Beruflich Dokumente
Kultur Dokumente
Introduction
June 2005
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 or repair 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.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
PO Box 97030
Redmond, WA 98073-9730 USA
http://www.genieindustries.com
e-mail: techsup@genieind.com
ii
TMZ-34/19
June 2005
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 identified in the
operators manual are also safety hazards
when maintenance and repair procedures
are performed.
TMZ-34/19
iii
June 2005
SAFETY RULES
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.
Workplace Safety
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.
TMZ-34/19
June 2005
Table of Contents
Introduction
Important Information ......................................................................................... ii
Section 1
Safety Rules
General Safety Rules ........................................................................................ iii
Section 2
Section 3
Rev
Specifications
Rev
Checklist A Procedures
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
TMZ-34/19
June 2005
TABLE OF CONTENTS
Section 3
Rev
C
B-2
B-3
B-4
B-5
B-6
Inspect the Tires and Wheels (including lug nut or lug bolt torque) .... 3 - 16
B-7
B-8
B-9
Checklist C Procedure
C-1
Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil .................................................... 3 - 22
C-2
C-3
Checklist D Procedures
D-1
D-2
D-3
D-4
D-5
Checklist E Procedure
E-1
vi
TMZ-34/19
June 2005
TABLE OF CONTENTS
Section 4
Rev
Repair Procedures
Introduction .................................................................................................. 4 - 1
Platform Controls
1-1
1-2
Platform Components
2-1
Platform .............................................................................................. 4 - 5
2-2
3-2
Boom Components
4-1
Boom ................................................................................................ 4 - 12
4-2
Ground Controls
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
6-2
6-3
TMZ-34/19
vii
June 2005
TABLE OF CONTENTS
Section 4
Rev
C
Repair, continued
Manifolds
7-1
7-2
7-3
7-4
Axle Components
9-1
Axle .................................................................................................. 4 - 46
9-2
Trailer Components
10-1 Trailer Brakes ................................................................................... 4 - 47
10-2 Parking Brake ................................................................................... 4 - 47
Outriggers
11-1 Outrigger Components ...................................................................... 4 - 48
11-2 Outrigger Cylinder ............................................................................. 4 - 49
viii
TMZ-34/19
June 2005
TABLE OF CONTENTS
Section 5
Rev
Chart
Title
10
11
12
13
14
TMZ-34/19
ix
June 2005
TABLE OF CONTENTS
Section 6
Rev
Schematics
Introduction .................................................................................................. 6 - 1
TMZ-34/19
June 2005
Section 2 Specifications
Specifications
REV C
Machine Specifications
Performance Specifications
Batteries
Type
6V DC
Group
T-105
Quantity
Battery capacity
Reserve capacity @ 25A rate
4
225AH
447 minutes
Fluid capacities
Hydraulic tank capacity
Hydraulic system capacity
(including tank)
1.5 gallons
5.7 liters
2.25 gallons
8.5 liters
Jib boom up
10 to 15 seconds
13 to 18 seconds
Primary boom up
30 to 35 seconds
21 to 26 seconds
Secondary boom up
15 to 20 seconds
13 to 18 seconds
55 to 60 seconds
ST195/75-D14
5 @ 1/2 -20
90 to 120 ft-lbs
122 to 162 Nm
65 psi
4.5 bar
195/65R15 91T
5 @ 1/2 -20
90 to 120 ft-lbs
122 to 162 Nm
44 psi
3 bar
4.00 / 3.50-4
10 in
25.4 cm
50 psi
3.4 bar
TMZ-34/19
2-1
Section 2 Specifications
June 2005
REV C
SPECIFICATIONS
Hydraulic Specifications
Pump type:
Displacement
per revolution
1.5 gpm
5.7 L/min
3200 psi
220.6 bar
Hydraulic tank
return filter
Gear
0.057 cu in
0.93 cc
10 micron with
18 psi / 1.2 bar bypass
1200 psi
82.7 bar
Optional fluids
Biodegradable
Fire resistant
Mineral based
2-2
TMZ-34/19
June 2005
Section 2 Specifications
REV C
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2
50 in-lbs / 6 Nm
SAE No. 4
13 ft-lbs / 18 Nm
SAE No. 6
18 ft-lbs / 24 Nm
SAE No. 8
50 ft-lbs / 68 Nm
SAE No. 10
55 ft-lbs / 75 Nm
SAE No. 12
75 ft-lbs / 102 Nm
60 ft-lbs
81 Nm
Specification
29 - 31
31.5 to 33.5
23 to 25
23 to 25
23 to 25
29 - 31
TMZ-34/19
2-3
Section 2 Specifications
June 2005
SPECIFICATIONS
REV C
Seal-Lok fittings
Torque
-4
11 ft-lbs / 14.9 Nm
-6
23 ft-lbs / 31.2 Nm
-8
40 ft-lbs / 54.2 Nm
-10
69 ft-lbs / 93.6 Nm
-12
93 ft-lbs / 126.1 Nm
-16
-20
-24
Seal-Lok Fittings
(hose end)
Torque
Torque
-4
16 ft-lbs / 21.7 Nm
-4
18 ft-lbs / 24.4 Nm
-6
35 ft-lbs / 47.5 Nm
-6
27 ft-lbs / 36.6 Nm
-8
60 ft-lbs / 81.3 Nm
-8
40 ft-lbs / 54.2 Nm
-10
-10
63 ft-lbs / 85.4 Nm
-12
-12
90 ft-lbs / 122 Nm
-16
-16
-20
-20
-24
-24
2-4
TMZ-34/19
June 2005
Section 2 Specifications
REV C
SPECIFICATIONS
SIZE
Grade 5
THREAD
LUBED
20
28
1/4
DRY
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
LUBED
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
100
90
11.3
10.1
80
120
9
13.5
140
120
15.8
13.5
110
160
12.4
18
130
140
14.7
15.8
LUBED
5/16
Grade 8
DRY
LUBED
DRY
LUBED
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
13
14
23
26
37
41
57
64
80
90
110
130
200
220
320
350
480
530
590
670
840
930
1460
1640
17.6
19
31.2
35.2
50.1
55.5
77.3
86.7
108.4
122
149
176
271
298
433
474
650
718
800
908
1138
1260
1979
2223
17
19
31
35
49
55
75
85
110
120
150
170
270
300
430
470
640
710
790
890
1120
1240
1950
2190
23
25.7
42
47.4
66.4
74.5
101.6
115
149
162
203
230
366
406
583
637
867
962
1071
1206
1518
1681
2643
2969
18
20
33
37
50
60
80
90
120
130
160
180
280
310
450
500
680
750
970
1080
1360
1510
2370
2670
24
27.1
44.7
50.1
67.8
81.3
108.4
122
162
176
217
244
379
420
610
678
922
1016
1315
1464
1844
2047
3213
3620
25
27
44
49
70
80
110
120
150
170
210
240
380
420
610
670
910
990
1290
1440
1820
2010
3160
3560
33.9
36.6
59.6
66.4
94.7
108.4
149
162
203
230
284
325
515
569
827
908
1233
1342
1749
1952
2467
2725
4284
4826
21
24
38
43
61
68
93
105
130
140
180
200
320
350
510
560
770
840
1090
1220
1530
1700
2670
3000
28.4
32.5
51.5
58.3
82.7
92.1
126
142
176
189
244
271
433
474
691
759
1044
1139
1477
1654
2074
2304
3620
4067
Class 4.6
Size
(m m )
5
6
7
LUBED
DRY
LUBED
Class 10.9
8.8
DRY
LUBED
Class 12.9
10.9
DRY
LUBED
12.9
DRY
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
in-lbs
Nm
16
19
45
1.8
3.05
5.12
21
36
60
2.4
4.07
6.83
41
69
116
4.63
7.87
13.2
54
93
155
6.18
10.5
17.6
58
100
167
6.63
11.3
18.9
78
132
223
8.84
15
25.2
68
116
1.95
7.75
13.2
22.1
91
155
260
10.3
17.6
29.4
LUBED
8
10
12
14
16
18
20
22
24
Class 8.8
4.6
DRY
LUBED
DRY
LUBED
DRY
LUBED
DRY
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
f t -lbs
Nm
5.4
10.8
18.9
30.1
46.9
64.5
91
124
157
7.41
14.7
25.6
40.8
63.6
87.5
124
169
214
7.2
14.4
25.1
40
62.5
86.2
121
166
210
9.88
19.6
34.1
54.3
84.8
117
165
225
285
14
27.9
48.6
77.4
125
171
243
331
420
19.1
37.8
66
105
170
233
330
450
570
18.8
37.2
64.9
103
166
229
325
442
562
25.5
50.5
88
140
226
311
441
600
762
20.1
39.9
69.7
110
173
238
337
458
583
27.3
54.1
94.5
150
235
323
458
622
791
26.9
53.2
92.2
147
230
317
450
612
778
36.5
72.2
125
200
313
430
610
830
1055
23.6
46.7
81
129
202
278
394
536
682
32
63.3
110
175
274
377
535
727
925
31.4
62.3
108
172
269
371
525
715
909
42.6
84.4
147
234
365
503
713
970
1233
TMZ-34/19
2-5
Section 2 Specifications
June 2005
2-6
TMZ-34/19
June 2005
Symbols Legend
Safety alert symbolused to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
TMZ-34/19
3-1
June 2005
Checklist
A+B
A+B+C
A+B+C+D
A+B+C+D+E
3-2
TMZ-34/19
Pre-Delivery Preparation
Fundamentals
Instructions
Pre-Delivery Preparation
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
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
(425) 881-1800
Genie UK
The Maltings, Wharf Road
Grantham, Lincolnshire
NG31- 6BH England
(44) 1476-584333
June 2005
3-4
TMZ-34/19
June 2005
Checklist A - Rev C
Y N R
Checklist B - Rev C
B-1 Batteries
Date
Hour meter
Machine owner
Serial number
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Make copies of this report to use for
each inspection.
Y N R
Semi-annually or
500 hours or 6000 mile
Inspection:
A+B+C
Checklist C - Rev C
Y N R
Checklist D - Rev C
Y N R
Checklist E - Rev C
Y N R
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
TMZ-34/19
3-5
June 2005
Checklist A Procedures
REV C
A-1
Perform Pre-operation Inspection
A-2
Perform Function Tests
3-6
TMZ-34/19
June 2005
REV C
CHECKLIST A
A-3
Perform Hitch Maintenance ANSI Models
PROCEDURES
A-4
Perform Axle Maintenance ANSI Models
84592
TMZ-34/19
3-7
June 2005
CHECKLIST A
PROCEDURES
REV C
A-5
Perform Axle Maintenance CE Models
A-6
Perform Axle Maintenance CE Models
3-8
84443
84443
TMZ-34/19
June 2005
REV C
CHECKLIST A
A-7
Perform Axle Maintenance ANSI Models
A-8
Perform Axle Maintenance ANSI Models
PROCEDURES
TMZ-34/19
3-9
June 2005
CHECKLIST A
PROCEDURES
REV C
A-9
Perform Axle Maintenance CE Models
A-10
Perform 30 Day Service
3 - 10
B-8
D-1
D-3
84443
TMZ-34/19
June 2005
REV C
CHECKLIST A
PROCEDURES
A-11
Grease the Turntable Rotation
Bearing and Rotate Gear
TMZ-34/19
3 - 11
June 2005
Checklist B Procedures
REV C
B-1
Inspect the Batteries
3 - 12
TMZ-34/19
June 2005
REV C
CHECKLIST B
PROCEDURES
B-2
Inspect the Electrical Wiring
TMZ-34/19
3 - 13
June 2005
CHECKLIST B
PROCEDURES
REV C
B-3
Test the Emergency Stop
B-4
Test the Key Switch
3 - 14
TMZ-34/19
June 2005
REV C
CHECKLIST B
PROCEDURES
B-5
Test the Manual Lowering
Operation
Testing the manual lowering operation for
malfunctions is essential for safe machine
operation. An unsafe working condition exists if the
manual lowering function does not operate in the
event of a main power loss.
1 Raise the primary boom approximately
1 foot / 0.3 m.
TMZ-34/19
3 - 15
June 2005
CHECKLIST B
PROCEDURES
REV C
B-6
Inspect the Tires and Wheels
(including lug nut or lug bolt
torque)
B-7
Service the Tongue Jack
3 - 16
TMZ-34/19
June 2005
REV C
CHECKLIST B
PROCEDURES
B-8
Inspect the Parking Brake
TMZ-34/19
3 - 17
June 2005
CHECKLIST B
PROCEDURES
REV C
B-9
Test the Horn
A functioning horn is essential to safe machine
operation. The horn is activated at the ground,
platform or drive controls and sounds at the ground
as a warning to ground personnel. An improperly
functioning horn will prevent the operator from
alerting ground personnel of hazards or unsafe
conditions.
1 Turn the key switch to platform control and
pull out the Emergency Stop button to the
on position at both the ground and
platform controls.
2 Push down the horn button at the platform
controls.
Result: The horn should sound.
3 Push down the horn button at the ground
controls.
B-10
Test the Flashing Beacon
(if equipped)
The flashing beacon is used to alert operators and
ground personnel of machine proximity and
motion. The flashing beacon is located on the
upper (primary) boom.
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. Pull out the red Emergency Stop
button to the on position at the drive controls (if
equipped).
Result: The beacons should flash.
2 Turn the key switch to platform controls.
Result: The beacons should flash.
3 - 18
TMZ-34/19
June 2005
REV C
CHECKLIST B
B-11
Test the Platform Rotation
(if equipped)
PROCEDURES
B-12
Inspect the Hydraulic Tank Cap
Venting System
TMZ-34/19
3 - 19
June 2005
CHECKLIST B
PROCEDURES
REV C
B-13
Perform Hitch Maintenance ANSI Models
B-14
Perform Axle Maintenance ANSI Models
3 - 20
TMZ-34/19
June 2005
REV C
CHECKLIST B
PROCEDURES
B-15
Perform Hydraulic Oil Analysis
TMZ-34/19
3 - 21
June 2005
Checklist C Procedures
C-1
Replace the
Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil
REV C
C-2
Perform Axle Maintenance ANSI Models
3 - 22
TMZ-34/19
June 2005
REV C
CHECKLIST
C PROCEDURES
C-3
Perform Hitch Maintenance CE Models
84443
TMZ-34/19
3 - 23
June 2005
Checklist D Procedures
REV C
D-1
Check the Turntable Rotation
Bearing Bolts
Tongue
11
9
7
13
15
Tongue
11
3
6
13
16
14
10
12
3
6
15
8
14
10
175 ft-lbs
237 Nm
Bearing-to-chassis, dry
105 ft-lbs
142 Nm
12
3 - 24
TMZ-34/19
June 2005
REV C
CHECKLIST
D-2
Inspect for
Turntable Bearing Wear
D PROCEDURES
a
b
c
d
turntable
dial indicator
drive chassis
turntable rotation bearing
To obtain an accurate
measurement, place the dial
indicator no more than
1 inch / 2.5 cm from the turntable
rotation bearing.
5 At the dial indicator, adjust it to "zero" the
indicator.
TMZ-34/19
3 - 25
June 2005
CHECKLIST
PROCEDURES
REV C
D-3
Replace the Hydraulic Tank
Return Filter
3 - 26
TMZ-34/19
June 2005
REV C
CHECKLIST
D-4
Perform Axle Maintenance ANSI Models
D PROCEDURES
D-5
Perform Hitch Maintenance ANSI Models
TMZ-34/19
3 - 27
June 2005
Checklist E Procedure
E-1
Test or Replace the Hydraulic Oil
REV C
250 in-lbs
28 Nm
188 in-lbs
21 Nm
40 in-lbs
4.5 Nm
30 in-lbs
3.4 Nm
3 - 28
TMZ-34/19
June 2005
Repair Procedures
About This Section
TMZ-34/19
4-1
June 2005
Platform Controls
REV C
N.C.
J1
POWER
OR
WH
GN
BK
N.C.
RD
POWER
RD
OR
OR
BK
How to
Remove the Circuit Board
GN
1-1
Circuit Board
WH
BL
U1
ALARM
J3
RD
ALARM
KEYPAD
BK
a
b
c
d
4-2
TMZ-34/19
June 2005
REV C
PLATFORM CONTROLS
1-2
Membrane Overlay
How to Replace the Overlay
Beginning with the 2000 model
year (from serial number
T3400-001 to date), the platform
control box was equipped with a
membrane overlay decal.
The following procedure will not
apply for TMZ-34 models
manufactured in the 1998 and
1999 model years (from serial
number T3498-001 to T3499-769).
14 PIN
RIBBON CABLE
3
4
5
6
7
8
10
11
12
13
14
PLATFORM CONTROLS
MEMBRANE DECAL PANEL
BN29 PRIMARY UP
BN30 PRIMARY DOWN
BN31 SECONDARY UP
BN32 SECONDARY DOWN
BN27 JIB UP
BN28 JIB DOWN
BN34 ROTATE RIGHT
BN33 ROTATE LEFT
BN5
HORN
TMZ-34/19
4-3
June 2005
REV C
PLATFORM CONTROLS
4-4
TMZ-34/19
June 2005
Platform Components
REV C
2-1
Platform
2-2
Platform Rotator (if equipped)
How to
Remove the Platform
How to
Remove the Platform Rotator
TMZ-34/19
4-5
June 2005
REV C
PLATFORM COMPONENTS
How to
Adjust the Platform Rotator
How to
Service the Platform Rotator
Rust or corrosion
Torque specification
Gear assembly retaining nut, dry
Binding
180 ft-lbs 5 ft-lbs
244 Nm 7 Nm
TMZ-34/19
June 2005
REV C
PLATFORM COMPONENTS
e
f
g
a
b
c
d
e
f
g
h
i
j
TMZ-34/19
4-7
June 2005
REV C
How to
Remove the Jib Boom
Perform this procedure with the
boom in the stowed position.
d
e
4-8
primary boom
primary linkage
jib boom mount
upper jib boom
jib boom cylinder barrel-end pivot pin
jib boom lift cylinder
lower jib boom
jib boom cylinder rod-end pivot pin
platform mount
TMZ-34/19
June 2005
REV C
TMZ-34/19
4-9
June 2005
REV C
3-2
Jib Boom Cylinder
How to
Remove the Jib Boom Cylinder
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
The jib boom lift cylinder raises and lowers the jib
boom. The jib boom lift cylinder is equipped with a
bi-directional solenoid valve to prevent movement
in the event of a hydraulic line failure.
a
4 - 10
primary boom
primary linkage
jib boom mount
upper jib boom
jib boom cylinder barrel-end pivot pin
jib boom lift cylinder
lower jib boom
jib boom cylinder rod-end pivot pin
platform mount
TMZ-34/19
June 2005
REV C
TMZ-34/19
4 - 11
June 2005
Boom Components
a
4 - 12
REV B
boom pivot
primary boom
secondary boom
hold-down clamp
TMZ-34/19
June 2005
REV B
BOOM COMPONENTS
4-1
Boom
TMZ-34/19
4 - 13
June 2005
BOOM COMPONENTS
REV B
4 - 14
TMZ-34/19
June 2005
REV B
BOOM COMPONENTS
TMZ-34/19
4 - 15
June 2005
REV B
BOOM COMPONENTS
4 - 16
TMZ-34/19
June 2005
REV B
BOOM COMPONENTS
TMZ-34/19
4 - 17
June 2005
REV B
BOOM COMPONENTS
4-2
Lift Cylinders
a
b
c
d
e
4 - 18
TMZ-34/19
June 2005
REV B
BOOM COMPONENTS
a
b
c
d
e
boom pivot
secondary boom
secondary boom lift cylinder rod-end pivot pin
secondary boom lift cylinder
secondary boom lift cylinder barrel-end pivot pin
TMZ-34/19
4 - 19
June 2005
Ground Controls
REV C
D7
VOLTAGE
REGULATOR
8 7 6 54 3 2 1
4 - 20
P1
EMERGENCY
STOP
N.O.
N.O.
P1
KS1
EMERGENCY
STOP
KEY
SWITCH
DIP SWITCH
D7
VOLTAGE
REGULATOR
N.O.
N.O.
N.C.
SW25
N.C.
DIP SWITCH
8 7 6 54 3 2 1
SW25A
KS1
KEY
SWITCH
a
b
c
d
e
f
a
b
c
d
e
f
g
voltage regulator D7
CPU circuit board U17
connector circuit board U21
key switch KS1
Emergency Stop button P2
key pad circuit board U15
TMZ-34/19
June 2005
REV C
GROUND CONTROLS
5-1
Ground Control Keypad
Circuit Board
TMZ-34/19
4 - 21
June 2005
REV C
GROUND CONTROLS
5-2
CPU Circuit Board
5-3
Connector Circuit Board
How to Remove
the CPU Circuit Board
1 Disconnect the battery pack from the machine.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
How to Remove
the Connector Circuit Board
1 Disconnect the battery pack from the machine.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
4 - 22
TMZ-34/19
June 2005
REV C
GROUND CONTROLS
5-4
Software Configuration
How to Determine
the DIP Switch Configuration
A diagnostic display was
incorporated into the ground
controls after serial number
T3402-115. The following
procedure will not apply to
machines before serial number
T3402-116.
a
b
TMZ-34/19
secondary down
turntable rotate counterclockwise
4 - 23
June 2005
REV C
GROUND CONTROLS
How to
Set the DIP Switch
N.O.
N.O.
P1
N.C.
KS1
KEY
SWITCH
EMERGENCY
STOP
D7
VOLTAGE
REGULATOR
SW25
SW25A
DIP SWITCH
DIP SWITCH
ON
ON
a
b
c
d
e
f
Position
On
On
Not used
Off
Outriggers
hydraulic
manual
Off
On
ON
All models
ON
Description
Toggle
ON
ON
5 - 16
4 - 24
Not used
TMZ-34/19
June 2005
REV C
GROUND CONTROLS
5-5
Membrane Overlay
The following procedures will not
apply for machines manufactured
in the 1998 and 1999 model years.
How to
Replace the Overlay
1 Disconnect the battery pack from the machine.
GROUND CONTROLS
MEMBRANE DECAL PANEL
MODELS WITH
HYDRAULIC OUTRIGGERS
SECONDARY DOWN
BN41
BN52
PRIMARY UP
BN38
PRIMARY DOWN
BN39
BN53
HORN
BN35
BN44
BN45
BN46
16
15
14
13
12
8
7
6
5
2
1
11
10
9
BN40 SECONDARY UP
MODELS WITH
MANUAL OUTRIGGERS
PRIMARY UP
BN38
PRIMARY DOWN
BN39
HORN
BN35
BN44
BN45
BN46
BN40 SECONDARY UP
15
14
13
12
8
7
6
5
10
9
NOTE
THE RANDOM ORDER OF THE 16-PIN
RIBBON CONNECTOR IS DONE ONLY TO
SHOW THE WIRE CIRCUITS. ON THE
MACHINE, THE WIRES OF THE RIBBON
CABLE, WHERE THEY CONNECT WITH
THE CIRCUIT BOARD ARE IN NUMERIC
ORDER FROM 1 TO 16.
THE CIRCUIT BOARD IS MARKED AT ONE
END OF THE BOARD-TO-CABLE
CONNECTION WITH THE NUMBER 1.
CAREFULLY INSPECT THE CIRCUIT
BOARD TO LOCATE THE NUMBER 1
WIRE OF THE RIBBON CABLE.
GROUND CONTROLS
MEMBRANE DECAL PANEL
TMZ-34/19
4 - 25
June 2005
REV C
GROUND CONTROLS
4 - 26
TMZ-34/19
June 2005
REV C
GROUND CONTROLS
5-6
Level Sensor
All models:
6 Turn the key switch to the off position.
7 Locate the tilt level sensor next to the ground
control box.
a
b
c
TMZ-34/19
battery charger
ground control box
level sensor
4 - 27
June 2005
REV C
GROUND CONTROLS
4 - 28
TMZ-34/19
June 2005
REV C
GROUND CONTROLS
TMZ-34/19
4 - 29
June 2005
GROUND CONTROLS
REV C
5-7
Interacter Battery Charger
The Interacter 24/25 battery charger, used on
machines before serial number T3403-131, is a
three-stage, microprocessor-controlled 24V 25A
charger, with short circuit and reverse battery
protection, constant current, and constant voltage
with temperature compensated charging voltage.
Callout
LED
Description
20-25A
Red
15-20A
Red
10-15A
Red
5-10A
Red
Charge
Red
80%
Yellow
Ready
Green
A
-25
20 20A
15 15A
10 0A
E
5-1ARG
CH
%
80 DY
A
E
R
a
b
ON
c
T
SE
RE
a
b
c
d
4 - 30
LEDs
on/off switch
AC input connector
fuse panel
Current settings
Normal
Liquid
Gel
29V
27.6V
31V
27.7V
28V
27.5V
TMZ-34/19
June 2005
REV C
GROUND CONTROLS
How to
Install a Circuit Board
DIP Switch
Battery Charger
Circuit Board
Normal
Liquid
Gel
OFF
OFF
OFF
ON
OFF
ON
TMZ-34/19
4 - 31
June 2005
GROUND CONTROLS
REV C
5-8
Lester Battery Charger
d
e
f
f
a
b
4 - 32
c
d
e
TMZ-34/19
Worldwide model
45A circuit breaker (output)
AC input connector
June 2005
TMZ-34/19
4 - 33
June 2005
REV B
6-1
Hydraulic Power Unit Components
The hydraulic power unit is located under the side cover opposite the ground control side of the machine.
Index
No.
Description
10
11
12
13
14
15
Check valve ....................................... G ........... One way valve for pump output ............ 155 in-lbs / 17.5 Nm
4 - 34
Schematic
Item
Function
TMZ-34/19
Torque
June 2005
REV B
15
5
6
14
13
12
11
10
TMZ-34/19
4 - 35
June 2005
REV B
6-2
Valve Adjustments Hydraulic Power Unit
How to
Adjust the System Relief Valve
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the hydraulic power
unit.
2 Turn 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.
3 Fully raise the primary boom.
a
a
b
c
d
e
f
4 - 36
hydraulic tank
test port
pump motor
pump
lock nut
relief valve adjusting screw
TMZ-34/19
June 2005
REV B
6-3
Hydraulic Pump
How to
Test the Hydraulic Pump
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
Perform this procedure with the
manual override knob turned fully
counterclockwise to the closed
position.
TMZ-34/19
4 - 37
June 2005
REV B
How to Remove
the Hydraulic Power Unit
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
4 - 38
TMZ-34/19
June 2005
REV B
How to
Remove the Hydraulic Pump
1 Remove the power unit. See 6-3, How to
Remove the Hydraulic Power Unit.
2 Remove the drain plug from the hydraulic tank
and completely drain the tank into a suitable
container. See capacity specifications.
3 Disconnect the hydraulic oil return line from the
manifold side of the hydraulic oil filter.
4 Remove the hydraulic tank mounting fasteners
and remove the tank from the power unit.
5 Remove the pump mounting fasteners and
remove the pump from the motor.
Component damage hazard.
Improper alignment during
assembly can damage the
pump-to-motor seal. Use caution
when installing the pump onto the
motor.
TMZ-34/19
4 - 39
June 2005
Manifolds
REV C
7-1
Turntable Rotation Manifold Components
The turntable rotation manifold is located on the power unit side of the machine.
Index
No.
1
Schematic
Item
Function
Description
Torque
Solenoid valve,
3 position 4 way N.C. ........................ H ........... Turntable rotate left/right ................... 10-12 ft-lbs / 14-16 Nm
Coil nut (item H) .................................................................................................................... 4-5 ft-lbs / 5-7 Nm
Relief valve ........................................ I ............ Turntable rotate circuit ...................... 35-40 ft-lbs / 47-54 Nm
Y23
4 - 40
TMZ-34/19
June 2005
REV C
MANIFOLDS
7-2
Valve Adjustments Turntable Rotation Manifold
How to Adjust the Turntable
Rotation Relief Valve
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the test port on the power unit.
2 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.
3 Rotate the turntable in a counterclockwise
direction until it rests against the turntable
rotation stop.
4 Activate a function enable button and hold the
turntable rotate left button and observe the
pressure reading on the pressure gauge. Turn
the machine off.
5 Hold the relief valve (item I) and remove the
cap.
6 Adjust the internal hex socket. Turn it clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Refer to Section 2,
Specifications.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
7 Install the relief valve cap.
8 Repeat steps 2 through 6 to confirm the relief
valve pressure.
TMZ-34/19
4 - 41
June 2005
MANIFOLDS
REV C
7-3
Outrigger Manifold Components
The outrigger manifold is located above the turntable rotation motor on the power unit side of the machine.
Index
No.
Description
Solenoid valve,
3 position 4 way N.C. ........................ K ........... Outrigger
regeneration circuit ........................... 10-12 ft-lbs / 14-16 Nm
Solenoid valve,
3 position 4 way N.C. ........................ L ........... Outrigger extend/retract .................... 10-12 ft-lbs / 14-16 Nm
Schematic
Item
Function
Torque
Y41
Y39
Y48
4 - 42
TMZ-34/19
June 2005
REV C
MANIFOLDS
7-4
Valve Coils
29 - 31
31.5 to 33.5
23 to 25
23 to 25
23 to 25
Specification
29 - 31
TMZ-34/19
4 - 43
June 2005
MANIFOLDS
REV C
10 W
RESISTOR
a
b
c
d
27287
multimeter
9V DC battery
10W resistor
coil
9V
BATTERY
COIL
4 - 44
TMZ-34/19
June 2005
REV B
8-1
Turntable Rotation Motor
How to Remove the Turntable
Rotation Motor
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
1 Secure the turntable from rotating by securing
the primary boom to the trailer tongue with the
hold-down latches.
2 Remove the turntable rotation manifold
mounting fasteners securing the manifold to the
motor.
3 Remove the turntable rotation motor gear
mounting fastener from under the turntable and
remove the turntable rotation motor gear.
4 Remove the turntable rotation motor mounting
fasteners and remove the turntable rotation
motor from the machine.
TMZ-34/19
4 - 45
June 2005
Axle Components
REV B
9-1
Axle
9-2
Hub and Bearings
4 - 46
TMZ-34/19
June 2005
REV C
Trailer Components
10-1
Trailer Brakes
10-2
Parking Brake
ANSI models:
84443
TMZ-34/19
84443
4 - 47
June 2005
Outrigger Components
REV B
11-1
Outrigger Components
4 - 48
TMZ-34/19
June 2005
REV B
OUTRIGGER COMPONENTS
11-2
Outrigger Cylinder
How to Remove an Outrigger
Cylinder
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
Fitting Torque Specifications.
TMZ-34/19
4 - 49
June 2005
OUTRIGGER COMPONENTS
REV B
a
b
4 - 50
TMZ-34/19
June 2005
TMZ-34/19
5-1
June 2005
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
5-2
problem
solved
Inspect
and test
Perform
repair
TMZ-34/19
June 2005
REV A
Fault
Condition
Possible Cause
Solution
Normal operation
0001
Outriggers up, no
retract structure
switches
Faulty switches OR
faulty harness OR
faulty circuit board
Repair or replace
switches or harness
OR replace CPU board
0002
Outrigger up, no
negative angle switch
Repair or replace
switch or harness OR
replace CPU board
Level machine OR
charge batteries OR
replace outrigger
switches OR consult
Genie Industries
Service Department
0003
Level machine OR
repair or replace wire
Machine out of level OR
harness or connections
faulty wire harness OR
OR replace outrigger
faulty level sensor OR
switches OR consult
faulty circuit board
Genie Industries
Service Department
0009
0010
ECM/platform
communications fault
Machine functions
inoperative
Repair or replace
control cable OR
replace circuit boards
0011
Machine functions
inoperative
0012
ECM/drive
communications fault
0015
Repair or replace
control cable OR
replace circuit boards
Replace ground key
pad or touch pad OR
replace circuit boards
0021
0022
TMZ-34/19
5-3
June 2005
Fault Code
5-4
REV A
Fault
Condition
0025
0026
0029
0030
0031
0032
0033
0034
0035
0036
0037
0038
TMZ-34/19
Possible Cause
Solution
June 2005
REV A
Fault Code
Fault
Condition
Possible Cause
Solution
0039
0040
0041
0042
0045
0046
0047
Rotate left
(counterclockwise) coil
fault
0048
Rotate left
(counterclockwise) coil
fault
0049
0050
0091
0092
TMZ-34/19
5-5
June 2005
Chart 1
All Functions
Will Not
Operate (before
serial number
T3400-001)
Be sure the 5A fuse
inside the ground
controls box is not
blown.
REV B
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VGIQYGTJINKIQ\URZGMK
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5-6
TMZ-34/19
June 2005
REV B
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
CHART 1
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MXU[TJIUTZXURYIUTZGIZ
MUUJ
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IUTZGIZ
HGJ
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-KTOK/TJ[YZXOKY9KX\OIK
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<
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)6;IOXI[OZHUGXJ;
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
TMZ-34/19
5-7
June 2005
Chart 2
Pump Motor
Will Not
Operate
REV B
6XKYYGTJNURJG
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L[TIZOUTKTGHRKH[ZZUT
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5-8
8KVRGIK3
TMZ-34/19
June 2005
Chart 3
REV B
All Functions
Inoperative,
Power Unit
Starts and Runs
HGJ
8KSU\KZNKXKYKX\UOX
8KVRGIKSUZUXUXV[SV
LXUSZNKVU]KX[TOZ
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IUTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
TMZ-34/19
5-9
June 2005
Chart 4
Ground
Controls
Inoperative
Be sure the key
switch is turned to
ground control.
REV B
:[XTQK_Y]OZINZU
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MXU[TJIUTZXURGTJV[RR
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/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 10
TMZ-34/19
June 2005
Chart 5
REV B
Platform
Controls
Inoperative
Be sure all
cables from
turntable through
the boom linkage
are in good
condition with no
kinks or abrasions.
Be sure the key
switch is turned to
platform control.
:[XTQK_Y]OZINZU
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58IUTY[RZ-KTOK
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*KVGXZSKTZ
TMZ-34/19
5 - 11
June 2005
Chart 6
Jib Boom Up
Function
Inoperative
Be sure all other
functions operate
normally.
REV B
=OZNQK_Y]OZINZ[XTKJ
6XKYYGTJNURJG
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XKVGOXUXXKVRGIKZNK
YURKTUOJ\GR\KIGXZXOJMK
OZKS'UTZNKI_ROTJKX
5 - 12
TMZ-34/19
June 2005
Chart 7
REV B
=OZNQK_Y]OZINZ[XTKJ
6XKYYGTJNURJG
8KVRGIKZNKMXU[TJ
ZUMXU[TJIUTZXURGTJ
L[TIZOUTKTGHRKH[ZZUT
IUTZXURQK_VGJIOXI[OZ
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GTJZNKPOHHUUSJU]T
H[ZZUTV[RRKJU[ZZUZNK
H[ZZUTUTZNKMXU[TJ
UTVUYOZOUTGZHUZN
VGTKROTZNKJU]T
;58XKVRGIK;
JOXKIZOUTGTJINKIQ
58IUTY[RZ-KTOK
IUTZXURYVXKYYGTJNURJ
\URZGMKGIXUYYZNK]NZ
/TJ[YZXOKY9KX\OIK
GL[TIZOUTKTGHRKH[ZZUT
GTJHRQ]OXKYGZ
*KVGXZSKTZ
GTJZNKPOHHUUSJU]T
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VGTKROTZNKJU]T
NGXTKYYIUTTKIZUX
JOXKIZOUTGTJINKIQ
IOXI[OZHUGXJ;
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UNSY
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[TOZ
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VGMK
TMZ-34/19
5 - 13
June 2005
CHART 7
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
REV B
6XKYYGTJNURJG
8KVGOXUVKTOT]NZGTJ
L[TIZOUTKTGHRKH[ZZUT
GTJZNKPOHHUUSJU]T
HRQ]OXKYLXUSZKXSOTGRY
<
GTJ UL
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VGTKROTZNKJU]T
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JOXKIZOUTGTJINKIQ
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\URZGMKGIXUYYZNK]NZ
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]OXKNGXTKYYIUTTKIZUX
IOXI[OZHUGXJ;
<
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XKVRGIKZNK)6;IOXI[OZ
HUGXJ;58XKVRGIK
;58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 14
TMZ-34/19
June 2005
Chart 8
REV B
Primary Boom
Up Function
Inoperative
Be sure all other
functions operate
normally.
=OZNQK_Y]OZINZ[XTKJ
6XKYYGTJNURJG
ZUMXU[TJIUTZXURGTJ
L[TIZOUTKTGHRKH[ZZUT
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OZKS(
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GTJINKIQ\URZGMK
;
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UNSY
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TMZ-34/19
5 - 15
June 2005
Chart 9
Primary Boom
Down Function
Inoperative
Be sure all other
functions operate
normally.
REV B
=OZNQK_Y]OZINZ[XTKJ
6XKYYGTJNURJG
8KVRGIKZNKMXU[TJ
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L[TIZOUTKTGHRKH[ZZUT
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JU]TH[ZZUTUTZNK
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58IUTY[RZ-KTOK
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INKIQ\URZGMKGIXUYY
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GL[TIZOUTKTGHRKH[ZZUT
ZNK]NZGTJHRQ]OXKYGZ
*KVGXZSKTZ
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MXU[TJVGTKROTZNK
NGXTKYYIUTTKIZUX
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<
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UNSY
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UNSY
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VGMK
5 - 16
TMZ-34/19
June 2005
REV B
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
CHART 9
6XKYYGTJNURJG
*OYIUTTKIZZNK]OXKYZU
L[TIZOUTKTGHRKH[ZZUT
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UNSY
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XKYZXOIZOUTYQKKVOTM
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JU]TH[ZZUTUTZNK
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L[TIZOUTLXUSUVKXGZOTM
MXU[TJVGTKROTZNK
IUOR9KK8KVGOX9KIZOUT
58XKVGOXUXXKVRGIKZNK
JU]TJOXKIZOUTGTJ
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INKIQ\URZGMKGIXUYY
UXOTLOTOZK
XKVRGIKZNKYURKTUOJ
ZNK]NZGTJHRQ]OXKYGZ
UNSY
\GR\KIGXZXOJMKOZKS(
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UTZNKI_ROTJKX58
\GR\KOZKS+UTZNK
8KVRGIKZNKVXUVUXZOUTGR
XKVRGIKZNKVXUVUXZOUTGR
N_JXG[ROIVU]KX[TOZ
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\GR\KIGXZXOJMKOZKS+
OZKS+
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6XKYYGTJNURJG
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L[TIZOUTKTGHRKH[ZZUT
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<
GTJ UL
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MXU[TJVGTKROTZNK
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HUGXJ;58XKVRGIK
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*KVGXZSKTZ
TMZ-34/19
5 - 17
June 2005
Chart 10
Secondary
Boom Up
Function
Inoperative
Be sure all other
functions operate
normally.
REV B
=OZNQK_Y]OZINZ[XTKJ
6XKYYGTJNURJG
ZUMXU[TJIUTZXURGTJ
L[TIZOUTKTGHRKH[ZZUT
ZNK+SKXMKTI_9ZUV
GTJZNKYKIUTJGX_
H[ZZUTV[RRKJU[ZZUZNK
HUUS[VH[ZZUTUTZNK
UTVUYOZOUTGZHUZNZNK
MXU[TJVGTKROTZNK[V
YKIUTJGX_HUUSROLZ
JOXKIZOUTGTJINKIQ
I_ROTJKXYURKTUOJ\GR\K
IUTZXURYVXKYYGTJNURJ
\URZGMKGIXUYYZNK]NZ
IUOROZKS)
GL[TIZOUTKTGHRKH[ZZUT
GTJHRQ]OXKYGZ
GTJZNKYKIUTJGX_
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IUTTKIZUX0GZZNK]OXK
MXU[TJVGTKROTZNK[V
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JOXKIZOUTGTJINKIQ
IOXI[OZHUGXJ;
<
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8KVGOXUVKTOT]NZGTJ
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58IUTY[RZ-KTOK
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UNSY
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OZKS)
5 - 18
TMZ-34/19
June 2005
Chart 11
REV B
Secondary
Boom Down
Function
Inoperative
Be sure all other
functions operate
normally.
=OZNQK_Y]OZINZ[XTKJ
6XKYYGTJNURJG
8KVRGIKZNKMXU[TJ
ZUMXU[TJIUTZXURGTJ
L[TIZOUTKTGHRKH[ZZUT
IUTZXURQK_VGJIOXI[OZ
ZNK+SKXMKTI_9ZUV
GTJZNKYKIUTJGX_
H[ZZUTV[RRKJU[ZZUZNK
HUUSJU]TH[ZZUTUT
UTVUYOZOUTGZHUZNZNK
ZNKMXU[TJVGTKROTZNK
;58XKVRGIK;
JU]TJOXKIZOUTGTJ
58IUTY[RZ-KTOK
IUTZXURYVXKYYGTJNURJ
INKIQ\URZGMKGIXUYY
/TJ[YZXOKY9KX\OIK
GL[TIZOUTKTGHRKH[ZZUT
ZNK]NZGTJHRQ]OXKYGZ
*KVGXZSKTZ
GTJZNKYKIUTJGX_
HUUSJU]TH[ZZUTUT
IUTTKIZUX0GZZNK]OXK
ZNKMXU[TJVGTKROTZNK
NGXTKYYIUTTKIZUX
JU]TJOXKIZOUTGTJ
IOXI[OZHUGXJ;
<
MXU[TJGTJVRGZLUXS
HUGXJ;58XKVRGIK
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INKIQ\URZGMKGIXUYY
ZNK]OXKYGZZNK
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UX
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UNSY
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8KVRGIKZNKYKIUTJGX_
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UNSY
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VGMK
TMZ-34/19
5 - 19
June 2005
CHART 11
)UTZOT[KJLXUSZNK
VXK\OU[YVGMK
REV B
6XKYYGTJNURJG
*OYIUTTKIZZNK]OXKYZU
L[TIZOUTKTGHRKH[ZZUT
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XKYZXOIZOUTYQKKVOTM
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N_JXG[ROIVU]KX[TOZ
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;58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 20
TMZ-34/19
June 2005
Chart 12
REV B
Turntable
Rotate Left
Function
Inoperative
Be sure all other
functions operate
normally.
Be sure the needle
valve is not in the open
position.
=OZNZNKQK_Y]OZIN
6XKYYGTJNURJG
Z[XTKJZUMXU[TJIUTZXUR
L[TIZOUTKTGHRKH[ZZUT
GTJZNK+SKXMKTI_
GTJZNKZ[XTZGHRKXUZGZK
9ZUVH[ZZUTV[RRKJU[ZZU
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VGTKROTZNKRKLZJOXKIZOUT
ZNKZ[XTZGHRKXUZGZKRKLZ
GTJINKIQ\URZGMK
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IUTZXURYVXKYYGTJNURJ
GIXUYYZNK]NZGTJHRQ
OZKS.
GL[TIZOUTKTGHRKH[ZZUT
]OXKYGZZKXSOTGRY
GTJZNKZ[XTZGHRKXUZGZK
GTJ ULIUTTKIZUX0
RKLZH[ZZUTUTZNKMXU[TJ
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IUTTKIZUXIOXI[OZHUGXJ
GTJINKIQ\URZGMK
;
<
MXU[TJGTJVRGZLUXS
8KVGOXUVKTOT]NZGTJ
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<
GTJ UL
IUTTKIZUX0GZ;ZU
GIXUYYZNK]OXKYGZZNK
Z[XTZGHRKXUZGZKRKLZ
<
YURKTUOJ\GR\KIUOR
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8KVRGIKZNKMXU[TJ
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OTLOTOZK
ZNKZ[XTZGHRKXUZGZKRKLZ
UNSY
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ZKYZZNKXKYOYZGTIKULZNK
8KVRGIKZNKZ[XTZGHRK
XUZGZKRKLZYURKTUOJ\GR\K
IUOR
\GR\KIUOR9KK8KVGOX
9KIZOUT
ZU
UNSY
)UTTKIZGZUVYO
)NKIQLUXSKINGTOIGR
ZUHGXVXKYY[XK
XKYZXOIZOUTYQKKVOTM
MG[MKZUZNKW[OIQ
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JOYIUTTKIZIU[VROTMUT
VYO
L[TIZOUTLXUSUVKXGZOTM
ZNKVU]KX[TOZOZKS*
58XKVGOXUXXKVRGIK
'IZO\GZKZ[XTZGHRKXUZGZK
N_JXG[ROISUZUX58
RKLZL[TIZOUTGTJINKIQ
Z[XTZGHRKXUZGZKSGTOLURJ
ZNKVXKYY[XK
SG_NG\KGTOTZKXTGR
JKLKIZ)UTY[RZ-KTOK
RKYYZNGT
/TJ[YZXOKY9KX\OIK
VYO
*KVGXZSKTZ
8KGJP[YZXKROKL\GR\K
OZKS/9KK8KVGOX
9KIZOUT58XKVGOXUX
XKVRGIKN_JXG[ROISUZUX
58XKVRGIKTKKJRK\GR\K
OZKS058Z[XTZGHRK
XUZGZKSGTOLURJSG_
NG\KGTOTZKXTGRJKLKIZ
)UTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
TMZ-34/19
5 - 21
June 2005
Chart 13
Turntable
Rotate Right
Function
Inoperative
Be sure all other
functions operate
normally.
REV B
=OZNZNKQK_Y]OZIN
6XKYYGTJNURJG
Z[XTKJZUMXU[TJIUTZXUR
L[TIZOUTKTGHRKH[ZZUT
GTJZNK+SKXMKTI_
GTJZNKZ[XTZGHRKXUZGZK
9ZUVH[ZZUTV[RRKJU[ZZU
XOMNZH[ZZUTUTZNK
ZNKUTVUYOZOUTGZHUZN
MXU[TJVGTKROTZNKXOMNZ
Z[XTZGHRKXUZGZKXOMNZ
JOXKIZOUTGTJINKIQ
YURKTUOJ\GR\KIUOR
IUTZXURYVXKYYGTJNURJ
\URZGMKGIXUYYZNK]NZ
OZKS.
GL[TIZOUTKTGHRKH[ZZUT
GTJHRQ]OXKYGZ
GTJZNKZ[XTZGHRKXUZGZK
XOMNZH[ZZUTUTZNK
IUTTKIZUX0GZZNK]OXK
MXU[TJVGTKROTZNKXOMNZ
NGXTKYYIUTTKIZUX
JOXKIZOUTGTJINKIQ
IOXI[OZHUGXJ;
<
MXU[TJGTJVRGZLUXS
8KVGOXUVKTOT]NZGTJ
HRQ]OXKYLXUSZKXSOTGRY
<
GTJ ULIUTTKIZUX
0GZ;ZUZNK
\URZGMKGIXUYYZNK]OXKY
GZZNKZ[XTZGHRKXUZGZK
<
RKLZYURKTUOJ\GR\KIUOR
OZKS.
8KVRGIKZNKMXU[TJ
IUTZXURQK_VGJIOXI[OZ
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;58XKVRGIK;
58IUTY[RZ-KTOK
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ZNKZ[XTZGHRKXUZGZKXOMNZ
YURKTUOJ\GR\KIUORGTJ
OTLOTOZK
UNSY
ZKYZZNKXKYOYZGTIKULZNK
8KVRGIKZNKZ[XTZGHRK
XUZGZKXOMNZYURKTUOJ
\GR\KIUOR
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9KIZOUT
ZU
UNSY
)UTTKIZGZUVYO
)NKIQLUXSKINGTOIGR
ZUHGXVXKYY[XK
XKYZXOIZOUTYQKKVOTM
MG[MKZUZNKW[OIQ
Z[XTZGHRKXUZGZKXOMNZ
JOYIUTTKIZIU[VROTMUT
VYO
L[TIZOUTLXUSUVKXGZOTM
ZNKVU]KX[TOZOZKS*
58XKVGOXUXXKVRGIK
'IZO\GZKZ[XTZGHRKXUZGZK
N_JXG[ROISUZUX58
XOMNZL[TIZOUTGTJINKIQ
Z[XTZGHRKXUZGZKSGTOLURJ
ZNKVXKYY[XK
SG_NG\KGTOTZKXTGR
JKLKIZ)UTY[RZ-KTOK
RKYYZNGT
/TJ[YZXOKY9KX\OIK
VYO
*KVGXZSKTZ
8KGJP[YZXKROKL\GR\K
OZKS/9KK8KVGOX
9KIZOUT58XKVGOXUX
XKVRGIKN_JXG[ROISUZUX
58XKVRGIKTKKJRK\GR\K
OZKS058Z[XTZGHRK
XUZGZKSGTOLURJSG_
NG\KGTOTZKXTGRJKLKIZ
)UTY[RZ-KTOK/TJ[YZXOKY
9KX\OIK*KVGXZSKTZ
5 - 22
TMZ-34/19
June 2005
Chart 14
REV A
Parking Brake
Function
Inoperative
Be sure that the parking
brake cables are
properly connected and
are in good condition.
'JP[YZVGXQOTMHXGQK
9KK8KVGOX9KIZOUT
'VVR_ZNKVGXQOTMHXGQK
SGINOTK
SU\KY
'JP[YZZNKHXGQKY58
XKVRGIKHXGQKYNUKY
9KKHXGQKSGT[LGIZ[XKY
GTJGZZKSVZZUV[YNZNK
SGT[GRLUXVXUIKJ[XKY
SGINOTK
UTJOYGYYKSHROTMZNK
HXGQKY
SGINOTK
JUKYTUZ
SU\K
:NKVGXQOTMHXGQKOY
UVKXGZOTMIUXXKIZR_
TMZ-34/19
5 - 23
June 2005
5 - 24
TMZ-34/19
June 2005
Section 6 Schematics
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
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.
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.
Malfunction
discovered
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
TMZ-34/19
problem
solved
Inspect
and test
Perform
repair
6-1
Section 6 Schematics
June 2005
ABBREVIATION LEGEND
ABBREVIATION LEGEND
Item
Description
Item
Description
B5
BN
Four 6V batteries
Button
BN5 = Horn
BN12 = Function enable high
BN13 = Function enable low
BN26 = Function enable medium
BN27 = Jib boom up
BN28 = Jib boom down
BN29 = Primary up
BN30 = Primary down
BN31 = Secondary up
BN32 = Secondary down
BN33 = Rotate left
BN34 = Rotate right
BN35 = Horn
BN36 = Jib boom up
BN37 = Jib boom down
BN38 = Primary up
BN39 = Primary down
BN40 = Secondary up
BN41 = Secondary down
BN42 = Rotate left
BN43 = Rotate right
BN44 = Function enable high
BN45 = Function enable medium
BN46 = Function enable low
30A Circuit breaker, controls
Voltage regulator
Enclosure
EN1 = Platform control box
EN2 = Ground control box
Fuse
F6 = 275A, Function
F10 = 5A, System power
Flashing beacons (option)
Gauge
G6 = Hour meter
G7 = Battery charge indicator (option)
G8 = Diagnostic display
Horn or alarm
H1 = Horn
H5 = Multifunction alarm
Key switch
Light or LED
L5 = Power (ground)
L12 = Left front outrigger
L13 = Right front outrigger
L14 = Left rear outrigger
L15 = Right rear outrigger
L18 = Emergency Stop (platform)
L19 = Power (platform)
L33 = Right rear tail light
L34 = Left rear tail light
L35 = Right side marker
L36 = Left side marker
L45 = Emergency Stop (ground)
Limit switch
LS1 = Structure retract
LS2 = Primary boom up
LS11 = Jib boom down
LS12 = Left front outrigger
LS13 = Right front outrigger
LS14 = Left rear outrigger
LS15 = Right rear outrigger
LS17 = Negative boom angle
LS27 = Turntable
Hydraulic power unit
Normally closed
Normally closed held open
Normally open
Normally open held closed
Power switch
P1 = Emergency Stop button at ground controls
P2 = Emergency Stop button at platform controls
Quick disconnect
QD1 = Primary battery disconnect
QD3 = Control cable at platform
QD4 = Control cable at ground
QD12 = Trailer connector
QD19 = Trailer harness connector
Level sensor
Switch
SW13 = Left front outrigger
SW14 = Right front outrigger
SW15 = Left rear outrigger
SW16 = Right rear outrigger
SW25 = DIP switch
Terminal base
Electronic component
U3 = Platform controls circuit board
U6 = Motor controller
U9 = Battery charger
U15 = Key pad circuit board
U21 = Connector circuit board
U22 = CPU/display circuit board
Valve coil
Y9 = Proportional (function)
Y23 = Turntable rotate left
Y24 = Turntable rotate right
Y39 = Outrigger up (retract)
Y41 = Outrigger regen
Y45 = Primary boom
Y46 = Secondary boom
Y47 = Jib boom
Y48 = Outrigger level
CB2
D7
EN
FB
G
KS1
LS
M5
N.C.
N.C.H.O.
N.O.
N.O.H.C.
P
QD
S7
SW
TB
U
6-2
Description
Black
Blue
Green
Orange
Red
White
Yellow
TMZ-34/19
June 2005
Section 6 Schematics
TMZ-34/19
6-3
Section 6 Schematics
June 2005
L35
RIGHT SIDE MARKER
BK
GN
QD19
QUICK DISCONNECT
BN
BN1
BN
WH
BN2
WH
QD12
TRAILER
PLUG
BK
BN
WH
WH
WH
L33
BN
GN
L34
6
1
2
3
3
4
GN
YL
BN1
BN2
WH
YL
1
WH
TB TERMINAL BASE
RD
RD
BK
BN
YL
GN
BK
BL
L36
CE Models
BL
L35
RIGHT SIDE MARKER
QD19
QUICK DISCONNECT
BN
BN
GN
BN
WH
QD12
WH
TRAILER PLUG
WH
BK
WH
L33
BK
GN
RD
BL
YL
BN
GN
RD
5
6
BL
YL
TB TERMINAL BASE
7
3
L34
LEFT REAR TAIL LIGHT
YL
L36
LEFT SIDE MARKER
1 YL
2 BL
5 BN
3 WH
6 RD
4 GN
7 BK
6-4
TMZ-34/19
June 2005
Section 6 Schematics
GROUND
M5
LS2
LS17
PLATFORM
N.C.
N.O.H.C.
Motor
Limit switch
Circuit connection
M-
B+
A2
B-
G6
Hour meter
6 5 4 3 2
DIP switch
Motor controller
24V DC
5V DC
Fuse
Horn or alarm
Voltage regulator
Circuit breaker
LED
5V
24V
Circuits crossing
no connection
Solenoid valve
S7
LEVEL SENSOR
Button or switch
Level sensor
Battery
TMZ-34/19
6-5
Section 6 Schematics
June 2005
Electrical Schematic
Models with Manual Outriggers
(from serial number T3498-001 to T3499-361)
REV B
EN2
EN1
BN35 BN36 BN37 BN38 BN39 BN40 BN41 BN42 BN43 BN44 BN45 BN46
BN5
U3
U15
L13
L14
G7
L15
J2
4 3 2 1
J9
J2
J6
RD
WH
GN
BK
OR
+
+
6-6
15 9
J4
BK
WH
BK
WH
Y9 PROPORTIONAL VALVE
RD
WH
BK
13 7
12 18
22 21
WH
BK
5 10
BK
WH
WH
BK
2 7
WH
BK
4 9
WH
BK
LIFT STRUCTURE
1 5
+
AC INPUT
24V+
1
B-
24 20
A1
T2
M- B+
M5
- NOTE -
0-5V
MOTOR
WH
BK
D1
M5
BATTERY
CHARGER
WH
BK
275A
FUSE
2 7
F6
U9
MACHINE SHOWN
IN THE STOWED
POSITION WITH
THE POWER OFF
U6
MOTOR
CONTROLLER
J5
4 9
RD
QD1 (+)
FOUR 6V
BATTERIES
OUT - RIGHT
22 18 21 16
1 5
WH
BK
N.O.H.C.
24 20
WH
BK
WH
LEVEL
SENSOR
5V
LS1
LS1
24V
S7
B5
BK
WH
J8
OUT - LEFT
22 18 21 16
24 25
10
PUMP SPEED
WH
BK
20
PUMP ENABLE
BK
HORN
GROUND
X-AXIS (0-5V)
H5
24V +
1 2
J7
15
BK
WH
Y-AXIS (0-5V)
4 3
12 13
LEVEL SENSOR -
18
WH
BK
POWER
6
U21
CONNECTOR PC BOARD
BK
PLATFORM
QD4
BK
WH
34 PIN
DUAL-ROW
RIBBON CABLE
L19
P2 EMERGENCY STOP
BK
WH
10 PIN
RIBBON CABLE
WH
BK
J1
L18
HORN
QD3
RD
BK
J3
RD
KEY
SWITCH
BK
J4
BASE
KS1
RD
U22
CPU / DISPLAY BOARD
VOLTAGE REGULATOR
BK
BK
H1
5V DC
D7
BK
34 PIN
DUAL-ROW
RIBBON CABLE
24V DC
J2
1
OR
U15
5A FUSE
EMERGENCY
STOP
VOLTAGE
REGULATOR
KEYPAD PC BOARD
F10
P1
5V DC
D7A
WH
BK
L12
L45
24V DC
PLATFORM
CONTROLS
PRINTED
CIRCUIT
BOARD
KEYPAD PC BOARD
L5
QD1 (-)
ES0061C
TMZ-34/19
June 2005
Section 6 Schematics
Electrical Schematic
Models with Manual Outriggers
(from serial number T3499-362 to T3499-769)
REV A
EN2
EN1
BN35 BN36 BN37 BN38 BN39 BN40 BN41 BN42 BN43 BN44 BN45 BN46
BN5
U3
U15
L13
L14
G7
L15
J2
4 3 2 1
J2
J6
+
+
ES0061D
15 9
J4
BK
WH
BK
WH
Y9 PROPORTIONAL VALVE
RD
WH
BK
13 7
12 18
22 21
BK
WH
WH
BK
5 10
BK
WH
WH
BK
2 7
WH
BK
4 9
WH
BK
WH
BK
LIFT STRUCTURE
1 5
+
AC INPUT
24V+
1
B-
24 20
A1
T2
M- B+
M5
- NOTE -
0-5V
MOTOR
WH
BK
D1
M5
2 7
275A
FUSE
MACHINE SHOWN
IN THE STOWED
POSITION WITH
THE POWER OFF
U6
MOTOR
CONTROLLER
J5
4 9
WH
BK
F6
BATTERY
CHARGER
FOUR 6V
BATTERIES
OUT - RIGHT
22 18 21 16
1 5
RD
QD1 (+)
U9
24 20
WH
BK
N.O.H.C.
LS1
LEVEL
SENSOR
5V
LS1
WH
S7
B5
RD
WH
GN
BK
OR
J8
OUT - LEFT
22 18 21 16
24 25
10
PUMP SPEED
WH
BK
20
PUMP ENABLE
BK
HORN
GROUND
X-AXIS (0-5V)
Y-AXIS (0-5V)
H5
24V +
1 2
J7
15
BK
WH
24V
LEVEL SENSOR -
4 3
12 13
POWER
18
U21
CONNECTOR PC BOARD
WH
BK
BK
QD4
BK
WH
J9
L19
P2 EMERGENCY STOP
BK
WH
34 PIN
DUAL-ROW
RIBBON CABLE
10 PIN
RIBBON CABLE
WH
BK
BK
J1
L18
HORN
QD3
RD
BK
J3
RD
J4
BK
BK
PLATFORM
U22
CPU / DISPLAY BOARD
VOLTAGE REGULATOR
GROUND
RD
KS1
KEY SWITCH
H1
5V DC
D7
BK
34 PIN
DUAL-ROW
RIBBON CABLE
24V DC
J2
1
OR
U15
5A FUSE
EMERGENCY
STOP
VOLTAGE
REGULATOR
KEYPAD PC BOARD
F10
P1
5V DC
D7A
WH
BK
L12
L45
24V DC
PLATFORM
CONTROLS
PRINTED
CIRCUIT
BOARD
KEYPAD PC BOARD
L5
QD1 (-)
TMZ-34/19
6-7
Section 6 Schematics
June 2005
Electrical Schematic
Models with Manual Outriggers
(from serial number T3400-001)
REV B
G8 AVAILABLE
AFTER
SERIAL NUMBER
T3402-115
PRIMARY UP
BN38
PRIMARY DOWN
BN39
HORN
BN35
G8
DIAGNOSTIC
DISPLAY
BN44
BN45
BN46
BN40 SECONDARY UP
D7
VOLTAGE REGULATOR
J2
J3
7 PIN
JUMPER CABLE
11 PIN
JUMPER CABLE
26 PIN
RIBBON CABLE
40 PIN
RIBBON CABLE
J2
J1
J3
J4
BK
CONNECTOR PC BOARD
P1
LS11
N.O.H.C.
N.O.H.C.
AC INPUT
0-5V
U6
6
18
33
23
3
14
L12
- NOTE -
MACHINE SHOWN
IN THE STOWED
POSITION WITH
THE POWER OFF
MOTOR
CONTROLLER
6-8
24V+
+
B-
N.O.
L15
B+
L14
T2
M-
A1
MOTOR
SW13
N.C.
M5
SW15
N.O.
N.O.
LS27
FLASHING BEACONS + (OPTION)
FLASHING BEACONS -
D1
M5
FB
FOUR 6V
BATTERIES
SW14
N.O.
N.O.H.C.
QD1 (+)
275A
FUSE
SW16
LS2
BATTERY
CHARGER
30
19
4
16
22
10
24
25
27
15
27
LS17
G6
F6
J8
P3
U9
OUTRIGGER
PUMP ENABLE
24V +
CIRCUIT BREAKER
17
ENGINE
P4
RD
U21
8
20
P5
RD
J9
G7
BK
CB2 30A
B5
DIP SWITCH
J6
2 1
P1 EMERGENCY STOP
SW25A
8 7 6 54 3 2 1
J8
J4
DIP SWITCH
U22
L13
5V DC
29
17
32
21
PLATFORM
24V DC
J7
1 2 3 4 5 6
SW25
8 7 6 54 3 2 1
2
4
HORN
L15
PUMP SPEED
H5
L14
GROUND
CONTROL
BOX
L13
BK
16 PIN
RIBBON CABLE
GROUND
EN2
L12
BN
RD
OR
15
14
13
12
8
7
6
5
10
9
16
QD1 (-)
ES0209D
ES0209F
TMZ-34/19
June 2005
Section 6 Schematics
Electrical Schematic
Models with Manual Outriggers
(from serial number T3400-001)
REV B
U3
J4
24V DC
14 PIN
RIBBON CABLE
PLATFORM
CONTROLS
PRINTED
CIRCUIT
BOARD
5V DC
D7A
PLATFORM CONTROLS
MEMBRANE DECAL PANEL
3
4
5
6
7
8
10
11
12
13
14
BN29 PRIMARY UP
BN30 PRIMARY DOWN
BN31 SECONDARY UP
BN32 SECONDARY DOWN
BN27 JIB UP
VOLTAGE
REGULATOR
J2
1
DATA GND
DATA +
BN5
RD
BK
24V +
L46
J3
4 3 2 1
H2
HORN
HORN
P2
RD
BL
OR
WH
GN
BK
EMERGENCY
STOP
QD3
QD4
EN2
GROUND CONTROL
BOX
J5
P2
U21
35
3
Y-AXIS
33
34
2
X-AXIS
32
CONNECTOR PC BOARD
PROPORTIONAL VALVE
ROTATE LEFT
ROTATE RIGHT
Y9
Y23
Y24
5V
SECONDARY BOOM
JIB BOOM
Y46
Y47
PRIMARY BOOM
Y45
24V
LEVEL SENSOR -
6
+
21
7
30
13
+
22
8
31
14
23
10
LIFT / DRIVE
S7
LEVEL SENSOR
ES0209D
ES0209F
TMZ-34/19
6-9
Section 6 Schematics
June 2005
Electrical Schematic
Models with Hydraulic Outriggers
REV B
SECONDARY DOWN
BN41
BN52
PRIMARY UP
BN38
PRIMARY DOWN
BN39
BN53
HORN
BN35
G8 AVAILABLE
AFTER
SERIAL NUMBER
T3402-115
G8
DIAGNOSTIC
DISPLAY
BN44
BN45
BN46
D7
SW25A
VOLTAGE REGULATOR
J2
J3
7 PIN
JUMPER CABLE
11 PIN
JUMPER CABLE
26 PIN
RIBBON CABLE
40 PIN
RIBBON CABLE
J2
J1
J3
J4
BK
CONNECTOR PC BOARD
P1
AC INPUT
0-5V
U6
18
6
14
3
30
19
33
23
- NOTE -
MACHINE SHOWN
IN THE STOWED
POSITION WITH
THE POWER OFF
MOTOR
CONTROLLER
6 - 10
24V+
+
B-
Y35
B+
Y34
T2
M-
A1
MOTOR
M5
M5
FOUR 6V
BATTERIES
D1
275A
FUSE
LS12
N.C.H.O.
N.C.
BATTERY
CHARGER
LS14
N.C.H.O.
LS27
FB
F6
N.C.H.O.
N.O.H.C.
G6
LS13
N.C.H.O.
N.O.H.C.
LS2
QD1 (+)
20
8
16
4
22
27
15
27
24
25
17
10
LS15
LS11
N.O.H.C.
PUMP ENABLE
LS17
U9
J8
OUTRIGGER
24V +
CIRCUIT BREAKER
P3
ENGINE
P4
RD
U21
Y33
P5
RD
J9
G7
BK
CB2 30A
B5
DIP SWITCH
J6
2 1
P1 EMERGENCY STOP
8 7 6 54 3 2 1
J8
J4
DIP SWITCH
U22
Y36
5V DC
29
17
32
21
PLATFORM
24V DC
J7
1 2 3 4 5 6
SW25
8 7 6 54 3 2 1
2
4
HORN
L15
PUMP SPEED
H5
L14
GROUND
CONTROL
BOX
L13
BK
16 PIN
RIBBON CABLE
GROUND
EN2
L12
BN
RD
OR
16
15
14
13
12
8
7
6
5
2
1
11
10
9
BN40 SECONDARY UP
QD1 (-)
ES0210D
ES0210E
TMZ-34/19
June 2005
Section 6 Schematics
Electrical Schematic
Models with Hydraulic Outriggers
REV B
U3
J4
24V DC
14 PIN
RIBBON CABLE
PLATFORM
CONTROLS
PRINTED
CIRCUIT
BOARD
5V DC
D7A
PLATFORM CONTROLS
MEMBRANE DECAL PANEL
3
4
5
6
7
8
10
11
12
13
14
BN29 PRIMARY UP
BN30 PRIMARY DOWN
BN31 SECONDARY UP
BN32 SECONDARY DOWN
BN27 JIB UP
VOLTAGE
REGULATOR
J2
1
DATA GND
DATA +
BN5
RD
BK
24V +
L46
J3
4 3 2 1
H2
HORN
HORN
P2
RD
BL
OR
WH
GN
BK
EMERGENCY
STOP
QD3
QD4
EN2
GROUND CONTROL
BOX
J5
P2
U21
4
Y24
Y23
2
3
+
OUTRIGGER LEVEL (EXTEND) COIL
OUTRIGGER REGEN COIL
Y48
Y41
Y-AXIS
X-AXIS
ROTATE RIGHT
Y24
GROUP A GROUND
OUTRIGGER UP (RETRACT) COIL
ROTATE LEFT
Y23
LEVEL SENSOR
Y39
PROPORTIONAL VALVE
Y9
5V
SECONDARY BOOM
JIB BOOM
Y46
Y47
PRIMARY BOOM
Y45
S7
21
1
35
33
34
32
24V
LEVEL SENSOR -
6
+
21
7
30
13
+
22
8
31
14
CONNECTOR PC BOARD
23
10
LIFT / DRIVE
ES0210D
ES0210E
TMZ-34/19
6 - 11
Section 6 Schematics
June 2005
6 - 12
TMZ-34/19
June 2005
Section 6 Schematics
REV A
Y41
Filter
Solenoid operated
2 position 3 way
directional valve
Bi-directional motor
Y9
Check valve
Proportional valve
Y24
Y23
Y45
Motor
Solenoid operated
2 position 2 way
directional valve
Relief valve
Solenoid operated
3 position 4 way
directional valve
0.037 in
9.4 mm
2000 psi
137.9 bar
3:1
4000 psi
275.8 bar
3:1
Counterbalance valve
D
Y9
H
Y23
Y24
Y41
Turntable manifold
components
Y39
Y48
Outrigger manifold
components
TMZ-34/19
6 - 13
Section 6 Schematics
June 2005
Hydraulic Schematic
Models with Manual Outriggers
(from serial number T3498-001 to T3499-769)
PRIMARY
BOOM
LIFT
CYLINDER
SECONDARY
BOOM
LIFT
CYLINDER
Y45
JIB
BOOM
LIFT
CYLINDER
Y46
0.037 in
9.4 mm
0.037 in
9.4 mm
REV A
Y47
0.037 in
9.4 mm
TEST
Y9
B
1200 psi
82.7 bar
3 gpm
11.3 L/min
I
3200 psi
220.6 bar
T
35 psi
2.4 bar
M
1.5 gpm
5.7 L/min
Y24
Y23
18 psi
1.2 bar
TURNTABLE
ROTATE
MANIFOLD
H
T
HS00007A
6 - 14
TMZ-34/19
June 2005
Section 6 Schematics
Hydraulic Schematic
Models with Manual Outriggers
(from serial number T3400-001 to T3400-265)
REV A
PRIMARY
BOOM
LIFT
CYLINDER
SECONDARY
BOOM
LIFT
CYLINDER
Y45
JIB
BOOM
LIFT
CYLINDER
Y46
0.037 in
9.4 mm
0.037 in
9.4 mm
Y47
0.037 in
9.4 mm
TEST
Y9
3 gpm
11.3 L/min
F
3200 psi
220.6 bar
1200 psi
82.7 bar
T
35 psi
2.4 bar
1.5 gpm
5.7 L/min
Y24
Y23
18 psi
1.2 bar
TURNTABLE
ROTATE
MANIFOLD
H
T
HS0132A
TMZ-34/19
6 - 15
Section 6 Schematics
June 2005
Hydraulic Schematic
Models with Manual Outriggers
(after serial number T3400-265)
PRIMARY
BOOM
LIFT
CYLINDER
REV A
SECONDARY
BOOM
LIFT
CYLINDER
Y45
JIB
BOOM
LIFT
CYLINDER
Y46
0.037 in
9.4 mm
0.037 in
9.4 mm
Y47
0.037 in
9.4 mm
TEST
Y9
3 gpm
11.3 L/min
F
3200 psi
220.6 bar
1200 psi
82.7 bar
T
35 psi
2.4 bar
M
1.5 gpm
5.7 L/min
Y24
Y23
18 psi
1.2 bar
TURNTABLE
ROTATE
MANIFOLD
H
T
HS0132B
6 - 16
TMZ-34/19
June 2005
Section 6 Schematics
Hydraulic Schematic
Models with Hydraulic Outriggers
(before serial number T3400-266)
REV A
LEFT FRONT
OUTRIGGER
CYLINDER
Y35
RIGHT FRONT
OUTRIGGER
CYLINDER
0.037 in
9.4 mm
0.037 in
9.4 mm
LEFT REAR
OUTRIGGER
CYLINDER
Y33
RIGHT REAR
OUTRIGGER
CYLINDER
SECONDARY
BOOM
LIFT
CYLINDER
JIB
BOOM
LIFT
CYLINDER
C2
C1
2000 psi
137.9 bar
3:1
4000 psi
275.8 bar
3:1
V2
Y45
Y46
0.037 in
9.4 mm
0.037 in
9.4 mm
V1
Y47
Y41
0.037 in
9.4 mm
Y39
Y48
L
OUTRIGGER MANIFOLD
TEST
Y34
0.037 in
9.4 mm
0.037 in
9.4 mm
PRIMARY
BOOM
LIFT
CYLINDER
Y36
T
P
Y9
J
3 gpm
11.3 L/min
F
3200 psi
220.6 bar
1200 psi
82.7 bar
35 psi
2.4 bar
M
1.5 gpm
5.7 L/min
Y24
Y23
18 psi
1.2 bar
TURNTABLE
ROTATE
MANIFOLD
H
T
HS0133A
TMZ-34/19
6 - 17
Section 6 Schematics
June 2005
Hydraulic Schematic
Models with Hydraulic Outriggers
(after serial number T3400-265)
REV A
LEFT FRONT
OUTRIGGER
CYLINDER
Y35
RIGHT FRONT
OUTRIGGER
CYLINDER
0.037 in
9.4 mm
0.037 in
9.4 mm
LEFT REAR
OUTRIGGER
CYLINDER
Y33
RIGHT REAR
OUTRIGGER
CYLINDER
SECONDARY
BOOM
LIFT
CYLINDER
JIB
BOOM
LIFT
CYLINDER
C2
C1
2000 psi
137.9 bar
3:1
4000 psi
275.8 bar
3:1
V2
Y45
Y46
0.037 in
9.4 mm
0.037 in
9.4 mm
V1
Y47
Y41
0.037 in
9.4 mm
Y39
Y48
Y34
0.037 in
9.4 mm
0.037 in
9.4 mm
PRIMARY
BOOM
LIFT
CYLINDER
Y36
L
OUTRIGGER MANIFOLD
TEST
T
P
Y9
J
3 gpm
11.3 L/min
F
3200 psi
220.6 bar
1200 psi
82.7 bar
35 psi
2.4 bar
M
1.5 gpm
5.7 L/min
Y24
Y23
18 psi
1.2 bar
TURNTABLE
ROTATE
MANIFOLD
H
T
HS0133B
6 - 18
TMZ-34/19
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone
Phone
Fax
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Distributed By:
Part No.
52075
Rev C