 Hydraulic Schematic Aa Aa Wea d 156 Genie xiv Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Specifications Machine Specifications Fluid capacities Tires and wheels Front Rear Hydraulic tank 8 gallons Tire size 22 7 17 75 25 6x7x22in 30 3 liters solid rubber 56 x 17 8 x 45 cm 56x 17 8 x Hydraulic system 10 gallons 45 cm including tank 37 9 liters Overall tire diameter 22in 25 6in Drive hubs 23 oz 55 9 cm 65 cm 0 68 liter Wheel diameter 18 4 in 22 in Drive hub oil type EP 80 90W gear oil 46 7 cm 56 cm API service classificat
49. Ultra duty grease EP NLGI 1 lithium based or equivalent Genie BRAND Z 40 23N Z 40 23N RJ 19 Part No 119817 Service Manual September 2015 Checklist B Procedures B 1 Inspect the Battery Genie specifications require that this procedure be 4 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables performed every 250 hours or quarterly whichever comes first 6 Proper battery condition is essential to good engine and machine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine and component damage and hazardous conditions 7 8 Electrocution burn hazard AWARNING Contact with electrically charged circuits could result in death or serious injury Remove all rings 9 watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Disconnect each battery pack from the machine 2 Release the battery pack latch and rotate the battery pack out and away from the chassis 3 Remove the cover from each battery box 10 11 Genie Be sure that the battery retainers and cable connections are tight Fully charge the batteries Allow the batteries to rest 24 hou
50. a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications Genie 26 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Checklist B Procedures B 10 5 Lower the boom to the stowed position and Test the Drive Speed Raised or extend the boom 1 foot 30 cm Extended Position 6 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 7 Bringthe machine to top drive speed before Genie specifications require that this procedure be reaching the start line Begin timing when your performed every 250 hours or quarterly whichever reference point on the machine crosses the comes first start line Proper drive functions are essential to safe 8 Continue at full speed and note the time when machine operation The drive function should the machine reference point crosses the finish respond quickly and smoothly to operator control line Refer to Specifications Performance Drive performance should also be free of hesitation Specifications jerking and unusual noise over the entire proportionally controlled speed range Note Se
51. allow oil to squirt or spray 5 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin Do not remove the pin 6 Remove the external snap rings from the slave cylinder barrel end pivot pin Do not remove the pin 7 Place a block of wood under the barrel of the slave cylinder for support Protect the cylinder rod from damage 8 Use a soft metal drift to remove the rod end pivot pin AWARNING Crushing hazard The platform could fall if not properly supported Component damage hazard The slave cylinder rod may become damaged if it is allowed to fall if not properly supported by the lifting device 9 Use a soft metal drift to remove the barrel end pivot pin 10 Carefully pull the cylinder with hydraulic hoses out of the boom Genie 56 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 A ZA A ALE How to Bleed the Slave Cylinder 1 Part No 119817 Raise the primary boom to a horizontal position Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Service Manual Platform Components 2 2 Platform Rotator How to Bleed the Platform Rotator Note This procedure will require two people 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right and then to the left through two pla
52. code screen momentarily activate the drive enable toggle switch to the left direction until FAULTS is shown on the display To exit programming mode 15 Push in the red Emergency Stop button at the platform controls Wait approximately 5 seconds and then pull out the red Emergency Stop button out to the on position Genie 108 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Control System Fault Codes How to Retrieve Control System 8 Usethe fault code table on the following pages Fault Codes from the Ground to aid in troubleshooting the machine by Control pinpointing the area or component affected nir 9 Note Only control system fault codes be 1 the key switch to platform control retrieved from TCON Motor controller fault codes can only be retrieved by following the procedure 2 Pull out the red Emergency Stop button to the using the platform controls See How to Retrieve on position at both the ground and platform Control System Fault Codes from the Platform controls Controls Open the ground controls side turntable cover 4 Locate the turntable control module TCON underneath the ground control box 5 Visually inspect the flashing green and red LEDs on the controller O m bul Note The LED indicates the source of the error R 2 and the green LED indicates the error type 6 Determine the error sour
53. display will show ACCEL RAMP 13 Momentarily activate the steer rocker switch in 20 the right direction until you see the CALIBRATE CENTER screen 14 Momentarily activate the drive enable toggle 21 switch in the right direction to enter the CALIBRATE CENTER screen Result The display will show NO 15 Momentarily activate the steer rocker switch in the right direction Result The display will show YES 16 Momentarily activate the drive enable toggle 23 switch in the right direction to save the setting Result The alarm should sound indicating the 24 setting has been saved 17 Momentarily activate the steer rocker switch in the right direction until you see the CALIBRATE RIGHT screen 18 Adjust the steer wheels fully in the right direction Genie Part No 119817 BRAND Z 40 23N Z 40 23N RJ Steer Axle Components Momentarily activate the drive enable toggle switch in the right direction to enter the CALIBRATE RIGHT screen Result The display will show NO Momentarily activate the steer rocker switch in the right direction Result The display will show YES Momentarily activate the drive enable toggle switch in the right direction to save the setting Result The alarm should sound indicating the setting has been saved Momentarily activate the steer rocker switch in the right direction until you see the CALIBRATE LEFT screen Adjust the steer wheels fully in the left direction
54. 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 Genie Part No 119817 Z 40 23N Z 40 23N RJ 63 Service Manual AE PERI Jib Boom Components How to Bleed the Jib Boom Rotator Note This procedure will require two people 1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Connect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Open the top bleed valve but do not remove it 1 top bleed valve 2 clear hose 3 container 4 bottom bleed valve Move and hold the function enable toggle switch to either side and move and hold the jib boom rotate toggle switch to the right for approximately 5 seconds then release it Repeat three times AWARNING Crushing hazard Keep hands 64 and head clear of the boom during rotation Genie Z 40 23N Z 40 23N RJ September 2015 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 Fully rotate the jib boom to the left and continue holding the jib boom rotate toggle switch until air stops c
55. functions disabled overcharged exceeds 65V DC with excessive braking Batteries undercharged below 11V DC with load Replace right master AC motor controller 15 Value too low Slow functions Battery Charge or replace batteries charge less than 10 12 PR5 COIL 15 Value too low All functions disabled Check for short to main contactor Check diode on main contactor Replace main contactor Replace right master motor controller 13 5 CONTACT Main contactor 12 Value too high 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 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 14 RELIEF_VALVE 12 22 Value too high Fault Auxiliary functions only No primary or secondary up Check for open at proportional relief valve wh rd wire Replace coil Check for short to proportional relief valve Replace coil 110 Genie Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual iR aa RAND Control System Fault Codes Error Source Error Type ID Name ID Name Condition Solution 15 FOOTSWITCH 22 Fault All functions disabled Check for power into foot switch Che
56. jib AE boom lift cylinder hang down A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and 7 Remove the pin retaining fastener from the jib burn skin Loosen hydraulic boom lift cylinder barrel end pivot pin 2 4 8 Use a soft metal drift to remove the platform D Sot allow A rotator pivot pin and remove the platform AE rotator from the machine squirt or spray Crushing hazard The jib boom Note When removing a hose assembly or fitting AWARNING could el when the nie the O ring if equipped on the fitting and or hose removed if not properly end must be replaced All connections must be supported by the overhead torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 9 Remove the retaining fasteners from the 1 Remove the platform and the platform jib pad i cylinder rod end pivot pin Do not mounting weldment me pin 2 Support the platform rotator with a suitable 1 ar n x 4 aimar lifting device e jib boom cylinder rod end pivot pin 3 Tag disconnect and plug the platform rotator 11 PE all hose and cable clamps from the jib hydraulic hoses Cap the fittings on the com rotator Remove the platform Remove the 12 Tag disconnect and plug the jib boom lift platform mounting weldment and the platform cylinder hydraulic hoses Cap the fittings on rotator Refer to Repair Procedure How to the jib boom lift cyl
57. lbs lubricated 126 Nm Drive motor and hubs Drive hub mounting bolts lubricated 180 ft lbs 244 Nm Drive motor mounting bolts lubricated 5 ft lbs 6 8 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation o 6 7 40 23 Z 40 23N RJ Part No 119817 September 2015 Service Manual Specifications 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 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 a jam nut
58. lifting device erang 39 Use a soft metal drift to remove the upper 41 Remove the hose and cable cover and clamps A WARNING A WARNING Part No 119817 compression link pivot pin from the number 2 arm Remove the compression link from the machine Crushing hazard The number 2 arm could fall when the compression link is disconnected from the number 2 arm if not properly supported by the overhead crane Crushing hazard The compression link may fall if not properly supported when removed from the secondary boom assembly 42 43 Genie BRAND Z 40 23N Z 40 23N RJ 81 from the number 3 arm Remove the secondary boom drive speed limit switch mounting fasteners from the number 4 arm at the mid pivot end Do not disconnect the wiring Pull all of the cables and hoses from the number 3 arm and lay them over the turntable counterweight Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Remove the mounting fasteners from the cover located in the boom storage area to access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable pivot Service Manual September 2015 Secondary Boom Components 45 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
59. light should be flashing at both the ground and platform controls Note There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds 10 Test all machine functions from the platform controls Result All platform control functions should not operate 11 Turn the key switch to ground control 12 Testall 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 Genie BRAND Z 40 23N Z 40 23N RJ 59 Part No 119817 Service Manual September 2015 Platform Components 2 4 5 Platform Overload Recovery Message software 1256908A and later 6 If the platform controls LCD screen displays OVERLOAD RECOVERY the emergency lowering system has been used while the platform was overloaded 7 How to Clear the Platform Overload Recovery Message 8 Note This message shall be cleared by a person trained and qualified on the troubleshooting and repair of this machine Note Use the following chart to identify the 9 description of each LCD screen control button used in this procedure 1 the key switch to platform control 2 Pull out the red Emergency Stop button to the on position at both the ground and platform X controls Do not press down on the foot switch 10 4 Move and hold the drive enable toggle switc
60. maintain squareness between the outer and inner boom tubes D 2 Check the Turntable Rotation Bearing Bolts Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the secondary boom and place a safety chock on the lift cylinder rods Carefully lower the boom onto the lift cylinder safety chock AWARNING Crushing hazard Keep hands away from the cylinder and all moving parts when lowering the boom Note The lift cylinder safety chock is available through Genie After Market Support Genie part number 33484 2 Remove the center turntable cover fasteners Remove the cover from the machine Primary boom wear pad specifications Minimum Top and side wear pads 5 8 inch platform end of boom 15 9 mm Bottom wear pad 3 8 inch platform end of boom 9 5 mm Top bottom and side wear pads 3 8 inch pivot end of boom 9 5 mm 34 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 3 Confirm that each turntable mounting bolt is torqued in sequence to specification Refer to Specifications Machine Torque Specifications Bolt torque sequence 4 Install the center turntable cover 5 Remove the lift cylinder safety chock and lower
61. needed for high flow functions September 2015 Low flow functions 19 20 21 Momentarily activate one of the low flow functions full stroke Result The display will show the function direction and milliamps 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 function to complete a full cycle i e jib up Compare the machine function time with the function times listed Refer to Specifications Performance Specifications Determine whether the function time needs to increase or decrease To adjust a function speed release the foot switch Momentarily move the steer rocker switch in the right direction to increase or momentarily in the left direction to decrease Note Each time the steer rocker switch is momentarily pressed the time will change in 5 to 10mA increments 23 24 When function times have 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 Repeat steps 19 through 23 as needed for low flow functions To exit programming mode 25 Genie Z 40 23N Z 40 23N RJ Move and hold the drive enable toggle switch in the left direction until the display screen returns to SYSTEM READY Part No 119817 September 2015 Service Manual How to Adjust the Function Ramp Up Time
62. oy fo 1 O e RD Te Ts10 14 7 DRIVE SECONDARY JIB BOOM INVERTER PLATFORM uaHrs_ g BOOM OPTION OVERLOAD YONNE GEE LED ollo FD o 35 5 2 9 ovo e BNS TS TS7 148 2 HORN WORK LIGHT PLATF RM PLATF RM JIB ROTATE AUXILIARY TILT ALARM EMERGENCY STOP LEVEL ROTATE POWER LED 4 B Ganie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 153 Service Manual September 2015 FE Z Z WERKE Platform Control Box Wiring Diagram Options 154 September 2015 Service Manual Hydraulic Schematic 155 Service Manual September 2015 ha gt gt gt Hydraulic Schematic
63. relief valve cap Result The relief pressure meets specification Continue to step 7 Result The relief pressure does not meet specification Repeat this procedure beginning with step 3 AWARNING hazard Do not adjust 7 Genie BRAND Z 40 23N Z 40 23N RJ 93 the relief valve higher than specified Turn the machine off Remove the pressure gauge and install the proportional relief valve coil Service Manual September 2015 Manifolds 7 3 Jib Boom Platform Rotate Manifold Components Z 40 23N The jib boom platform rotate manifold is mounted to the jib boom Index Schematic No Description Function Torque Coil nut 4 5 ft lbs 5 7 Nm 1 Proportional solenoid valve AA Jib boom up down 18 20 ft lbs 25 27 Nm 3 position 4 way 2 Proportional solenoid valve AB Platform rotate 18 20 ft lbs 25 27 Nm 3 position 4 way AB e lt gt 94 Genie Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual aa asa 1 Manifolds 7 4 Jib Boom and Platform Jib Rotate Manifold Components Z 40 23N RJ The jib boom platform rotate manifold is mounted to the jib boom i Description Function Torque Coil nut 4 5 ft lbs 5 7 Nm 1 Proportional solenoid valve 3 position AA Jib boom up down 18 20 ft lbs 25 27 Nm 4 way 2 Propor
64. stands for Primary Lockout S 62 BST This is the circuit that communicates to the onboard computers of the machine that the boom is fully stowed S stands for safety 62 is the number of the circuit for boom stowed and BST stands for Boom Stowed P 48 LP P stands for power 48 is the circuit number for work lamps and LP stands for Lamp R 48 LP R stands for relay In this case it is the wire that feeds the relay coil for the work lamp All other numbers remain the same V61AXR V stands for valve power Number 61 stands for axle retracted circuit AXR stands for Axle retracted R46HN R stands for Relay output supplying power to the horn HN Number 46 is the circuit number for the horn Circuit prefix Control Data Engine Gauges Neutral Power Relay Output Safety OW U ZO MOUOOA Valve Genie 126 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 a Suffix GEN AF ANG ABV AFV AH APV ARV ASV AXE AXO AFP RAP BAT BEX BST BRK BV CAL CAN SHD CAT CNK DTH DTL DCN DE DEL DER Definition AC Generator Alternator Field Angle Auxiliary Boom Valve Auxiliary Forward Valve Auxiliary Hydraulic Pump Auxiliary Platform Valve Auxiliary Reverse Valve Auxiliary Steer Drive Valve Axle Extend Valve Axle Oscillate Axle Retract Valve Axle Front Position Axle Rear Position Battery Boom Extended Boom Stowed Brake Bypass Valves Calibrate CAN Signal
65. supported by the overhead crane Attach a lifting strap from an overhead crane to the upper pivot Using the overhead crane attached to the upper pivot raise the secondary boom assembly approximately 30 inches 76 cm Insert a 4 x4 x 11 inch 10 x 10 x 28 cm block between the number 2 arm and the boom rest Lower the secondary boom assembly onto the block Crushing hazard The secondary boom assembly could fall if not properly supported by the4 x 4 x 11 inch 10 x 10 x 28 cm block Service Manual September 2015 Secondary Boom Components 23 Pull all of the cables and hoses out through the upper pivot 30 Lower the number 2 arm onto the boom rest pad Component damage hazard 31 Insert a 4 x 4 x 81 2 inch 10 x 10 x 22 Cables and hoses can be block between the number 3 arm and the p if they are kinked or number 4 arm at the mid pivot end pinched 32 Attach a lifting strap from the overhead crane 24 Remove the hose and cable cover and clamps to the mid pivot for support Do not apply any from the top of the number 2 arm lifting pressure 25 Pull all of the hoses and cables out of the 33 Remove the pin retaining fasteners from the upper pivot and out through the mid pivot Lay number 2 3 and 4 arm pivot pins at the the hoses and cables on the ground mid pivot Do not remove the pins Component damage hazard 34 Use a soft metal drift to drive each pin out Cables and hoses can be Remove the mid pivot fro
66. the jib boom lift cylinder rod end pivot pin Do not remove the pin Genie Part No 119817 BRAND Z 40 23N Z 40 23N RJ 65 Service Manual September 2015 Primary Boom Components 4 1 6 disconnect and plug the hydraulic hoses from ports P and T at the jib boom platform Cable Track rotate manifold Cap the fittings on the The primary boom cable track guides the cables manod and hoses running up the boom It can be repaired AWARNING Bodily injury hazard Spraying link by link without removing the cables and hoses hydraulic oil can penetrate and that run through it Removing the entire primary burn skin Loosen hydraulic boom cable track is only necessary when connections very slowly to allow performing major repairs that involve removing the the oil pressure to dissipate primary boom gradually Do not allow oil to squirt or spray How to Remove the Cable Track 7 Tag and disconnect the hydraulic hoses from Note When removing a hose assembly or fitting the platform leveling slave cylinder at the the O ring if equipped on the fitting and or hose union and connect them together using a end must be replaced All connections must be connector Connect the hoses from the torqued to specification during installation Refer to cylinder together using a connector Specifications Hydraulic Hose and Fitting Torque EE Specifications AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and
67. the boom to the stowed position 6 Remove the drive chassis covers from both ends of the machine Checklist D Procedures Check to be sure that each bearing mounting bolt under the drive chassis is torqued in sequence to specification Refer to Specifications Machine Torque Specifications Bolt torque sequence Z 40 23N Z 40 23N RJ 35 Part No 119817 Service Manual September 2015 Checklist D Procedures D 3 Check the Axle Mounting Bolts Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque of the steer axle mounting bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Remove the drive chassis covers from both ends of the drive chassis 2 Locate the eight axle mounting bolts on each axle Torque the bolts to specification Refer to Specifications Machine Torque Specifications D 4 Check the Platform Rotation Mounting Bolts Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque of the platform rotation mounting bolts and jib boom rotation mounting bolts Z 40 23N RJ is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Check the torque of the fasteners at the plat
68. the primary boom drive speed limit 16 Place support blocks under the primary boom switch mounting fasteners and move the limit lift cylinder switch out of the way Do not disconnect the 21 wiring 17 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin 9 Locate the primary extension boom drive Use a soft metal drift to remove the pin speed limit switch inside the extension boom AWARNING Crushing hazard The boom lift 10 Remove the primary extension boom drive cylinder and primary boom will speed limit switch mounting fasteners Do not fall if not properly supported disconnect the wiring 11 Pull the limit switch and the wiring out of the Lower Hio OSMO the primary BOO extension tube and move it out of the way cylinder onto support blocks Protect the cylinder rod from damage 12 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the 19 Remove the retaining fasteners fromthe fittings on the cylinder porary Boon pivot pin E 20 Remove the primary boom pivot pin with a soft AWARNING hazard Spraying metal drift Carefully remove the primary boom n I from the machine and place it a structure RE RRR RPO capable of supporting it connections very slowly to allow the oil pressure to dissipate Bodily injury hazard Spraying gradually Do not allow oil to AWARNING hydraulic oil can penetrate and squirt or spray burn skin Loosen
69. 0 replace the coil Valve Coil Resistance Specification 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 Specification Description Specification Proportional solenoid valve 3 position 4 way 240 20 DC schematic items AA BG BK BN BS BU Solenoid valve 20V DC schematic item BG 240 Proportional solenoid relief valve 20V DC 220 schematic item BW Genie 96 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Turntable Rotation Components 8 1 Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly 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 Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom until the upper pivot is above the turntable covers Turn the machine off 2 Secure the turntable from rotating with the turntable rotation lock pin A WARNING Crushing hazard The turntable 4 rotation assembly could become unbalanced and fall when
70. 1 F 63 C Maximum continuous operating 189 F 87 C temperature Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Ganie 4 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Hydraulic Component Specifications Manifold Component Specifications Specifications Function pump Plug torque Type Fixed displacement gear pump SAE No 2 36 in lbs 4 Nm Displacement 0 244 cu in SAE No 4 10 ft lbs 13 Nm 465 No 6 14 ft lbs 19 Nm High pressure filter Beta 32200 with 101 psi SAE No 8 38 ft lbs 51 Nm 7 bar bypass SAE No 10 41 ft lbs 55 Nm Function manifold SAE No 12 56 ft lbs 76 Nm Proportional relief pressure variable 50 to 3000 psi 3 4 to 207 bar Primary boom down relief valve 2100 psi pressure 145 bar Platform level relief valve pressure 2500 psi 172 bar Platform level flow regulator 1800 psi 124 bar Turntable rotate relief pressure 0 6 2 27 L min Auxiliary pump Type Fixed displacement gear pump Displacement 0 5 gpm 1 9 L min Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Valve Coil Resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensiti
71. 2 120 162 105 142 gig 12 80 1084 110 149 120 162 150 203 130 16 18 90 122 120 162 130 176 170 230 140 189 ss LM 149 150 203 160 217 210 284 18 24 18 130 176 170 230 180 244 240 325 200 271 110 200 271 270 280 379 380 515 320 433 16 220 298 300 406 310 420 420 569 350 474 9 320 43 430 583 450 610 610 827 50 61 14 350 474 470 637 500 678 670 908 560 759 8 480 650 640 867 680 922 910 1233 770 1044 o 12 530 718 710 962 750 1016 990 1342 840 1139 11 7 590 800 790 1071 970 1315 1290 1749 1090 1477 12 670 908 890 1206 1080 1464 1440 1952 12290 1654 1 12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 8 981 1950 2648 2370 1160 4284 2670 2 12 1640 2223 2190 3000 FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 10 9 Class 12 9 23 c w 9 d d c w i 9 w i i d gt o No e W R mM ln l lt Njoj io o1 co gt gt _ s eie UE IND
72. 24 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual B 6 Test the Ground Control Override Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the red Emergency Stop button at the platform controls to the off position 2 Turn the key switch to ground controls and pull out the red Emergency Stop button to the ON position 3 Operate each boom function through a partial cycle at the ground controls Result All boom functions should operate Checklist B Procedures B 7 Test the Platform Self leveling Note Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained level by the platform leveling slave cylinder which is controlled by the platform leveling master cylinder located at the base of
73. 350 PLATFORM ROTATE LEFT T8 STEER JOYSTICK 28 11 C1668TG BLAWH WH RD gt 63510 JIB R TATE RIGHT T TURNTABLE ROTATE 09812 CIGSTRS WARD G182 PL WHBK C3ETI JIB ROTATE LEFT P2aBAT WH C36 12 PLATFORM EMERGENCY STOP JIB UP DN 28 1 C158JUD GRWH 1 RD gt 13 KEY SWITCH DRIVE JOYSTICK 6232 lt G160JPLWHRD 6954 DRIVE ENABLE LED PLAT ROTLEFT VALVE lt V17PRL GR G188PLA GR BK 8515 PLATFORM OVERLOAD LED OPTION PLAT ROT RIGHT VALVE 6284 lt VI amp PRR GR BK O28TTA 53516 TILT ALARM LED JIR UP VALVE 0296 lt Va3JU GR 264617 SPARE 4 JIB DOWN VALVE 024 lt V44UD GREK 203616 SPARE JIB ROT RIGHT VALVE 0287 lt VI98JAR WH RD 4 Panat wH C358 LODHEATER JIB ROT LEFT VALVE 5288 lt VIS2URL WHBK 703 SPARE ALARM 0295 O130TA WHAD SPARE 029 10 lt D amp 20ANeYL 56341 CAN BATTERY 29 11 E Ci84PWR Rb D81CAN GR C342 CAN BATTERY 62512 lt CIS4PWRRD Scs SPARE PCON CONTROL MODULE Soma SPARE Sess SPARE 4 Poss SPARE 5 CAT SPARE gt 4 8 SPARE 20949 SPARE WORKLIGHTS 20910 SPARE SPARE s CS412 SPARE E VGON DISPLAY MODULE ee INVERTER 1848 9 DRIVE 6 BE a F 2 Pi SEE 9 EE LER cgi e Ge 1 gt gt gt gt gt g
74. 3804 12 VOSPBR RETRACT HV Y Pasage ji lt B gt _weao eseiaww p 94 vis ES 5 a TI LA FLASHING 51 212 15 vertp ROK Cice PRIDN Hv 1 FUSE pp LEFT AC MOTOR CONTROLLER ANA EN CA lt gt vussu BL 5 7 EG UP HY 7 B X eee gt r cu lt gt visen Bak SEIZE SECON HY mrewren SOR I li _ lt gt voral wH SERB I RU Sim xm L z gt Lysa VosTRR WHBK CCWHV 3 e me R 1 c NC 1 SENSOR DAVE I H S s a0 ENABLE we M RD C134PWH 2014 12 BATT POWERI SERVICE 1 HORN 154 f i PRIMARY BOOM PRIMARY BOOM SECONDARY BOOM LMT SWITCH m m I I 1 I GND Le Genie BRAND 144 Z 40 23N Z 40 23N RJ Part No 119817 LABEL DESCRIPTION CIRCUIT BREAKER 24V DC CONTROLS CIRCUIT BREAKER 48V DC MASTER CRS HORN RELAY GR60 BRAKE RELAY CR61 KEYSWITCH RELAY CR62 PLATFORM EMERGENCY STOP RELAY Pi GROUND CONTROLS EMERGENCY STOP BUTTON KS1 KEYSWITCH G47FE WHBK P182BAT RD 181 OR P109PWR GR WH C182JR WHBK DB1CAN GR D82CAN YL C22P
75. 42 TT_CW_VALVE 12 Value too high Turntable rotate Check for open or short from TCON Turntable rotate 15 Value too low clockwise function P2 9 to the turntable CW coil clockwise valve disabled Replace coil 43 TT_CCW_VALVE 12 Value too high Turntable rotate Check for open or short from TCON Turntable rotate 15 Value too low counterclockwise P2 9 to the turntable CCW coil counter clockwise function disabled Replace coil 46 PROT CW VALV 12 Value too high Platform rotate clockwise Check for open or short from PCON Platform rotate 15 Value too low function disabled P2 3 to the platform rotate CW coil clockwise valve Replace coil 47 PROT CCW 12 Value too high Platform rotate Check for open or short from PCON Platform rotate 15 Value too low counterclockwise P2 4 to the platform rotate CCW coil Replace coil Part No 119817 Genie BRAND Z 40 23N Z 40 23N RJ 113 Service Manual September 2015 Am gt gt gt O Control System Fault Codes Error Source Error Type ID Name ID Name Condition Solution 51 DRIVE JYSTK 11 Shorted high 5V Drive function disabled Inspect and repair joystick wiring Drive joystick 12 Value too high Replace joystick 15 Value too low 16 Value at OV 17 Not calibrated Drive function disabled Calibrate joystick Replace joystick 52 AC R MOTOR 12 Value too high Drive function disabled Do no
76. 44 120410521 103 1021 Drive MOtOIS ete l denn aida 103 10 2 rrr tea 104 Motor Controllers nei o AE PEEP OE AGR 106 11 1 Motor Controllers esa A 106 Genie xii Z 40 23N Z 40 23N RJ Part No 119817 September 2015 no Ewy nn A Z i A O Table of Contents 107 Control System Fault Codes 108 How to Retrieve Control System Fault Codes from the Platform Controls 108 How to Retrieve Control System Fault Codes from the Ground Controls 109 Control System Fault Codes sse eene nennen 110 Motor Controller Fault 4 120 Motor Controller Fault 120 Drive Motor Thermal 123 Section 6 SchematiCS 125 INtPOGUCTION MM 125 Wire Circuit Legend eicere tete ege ident ee act ce eade 126 Wiring Coloring and nennen 130 Power Cable 135 Motor Contoller Pin 136 Ground Control Box Pin 137 Platform Control Box Pin 138 Turntable and Platform Controller Pin 139 Electrical
77. 5 222 2222 Primary Boom Components 2 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 Attach 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 AWARNING 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 rod end pivot pin and twist to remove the pin 7 Remove the master cylinder from the machine A WARNING Crushing hazard The master cylinder could become unbalanced and fall if not properly attached to the overhead crane Gri ________________ 76 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Secondary Boom Components O 0 Secondary Boom components 6 lower compression arm 1 upper pivot 7 turntable pivot 2 upper compression arm 8 counterweight Z 30N Z 30N RJ 3 mid pivot 9 upper secondary boom 4 compression link 5 lower secondary boom Genie BRAND Part No 119817 Z 40
78. 6 R46HRN WH 5 082 YL 5 D82CAN 5 V14PLUA OR GR WH 6 D81CAN GR YL 7 SPARE Be GREG 6 D81CAN 7 C T6PLF ORRD 8 p40gpwn NEEDS OR BK GR 8 C197RET WH GR WH 8 C46HRN BK 7 V15PLDB 192 9 D82CAN YL 9 _ DB2CAN YL OR BK WH BK 10 D81CAN GR 10 D81CAN GR on 8 V14PLUB OR 8 P109PWR Rh 11 R174PWR WH 11 C164PES RDWH 4 pisiow BL vsrsoos i 12 C130TA WH RD 12 C161SB WH BK 9 C184PSE OR 11 GND BL BK ki 10 P181BAT OR 12 SPARE 11 182 RD WH RD 12 CATFE WH BK 12 C134PWR RD Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 137 Service Manual September 2015 Platform Control Box Pin Legend E 000000 27 C31 Pin Numbering for 4 Pin Connector C31 1 P23BAT WH 2 C56FTS RD 138 O O R ND 2 a N O Pin Numbering for 12 Pin Connector C27 SPARE SPARE V17PRL GR V18PRR GR BK V43JU GR V44JD GR BK V193JRR WH RD V192JRL WH BK GND BR C134PWR S132LDS BL WH C175LDS WH BK Genie BRAND Z 40 23N Z 40 23N RJ 4 O O AR gt N NM NO ND m m m m m d d R 0 AR ND Pin Numbering for 24 Pin Connector C25 P23BAT WH P22BAT BKD
79. ALGR GIELIUD z RIHPWRWH pere j 2 GROUND BR ZGIET aT BA CisSPLAGRAM CIMPWRRO DCIS2 BATT Valva CZ7AUX AD D 55183 GAN 1 No Description G16PLF OR RD vs STEER LEFT l DBICAN GAN G187RET WH M4 BTEERRIGHT ciems mwm PRIECTRETTE yig G180TA cols GPBD 90 6446 PRI DNA PETLA 429 PLATFORMLEVEL UP ZA oie 5GI87 sEopownis PRIMARY BOOM UP n 7 Ba P1OBEWR GROW SC Bu e lisia Ji Baz ss oer sems anona j URE RET 6 I i f TEHE 8 32 ME tHe BER C185TRS WH RD SGI81O En SECONDARY BOOM DOWN BE y A hae as B 828 Bis Beg 8 4 ADAWH gt G1S 11 PRI UP DN T 64 SECONDARY BOOM kr BRE 8 558688 58 88 585 GRO 5018181 secupnurs l Y EXTEND Yan BOOM RETRACT 142 ahhh dow WTN cies fse diigo ERE catneuon SETET puue BIS IBS IS IB 18 815 815 8 58 8181881818 eum Sow rib suis og ZEbPE PQ eeZZER AP 2 lt GE FEL aes Lig cheatin ep sorene Seas en een Z 2 FERH 5 E u pun
80. BPWA GRAWH a SECONDARY 3 BOOM O BOOM t C342 C1618B WHK RD Q TURNTABLE 626 CAB amp IUD GRIWH ACTA 42 11 CI96PWR YL 3 4 084 ClesTRS WH RB 1868 4BV DC MASTER 15A FUNCTION 7369 emi tl PLATFORM PLATFORM C47FE WHIBK 24V DC CONTROLS 15A ey LEVE ROTATE ALARM 194PWR RD C1 12 G47FE WHBK P181PWR OR 01 10 P1BIBAT P182BAT RD 027 C16PLF OR AD cre P1OOPWR GRAWH 622 CI7PRLGR 327 C134PWR RD C18PRR GR BK R195PWR OR RD Ri81PWR OR 5132105 BL WH 22PWR BK D82CAN YL D41GAN GR C182JR WH BK P109PWR GR WH C184PBE OR P1B1BAT OR P182BAT RD CATFE WH BK C1APRR C17PRLGR C27AUX RD C133PLA GR BK 2 WH RD G156JUD GR WH C18PLF OR RD C187RETWH D82CAN YL D81CAN GR R174PWR WH WHRD P23BAT WH 22 BK GND BR C134PWA RD DB CAN YL D81GAN GR C27AUX RD C46HRN WH 8132115 BLAWH P181BATOR GND BR SPARE OR Ci34PWR RD C47FE WH BK C165TRS WH RD C168PLS WH P109PWR GR WH D82CAN YL D amp 1CAN GR C164PES RDAWH 6168158 WH BK
81. Boom Lockout Valve extend SLD Secondary Boom Lockout Valve riser down SP Spare SS Speed Sensor SA Start Aid Glow Plug or choke STR Starter STC Steer Control Signal SCW Steering Valve CW SCC Steering Valve CCW TSR Temp Sender TS Temp Switches TET Tether TAX Tilt Alarm X axis TAY Tilt Alarm Y axis TCN Ground Control Panel TRF Turntable Rotate Flow Control TRR Turntable Rotate Right CW TTA Turntable Tilt Alarm TTS Turntable Tilt Sensor TSW Test Switch Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 129 Service Manual September 2015 Schematics Wire Coloring Power Circuits 1 All cylinder extension colors are solid and all P10 retract functions are striped black When using P11 black wire the stripe shall be white P30 2 All rotations that are LEFT or CW are solid RIGHT or CCW are striped and black When P38 the wire is black the stripe is white P39 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 130 Genie Z 40 23N Z 40 23N RJ Primary boom extend valve Primary boom up valve Secondary boom down and extend valves Propel
82. C156JUD GR WH C17PRL GR C18PRR GR BK SPARE OUT C32RET WH RD SPARE DIG IN Genie BRAND Z 40 23N Z 40 23N RJ Right Motor Controller Master R195PWR OR RD C32BRK WH RD R181PWR OR R32RET BK P110RET BK C184PSE OR C28TTS RD BK V14PLUA OR C117FB RD R181PWR OR SPARE DIG OUT C181RET OR D185SEN WH D186SEN BL C192JR WH BK TXD SERIAL C199TS WH RD D187PSE BL SL32LDS BL WH C22PWR BK RXD SERIAL C26TSR WH RD V15PLDA OR BK V191PCEA WH RD P198SEN RD TXD SERIAL D81CAN GR D82CAN YL C66LS BL C111LFS OR SPARE DIG IN WH BK V36SCWA BL V37SCCA BL BK C86FLR OR Part No 119817 September 2015 Service Manual Ground Control Box Pin Legend Harness Legend 51 1 C4 2 eX C2 4 C1 5 C5 Pin Numbering for 12 pin connectors C1 Ground Control C2 Ground Control C3 Ground Control Box C4 Ground Control C5 Ground Control Box Harness Box Harness Harness Box Harness Box Harness 1 R195PWR 1 C18PRR GR BK 1 C4iRPM OR 1 P23BAT RD 1 C28TTS RD BK ORROD 2 C17PRL GR 2 C134PWR RD 2 P22BAT RD BK 2 V191PCEA R181PWR OR a 3 C47FE WH BK 3 GND RD WH WH RD S1321 DS 4 C133PLA GR BK 4 C165TRS WH RD 4 C134PWR V36SCWA BL BEWA WH BK 4 V37SCCA 5 C32RET WH RD 5 C163PLS BL WH i 4 C22PWR BK BL BK 6 C156JUD
83. D TURNTABLE ROTATE DRIVE STEERINGJOYSWK j 3 i SECONDARY PLATFORM DRIVE SPEED Y y JBENDI bh 0897 ssenDiBR ZGszi w Boom LEVEL ENABLE s CONTROLLER 5 Los PIG2JPW OR 0332 FIEZJPW OR C522 uw 42 alga cali up uP LEFT Sk Da 15 O164PES RDANH D 6888 07 1 082 8 t Ek gt i o te WHAI ae C1esTRE WHRD gt 5384 CIBUPLWHRD C924 Um E p mn 58 95299 song vb nene Gis C183PLS BLWH 6985 G1595TC BLWH gt C325 SE EE gt Li 29 55 2 2 M lg id 120n i BATTERY 6281 GND a X BATTERY CEB2 CIMPWR RD BYA H 8 C134PWR RD DG36 1_ BATTERY 5 0264 lt E 35 E a H 5 5 aROUND BN gt 6852 BATTERY u CAN 6284 DeICAN GN i 8 8 3 388 5 5 L oiMFOWHRD 56353 SPEED CONTROLLER PRI BOOM EXT RET 6285 C163PLS BLWH S T L 50 94 DRIVEENABLE TS FOOTSW VALVEPWR 28 6 lt C58FT8 RD GI6PLF OR RD C358 PLATFORM LEVEL UP DOWN TS LOAD SENSE 0247 lt 0175LDS WHBK CI6IABWHBK 6358 SECONDARY UP DOWN TS 5V Pi 20FWOR SPARE 3 GND 0289 lt GND BN GRYBK C958 PLATFORM ROTATE RIGHT TS PRI BOOM UP DN 02810 lt 164 RDWH GR gt 0
84. F 50 C Maximum continuous operating 171 F 77 C temperature Note An 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 5 5 cSt 104 F 40 C 15 0 cSt 40 F 40 C 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating 124 F 51 C temperature 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 8 0 cSt 104 F 40 C 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating 180 F 82 C temperature UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C 22 cSt 104 F 40 C 46 cSt 0 F 18 C 1300 Flash point None Pour point 8
85. GND BR C134PWR RD D82CAN YL D81CAN GR C27AUX RD C46HRN WH S132LDS BL WH R181PWR OR SPARE SPARE P49LPS WH BK C49GEN GR WH GND BR SPARE SPARE SPARE C48LPS WH RD GND BR C48LPS WH RD GND BR SPARE SPARE Part No 119817 September 2015 Service Manual PCON Platform Controller C28 1 GND BR 2 C134PWR RD 3 D82CAN YL 4 D81CAN GR 5 C163PLS BL WH 6 C56FTS RD 7 C175LDS WH BK 8 P162JPW OR 9 GND BR 10 C164PES RD WH 11 C159STC BL WH 12 C165TRS WH RD Part No 119817 Turntable and Platform Controller Pin Legend N O O R 11 12 PCON Platform Controller s 000000 Pin Numbering for 12 Pin Connectors TCON Turntable Controller TCON Turntable Controller C14 C41RPM OR C47FE WH BK 07 BK VO8PBR BK WH V01PBU RD V02PBD RD BK V10SBU BL V11SBD BL BK 9 V04TRL WH 10 VO5TRR WH BK 11 C134PWR RD 12 C134PWR RD O R 29 13 C156JUD GR WH 1 GROUND BR C160JPL WH RD 2 C134PWR RD V17PRL GR 3 D82CAN YL V18PRR GR BK 4 D81CAN GR V43JU GR 5 C163PLS BL WH V44JD GR BK 6 C68PBD RD V193JRR WH RD 7 C40SBD OR V192JRL WH BK 8 P109PWR GR WH C130TA WH RD 9 R110RET BR SPARE 10 C165TRS WH RD C134PWR RD 11 165 5 RD WH C134PWR RD 12 C161SB WH BK Genie
86. Genie A TEREX BRAND Serial Number Range from Z4007 100 Z 40 23N 2 40 23 Part 119817 Rev B September 2015 Service Manual September 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also 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 fu
87. ING Crushing hazard The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device 7 Lower the secondary boom to the stowed position 8 Tag disconnect and plug the hydraulic hoses on both of the secondary boom lift cylinders Cap the fittings on the cylinders Procedure How to Remove the Primary A WARNING Bodily injury hazard Spraying Boom hydraulic oil can penetrate and 2 Remove the master cylinder Refer to Repair burn skin Loosen hydraulic Procedure How to Remove the Platform connections very slowly to allow Leveling Master Cylinder the oil pressure to dissipate gradually Do not allow oil to 3 Attach a lifting strap from an overhead crane squirt or spray to the lug on the rod end of the primary boom lift cylinder Using the overhead crane raise the primary boom lift cylinder to a vertical position Genie 78 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 10 11 12 13 A WARNING 14 15 Part No 119817 Secondary Boom Components Remove the pin retaining fasteners from both sides of the secondary boom cylinder rodend pivot pin and barrel end pivot pin Do not remove the pins Attach a strap from an overhead crane to the lug on the rod end of one of the secondary boom lift cylinders for support Do not apply any lifting pressure Use a soft metal drift to drive the barrel end pivot pin half way out Lower th
88. NG Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION 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 Indicates that a specific result is expected after performing a series of steps M Indicates that an incorrect result has occurred after performing a series of steps 1 1 1 1 12 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Scheduled Maintenance Procedures Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Proced
89. Procedure How to Calibrate the Switch in the right direction to enter the VALVE Proportional Relief Valve AND PUMP SETTINGS menu 2 Turnthe key switch to platform control Result The display will show THRESHOLD CURRENT Pull out the red Emergency Stop buttons to the on position at both the ground and platform 10 Momentarily activate the steer rocker switch in controls the right direction until START PUMP GPM is h the display 4 not press down the foot switch shov 11 Momentarily activate the drive enable toggle Move and hold the drive enable toggle switch switch in the right direction to begin pump in the right direction while holding the steer waze calibration rocker switch in the right direction 86 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Hydraulic Pump 12 Press down on the foot switch Move and hold the primary boom rocker switch in the extend direction until the boom is fully extended and an audible alarm has sounded Result The alarm sounds Continue to step 13 Result The alarm does not sound Fully retract the primary boom and repeat steps 11 and 12 To exit programming mode 13 Move and hold the drive enable toggle in the left position until the display returns to SYSTEM READY mode Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 87 Service Manual September 2015 Manifolds 7 1 Function Ma
90. R RD GR BK 73 Secondary boom retract BK WH RD 74 Primary 1 Lockout RD WH 75 Primary 2 Lockout BK RD 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 Genie 132 Z 40 23N 2 40 23 RJ September 2015 Circuit Primary Function 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 Can 2 0 J1939 Shield Can 2 0 J1939 Low Can 2 0 J1939 High Tilt signal X axis Tilt signal Y axis Tilt sensor power Hydraulic Filter restricted Platform Level Safety Power Platform Level Safety Output Platform Level Safety Ground Proximity Kill Gate Interlock Motor Speed LO HI Motor Bypass Load Sensor Tether ESTOP return Tether Power Tether ESTOP Power J1708 high J1708 low Outrigger lowered Outrigger raised Pothole protector up Pothole protector down Proprietary Data buss l e ITT or AP Proprietary Data buss l e ITT or AP Part No 119817 September 2015 aa asa Color GR RD BL WH GR WH BK OR RD OR RD BK RD RD BK OR RD OR BL OR GR GR BK RD BK RD WH WH RD WH BK GR OR RD RD BK WH RD Circuit Primary Function Color 106 Spare BL 107 Alternator Field GR 108 Engine Status GR WH 109 Sensor Power GR BK 110 Sensor Return BL WH 111 Steer Signal RD 112 Steer Signal to Solenoid Valve RD WH 113 Multi function Valve RD
91. Setting The ramp up time setting of a function controls the time at which it takes for the function to reach maximum output when moved out of the neutral position The ramp up time of a function can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Begin this procedure with the rotary speed control at the platform turned fully in the clockwise direction 1 Turn the key switch to platform control 2 Pullout the red Emergency Stop button to the ON position at both the ground and platform controls Do not press down on 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 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 Platform Controls 9 Momentarily activate the steer rocker switch in the right direction until RAMP UP TIME is shown on the display 10 Momentarily activate the drive enable toggle switch in th
92. WR BK 5132108 BLWH R181PWR OR F185PWR R RD C130TA WHRD F174PWR WH D81CAN GR DB2CAN YL C107RET WH G18PLF OR RD C156JUD GR WH CS2RET WH RD C133PLA RD C17PRL GR GR BK Ci615B WH BK C164PES RD WH D81CAN GR D amp 2CAN YL P169PWR GRAWH SPARE R48HRN WH 163PLS BL WH G188TR WH RD G47FE C134PWR RD C41RPM OR GND BR G28TTS V191PCEA WHRD VS6SCWA BL 75 BL BK VI4PLUA VI5PLDA ORAK V15PLDB OR BK V14PLUB OR BL BK V36SGWB BL VA amp HPCEB WH RD C134PWR RD September 2015 Service Manual EE a K E Electrical Schematic Ground Controls GRE CATPE WHBK kar P182BAT RD ae 1 16 C82 E MAS 1 619 cia P109PWR GRAWH eu C182JR WH BK cte Sats C22PWR BK Lo d I ors GA KSI I CE a lm 2 C130TA WH RD SER kk S 62 11 R174PWR WH 55 a 1 5 2
93. able track could become connections very slowly to allow unbalanced and fall when the oil pressure to dissipate removed from the machine gradually Do not allow oil to squirt or spray 16 Support and secure the cable track to an overhead crane or other similar lifting device 12 Pull the jib boom platform rotator hydraulic hoses disconnected at the union through the 17 Remove the cable track tube retaining mounting ears of the rod end of the primary fasteners from the plafi rm end ofthe boom lift cylinder towards the platform extension tube Component damage 18 Remove the cable track mounting fasteners that attach the lower cable track tray to the hazard Cables and hoses can be primary boom damaged if they are kinked or pinched 19 Remove the cable track from the machine and place it on a structure capable of supporting it 13 Remove the cover from the bottom of the cable track A WARNING Crushing hazard If the upper and lower cable tracks are not 14 Pull all of the cables through the mounting properly secured together the ears of the rod end of the primary boom lift cable track could become cylinder towards the counterweight end of the unbalanced and fall when machine removed from the machine Genie Part No 119817 BRAND Z 40 23N Z 40 23N RJ 67 Service Manual September 2015 222 2222 Z c Primary Boom Components How to Repair the Primary Boom How to Shim the Primary Boom Cable Tra
94. again in the right direction while holding the steer rocker switch in the right direction Result Alarm sounds continue to step 15 Result Alarm does not sound continue to step 13 Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 49 Service Manual AE Platform Controls 13 14 15 16 17 18 50 Release the footswitch Momentarily activate the steer rocker in the left direction to decrease the value shown on the display in small increments Continue to step 14 Press down on the foot switch and activate the same function in the same direction Repeat step 13 until the alarm sounds while function is in motion Then release the foot switch and momentarily activate the steer rocker switch in the right direction 3 times Continue to step 17 Release the footswitch Momentarily activate the steer rocker in the right direction to increase the value shown on the display in small increments Continue to step 16 Press down on the foot switch and activate the same function in the same direction Repeat step 15 until the alarm no longer sounds while function is in motion Then momentarily activate the steer rocker switch in the right direction 2 times Continue to step 17 Momentarily activate the drive enable toggle switch in the right direction to save the new setting Result The alarm should sound indicating the setting has been saved Repeat steps 11 through 17 as
95. ake mounting fasteners even pattern until all spring tension has been a gt relieved Remove the fasteners 6 Remove the brake from the drive motor Ne Note Some parts may fall loose from the brake 5 assembly during removal Refer to the following om Y 1 illustrations to be sure the spring pattern is correct and that the rest of the brake components are assembled properly prior to installing the brake onto the drive motor Note When installing the brake torque the brake mounting fasteners to 7 4 ft lbs 10 Nm brake disk 1 brake plate spacer brake body 9 2 3 spring screw Oooh Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 105 Service Manual September 2015 Motor Controllers 11 1 Motor Controllers There are two drive motor controllers located inside the non steer axle one for each drive motor When viewed from the non steer end of the machine the right side motor controller is the master and the left side motor controller is the slave The master motor controller controls the right drive motor and the function pump The slave motor controller controls the left side drive motor and auxiliary power unit The motor controllers are also AC voltage inverters which take the DC voltage from the system batteries and convert the voltage to AC power for the drive motors The motor controllers are in communication with
96. at 6 wire deustch plug on motor Check resistance on thermal sensor 54 BRAKE_RIGHT Right side AC motor brake Value too high Drive function disabled Check for 48V DC to brake Check for 48V DC on 1 Replace brake Replace right master AC motor controller 15 Value too low Drive function disabled Check for 48V DC to brake Check for 48V DC on 1 Replace brake Replace right master AC motor controller Part No 119817 Genie BRAND Z 40 23N Z 40 23N RJ 115 Service Manual A R gt A AQQ R AA Control System Fault Codes September 2015 Error Source Error Type ID Name ID Name Condition Solution 55 BRAKE LEFT Left 12 Value too high Drive function disabled Check for 48V DC to brake Check side motor brake for 48V DC on R 1 Replace brake Screen Replace left slave AC motor controller 15 Value too low Drive function disabled Check for 48V DC to brake Check for 48V DC on R 1 Replace brake Replace left slave AC motor controller 56 TACH R MOTOR 22 Fault Drive function disabled Check wiring at the 6 wire deustsch Right side AC drive plug at the drive motor Check for motor encoder 12V DC on pins 1 and 2 Replace encoder Replace right master AC motor controller 57 TACH MOTOR 22 Fault Drive function disabled Check wiring at the 6 wire deutsch Left side AC
97. atform level toggle switch will increase or decrease the relief pressure in increments of approximately 50 psi 3 bar 6 Move and hold the jib boom toggle switch in the up direction Result The pressure gauge shows 2100 psi 124 bar Continue to step 8 M Result The pressure does not show 2100 psi 124 bar Continue to step 7 Note Do not activate the function enable toggle switch while making this adjustment Manifolds 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 approximately 50 psi 3 bar 8 Move hold the primary boom toggle switch in the retract direction Result The pressure gauge shows 2500 psi 172 bar Continue to step 10 Result The pressure gauge does not show 2500 psi 172 bar continue to step 9 Note Do not activate the function enable toggle switch while making this adjustment 9 Move and hold the primary boom toggle switch in the retract 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 b
98. ce The flashing red LED when combined with short or long pauses between the flash tells the service technician the specific source of the error Error source code 32 for example would appear as three quick red flashes followed by A a short pause of almost two seconds then two M more quick red flashes Error source code 33 would appear as three quick red flashes followed by a short pause then three more quick red flashes followed by a long pause 7 Determine the error type The flashing green LED when combined with short or long 1 green LED pauses between the flash tells the service 2 red LED technician the specific error type Error type code 12 for example would appear as one quick green flash followed by a short pause of almost two seconds then two more quick green flashes followed by a long pause Error type code 15 would appear as one quick green flash followed by a short pause then five more quick green flashes followed by a long pause 3 turntable control module TCON Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 109 Service Manual September 2015 Control System Fault Codes Main contactor coil Error Source Error Type 11 BATTERY_PWR 12 Out of range Main contactor open Do not operate machine with Battery power will not close All batteries charging Batteries screen
99. ck 1 Extend the boom until the wear pads Component damage hazard accessible The boom cable track can be 2 Loosen the wear pad mounting fasteners damaged if it is twisted 3 Install the new shims under the wear pad to Note A 7 link repair section of cable track is obtain zero clearance and zero drag available through the Genie Service Parts 4 Tighten the mounting fasteners Department 5 Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Note Always maintain squareness between the outer and inner boom tubes 1 link separation point 2 lower clip 1 Use a slotted screwdriver to pry down on the lower clip 2 To remove a single link open the lower clip and then use a screw driver to pry the link to the side 3 Repeat steps 1 and 2 for each link Gi S 68 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Primary Boom Components How to Remove the Primary 3 Remove the cable track Refer to Repair Boom Procedure How to Remove the Cable Track m 4 Remove the hose and cable guard from the A WARNING Bodily injury hazard This upper pivot procedure requires specific repair skills lifting equipment and a Bodily injury hazard Spraying suitable workshop Attempting AWARNING hydraulic oil can penetrate and this procedure without these skills burn skin Loosen hydraulic and tools could result in death or connections very
100. ck for power to PCON at P1 6 with foot switch depressed 24 Time out All functions disabled Release foot switch and press again 16 SPEED DIAL 12 Value too high Function speeds Check for 5V DC orange wire Rotary speed reduced Check output 0 4 7V DC wh rd controller Check input at VCON at V1 3 Replace rotary controller 17 LIFT PUMP 12 Value too high Auxiliary functions only Check for 48V DC to main function pump Replace right master AC motor controller 15 Value too low Auxiliary functions only Do not operate machine with batteries charging Check for 48V DC to main function pump Replace right master AC motor controller 22 Fault Auxiliary functions only Allow main pump to cool down Check for air restriction to electric motor Check relief valve settings at main manifold 18 TACH LIFTPMP Lift 22 Fault Auxiliary functions only Check 3 wire plug on encoder at pump motor pump motor Check 5V DC red encoder wire Replace motor 19 AUX PUMP 12 Value too high Auxiliary functions Check fuse F1 200A Check for Auxiliary pump disabled 24V DC to Aux pump Replace Aux pump Replace left slave AC motor controller 15 Value too low Auxiliary functions Check for 24V DC to Aux pump disabled Replace Aux pump Replace left slave AC motor controller Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 111 Service
101. d coil for function causing fault Fault at power up replace right Master AC motor controller 15 Value too low Steering and platform level functions disabled Flashing beacon disabled option Check wiring and coil for function causing fault Fault at power up replace right Master AC motor controller 63 STEER_SENSOR Steer angle sensor Part No 119817 11 Shorted high 5V Wheel speed correction Check for 5V DC GR WH at steer 12 Value too high is disabled Drive speed sensor 15 Value too low reduced Check for 0 5V DC orange output 16 Value at OV at steer sensor Check for 0 5V DC orange at R 30 on right master AC motor controller Replace steer sensor 17 Not calibrated Wheel speed correction Replace steer sensor is disabled Drive speed Genie BRAND Z 40 23N Z 40 23N RJ Re calibrate steer sensor reduced 117 Service Manual A R gt A AQQ R AA Control System Fault Codes September 2015 Error Source Error Type ID Name ID Name Condition Solution 66 AC L OUTPUT Left 12 Value too high Hour meter brake Check wiring and coil for function side AC motor relay and tilt sensor causing fault Fault at power up controller output alarm disabled Platform replace left slave AC motor overload alarm disabled controller option 15 Value too low Hour meter brake relay
102. d service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Instructions Use the operators manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Comments Pre delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company September 2015 Service Manual iz This page intentionally left blank
103. death or serious injury machine from rolling and property damage 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer tires 3 Liftthe wheels off the ground and place jack stands under the drive chassis for support Genie 1 10 0 0 Part No 119817 Z 40 23N Z 40 23N RJ 37 Service Manual September 2015 Checklist D Procedures D 6 Replace the Drive Hub Oil Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may result in component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the Drive the machine to rotate the hub until one of the plugs is located on top and the other one is at 90 degrees 1 Plugs 4 Fillthe hub with oil from the top hole until the oil level is even with the bottom of the side plug hole Refer to Specifications Machine Specifications Install the plugs into the drive hub 6 Repeatsteps 1 through 5 for the other drive hub D 7 Replace the High Pressure Hydraulic Filter Element Genie specifications require that this procedure be performed every 1000 hours
104. decrease the pressure Install the relief valve cap Result The relief pressure meets specification Continue to step 7 Result The relief pressure does not meet specification Repeat this procedure beginning with step 3 AWARNING hazard Do not adjust the relief valve higher than specified Turn the machine off Remove the pressure gauge and install the proportional relief valve coil Part No 119817 September 2015 aa asa gt gt gt How to Adjust the Platform Level Relief Valve 1 Part No 119817 Turn the machine off Locate the proportional relief valve item BW on the function manifold Remove the coil nut and remove the coil from the valve cartridge and set aside Do not disconnect the coil electrical connector Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the test port TP2 on the function manifold Turn the key switch to ground controls Move and hold the function enable toggle switch to either side 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 Turn the machine off Hold the platform level relief valve with a wrench and remove the cap item BD Service Manual Manifolds Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the
105. diately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Machine Configuration Unless otherwise specified perform each Genie BRAND Z 40 23N Z 40 23N RJ 11 procedure with the machine in the following configuration e Machine parked on a firm level surface e Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked e All external AC power supply disconnected from the machine e Boom in the stowed position e Turntable secured with the turntable rotation lock Service Manual September 2015 Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert A personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNI
106. drive plug at the drive motor Check for motor encoder 12V DC on pins 1 and 2 Replace encoder Replace left slave AC motor controller 58 AC R CTRLR Right 13 No response All functions disabled Check can bus circuit for open side Master AC Check can bus resistor Isolate all motor controller other modules simultaneously Replace right Master AC motor controller 22 Fault All functions disabled or Cycle power off and back on If fault limited persist replace right master AC motor controller See motor controller fault code chart 59 CTRLR Left 22 Fault All functions disabled or Cycle power off and back on If fault side Slave AC limited persist replace left slave AC motor motor controller controller See motor controller fault code chart Genie 116 Z 40 23N 2 40 23 RJ Part No 119817 September 2015 Service Manual Control System Fault Codes disabled Error Source Error Type D Name 61 STEER_JYSTK 11 Shorted high 5V Steering function Repair Joystick wire connections or Joystick steer 12 Value too high disabled replace Joystick 15 Value too low 16 Value at OV 17 Not calibrated Steering function Calibrate joystick Replace joystick 62 AC_R_OUTPUT controller output Right side AC motor 12 Value too high Steering and platform level functions disabled Flashing beacon disabled option Check wiring an
107. e Inside of the platform control box Inspect for a liberal coating of dielectric grease at the following locations e All wire harness connectors to the platform control box e All wire harness connectors to the platform control module PCON located inside of the platform control box Part No 119817 September 2015 Service Manual B 3 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Specifications Machine Specifications 4 Check the pressure in each air filled tire Checklist B Procedures B 4 Check the Drive Hub Mounting Bolts Genie specifications require t
108. e barrel end of the secondary boom lift cylinder and let it hang down Use a soft metal drift to drive the rod end pivot pin half way out Remove the secondary boom lift cylinder from the machine Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane 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 Repeat steps 12 through 15 for the other secondary boom lift cylinder Attach a lifting strap from an overhead crane to the upper pivot for support Do not lift it Gen BRAND Z 40 23N Z 40 23N RJ 79 16 17 18 19 A WARNING A WARNING 20 21 22 A WARNING Attach a lifting strap from a second overhead crane to the number 1 arm at the mid point between the upper pivot and mid pivot 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 Use a soft metal drift to drive both pins out Remove the number 1 arm from the machine Crushing hazard The number 1 arm could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Crushing hazard The upper pivot could fall when the number 1 arm is removed from the machine if not properly
109. e end has been tightened beyond finger tight reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting Refer to Illus 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 e 2 3 retained properly Position the tube and nut squarely on the face a seal end of the fitting and tighten the nut finger tight Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section Illustratio hex nut b reference mark c body hex fitting Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Genie Z 40 23N Z 40 23N RJ tration 1 i E n1 Part No 119817 September 2015 Service Manual aa asa AA Z ZA A LE Specifications 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Illustration 2 Note Use the JIC 37 Fitting table in this section to determine the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to prop
110. e right direction to enter RAMP UP TIME calibration mode 11 Press down on the foot switch and momentarily activate the function to be corrected Result The display will show the function direction and milliamps 12 Press down on the foot switch start a timer and activate the same function in the same direction Note how long it takes the function to reach maximum speed This is the ramp up time 13 Compare the function ramp up time with the table on the next page and determine whether the ramp up time needs to increase or decrease Genie BRAND Z 40 23N Z 40 23N RJ 51 Part No 119817 Service Manual September 2015 nam EA Platform Controls 14 adjust the ramp up time setting release the exit programming mode foot switch Momentarily move the steer rocker switch in the right direction to increase or momentarily in the left direction to decrease 17 Move and hold the drive enable toggle switch in the left direction until the display screen returns to SYSTEM READY Note Each time the steer rocker switch is Ramp rate factory settings momentarily pressed the time will change in Primary boom up down 1 second 0 1 second increments Secondary boom up down Note Changing the ramp up time setting in one accelerate 1 second direction will also change the opposite direction Turntable rotate 15 When ramp
111. e the resistance between pins 5 and 6 on the Deutsch connector going into the motor housing Compare value to chart on right Part No 119817 Z 40 23N Z 40 23N RJ 123 Service Manual September 2015 D Motor Controller Fault Codes Temperature Resistance Temperature Resistance F C Ohm F C Ohm 40 40 355 320 160 1415 22 1 30 386 338 170 1493 4 20 419 347 180 1572 14 10 455 374 190 1654 32 0 493 392 200 1739 50 10 533 410 210 1825 68 20 576 428 220 1914 77125 598 446 230 2006 86 30 621 464 240 2099 104 40 668 482 250 2195 122 50 718 500 260 2293 140 60 769 518 270 2392 158 70 824 536 280 2490 176 80 880 554 290 2584 194 90 939 572 300 2668 212 100 1000 230 110 1063 248 120 1129 266 130 1197 284 140 1268 302 150 1340 Genie 124 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Observe and Obey Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine before operating the machine Before Troubleshooting V Immediately tag and remove from service a damaged or malfunctioning machine A WARNING
112. eer 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 right direction until THRESHOLD is shown on the display Platform Controls 9 Momentarily activate the steer rocker switch in the right direction until RAMP DOWN TIME is shown on the display 10 Momentarily activate the drive enable toggle switch in the right direction to enter RAMP DOWN TIME calibration mode 11 Press down on the foot switch and momentarily activate the function to be corrected Result The display will show the function direction and milliamps 12 Press down on the foot switch start a timer and activate the same function in the same direction Note how long it takes the function to reach maximum speed This is the ramp down time 13 Compare the function ramp down time with the table on the next page and determine whether the ramp down time needs to increase or decrease 14 adjust the ramp down time setting release the foot switch Momentarily move the steer rocker switch in the right direction to increase or momentarily in the left direction to decrease Note Each time the steer rocker switch is momentarily pressed the time will change in 0 1 second increments Note Changing the ramp down time setting in one di
113. eginning with step 6 Note Momentarily activating the platform level toggle switch will increase or decrease the relief pressure in increments of approximately 50 psi 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 Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 91 Service Manual DN A OO gt gt 2 S KL TS S USAS Manifolds How to Adjust the Secondary Boom Down Relief Valve 1 92 Turn the machine off Locate the proportional relief valve item BW on the function manifold Remove the coil nut and remove the coil from the valve cartridge and set aside Do not disconnect the coil electrical connector Connect O to 5000 psi 0 to 350 bar pressure gauge to the test port TP1 on the function manifold Turn the key switch to ground controls With the secondary boom fully lowered move and hold the function enable toggle switch 10 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 Turn the machine off Hold the secondary boom down relief valve with a wrench and remove the cap item BP Genie Z 40 23N Z 40 23N RJ September 2015 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to
114. ent damage Dealer service is strongly recommended 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 Hydraulic Hose and Fitting Torque Specifications 1 With the secondary boom in the stowed postion raise the primary boom until it is above the secondary boom lift cylinder rod end pivot pin Genie 82 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Secondary Boom Components 2 disconnect and plug the hydraulic hoses 7 Remove the secondary boom lift cylinder from on the secondary boom lift cylinder Cap the the machine fittings on the cylinder AWARNING Crushing hazard The secondary AWARNING Bodily injury hazard Spraying boom lift cylinder could become hydraulic oil can penetrate and unbalanced and fall when burn skin Loosen hydraulic removed from the machine if not connections very slowly to allow properly attached to the the oil pressure to dissipate overhead crane gradually Do not allow oil to squirt or spray Component damage hazard When removing a secondary 3 Remove the pin retaining fasteners from the boom lift cylinder from the secondary boom lift cylinder rod end pivot pin machine be careful not to and barrel end pivot pin Do not remove the damage the counterbalance pins valve at the barrel end of the cylinder 4 A
115. erate 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 Safety Rules 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 Genie BRAND Z 40 23N Z 40 23N RJ vii 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 t
116. erly tighten the joint after it has been loosened o Illustration 2 a body hex fitting b reference mark c 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 Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 9 Service Manual September 2015 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Grade 5 2 Grade inibs Nm in bs inibs Nm intbs Nm Nm 44 20 80 9 100 ma 10 124 140 158 130 147 28 90 1041 120 135 120 135 160 18 140 158 t ft lbs Nm ft lbs Nm Nm Nm ft lbs Nm sig 18 13 176 17 23 18 24 25 339 21 24 24 14 19 19 257 20 2711 27 366 24 325 16 23 312 31 42 33 447 44 596 38 515 24 26 352 35 474 37 501 49 664 43 583 me 14 37 501 49 664 50 678 70 947 61 827 20 41 555 55 745 60 813 80 1084 68 921 13 57 773 75 1016 80 1084 110 149 92 126 20 64 867 85 115 90 12
117. f Remove the dial indicator from the machine Part No 119817 September 2015 Service Manual E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is essential for good machine performance and 1 Checklist E Procedures Close the two hydraulic tank shut off valves at the hydraulic tank Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition ARE 2 Remove the drain plug from the hydraulic tank Dry oik ane suction and completely drain the tank into a container Miers may 2 PODA CNET of suitable capacity Refer to Specifications perform poorly and continued use may cause Machine Speciications component damage Extremely dirty conditions may require oil changes to be performed more 3 disconnect and plug the two suction frequently hoses from the hydraulic tank Note Before replacing the hydraulic oil the oil may 4 disconnect and plug the two supply be tested by an oil distributor for specific levels of hoses for the auxiliary powe
118. fasteners from the non steer end of the chassis Remove the cover 3 Remove the axle covers fasteners from the the non steer axle Remove the covers Non steer Axle Components Genie BRAND Z 40 23N Z 40 23N RJ Part No 119817 Tag and disconnect the power cables from the drive motor Tag and disconnect the electrical connectors for the brake speed and temperature sensors at the drive motor Remove the drive motor fasteners Support and slide the drive motor shaft out of the drive hub Remove the drive motor from the machine 103 Service Manual September 2015 Non steer Axle Components 10 2 Drive Brake How to Remove a Drive Brake Proper brake action is essential to safe machine operation The machine uses drive motor regenerative braking to slow and stop the machine Spring applied electrically released individual wheel brakes hold the machine once it has stopped The drive motor regenerative braking should operate smoothly free of hesitation and jerking 1 Block the steer wheels to prevent the machine from rolling 2 Disconnect the battery packs from the machine 3 Remove the chassis cover fasteners from the non steer end of the chassis Remove the cover 1 1 1 1 1 o 104 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Non steer Axle Components 4 and disconnect the electrical connector from the brake 5 Loosen the br
119. form rotator Refer to Specifications Machine Torque Specifications 2 Z 40 23N RJ Check the torque of the fasteners at the jib boom rotator Refer to Specifications Machine Torque Specifications Genie 36 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Checklist D Procedures D 5 4 Disengage the drive hubs by turning over the Check the Free wheel drive hub disconnect caps on each non steer wheel hub Configuration Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge could result in death or serious injury and property damage A WARNING Collision hazard Select a work site that is firm and level Component damage hazard If the machine must be towed do m 9 1 Hub Disengaged Position 2 Hub Engaged Position 5 Manually rotate each non steer wheel Result Each non steer wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the jack stands not exceed 2 mph 3 2 km h AWARNING Collision hazard Failure to re engage the drive hubs could 1 Chock the steer wheels to prevent the result in
120. g fasteners Do not and tools could result in death or disconnect the wiring serious injury and significant 7 Pull the limit switch and the wiring out of the component damage Dealer extension tube and move it out of the way service is strongly recommended 8 Atthe platform end of the boom remove the Note When removing a hose assembly or fitting external snap rings from the extension the O ring if equipped on the fitting and or hose cylinder rod end pivot pin Use a soft metal end must be replaced All connections must be drift to remove the pin torqued to specification during installation Refer to 9 Remove the barrel end pivot pin retainin Specifications Hydraulic Hose and Fitting Torque fasteners 9 Specifications 10 Place a support block under the barrel end of 1 2 primary boom to a horizontal the primary boom extension cylinder 2 Extend the primary boom until the primary boom extension cylinder rod end pivot is accessible in the primary boom extension tube Genie 74 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 12 Support and slide the extension cylinder out of the upper pivot A WARNING Crushing hazard The extension cylinder could fall when removed from the extension boom if not properly supported Component damage hazard Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom Com
121. h in the right direction while holding the steer 11 rocker switch in the right direction Genie 60 Z 40 23N Z 40 23N RJ When the display leaves SYSTEM READY mode release the drive enable toggle switch and the steer rocker switch Result The display will show FAULTS Momentarily activate the drive enable toggle switch in the right direction Result The display will show ACTIVE FAULTS Momentarily activate the steer rocker switch in the right direction until RESET OVERLOAD MSG is shown on the display Momentarily activate the drive enable toggle Switch in the right direction Result The display will show ENTER PASSWORD Momentarily active the steer rocker switch in the following order Steer right steer right steer right steer left Result A one second audible alarm pulse verifies the message has been reset Result The alarm does not sound Repeat this procedure starting with step 8 Push in the red Emergency Stop button to the off position Pull out the red Emergency Stop button to the on position OVERLOAD RECOVERY is not shown on the display Part No 119817 September 2015 aa asa I RAZIE ZA A LE Service Manual Jib Boom Components 3 1 5 Remove the pin retaining fasteners from the jib boom leveling arm pivot pin at the platform Jib Boom rotator 6 Use a soft metal drift to remove the leveling How to Remove the Jib Boom arm pivot pin Let the leveling arms and
122. hat this procedure be performed every 250 hours or quarterly whichever comes first Maintaining proper torque of the drive hub mounting bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage Remove the axle covers from the non steer axle 2 Check the torque of the drive hub bolts Refer to Specifications Machine Specifications Genie BRAND Z 40 23N Z 40 23N RJ 23 Part No 119817 Service Manual September 2015 Checklist B Procedures B 5 3 Check the Drive Hub Oil Level and Fastener Torque 4 Genie specifications require that this procedure be performed every 250 hours or quarterly whichever 6 comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 1 drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole Genie If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole Install the plug s into the drive hub Check the torque of the drive hub mounting bolts Refer to Specifications Machine Specifications Repeat this procedure for each drive hub
123. he battery is fully charged Proceed to step 13 M Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 217 Replace the battery 13 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 14 Install the vent caps and neutralize any electrolyte that may have spilled Checklist B Procedures B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Open both turntable covers 2 Inspect the following areas for burnt chafed corroded and loose wires e Hydraulic power unit e High pressure filter e Inside of the ground control box e Turntable manifold wiring 3 Inspectfor a liberal coating of dielectric grease at the following locations e All wire harness connectors to the ground control box e All wire harness connectors t
124. he pressed in races must be replaced 10 Remove the dust cap from the hub Remove the cotter pin from the castle nut 11 Remove the castle nut 12 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 13 Place the hub on flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 14 15 16 17 18 19 20 21 22 23 Pack both bearings with clean fresh grease Place the large inner bearing into the rear of the hub Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Slide the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur Fill the hub cavity with clean fresh grease Place the outer bearing into the hub Install the washer and castle nut Tighten the slotted nut to 158 ft lbs 214 Nm to seat the bearings Loosen the castle nut and re tighten to 35 ft lbs 47 Nm Install a new cotter pin Bend the cotter pin to lock it in Note Always use a new cotter pin when installing a castle nut 24 O 44 2 40 23 Z 40 23N RJ Part No 119817 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Specifications Machine Specifications September 2015 Service Manual Observe and Obey Repair procedures shall be completed by
125. his machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition M Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Checklist A Procedures 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition M Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Genie BRAND Z 40 23N Z 40 23N RJ 17 Part No 119817 Service
126. hours B 10 Drive speed raised Annually B 11 Alarm package every 1000 hours B 12 Electrical contactors Two yearor A B C D E B 13 Hydraulic oil analysis every Ss 2000 hours B 14 Test the Emergency Power System Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable remove from service R repaired Genie BRAND 16 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using t
127. ht and the alarm is on Slowly tighten the load spring adjustment nut by turning it clockwise just until the overload indicator light and alarm turns off Note The platform will need to be moved up and down and allowed to settle between adjustments Note There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Result The overload indicator light and alarm is off Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the overload indicator light and alarm turn on Note There may be an approximate 2 second delay before the overload indicator light turns on and the alarm sounds Note The platform will need to be moved up and down and allowed to settle between adjustments Platform Components Confirm the setting 6 the key switch to platform control 7 Liftthetest 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 platform controls Note There may be an approximate 2 second delay before the overload indicator light and alarm turn off 9 Addan additional 10 Ib 4 5 kg test weight to the original test weight to overload the platform Result The alarm should sound The platform overload indicator
128. hydraulic connections very slowly to allow 13 Lower the primary boom to a horizontal the oil pressure to dissipate 14 Attach a 5 ton 5 000 kg overhead crane to gradually Do allow oil to the center point of the primary boom ROME or Spray 15 Attach a similar lifting device to the primary 21 Attach a lifting strap from an overhead crane boom lift cylinder to the primary boom lift cylinder Genie 70 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 22 Place 2 x 4 x 18 inch 5 x 10 x 46 cm support blocks under the cylinder across the secondary boom 23 Remove the pin retaining fastener from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device 24 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage 25 Remove the pin retaining fastener from the primary boom pivot pin 26 Remove the primary boom pivot pin with a soft metal drift Carefully remove the primary boom assembly from the machine AWARNING Crushing hazard The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Primary Boom Components How to Disassemble the Primary Boom Note Complete disassembly of the boom is o
129. ications 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 CAUTION hot oil Contact with hot oil may cause severe burns Genie 84 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 6 2 How to Remove the Function Pump The function pump motor operates at various speeds depending on the flow and pressure required for the machine function selected A speed sensor built into the pump motor enables the control system to monitor and control the speed of the pump motor which controls the flow output of the pump 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 Hydraulic Hose and Fitting Torque Specifications 1 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications 2 Remove the drain plug from the hydraulic tank Completely drain the hydraulic tank into a container of suitable capacity CAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns Hydraulic Pump 3 Tag disconnect and plug the hydraulic hoses from the pump Cap the fittings on the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic c
130. 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 1 1 1 vi Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 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 A ADANGER 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 AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Indicates a potentially hazardous gt Part 119817 situation which if not avoided may cause minor or mod
131. in the locked position A WARNING Crushing hazard The turntable rotation assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 98 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 9 1 Steer Angle Sensor How to Replace the Steer Angle Sensor The steer angle sensor installed on the steer yoke pivot pin is monitored by the control system to determine steer angle The control system uses the steer angle input along with pre programmed parameters to vary the speed of each drive motor while steering to minimize tire and to help minimize turning radius Drive speed is also reduced proportionately depending on the steer angle to minimize lateral platform acceleration 1 Adjust the steer tires so they are in a straight driving position Turn the key switch to the off position Push in the red Emergency Stop buttons to the off position at both the ground and platform controls 4 Remove the drive chassis cover at the steer end of the machine 5 Remove the cable clamp securing the steer sensor cable to the chassis 6 Tag and disconnect the steer sensor harness from the main harness Steer Axle Components 7 Remove the steer sensor cover retaining fasteners 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 sens
132. inder Remove the Platform Rotator Bodily injury hazard Sprayin 4 Attach a lifting strap from an overhead crane AWARNING ol can 2 to the jib boom for support burn skin Loosen hydraulic Component damage hazard 2 pu sa i allow Hoses can be damaged if they ho E 2 kinked pinched KOSA squirt or spray Genie 4 119817 Z 40 23N 2 40 23 RJ 61 Service Manual September 2015 Jib Boom Components 13 Remove the mounting fasteners from the jib boom platform rotate manifold and lay the manifold to the side Do not remove the hoses or disconnect the wiring Component damage hazard Hoses can be damaged if they are kinked or pinched 14 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 15 Use a soft metal drift to remove the jib boom rod end pivot pin Remove the jib boom lift cylinder from the machine A WARNING Crushing hazard The jib boom could fall when the pin is removed if not properly supported by the overhead crane 16 Remove the pin retaining fastener from the jib boom pivot pin Do not remove the pin 17 Attach a lifting strap from an overhead crane to the jib boom 18 Use a soft metal drift to remove the jib boom pivot pin Carefully remove the jib boom from the machine A WARNING Crushing hazard The jib boom could fall when the pin is removed if not properly supported by the overhead crane 3 2
133. ion controller code 65517 Analog input No functions or drive If problem is c ons is tant replac e the AC controller 65520 Hardware fault No functions or drive Replace the AC motor controller 65531 Wrong set battery Cut out valves function pump Replace the AC motor controller propel stopped MC opened EB applied 21808 EEPROM time out Functions and drive will revert to Cycle power off and back on factory default settings If the fault disappears all valve settings will have to be readjusted If fault is maintained replace the AC motor controller 13912 High temperature Functions and drive start to Let the AC motor controllers cool degrade and quit One or both off motor controllers have exceeded f fault persist with AC motor 85 185 controllers cooled replace faulty AC motor controller 65516 Current gain Functions and drive will revert to Readjust the max current Setting factory default settings 16913 Thermic sensor time Function and drive speeds will Replace the AC motor controller out slow down 65512 Slip profile No drive Replace the AC motor controller 65360 Forward Reverse Propel is stopped node 2 only Replace the right master AC motor controller 65508 Plat Gnd switch open Node 2 only Replace the right master AC motor controller 65521 Check up needed Continuous normal operation Perform scheduled maintenance node 2 only Part No 119817 Genie BRAND Z 40 23N Z 40 23N RJ
134. ion GL5 Wheel width 7 in 7 in Batteries Wheel lugs 8 518 18 9 5 8 18 a a Type 6V DC Lug nut torque Group size L16GH lubricated 94 ft lbs 94 ft lbs Quantity 8 127 5 Nm 127 5 Nm Capacity 350 AH dry 125 ftlbs 125 ftlbs Reserve capacity 25A 750 minutes 169 5 Nm 169 5 Nm rate For operational specifications refer to the Weight each 106 Ibs Operator s Manual 48 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 119817 Z 40 23N Z 40 23N RJ Service Manual September 2015 Specifications Performance Specifications Z 40 23N and Z 40 23N RJ Drive speed maximum Drive speed stowed 4 5 mph 7 24 km h 40 ft 6 0 sec 12 2 6 0 sec Drive speed stowed CE models 3 75 mph 6 km h 40ft 7 3 sec 12 2 7 3 sec Drive speed boom raised or extended all models 0 68 mph 1 09 km h 40 ft 40 sec 12 2 m 40 sec Braking distance Boom function speeds maximum from platform controls with rated load secured to platform Jib boom up Jib boom down 18 to 24 seconds 18 to 24 seconds Jib boom rotate 180 Z40 23N RJ 18 to 24 seconds Primary boom up 26 to 30 seconds Primary boom down 27 to 31 seconds Primary boom extend Primary boom retract 15 to 19 seconds 15 to 19 seconds Turntable rotate 355 62 to 75 seconds Pla
135. ircuit 18 20 ft lbs 25 27 Nm 15 Check valve 4 psi 0 3 bar BY Prevents oil from draining out of 18 20 ft lbs 25 27 Nm jib rotate manifold back to tank 16 Shuttle valve BF Platform level 18 20 ft lbs 25 27 Nm 17 Check valve dual pilot BE Platform level 20 ft lbs 27 Nm 18 Check valve 25 psi 1 7 bar BB Prevents oil from draining out of 18 20 ft lbs 25 27 Nm manifold 19 Relief valve 2500 psi 172 bar BD Platform level relief 18 20 ft lbs 25 27 Nm 20 Solenoid valve 3 position 4 way BG Platform level up down 16 20 ft lbs 24 27 Nm 88 Genie Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Manifolds BU BM BS BX BA OA Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 89 Service Manual NA PO gt gt 2 C CC S S S Manifolds 7 2 Valve Adjustments Function Manifold How to Calibrate the Proprotional Relief Valve Note This procedure must be performed at the ground controls with the jib boom in the fully elevated position 1 90 Turn the key switch to the off position and push in the red Emergency Stop button to the off position Connect a 0 to 3000 psi 0 to 207 bar pressure gauge to test port TP1 on the function manifold Turn the key switch to the ground control position Pull ou
136. itch w Note To conserve battery power test each function through a partial cycle Result boom functions operate 4 Close the emergency power switch cover and secure the cover with a security tie if equipped Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 29 Service Manual September 2015 _ Checklist Procedures 5 the key switch to platform controls At the platform controls break the security tie and lift the emergency power switch cover if equipped 7 Press down on the foot switch and simultaneously hold the emergency power switch on and activate each boom function Note To conserve battery power test each function through a partial cycle Result All boom functions operate 8 Close the emergency power switch cover and secure the cover with a security tie if equipped Gri 1 1 1hA o 30 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual C 1 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not
137. its could result in death or serious injury Remove all rings watches and other jewelry Tag and disconnect the cables from the engine starting battery located on the engine side of the machine Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 12 13 A WARNING A WARNING 14 15 16 A WARNING September 2015 Attach an overhead crane or similar lifting device to the battery box for the auxiliary power unit batteries Remove the battery box retaining fasteners and carefully remove the battery box from the machine Crushing hazard The battery box could become unbalanced and fall when removed from the machine if not properly supported Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Remove the hydraulic tank retaining fasteners Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an appropriate lifting device Remove the hydraulic tank from the machine Crushing hazard The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine 17 Remove the suction strainers from the tank Genie Z 40 23N Z 40 23N RJ and clean them using a mild solvent Part No 119817
138. l that may have spilled during them the installation procedure 2 Block the non steer wheels then center 28 Start the engine and check for leaks lifting jack under the steer axle Part No 119817 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement Genie BRAND Z 40 23N Z 40 23N RJ 43 Service Manual September 2015 Checklist E Procedures 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Note Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 8 Loosen the castle nut one full turn and then re tighten to 35 ft lbs 47 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is no side to side or up and down movement continue with step 11 and grease the wheel bearings M Result If there is side to side or up and down movement continue to step 11 and replace the wheel bearings with new ones Note When replacing a wheel bearing both the inner and outer bearings including t
139. lave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder Note Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop 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 Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place blocks 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 AWARNING 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
140. lect a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 3 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 4 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications Genie 0 0 Part No 119817 Z 40 23N Z 40 23N RJ 27 Service Manual September 2015 Checklist B Procedures B 11 Test the Alarm Package if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes e Travel alarm e Descent alarm e Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the ON position at both the ground and platform controls Result The flashing beacon should be on and flashing N Turn the key switch to platform control Result The flashing beacon should be on and flashing 3 Press down the foot s
141. lines on the ground 40 feet 12 2 m apart Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 16 17 18 Service Manual Platform Controls 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 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 meets specification Continue to step 19 Result The drive speed does not meet specification Continue to step 18 to adjust the drive speed Momentarily move the steer rocker switch in the right direction to increase or momentarily in the left direction to decrease Repeat steps 16 and 17 Note Adjusting this setting will affect the stowed drive speed in forward and reverse 19 Momentarily activate the drive enable toggle switch to the right direction to save your changes Result The alarm should sound indicating the setting has been saved To exit programming mode 20 Genie BRAND Z 40 23N Z 40 23N RJ 55 Move and hold the drive enable toggle switch in the left direction until the display screen returns to SYSTEM READY Service Manual September 2015 Platform Components 2 1 Platform Leveling S
142. m the secondary damaged if they are kinked or boom assembly pinched A WARNING Crushing hazard The mid pivot could become unbalanced and 26 Remove the pin retaining fastener from the fall when removed from the number 2 arm pivot pin at the upper pivot Use secondary boom assembly if not a soft metal drift to remove the pin properly supported by the 27 Remove the upper pivot from the machine overhead crane AWARNING Crushing hazard The upper 35 Attach the lifting strap from an overhead crane pivot could become unbalanced to the center point of the number 2 arm for and fall when removed from the support Do not apply any lifting pressure machine if not properly attached to the overhead crane 28 Attach the lifting strap from an overhead crane to the number 2 arm at the upper pivot end 29 Raise the number 2 arm slightly and remove the 4 x A x 11 inch 10 x 10 x 28 cm block Genie 80 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Secondary Boom Components 36 Remove the pin retaining fasteners from both 40 Remove the number 2 arm from the machine compression link pivot pins Do not remove the pins AWARNING Crushing hazard The number 2 arm could become 37 Use a soft metal drift to remove the lower unbalanced and fall when compression link pivot pin at the number removed from the secondary 3 arm boom assembly if not properly 38 Support the compression link with an supported by the overhead appropriate
143. models with rotating jib boom 6 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not The platform rotator is a hydraulically activated remove the pin helical gear assembly used to rotate the jib boom 7 Place a block of wood under the platform 180 degrees leveling slave cylinder for support Protect the cylinder rod from damage How to Remove the Jib Boom 8 Remove the pin retaining fasteners from the Rotator jib boom bell crank at the extension boom Use a soft metal drift to remove the pin Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose 9 Use a soft metal drift to remove the slave end must be replaced All connections must be cylinder rod end pivot pin torqued to specification during installation Refer to 10 Remove the jib boom bell crank from the Specifications Hydraulic Hose and Fitting Torque extension boom Specifications Crushing hazard The jib boom 1 Remove the jib boom Refer to Repair AWARNING bellcrank may become Procedure How to Remove the Jib Boom unbalanced and fall if it is not 2 Support and secure the jib boom rotator to an Ada aati when it is appropriate lifting device removed from the machine 3 Remove the eight mounting bolts from the jib boom rotator mount 4 Remove the center bolt Carefully remove the jib boom rotator from the machine A WARNING Crushing hazard The jib boom rotator could become unbalanced and fall when removed
144. nal valve H HH qun 2 position 2 way solenoid valve Part No 119817 Genie BRAND Z 40 23N Z 40 23N RJ 141 Service Manual September 2015 a m iss A This page intentionally left blank 1 1 1 142 2 40 23 Z 40 23N RJ Part No 119817 September 2015 Service Manual Electrical Schematic Chassis 143 Service Manual September 2015 Electrical Schematic Chassis A B G H J K L M
145. nbalanced and fall when removed from the machine if not properly attached to the overhead crane AWARNING Crushing hazard The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ 73 Service Manual September 2015 Primary Boom Components 4 4 3 Remove the hose and cable guard from the upper pivot Primary Boom Extension Cvlind 4 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The AWARNING Bodily injury hazard Spraying primary boom extension cylinder is equipped with hydraulic oil can penetrate and counterbalance valves to prevent movement in the burn skin Loosen hydraulic event of a hydraulic line failure connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to How to Remove the Primary Boom Extension Cylinder 5 Locate the primary extension boom drive AWARNING Bodily injury hazard This speed limit switch inside the extension boom procedure requires specific repair at the pivot end skills lifting equipment and a suitable workshop Attempting 6 Remove the primary extension boom drive this procedure without these skills speed limit switch mountin
146. nded 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 Specifications 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 valves 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 40 22 4 40 30 20 10 0 14 32 50 68 86 104 122 F 10 20 30 40 50 Ambient air temperature 1 Chevron hydraulic 5606 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Genie BRAND Z 40 23N Z 40 23N RJ 3 Part No 119817 Service Manual September 2015 Specifications Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C 7 5 cSt 104 F 40 C 33 5 Brookfield Viscosity cP 4 F 20 C 1040 cP 22 F 30 C 3310 Flash point 375 F 190 C Pour point 58
147. ng out of the bleed screw Close the bleed screw Crushing hazard Keep clear of the platform during rotation Clean up any hydraulic oil that may have spilled Rotate the platform fully in both directions and inspect the bleed screws for leaks September 2015 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 of the machine is compromised and it could tip over Note Perform this procedure with the machine on a firm level surface 1 the key switch to platform control 2 Determine the maximum platform capacity Refer to the machine serial plate 3 Remove all weight tools and accessories from the platform Note Failure to remove all weight tools and accessories from the platform will result in an incorrect calibration 4 Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor Genie Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Determine the limit switch trigger point 5 Gently move the platform up and down by hand so it bounces approximately 1 to 2 inches 2 5 to 5 cm Allow the platform to settle Result The overload indicator lig
148. nifold Components The function manifold is located behind the ground controls turntable cover Index zi Schematic No Description Function Torque Coil nut 4 5 ft lbs 5 7 Nm 1 Proportional solenoid valve BU Primary boom extend retract 16 20 ft lbs 24 27 Nm 3 position 4 way Orifice 0 046 inch 1 17 mm BM Secondary boom down Proportional solenoid valve BS Primary boom up down 16 20 ft lbs 24 27 Nm 3 position 4 way 4 Proportional solenoid valve BC Steer left right 16 20 ft lbs 24 27 Nm 3 position 4 way 5 Proportional solenoid valve BN Secondary boom up down 18 20 ft lbs 25 27 Nm 3 position 4 way Relief valve 2100 psi 145 bar BP Secondary boom down 18 20 ft lbs 25 27 Nm 7 Pressure compensator valve 80 psi BL Turntable rotate circuit 25 25 ft lbs 34 36 7 Nm 5 5 bar 8 Proportional solenoid BK Turntable rotate left right 18 20 ft lbs 25 27 Nm valve 3 position 4 way 9 Shuttle valve BJ Turntable rotate circuit 4 5 ft lbs 5 7 Nm 10 Counterbalance valve 1000 psi BT Primary boom down 44 52 ft lbs 60 70 Nm 70 bar 11 Proportional relief valve 50 to BW System relief 18 20 ft lbs 25 27 Nm 3000 psi 3 to 207 bar 12 Needle valve BH Primary level up down 18 20 ft lbs 25 27 Nm 13 Check valve 4 psi 0 3 bar BA Prevents oil from draining from 20 ft lbs 27 Nm turntable rotate circuit back to tank 14 Check valve 25 psi 1 7 bar BX System relief valve c
149. nly necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom Refer to Repair Procedure How to Remove the Extension Cylinder 1 Remove the primary boom Refer to Repair Procedure How to Remove the Primary Boom 2 Place blocks under the extension cylinder for support 3 Remove the retaining fasteners from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 4 Remove and label the location of the wear pads from the top side of the boom tube at the platform end of the boom Note Pay careful attention to the location and amount of shims used with each wear pad Genie BRAND Z 40 23N Z 40 23N RJ 71 Part No 119817 Service Manual September 2015 Primary Boom Components 5 Support and slide the extension tube and extension cylinder assembly out of the boom tube A WARNING Crushing hazard The boom extension tube could fall when removed from the boom if not properly supported Note During removal the overhead crane strap will need to be adjusted for proper balancing 6 Remove the external snap rings from the extension cylinder rod end pivot pin at the platform end of the extension tube Use a soft metal drift to remove the pin 7 Support and slide the extension cylinder out of the base end of the extension tube Place the extension cylinder on blocks for support AWARNING
150. o 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 2015 BZ gt TI Table of Contents Introduction Introduction Important ii Find a Manual for this aaa aaa nennen ii Revision a iii Serial Number Legend rnm dy ter t rd pe hinges V Section 1 Safety vi General Safety vi Section 2 a d a Ode De ERE Ra SR 1 Machine Specifications 1 Performance Specifications aaa aaa 2 Fydraulic SpeCifiCatloN ois 3 Hydraulic Component Specifications 2 22 000 5 Manifold Component 2 5 Machine Torque 6 Hydraulic Hose and Fitting Torque Specifications 7 Torque Procedure 8 SAE Metric Fasteners Torque 10 Genie viii Z 40 23N Z 40 23N RJ Part No 119817 September 2015 NN A
151. o the turntable control module TCON located under the ground control box Genie BRAND Z 40 23N Z 40 23N RJ 21 Part No 119817 Service Manual ja A PRE Checklist B Procedures 10 11 12 13 22 Remove the drive chassis cover from the 14 nonsteer end of the machine 15 Inspect the following areas for burnt chafed corroded pinched and loose wires 16 e Drive motors e Motor controllers e Electrical contactor Inspect for a liberal coating of dielectric grease at the following locations e Motor controller wire harness connectors 17 Remove the drive chassis cover from the steer end of the machine Remove the cover from the fuse box located above the steer axle Inspect the following areas for burnt chafed corroded pinched and loose wires e Fuses e Steer sensor and harness Install the fuse box cover and both drive chassis covers Raise the secondary boom until the mid pivot is approximately 10 feet 3 m off the ground Remove the center turntable cover Inspect the following areas for burnt chafed and pinched cables e Turntable area Auxiliary power unit Genie Z 40 23N Z 40 23N RJ September 2015 Install the center turntable cover Lower the boom to the stowed position and turn the machine off Inspect the following areas for burnt chafed corroded pinched and loose wires e Cable track on the primary jib and secondary booms e Jib boom to platform cable harness
152. oad indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped September 2015 5 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Result The platform overload indicator lights are on and the alarm is sounding Calibrate the platform overload system Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped Illustration 1 6 Using a suitable lifting device place additional 10 Ibs 23 kg of weight onto the platform Result The alarm should sound The platform overload indicator lights should be flashing at both the ground and platform controls Result The alarm does not sound the platform overload indicator lights are not flashing Calibrate the platform overload system Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Genie 0 2 2 40 23 Z 40 23N RJ Part No 119817 September 2015
153. oming out of the bleed screw AWARNING Crushing hazard Keep hands and head clear of the jib boom during rotation Rotate the jib boom to the right until the jib boom is centered Open the bottom bleed screw Rotate the jib boom to the right and continue holding the platform rotate toggle switch until air stops coming out of the bleed screw AWARNING Crushing hazard Keep hands and head clear of the jib boom during rotation Close the bleed screw 10 Rotate the jib boom full left and right and inspect the bleed screws for leaks AWARNING Crushing hazard Keep hands and head clear of the jib boom during rotation Turn the key switch to the off position and clean up any hydraulic oil that may have spilled Part No 119817 September 2015 I ssm wJ 8 3 4 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder 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 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weigh
154. onnections 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 Genie BRAND Z 40 23N Z 40 23N RJ 85 Part No 119817 Service Manual September 2015 Hydraulic Pump How to Calibrate the Function 6 When the display leaves SYSTEM READY Pump mode release the drive enable toggle switch and the steer rocker switch Calibration of the function pump is essential to Result The display will show FAULTS good machine performance and service life Continued use of an uncalibrated or improperly 7 activate the steer rocker switch in calibrated function pump could result in reduced the right direction until SETTINGS is shown on machine performance The function pump must be the display calibrated before machine functions are calibrated 8 Momentarily activate the drive enable toggle or before adjusting boom function speeds switch in the right direction to enter the Note This procedure must be performed with the SETTINGS menu rotary speed controller turned to the full clockwise Result The display will show VALVE AND position PUMP SETTINGS 1 Calibrate the proportional relief valve Refer to 9 Momentarily activate the drive enable toggle Repair
155. or 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 activator pin is engaged into the sensor Note The arrow on the steer sensor cover should point towards the front of the machine 9 Connect the steer sensor harness to the main harness 10 Seta voltmeter to read DC voltage Probe the back of the electrical connector at the orange wire using the positive lead of the voltmeter Probe the back of the electrical connector at the black wire using the negative lead of the voltmeter 11 Turn the key switch to platform control 12 Pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Genie BRAND Z 40 23N Z 40 23N RJ 99 Part No 119817 Service Manual September 2015 Steer Axle Components 13 Adjust the steer sensor cover so that the volt 5 meter reads 2 5V DC 14 Tighten steer sensor cover fasteners 15 Install the cable clamp to secure the steer sensor cable to the drive chassis 16 Install the drive chassis cover P 17 Calibrate the steer sensor See How to Calibrate the Steer Angle Sensor 7 How to Calibrate the Steer Angle Sensor 8 1 Turn the key switch to platform control 2 Pullout the red Emergency Stop button to the 9 on position at both the gr
156. or annually whichever comes first Replacement of the high pressure hydraulic filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filters be replaced more often The high pressure hydraulic filter is equipped with a sensor that will detect a clogged filter If the filter becomes clogged a warning or fault message will be shown on the LCD display screen at the platform controls The sensor and its accompanying fault should not be used as an indication of when to perform machine maintenance CAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 1 Openthe power unit side turntable cover and locate the high pressure hydraulic filter above the power unit 2 Place a suitable container under the hydraulic filter Genie 38 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 3 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing 4 Remove the filter element from the housing Inspect the housing seal and replace it if necessary 6 Install the new filter element into the housing and tighten securely 7 Clean up oil that may have spilled during the installation procedure 8 the key switch to ground controls and pull the red
157. or reference 2 Lower the boom to the stowed position 3 Turn the key switch to platform controls 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 5 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 6 Measure the distance between the test line and your machine reference point Refer to Specifications Performance Specifications Note The brakes must be able to hold the machine on any slope it is able to climb B 9 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turnthe key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the boom to the stowed position 4 Choose a point on the machine i e contact patch of
158. orm control 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls Do not press down the foot switch 4 Move and hold the drive enable toggle switch in the right direction and hold 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 To access active faults 6 Momentarily activate the drive enable toggle Switch in the right direction until ACTIVE FAULTS is shown on the display 7 Momentarily 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 direction until MOTOR CONTROLLER FAULTS is shown on the display 11 Momentarily activate the drive enable toggle switch in the right direction to access the motor controller fault codes 12 Activate the steer rocker switch in the right direction to scroll through the fault codes 13 Refer to the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected 14 To exit the fault
159. otor controller 16913 Current sensor time No functions or drive Replace the AC motor controller out 21776 EEPROM warning No functions or drive Replace the AC motor controller Genie 122 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Motor Controller Fault Codes Drive Motor Thermal Sensor The thermal sensor is monitored by the motor controllers to maintain optimum performance and as a thermal shutdown protection device Normal safe operating range is between 40 F 40 C and 131 F 55 at an 85 duty cycle Thermal faults will occur when the temperature exceeds its threshold of 302 F 150 C Then drive speeds will be reduced by 50 Thermal shut down occurs at 392 F 200 C How to Test the Thermal Sensor 1 Disconnect the battery packs from the machine A WARNING 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 Genie BRAND Remove the fasteners from the axle covers from the non steer axle Remove the covers 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 Measure the drive motor case temperature using a thermometer Measur
160. ound and platform controls 3 Using the thumb rocker switch on the drive 10 joystick adjust the steer wheels so they are pointing straight ahead in line with the nonsteer wheels Release the foot switch 4 Move and hold the drive enable toggle switch in the right direction while holding the steer 11 rocker switch in the right direction Genie 100 Z 40 23N Z 40 23N RJ When the display leaves SYSTEM READY mode release the drive enable toggle switch and the steer rocker switch on the drive steer joystick Result The display will show FAULTS Momentarily activate the steer rocker switch in the right direction until SETTINGS is shown on the display Momentarily activate the drive enable toggle switch in the right direction until VALVE AND PUMP SETTINGS is shown on the display Momentarily activate the steer rocker switch in the right direction until you see the AUTHORIZATION screen Momentarily activate the drive enable toggle switch in the right direction to enter the AUTHORIZATION screen Using the rocker switch on the drive joystick momentarily activate steer left left right and left Result The alarm should sound Momentarily activate the steer rocker switch in the right direction until you see the DRIVE SETTINGS screen Part No 119817 Service Manual September 2015 12 Momentarily activate the drive enable toggle 19 Switch in the right direction to enter the DRIVE SETTINGS menu Result The
161. ponent damage hazard Hoses and cables can be damaged if the primary boom extension cylinder is dragged across them Note Note the length of the cylinder after removal The cylinder must be at the same length for installation Primary Boom Components 4 5 Platform Leveling Master Cylinder The platform leveling master cylinder acts as a pump 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 AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 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 Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom until both the rodend and barrel end pivot pins of the master cylinder are accessible Genie BRAND Z 40 23N Z 40 23N RJ 75 Part No 119817 Service Manual September 201
162. r pivot pins Genie 72 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Support both ends of the primary boom lift cylinder with a second overhead crane or similar lifting device Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING 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 Service Manual Primary Boom Components Lower the rod end of the lift cylinder onto the block Protect the cylinder rod from damage AWARNING Crushing hazard The primary boom could become unbalanced and fall when removed from the machine if not properly attached to the overhead crane 10 Remove the primary boom lift cylinder barrelend pivot pin retaining fasteners Use a slide hammer to remove the barrel end pivot pin Carefully remove the primary boom lift cylinder from the machine squirt or spray AWARNING Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device 7 Place a support block across both turntable covers under the primary boom lift cylinder 8 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Crushing hazard The primary Use a soft metal drift to remove the pin AWARNING boom could become u
163. r short from TCON Primary boom 15 Value too low disabled P2 4 to the retract coil Replace retract valve coil 32 SEC_UP_VALVE 12 Value too high Secondary up function Check for open or short from TCON Secondary boom up 15 Value too low disabled P2 7 to the secondary up coil valve Replace coil Genie 112 Z 40 23N 2 40 23 RJ Part No 119817 September 2015 Service Manual Control System Fault Codes Error Source Error Type ID Name ID Name Condition Solution 33 SEC DN VALVE 12 Value too high Secondary down function Check for open or short from TCON Secondary boom 15 Value too low disabled P2 8 to the secondary down coil down valve Replace coil 36 JIB UP VALVE 12 Value too high Jib up function disabled Check for open or short from PCON Jib boom up valve 15 Value too low P2 5 to the jib up coil Replace coil 37 JIB DN VALVE Jib 12 Value too high Jib down function Check for open or short from PCON boom down valve 15 Value too low disabled P2 6 to the jib down coil Replace coil counter clockwise function disabled 41 TT_ROT_JYSTK 11 Shorted high 5V Turntable rotate Inspect and repair joystick wiring Turntable rotate 12 Value too high functions disabled Replace joystick joystick 15 Value too low 16 Value at OV 17 Not calibrated Turntable rotate Calibrate joystick Replace joystick functions disabled
164. r troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert A personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous A CAUTION 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 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 Qai 1 1 1 1 46 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 1 1 Joysticks How to Calibrate a Joystick The joysticks on this machine utilize digital Hall Effect technology for proportional control If a joystick is disconnected or replaced it must be calibrated before that particular machine function will operate Note The joystick must be calibrated before the threshold max out or ramp rate can be se
165. r units Cap the contamination to verify that changing the oil is fittings on the hydraulic tank necessary If the hydraulic oil is not replaced at the 5 disconnect and plug the hydraulic hose a year RAS from the drive motor case drain filter at the LL hydraulic tank Cap the fitting on the hydraulic Note When removing a hose assembly or fitting tank the O ring if equipped on the fitting and or hose 6 Tag disconnect and plug the hydraulic hose at end must be replaced connections must be the return filter Cap the fitting on the return torqued to specification during installation Refer to filter housing Specifications Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the boom in the stowed position Genie 5 5 Part No 119817 Z 40 23N Z 40 23N RJ 41 Service Manual ANN gt DLL EB Checklist E Procedures 7 AWARNING 10 A WARNING 11 A WARNING 42 Remove the turntable cover using a suitable lifting device Crushing hazard The turntable cover may become unbalanced and fall if not properly supported and secured to a suitable lifting device Remove the ground control box mounting fasteners Move the ground control box out of the way Remove the cover from the auxiliary power unit batteries Tag and disconnect the cables from the auxiliary power unit batteries Electrocution burn hazard Contact with electrically charged circu
166. rection to be corrected Slowly turn the rotary speed control in the clockwise direction just until the function begins to move Momentarily activate the drive enable toggle switch in the right direction Result The alarm should sound indicating the setting has been saved Joystick controlled functions Note Begin this procedure with the rotary speed control at the plaform controls turned fully in the clockwise direction 11 Press down on the foot switch and slowly move the joystick in the direction to be corrected until the function begins to move Momentarily activate the drive enable toggle switch in the right direction Result The alarm should sound indicating the setting has been saved To exit programming mode 12 Move and hold the drive enable toggle switch in the left direction until the display screen returns to SYSTEM READY Genie 48 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Platform Controls How to Adjust the Maximum 5 When the display leaves SYSTEM READY Speed Settin mode release the drive enable toggle switch 9 and the steer rocker switch The maximum speed setting of a joystick and toggle switch controls the maximum speed of a PRPUCTNEG PIE WI SHOWER ETF machine function Whenever a hydraulic cylinder 6 Momentarily activate the steer rocker switch in drive motor or hydraulic pump is replaced the the right direction until SETTINGS is shown on ma
167. rection will also change the opposite direction Genie BRAND Z 40 23N Z 40 23N RJ 53 Part No 119817 Service Manual September 2015 Platform Controls 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 down time factory settings Primary boom up down decelerate 1 5 second Secondary boom up down decelerate 0 65 second Turntable rotate decelerate 0 25 second Extend Retract decelerate 0 5 seconds Jib up down decelerate 0 25 second Platform rotate decelerate 0 15 second Jib rotate if equipped decelerate 0 25 seconds How to Adjust the Max Speed Drive 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 direction while holding the steer rocker switch in the right direction
168. rform 30 Day Service The 30 day maintenance procedure is a onetime procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures All Models e 3 Inspect the Tires Wheels and Lug Nut Torque e 4 Check the Drive Hub Mounting Bolts e D 2 Check the Turntable Rotation Bearing Bolts e 0 3 Check the Axle Mounting Bolts e D 4 Check the Platform Rotation Mounting Bolts D 7 Replace the Hydraulic Filters Checklist A Procedures A 5 Grease the Turntable Rotation Bearing and Worm Drive Gear Genie specifications require that this procedure be performed every 100 hours of operation Perform this procedure more often if dusty conditions exist Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Open the ground controls side turntable cover 2 Locate the grease fitting for the turntable rotate bearing 3 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 4 Apply grease to each tooth of the drive gear located under the turntable Grease Specification Chevron
169. rocedure 4 2 Electronic Version Section Fault Codes All charts the update Section Schematics Legends and schematics Click on any content or procedure in the Table of Contents to view Genie Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Introduction Serial Number Legend Genie A TEREX COMPANY Model Z 40 23 Serial number 2402307 12345 Model year 2007 Manufacture date 02 01 07 Electrical schematic number Machine unladen weight Rated work load including occupants XX kg Maximum number of platfrm occupants XX Maximum allowable side force XXN Maximum allowable inclination of the chassis 0 deg Maximum wind speed XX m s Maximum platform height XX m Maximum platform reach XX m Gradeability N A Country of manufacture USA This machine complies with Genie Industries 18340 NE 76th Street Redmond WA 98052 USA DOMEN 1 Model 2 Model year 3 Sequence number 4 Serial number stamped on chassis 5 Serial label located under cover Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ V Service Manual September 2015 Safety Rules 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
170. rs before continuing this procedure to allow the battery cells to equalize Put on protective clothing and eye wear Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 13 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 10 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 20 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual 12 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 below 80 F 26 7 Result All battery cells display a specific gravity of 1 277 or greater T
171. s Color Circuit Primary Function Color Circuit Primary Function OR RD 155 Pressure Comp Enable GR WH 176 Secondary Extend Retract Flow GN WH 156 Jib Up Down Control BK RD 157 Jib Extend Retract BL RD 177 Extend Retract Lockout BL RD 158 Steer Signal Rocker BK 178 Control Module Status Light BL WH 159 Steer Joystick Signal GR 179 Drive Power Relay WH RD 160 Propel Joystick Signal BK 180 Lift Power Relay WH BK 161 Secondary Boom Joystick OR 181 48 volt Alternator Field or Signal battery OR 162 Joystick 5V DC power RD 182 24 volt battery BL WH 163 Primary Extend Retract Signal BL 183 or Load Sense RD WH 164 Primary PAT Signal WH 184 Program Set up Enable WH RD 165 Rotate a WH 185 Encode A OR 166 Boom Length Signal Safety BL 186 Encode SRBE ca BL 187 Bootstrap or Program Enable BL RD 168 Primary Boom Hydraulic SR onal Gross Check Lockout BK 189 Data Receive GN 169 Envelope Active LED BK WH 190 Data Transmit WH RD 170 Load Sense Relay Source WH RD 191 Multi function Pressure Relief WH BK 171 Load Sense Relay Sink WH BK 192 Jib Rotate Left BL 172 Up Down Flow Control Ground WH RD 193 Jib Rotate Right BK 173 Extend Retract Flow Control WH RD 194 Speed Select Input rouna OR RD 195 Electric Brake Source WH 174 Power Ground YL 196 2 5 volt Sensor Power WH BK 175 Load Sensor Signal Operational Gania 134 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 AP2
172. sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Checklist C Procedures 2 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over The platform overload system is designed to detect an overloaded platform and prevent machine operation anytime the machine is turned on When activated the system halts all normal boom operation giving visual and audible warning to the operator Models equipped with the platform overload option are provided with additional machine components an adjustable spring loaded platform support subassembly a limit switch an electronic module which receives the overload signal and interrupts power and an audio visual warning indication to alert the operator of the overload Genie
173. slowly to allow serious injury and significant the oil pressure to dissipate component damage Dealer gradually Do not allow oil to Service is strongly recommended squirt or spray Note Perform this procedure with the boom in the 5 Raise the primary boom until the master stowed position cylinder barrel end pivot pin is accessible Note When removing a hose assembly or fitting 6 Remove the pin retaining fastener from the the O ring if equipped on the fitting and or hose master cylinder barrel end pivot pin Use a soft end must be replaced All connections must be metal drift to remove the pin Lower the torqued to specification during installation Refer to cylinder and let it hang down Specifications Hydraulic Hose and Fitting Torque Specifications Component damage hazard When lowering the master 1 Remove the jib boom Refer to Repair cylinder down be sure not to Procedure How to Remove the Jib Boom damage the master cylinder 2 Models without rotating jib boom Remove hoses or Minge the jib boom bellcrank Refer to Repair gt 7 Locate the primary boom drive speed limit Procedure How to Remove the Jib Boom switch inside the upper pivot Bellcrank Models with rotating jib boom Remove the jib boom rotator Refer to Repair Procedure How to Remove the Jib Boom Rotator Ganie 1 0 0 0 Part No 119817 Z 40 23N Z 40 23N RJ 69 Service Manual Primary Boom Components September 2015 8 Remove
174. t NA PLATFORM CONTROL BOX MIMIMIMIMIMINIMINIE e eem X 9 M M 2 E 88 SB SESS BB B B 7 M E 5 ll 5 m x HH HEER FRE Sh Ez 8 5 Bac a gt 282 2 5 TO C4 AT GROUND GONTROL BOX ES CASGEN OR AEP Paps WHBK c PALPSBURD amp 5 I 1 2 8 a i C46GEN OR 2 1 H 82 5 5 m Ek GND ORBK a OVERLOAD 5 lt FST ALBO FOOTSWITCH HT sz Genie BRAND 148 Z 40 23N Z 40 23N RJ Part No 119817 D September 2015 Service Manual Ground Control Box Wiring Diagram K L M TS68 P109PWR GRAWH TS62 C186PWR YL cei C2gTTS RD BK 1857 C134PWR RD C134PWR RD KS1 1 P22BAT BK 285 36 P22BAT BK P181BAT OR 184 OR P181BAT OR V15PLDB V15PLDA OR BK V14PLUB OR V14PLUA OR V378CCB 7 BL BK V38BCWB BL V35SCWA BL V191PCEA WH RD V191PCEB WH RD BR GND C134PWR AD ALARM C134PWR RD ABOTA WH RD 02 12 OR P22BAT L 56560060000000J RD C134PWR P161BAT OR P23BAT WH
175. t 1 Turn the key switch to platform control 2 Pullout the red Emergency Stop button to the ON position at both the ground and platform controls Open the platform control box 4 Selecta joystick to calibrate Do not press down on the foot switch 5 Disconnect the wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds Result The alarm should sound a long beep indicating the joystick has lost calibration After 3 seconds the alarm should sound a short beep to enter calibration mode Connect the wire harness connector to the joystick Result The alarm should sound a long beep setting the neutral calibration point Geni BRAND Z 40 23N Z 40 23N RJ Part No 119817 Platform Controls 7 Move the joystick full stroke and hold for 5 seconds in each direction Result The alarm should sound a short beep indicating successful joystick calibration in each direction 8 Joysticks with a thumb rocker switch Press down and hold the thumb rocker switch in each direction Result The alarm should sound a short beep indicating successful joystick calibration in each direction 9 Repeat this procedure for each joystick controlled machine function Note No machine function should operate while performing the joystick calibration procedure 47 Service Manual September 2015 Platform Controls How to Adjust the Joystick Threshold Set
176. t of the boom on the blocks 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Service Manual Jib Boom Components 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 Support the jib boom with a suitable lifting device Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin Let the cylinder hang down Crushing hazard The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the jib boom lift cylinder from the machine Bodily injury hazard Spraying A WARNING hydraulic oil can penetrate and AWARNING Crushing hazard The jib boom burn skin Loosen hydraulic lift cylinder may become connections very slowly to allow unbalanced and fall when it is the oil pressure to dissipate removed from the machine if it is gradually Do not allow oil to not properly supported by the squirt or spray overhead crane 3 Remove the pin retaining fasteners from
177. t operate machine with Right side drive batteries charging Check cable motor connections Check for 33V AC across any two legs on drive motor at full stick Replace right drive motor Replace right master AC motor controller 15 Value too low Drive function disabled Check cable connections Check for 33V AC across any two legs on drive motor at full stick Replace right drive motor Replace right master AC motor controller 22 Fault Drive function disabled Check wires to thermal sensor at 6 wire deutsch plug on motor Check resistance on thermal sensor Gene O0 1 114 2 40 23 Z 40 23N RJ Part No 119817 September 2015 iR aa RAND Control System Fault Codes Service Manual ID Error Source Name Error Type ID Name Condition Solution 53 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 Drive function disabled Check cable connections Check for 33V AC across any two legs on drive motor at full stick Replace right drive motor Replace right master AC motor controller 22 Fault Drive function disabled Check wires to thermal sensor
178. t 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 Genie Z 40 23N Z 40 23N RJ September 2015 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 slow blinking light to a rapid blinking light Result The green LED on the TCON does not blink rapidly Push in the red Emergency Stop button to the off position and repeat this procedure beginning with step 3 3 1 green LED 2 red LED 3 turntable control module TCON Part No 119817 September 2015 Service Manual 4 Move hold the secondary boom toggle switch in the down direction Result The pressure gauge shows 1100 psi 76 bar Continue to step 6 MM Result The pressure gauge does not show 1100 psi 76 bar Continue to step 5 Note Do not activate the function enable toggle switch while making this adjustment 5 Move hold the secondary boom toggle switch in the down 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 4 Note Momentarily activating the pl
179. tform rotate 180 9 to 15 seconds Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie On paved surface 5 to 7 ft 1 5 to 2m Gradeability See Operator s Manual 2 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual Hydraulic 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 conditioning and foam and aeration suppression properties Cleanliness level ISO 15 13 minimum Water content 250 ppm maximum Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron 5606A Petro Canada Environ MV 46 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 Mineral based Biodegradable Fire resistant Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Exte
180. tform 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 AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw AWARNING Crushing hazard Keep clear of the platform during rotation Genie BRAND Z 40 23N Z 40 23N RJ 57 Service Manual Platform Components 5 AWARNING A WARNING 58 Open the bottom bleed screw on the rotator but do not remove it Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right Continue holding the toggle switch until air stops comi
181. 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 the machine A WARNING Crushing hazard The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 49 Remove the pin retaining fasteners from the number 4 arm at the turntable pivot Do not remove the pin 50 Attach a lifting strap from the overhead crane to the center point of the number 4 arm Do not apply any lifting pressure 51 Use a slide hammer to remove the number 4 arm from the turntable pivot through the access hole in the counterweight 52 Remove the number 4 arm from the machine A WARNING Crushing hazard The number 4 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 5 2 Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Secondary Boom Lift Cylinder A WARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant compon
182. the primary boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 the key switch to ground controls and pull out the red Emergency Stop button to the ON position at both the ground and platform controls N Lower the boom to the stowed position Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch 4 Raise and lower the primary boom through a full cycle Result The platform should remain level at all times to within 5 degrees Genie BRAND Z 40 23N Z 40 23N RJ 25 Part No 119817 Service Manual September 2015 Checklist B Procedures B 8 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational AWARNING Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration Refer to maintenance procedure Confirm the Proper Brake Configuration Note Select a test area that is firm level and free of obstructions 1 test line on the ground f
183. 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 alarm etc Refer to Fault Codes section for a list of fault codes and additional information For further information or assistance consult the Genie Product Support 106 Z 40 23N Z 40 23N RJ VCON Visual Controller LCD Display Right Master Motor Left Slave Motor Controller Controller TCON System 2 Outputs Lift NODE 5 Controller Master Pump Net Master Outputs AUX Pump KN w PCON Drive Steer NODE 3 Right Drive NODE 4 Left Drive Inputs Motor Motor Genie Part No 119817 September 2015 Service Manual Observe and Obey Part 119817 Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface e Key switch in the off position with the key removed The red
184. time has been achieved activate accelerate 1 second the drive enable toggle switch to the right to Extend Retract save your changes accelerate 0 5 second Result The alarm should sound indicating the Jib up down 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 Genie 52 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual How to Adjust the Function Ramp Down Time Setting The ramp down time setting of a function controls the time at which it takes for the function to come to a complete stop when returned to the neutral position The ramp down time of a function can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Begin this procedure with the rotary speed control at the platform turned fully in the clockwise direction 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 Do not press 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 st
185. ting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate Note Perform this procedure with the boom in the stowed position 1 Turn the key switch to platform control Do not start the engine 2 Pull out the red Emergency Stop button to the ON position at both the ground and platform controls Do not press 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 display 7 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND PUMP SETTINGS is shown on the display 8 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 direction 10 Press down on the foot switch and activate the function in the di
186. tional solenoid valve 3 position AB Platform rotate left right 18 20 ft lbs 25 27 Nm 4 way 3 Proportional solenoid valve 3 position AC Jib boom rotate left right 18 20 ft lbs 25 27 Nm 4 way 3 AC 2 AB 1 e 22 0 9 Q Genie LL 0 0 Part No 119817 Z 40 23N Z 40 23N RJ 95 Service Manual September 2015 Manifolds 7 5 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures Note 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 Q Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 1
187. ttach a strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder for support Do not apply any lifting pressure 5 Usea soft metal drift to drive the barrel end pivot pin half way out Lower the barrel end of the secondary boom lift cylinder and let it hang down 6 Use a soft metal drift to drive the rod end pivot pin half way out Genie 1 1 1 1 1 1 1 Part No 119817 Z 40 23N Z 40 23N RJ 83 Service Manual September 2015 Hydraulic Pump 6 1 3 How to Remove the Auxiliary Remove the center turntable cover fasteners Remove the cover from the machine 5 Tag disconnect and plug the hydraulic hoses Pump from the auxiliary pump Cap the fittings on the pump How to Remove the Auxiliary AWARNING Bodily injury hazard Spraying Pump hydraulic oil can penetrate and burn skin Loosen hydraulic Note When removing a hose assembly or fitting connections very slowly to allow the O ring if equipped on the fitting and or hose the oil pressure to dissipate end must be replaced All connections must be gradually Do not allow oil to torqued to specification during installation Refer to squirt or spray Specifications Hydraulic Hose and Fitting Torque Specifications 6 Remove the auxiliary pump mounting bolts Carefully remove the pump 1 Raise the secondary boom approximately 6 ft 2 m Turn the machine off 2 Place a suitable container under the hydraulic tank Refer to Specifications Machine Specif
188. ture printings of this and all other manuals Contact Us Internet www genielift com E mail awp techpub terex com Genie Z 40 23N 2 40 23 RJ Find a Manual for this Model Go to http www genielift com Use the links to locate Operator s Parts or Service Manuals Copyright 2011 by Terex Corporation 119817 Rev B September 2015 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 Part No 119817 September 2015 Service Manual Introduction Revision History Revision Date Section Procedure Page Description A4 12 2014 Repair Added 2 4 Platform Overload Recovery B 9 2015 Added ending serial break to front cover Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 Electronic Version Click on any content or procedure in the Table of Contents to view Section Fault Codes All charts the update Section Schematics Legends and schematics Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ iii Service Manual Introduction September 2015 Revision History Revision Date Section Procedure Page Description Reference Examples Section Maintenance B 3 Section Repair P
189. ures section and the Maintenance Inspection Report have been divided into subsections Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Genie BRAND Z 40 23N Z 40 23N RJ 13 Part No 119817 Service Manual September 2015 O c PNG AN Pre Delivery Preparation Report Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualifie
190. ve 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 Specification Genie BRAND Part No 119817 Z 40 23N Z 40 23N RJ Description Specification Solenoid valve 3 position 4 way 20V DC 240 schematic item BG Proportional solenoid valve 3 position 4 way 240 20V DC schematic items AA AB AC BC BG BK BN BS and BU Proportional solenoid relief valve 20V DC 220 schematic item BW 5 Service Manual September 2015 M gt gt KR A umug Specifications Machine Torque Specifications Platform rotator 3 4 10 center bolt GR 8 dry 380 ft lbs 515 Nm 3 4 10 center bolt GR 8 lubricated 280 ft lbs 379 Nm 3 8 16 bolts GR 8 dry 44 ft lbs 60 Nm 3 8 16 bolts GR 8 lubricated 33 ft lbs 45 Nm Jib boom rotator Z 40 23N RJ 1 8 center bolt GR 5 dry 640 ft lbs 868 Nm 1 8 center bolt GR 5 lubricated 480 ft lbs 650 Nm 1 2 13 bolts GR 5 dry 75 ft lbs 102 Nm 1 2 13 bolts GR 5 lubricated 57 ft lbs 77Nm Axles 5 8 11 mounting bolt GR 5 dry 150 ft lbs 203 Nm 5 8 11 mounting bolt GR 5 lubricated 101 ft lbs 149 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Rotate bearing motor brake mounting bolts 93 ft
191. witch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction B 12 Inspect the Electrical Contactor Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the electrical contactor in good condition is essential to safe machine performance Failure to locate a worn or damaged contactor could result in unsafe operating conditions and may cause component damage 1 Remove the drive chassis cover from the non steer end of the machine and locate the electrical contactor mounted to the inside of the non steer axle 2 Locate the electrical contactor mounted on the fuse bracket 3 Visually inspect the contact points of the contactor for the following items e Excessive burns e Excessive arcs e Excessive pitting A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactor if any damage is found Genie 28 Z 40 23N Z 40 23N RJ Part No 119817 September 2015 Service Manual B 13 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed ever
192. ximum speed setting should be adjusted to the display maintain optimum performance The maximum speed settings can be changed to compensate for 7 Momentarily activate the drive enable toggle hydraulic pump wear and to maintain peak switch in the right direction until VALVE AND performance from the machine PUMP SETTINGS is shown on the display 8 Momentarily activate the drive enable toggle Noe Miele prem oy pes OiMa Spaad switch in the right direction until THRESHOLD High flow functions Primary up down is shown on the display secondary up down and extend retract 9 Momentarily activate the steer rocker switch in Low flow functions Platform rotate jib rotate jib the right direction until VALVE MAXIMUM up down and turntable rotate CURRENT is shown on the display 10 Momentarily activate the drive enable toggle Note Begin this procedure with the rotary speed control at the platform turned fully in the clockwise direction 1 Turn the key switch to platform control switch in the right direction to enter VALVE MAXIMUM CURRENT calibration mode High flow functions 2 Pull out the red Emergency Stop button to the 1 1 1 ON position at both the ground and platform controls Result The display will show the function Do not press down the foot switch 12 Press down on the foot switch and activate the Move ana hele ame Se toggle switch same function in the same direction
193. y 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications refer to Specifications Hydraulic Specifications Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Refer to Maintenance Procedure Test or Replace the Hydraulic Oil Checklist B Procedures B 14 Test the Emergency Power System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Testing the emergency power system regularly is essential to safe machine operation if the primary power source fails 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Atthe ground controls break the security tie and lift the emergency power switch cover if equipped Simultaneously hold the emergency power switch on and activate each boom function toggle sw

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