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REV B

Section 4 • Repair Procedures

June 2005

Part No. 52075

TMZ-34/19

4 - 49

Models with hydraulic outriggers:

1 Attach a lifting strap from an overhead crane to

the pad end of the outrigger. Do not apply any
lifting pressure.

2 Tag and disconnect the wire harness from the

outrigger limit switch.

3 Remove the pin retaining fasteners from the

outrigger pivot pin. Do not remove the pin.

4 Remove the pin retaining fasteners from the

outrigger cylinder rod-end pivot pin.

5 Place a rod through the hole in the outrigger

cylinder rod-end pivot pin and twist to remove
the pin. Remove the outrigger cylinder rod-end
pivot pin from the machine.

6 Secure the rod-end of the cylinder to the

chassis.

7 Place a rod through the hole in the outrigger

pivot pin and twist to remove the pin. Remove
the outrigger pivot pin from the machine.

Crushing hazard. The outrigger
could fall if not properly supported
when the pivot pin is removed
from the machine.

Crushing hazard. The outrigger
cylinder could fall if not properly
supported when the outrigger is
removed from the machine.

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.

1 Extend the outrigger until the pad just touches

the ground. Do not rest the weight of the
machine on the outrigger.

2 Remove the cylinder guard mounting fasteners

from the rod end of the outrigger cylinder and
remove the cylinder guard from the machine.

3 Tag and disconnect the wire harness from the

outrigger cylinder valve coil.

4 Tag, disconnect and plug the hydraulic hoses

from the outrigger cylinder. Cap the fittings on
the cylinder.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.

OUTRIGGER COMPONENTS

800-610-4101

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Summary of Contents for TMZ-34/19

Page 1: ...Service Manual Part No 52075 Rev C June 2005 800 610 4101 ActionRental com ...

Page 2: ...ed 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 wil...

Page 3: ...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 worksh...

Page 4: ...aintenanceinformation Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like...

Page 5: ...cheduledMaintenanceProcedures Introduction 3 1 Pre deliveryPreparationReport 3 3 MaintenanceInspectionReport 3 5 C ChecklistAProcedures A 1 PerformPre operationInspection 3 6 A 2 Perform Function Tests 3 6 A 3 Perform Hitch Maintenance ANSI Models 3 7 A 4 Perform Axle Maintenance ANSI Models 3 7 A 5 Perform Axle Maintenance CE Models 3 8 A 6 Perform Axle Maintenance CE Models 3 8 A 7 Perform Axle ...

Page 6: ...pped 3 19 B 12 Inspect the Hydraulic Tank Cap Venting System 3 19 B 13 Perform Hitch Maintenance ANSI Models 3 20 B 13 Perform Axle Maintenance ANSI Models 3 20 B 14 Perform Hydraulic Oil Analysis 3 21 C ChecklistCProcedure C 1 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil 3 22 C 2 Perform Axle Maintenance ANSI Models 3 22 C 3 Perform Hitch Maintenance CE Models 3 23 C...

Page 7: ...Cylinder 4 10 B BoomComponents 4 1 Boom 4 12 4 2 Lift Cylinders 4 18 C GroundControls 5 1 Ground Control Keypad Circuit Board 4 20 5 2 CPU Circuit Board 4 22 5 3 ConnectorCircuitBoard 4 22 5 4 SoftwareConfiguration 4 23 5 5 MembraneOverlay 4 25 5 6 LevelSensor 4 27 5 7 InteracterBatteryCharger 4 30 5 8 LesterBatteryCharger 4 32 B Hydraulic Power Unit 6 1 HydraulicPowerUnitComponents 4 34 6 2 Valve...

Page 8: ...4 41 7 3 OutriggerManifoldComponents 4 42 7 4 Valve Coils 4 43 B TurntableRotationComponents 8 1 TurntableRotationMotor 4 45 B AxleComponents 9 1 Axle 4 46 9 2 HubandBearings 4 46 C TrailerComponents 10 1 TrailerBrakes 4 47 10 2 Parking Brake 4 47 B Outriggers 11 1 OutriggerComponents 4 48 11 2 OutriggerCylinder 4 49 TABLE OF CONTENTS viii 800 610 4101 ActionRental com ...

Page 9: ...trolsInoperative 5 10 B 5 PlatformControlsInoperative 5 11 B 6 Jib Boom Up Function Inoperative 5 12 B 7 Jib Boom Down Function Inoperative 5 13 B 8 Primary Boom Up Function Inoperative 5 15 B 9 Primary Boom Down Function Inoperative 5 16 B 10 Secondary Boom Up Function Inoperative 5 18 B 11 Secondary Boom Down Function Inoperative 5 19 B 12 Turntable Rotate Left Function Inoperative 5 21 B 13 Tur...

Page 10: ... Models with Manual Outriggers fromserialnumberT3400 001 6 8 B Electrical Schematic Models with Hydraulic Outriggers 6 10 A HydraulicSymbolsLegendandComponentReference 6 13 A Hydraulic Schematic Models with Manual Outriggers fromserialnumberT3498 001toT3499 769 6 14 A Hydraulic Schematic Models with Manual Outriggers fromserialnumberT3400 001toT3400 265 6 15 A Hydraulic Schematic Models with Manua...

Page 11: ...re pressure cold 44 psi 3 bar Tongue jack jockey wheels Tire size pneumatic tire 4 00 3 50 4 Diameter 10 in 25 4 cm Tire pressure maximum cold 50 psi 3 4 bar Performance Specifications Boom function speeds maximum from ground controls no weight in platform Jib boom up 10 to 15 seconds Jib boom down 13 to 18 seconds Primary boom up 30 to 35 seconds Primary boom down 21 to 26 seconds Secondary boom ...

Page 12: ...Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Mineral based Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Use Chevron Aviation A hydraulic oil when in ambient temperatures consistently below 0 F 17 C Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Genie specifications require additiona...

Page 13: ...nd C Proportional solenoid valve N C 31 5 to 33 5Ω 24V DC schematic item E Solenoid valve 3 position 4 way N C 23 to 25Ω 20V DC schematic item H Solenoid valve 2 position 3 way 23 to 25Ω 20V DC schematic item K Solenoid valve 3 position 4 way N C 23 to 25Ω 20V DC schematic item L Solenoid valve 2 position 2 way 29 31Ω 24V DC schematic items M N O and P Continuous improvement of our products is a G...

Page 14: ... Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubric...

Page 15: ...DRY LUBED SAE FASTENER TORQUE CHART Grade 5 DRY LUBED This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Black Oxide Bolts Grade 8 LUBED 1 4 LUBED DRY LUBED DRY 1 1 2 9 16 5 8 3 4 7 8 1 1 1 8 1 1 4 5 16 3 8 7 16 1 2 Size mm in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m in lbs N m 5 16 1 8 21 2 4 41 4 63 54 6 18 58 6 63 7...

Page 16: ...Section 2 Specifications June 2005 2 6 TMZ 34 19 Part No 52075 This page intentionally left blank 800 610 4101 ActionRental com ...

Page 17: ...sition at both ground and platform controls Wheels chocked and parking brake applied All external AC power supply disconnected from the machine 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 personnel to potenti...

Page 18: ...tion Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of pr...

Page 19: ...nstructions 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 completed N no unable to complete R repaired Comments 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 inspec...

Page 20: ...June 2005 Section 3 Scheduled Maintenance Procedures 3 4 TMZ 34 19 Part No 52075 This page intentionally left blank 800 610 4101 ActionRental com ...

Page 21: ...00 km A 6 Axle maintenance CE models Perform after 200 miles A 7 Axle maintenance ANSI models Perform weekly A 8 Axle maintenance ANSI models Perform after 500 km A 9 Axle maintenance CE models Perform after 40 hours A 10 30 day service Perform every 100 hours A 11 Grease rotation bearing Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the ...

Page 22: ...tine 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 Checklist A Procedures A 2 Perform Function Tests 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 ...

Page 23: ...r Axle Operation Maintenance Service Manual Genie part number 84376 CHECKLIST A PROCEDURES A 3 Perform Hitch Maintenance ANSI Models Hitch specifications require that this procedure be performed daily Proper hitch maintenance following the hitch manufacturer s maintenance schedule is essential to good hitch performance and service life Failure to perform the maintenance procedures can lead to poor...

Page 24: ...e information is available in the Knott Axle Service Manual Knott part number P005 Knott Axle Service Manual Genie part number 84443 A 6 Perform Axle Maintenance CE Models Axle specifications require that this procedure be performed initially after the first 100 km Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life ...

Page 25: ...tenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 A 8 Perform Axle Maintenance ANSI Models Axle specifications require that this procedure be performed weekly Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintena...

Page 26: ...t damage Required maintenance procedures and additional axle information is available in the Knott Axle Service Manual Knott part number P005 Knott Axle Service Manual Genie part number 84443 A 10 Perform 30 Day Service The 30 day maintenance procedure is a one time procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for contin...

Page 27: ...earing and gear will result in component damage 1 Locate the grease fitting on the inside of the turntable rotation bearing The grease fitting is best located through the bulkhead opening behind the ground control box 2 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 gre...

Page 28: ...ge the batteries and allow the batteries to rest for 24 hours before performing this procedure This will allow the battery cells to equalize 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that the battery retaining fasteners are in place and secure 4 Remove the battery vent caps from all batteries and check the speci...

Page 29: ...able area Ground controls Turntable rotation manifold wiring Power unit wiring Outrigger manifold wiring if equipped 2 Inspect for a liberal coating of dielectric grease in the following locations Between the ground and platform controls All harness connectors Level sensor 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and p...

Page 30: ...e platform controls to the off position Result No machine functions should operate The red Emergency Stop button at the ground controls will stop all machine operation without regard to the position of the key switch B 4 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activatio...

Page 31: ... brass knob in a clockwise direction to open the proportional valve The individual boom manual lowering valves will not function until the proportional valve is open 6 Locate the manual lowering valve at the base of the secondary boom lift cylinder Push and hold the override knob until the secondary boom is fully lowered The override knob is protected by a black rubber cover 7 Locate the manual lo...

Page 32: ... Maintaining the tongue jack in good condition is essential to safe operation and good machine performance Failure to lubricate the internal gears and bearings of the jack and axle bolt could result in unsafe operating conditions and may cause component damage 1 Using a needle nose applicator pump a small amount of automotive grease through the lubrication opening on the side of the jack Rotate th...

Page 33: ... secured and installed into the brake backing plate 3 Set the parking brake If the brake cables are too tight the parking brake assembly will be difficult to apply If the brake cables are too loose the brakes will not activate when the lever is set 4 Attempt to manually push the machine Result The machine should not move Result The machine moves Proceed to step 5 5 Release the parking brake 6 Loos...

Page 34: ...sh down the horn button at the ground controls Result The horn should not sound 4 Turn the key switch to ground control 5 Push down the horn button at the ground controls Result The horn should sound 6 Push down the horn button at the platform controls Result The horn should not sound B 10 Test the Flashing Beacon if equipped The flashing beacon is used to alert operators and ground personnel of m...

Page 35: ... the Hydraulic Tank Cap Venting System Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machine to perform poorly Extremely dirty conditions may require that ...

Page 36: ...ake Actuators Owner Operator Manual Atwood part number MPD85778 Atwood Model MPD84132 Owner Operator Manual Genie part number 97403 B 14 Perform Axle Maintenance ANSI Models Axle specifications require that this procedure be performed quarterly or every 3000 miles whichever comes first Proper axle maintenance as specified in the axle manufacturer s maintenance schedule is essential to good axle pe...

Page 37: ...d continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often 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 t...

Page 38: ...ystem which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install a new cap onto the tank C 2 Perform Axle Maintenance ANSI Models Axle specifications require that this procedure be performed every 6 months or 6000 miles whichever comes first Required maintenance procedures and additiona...

Page 39: ... the hitch manufacturer s maintenance schedule is essential to good hitch performance and service life Failure to perform the maintenance procedures can lead to poor hitch performance and component damage Required maintenance procedures and additional axle information is available in the Knott Axle Service Manual Knott part number P005 Knott Axle Service Manual Genie part number 84443 CHECKLIST C ...

Page 40: ... bearing above the turntable is torqued in sequence to specification See below Bearing to turntable bolt torque sequence 2 Working through the bearing bolt access be sure that each turntable rotation bearing mounting bolt above the turntable is torqued in sequence to specification See below The rotate bearing bolt access is located next to the turntable rotate motor Bearing to chassis bolt torque ...

Page 41: ...ith the boom and no more than 1 inch 2 5 cm from the 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 a turntable b dial indicator c drive chassis d turntable rotation bearing 6 Lower the secondary boom to the stowed position and lower the primary boom to a horiz...

Page 42: ...filter wrench 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 2 Use a permanent ink marker to write the date and number of hours from the hour meter if equipped on the new filter 3 Apply a thin layer of fresh oil onto the gasket of the new oil filter...

Page 43: ...e Service Manual Genie part number 84376 D 5 Perform Hitch Maintenance ANSI Models Hitch specifications require that this procedure be performed annually Proper hitch maintenance following the hitch manufacturer s maintenance schedule is essential to good hitch performance and service life Failure to perform the maintenance procedures can lead to poor hitch performance and component damage Require...

Page 44: ...emove the tank from the machine 6 Remove the pick up filter from hydraulic pump suction tube 7 Clean the filter and tank using a mild solvent 8 Apply thread sealant to the threads of the drain plug Install the drain plug into the tank and torque to specification Torque specifications Hydraulic tank drain plug dry 250 in lbs 28 Nm Hydraulic tank drain plug lubricated 188 in lbs 21 Nm 9 Install the ...

Page 45: ...ich if not avoided may result in property damage Green used to indicate operation or maintenance information 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 Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediatel...

Page 46: ...eable For further information or assistance consult the Genie Industries Service Department 1 1 Circuit Board How to Remove the Circuit Board 1 Tag and disconnect the platform controls wire harness from the harness connector at the platform pivot 2 Remove the platform controls from the machine Release the clamp on the back of the platform controls and slide the controls up and off of the platform ...

Page 47: ...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 1 Remove the platform controls from the machine Open the clamp on the back of the platform cont...

Page 48: ...mage hazard The circuit board will become damaged if it comes in contact with solvent Do not allow solvent to contact the circuit board 9 Remove all the brown backing material from the new touch pad 10 Insert the large blue connector from the new touch pad through the slot Carefully align the low battery LED on the control box lid with the window in the new touch pad and lightly lay the touch pad ...

Page 49: ... hazard The platform may become unbalanced and fall if not properly supported when the toggle pin is removed 4 Lift and remove the platform from the mount Platform Components 2 2 Platform Rotator if equipped The platform rotator is a manually operated gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator 1 Remove the platform See 2 1 How to Remove the Platform 2 ...

Page 50: ...ghten the locknut Torque to specification Torque specification Gear assembly retaining nut dry 180 ft lbs 5 ft lbs 244 Nm 7 Nm How to Service the Platform Rotator 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform controls from the platform control box mount Release the clamp on the back of the platform control box and slide the controls up and off of the mount Lay the ...

Page 51: ...gear do not apply any grease to the remainder of the gear assembly components Grease on the balance of the gear components may result in slippage and poor rotator performance 14 Install the rotate handle shaft pinion and associated components into the gearbox 15 Thoroughly and heavily lubricate each tooth of the pinion using multipurpose grease 16 Install the rotate handle shaft cover Install and ...

Page 52: ...control box Install the platform controls into the outlet 4 Raise the jib boom 4 to 5 feet 1 2 to 1 5 m 5 Lower the jib boom until the platform mount rests on sawhorses or a work table of sufficient capacity 5 Mark the location of each cable retaining plate in the upper jib boom 6 Tag and remove the cable retaining plates from the upper jib boom 7 Attach a lifting strap from an overhead crane to t...

Page 53: ...supported when the pivot pin is removed JIB BOOM COMPONENTS 16 Tag disconnect and plug the hydraulic hoses at the jib boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 17 Tag and disconnect the wires ...

Page 54: ...sawhorses or a work table of sufficient capacity 3 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 Tag disconnect and plug the hydraulic hoses at the jib boom cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penet...

Page 55: ...an overhead crane to the lower jib boom Support the boom Do not apply any lifting pressure 10 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin 11 Using a soft metal drift remove the jib boom cylinder barrel end pivot pin Remove the jib boom cylinder from the machine Crushing hazard The jib boom cylinder could become unbalanced and fall if not properly supporte...

Page 56: ... d primary boom lift cylinder rod end pivot pin e primary boom f primary boom linkage g hold down clamp Boom Components f h i j k l m c d e b g a h jib boom mount i secondary boom lift cylinder barrel end pivot pin j secondary boom lift cylinder k secondary boom lift cylinder rod end pivot pin l secondary boom linkage m secondary boom 800 610 4101 ActionRental com ...

Page 57: ... to the jib boom pivot 12 Using a soft metal drift remove the primary linkage pivot pin at the jib boom mounting weldment BOOM COMPONENTS 4 1 Boom How to Disassemble the Boom This procedure in this section 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 compone...

Page 58: ...etal drift remove the primary boom linkage pivot pin at the boom pivot Crushing hazard The primary boom linkage could become unbalanced and fall if not properly supported when the pivot pin is removed 19 Remove the primary boom linkage from the machine Crushing hazard The primary boom linkage could become unbalanced and fall if not properly supported when removed from the machine 20 Carefully lay ...

Page 59: ... the primary boom lift cylinder Raise the cylinder to a vertical position 33 Remove the pin retaining fasteners from the primary boom lift cylinder barrel end pivot pin 34 Using a soft metal drift remove the primary boom lift cylinder barrel end pivot pin Crushing hazard The primary boom lift cylinder could fall if not properly supported when the pivot pin is removed 35 Remove the primary boom lif...

Page 60: ...amage hazard Cables and hoses can be damaged if they are kinked or pinched 48 Remove the rear cable guard from the secondary boom 49 Place blocks across the turntable pivot plates under the secondary boom lift cylinder 50 Remove the pin retaining bolt from the secondary boom lift cylinder rod end pivot pin 51 Using a soft metal drift remove the secondary boom lift cylinder rod end pivot pin Rest t...

Page 61: ...ulic 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 64 Tag and disconnect the wires from the secondary boom lift cylinder 65 Remove the pin retaining fasteners from the secondary boom lift cylinder barrel end pivot pin at the turntable pivot 66 Using a soft metal drift remove the secondar...

Page 62: ... lift cylinder with an overhead crane or similar lifting device 4 Remove the pin retaining fastener from the primary boom lift cylinder barrel end pivot pin a primary boom lift cylinder barrel end pivot pin b primary boom lift cylinder c primary boom lift cylinder rod end pivot pin d primary boom e secondary boom a b d c e 5 Using a soft metal drift remove the primary boom lift cylinder barrel end...

Page 63: ...rushing hazard The lift cylinder will fall if not properly supported 6 Lower the cylinder onto the secondary linkage 7 Attach an overhead crane to the boom pivot 8 Carefully raise the boom pivot with the overhead crane until the secondary boom is in a horizontal position BOOM COMPONENTS a boom pivot b secondary boom c secondary boom lift cylinder rod end pivot pin d secondary boom lift cylinder e ...

Page 64: ...ons on earlier models were replaced with a membrane overlay decal mounted on the exterior of the box N C N O N O KS1 KEY SWITCH P1 EMERGENCY STOP D7 VOLTAGE REGULATOR d e f a b c From serial number T3498 001 to T3499 769 a voltage regulator D7 b CPU circuit board U17 c connector circuit board U21 d key switch KS1 e Emergency Stop button P2 f key pad circuit board U15 From serial number T3400 001 t...

Page 65: ...f the box The following procedure will not apply for models manufactured in the 2000 and later model years How to Remove the Ground Control Keypad 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 GROUND CONTROLS 2 Remove the four lid retaini...

Page 66: ... Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 5 Remove the connector circuit board mounting fasteners and remove the connector circuit board 5 2 CPU Circuit Board The CPU circuit board controls all machine functions How to Remove the CPU Circuit Board 1 Disconnect the battery pack from the ma...

Page 67: ...can be configured by changing the combination of toggles of the DIP switch mounted on the CPU circuit board The following procedures will not apply for machines manufactured in the 1998 and 1999 model years 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 bef...

Page 68: ...following illustration to correctly identify the configuration of the DIP switch settings 4 Locate the DIP switch on the circuit board Move the DIP switch settings to correspond with the configuration of the machine options as illustrated below 5 Close the lid and install the fasteners DIP Switch Legend Toggle Description Position 1 All models On 2 Hour meter flashing beacon On 3 Not used Off 4 Ou...

Page 69: ...eners GROUND CONTROLS MEMBRANE DECAL PANEL 16 PIN RIBBON CABLE 16 15 14 13 12 8 7 6 5 11 2 10 1 9 BN44 BN39 FUNCTION ENABLE HIGH PRIMARY DOWN BN45 FUNCTION ENABLE MEDIUM BN46 BN35 BN38 BN53 BN52 BN41 FUNCTION ENABLE LOW HORN PRIMARY UP RIGHT FRONT OUTRIGGER LEFT FRONT OUTRIGGER SECONDARY DOWN BN37 BN36 BN43 BN50 BN47 BN48 BN42 BN49 JIB BOOM DOWN JIB BOOM UP ROTATE RIGHT LEFT REAR OUTRIGGER OUTRIGG...

Page 70: ... control box lid with the window in the new touch pad and lightly lay the touch pad onto the control box lid Repositioning the touch pad is possible if the touch pad is lightly adhered to the lid Do not apply any pressure to the touch pad 10 When satisfied with the position of the touch pad firmly press down the entire surface of the touch pad with your fingers 11 Loosen the control box lid retain...

Page 71: ...dure with the machine on a firm level surface that is free of obstructions 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 Result The power light should be on Models with hydraulic outriggers 3 Push and hold the auto level button Push and hold the extend outrigger button Result The outriggers will lower ...

Page 72: ...usting fasteners until the bubble in the top of the level sensor is centered in the calibration circles 13 Turn the key switch to ground control Adjust the side to side axis 14 Set a multimeter to read DC voltage 15 Without disconnecting the wire harness from the level sensor connect the negative lead of the multimeter to the black wire at the level sensor 16 Without disconnecting the wire harness...

Page 73: ...ve leads 22 Apply Sentry Seal to the adjusting nuts Test the machine 23 Raise the primary secondary and jib booms approximately 12 inches 30 cm Result The tilt sensor alarm should not sound 24 Press down one side of the tilt sensor and place the tilt sensor test tool under one of the posts Result The alarm located in the platform should sound at 180 beeps per minute after 1 second The interlock di...

Page 74: ...rge current is 40 of chargers nominal rating 5 10A Red Illuminates when charge current is 20 of chargers nominal rating NOTE If the batteries are fully discharged all of the above listed LEDs will illuminate at the same time if the batteries are not fully discharged not all will illuminate Charge Red Illuminates when battery is connected correctly and AC power is present LED turns off when battery...

Page 75: ...ng will increase battery life while decreasing the amount of cycles for the machine Normal setting will decrease the battery life while increasing the amount of cycles for the machine DIP switch location 8 Install the cover onto the battery charger Install and securely tighten the fasteners Do not over tighten DIP settings Normal Liquid Gel Toggle 1 OFF OFF ON Toggle 2 ON OFF OFF If not operating ...

Page 76: ...y adjusts to operate on 110V or 220V AC is equipped with and protected by three circuit breakers located on the face plate next to the AC input connector Two 8A circuit breakers are used on the input side of the charger circuit one 45A circuit breaker is used on the output side If not operating correctly check the following Good power supply at the AC power source Use only 12 AWG heavy duty extens...

Page 77: ...Section 4 Repair Procedures June 2005 Part No 52075 TMZ 34 19 4 33 This page intentionally left blank 800 610 4101 ActionRental com ...

Page 78: ...ng of the boom 155 in lbs 17 5 Nm Coil nut item E 5 7 ft lbs 7 9 Nm 4 24V DC electric motor Operates hydraulic pump 5 Motor bearing Aligns motor shaft into pump 6 Motor seal Seals motor from contaminants 7 Pressure relief valve F System relief 8 Pump 0 75 gallons per minute 3000 psi minimum 2 84 liters per minute 207 bar minimum 9 Pick up filter Filters hydraulic fluid entering the pump 10 O ring ...

Page 79: ...REV B Section 4 Repair Procedures June 2005 Part No 52075 TMZ 34 19 4 35 HYDRAULIC POWER UNIT D E G F 5 6 14 15 1 3 2 4 8 9 10 11 12 13 7 800 610 4101 ActionRental com ...

Page 80: ... nut 6 Adjust the relief valve screw 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 Hold the relief valve screw and tighten the lock nut Be sure the relief valve screw does not turn 8 Repeat steps 2 through 4 to confirm the relief valve pressure 9 Bleed ...

Page 81: ...essure to dissipate gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 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 4 Activate a function enable button and any lift function button at the ground controls Result If t...

Page 82: ...the fittings on the power unit 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 Tag and disconnect the electrical wiring from the valve coil 4 Tag and disconnect the power cables from the hydraulic power unit motor Electrocution hazard Contact with ...

Page 83: ...to 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 Us...

Page 84: ...chine Index Schematic No Description Item Function Torque 1 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 2 Relief valve I Turntable rotate circuit 35 40 ft lbs 47 54 Nm 3 Needle valve J Bypasses the relief valve to allow manual rotation of the turntable 25 30 ft lbs 34 41 Nm H I J Y24 Y23 3 2 1 800 610 4101 ActionRental c...

Page 85: ...nterclockwise 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 ...

Page 86: ...otation motor on the power unit side of the machine Index Schematic No Description Item Function Torque Coil nut items K and L 4 5 ft lbs 5 7 Nm 1 Solenoid valve 3 position 4 way N C K Outrigger regeneration circuit 10 12 ft lbs 14 16 Nm 2 Solenoid valve 3 position 4 way N C L Outrigger extend retract 10 12 ft lbs 14 16 Nm K L 1 2 Y41 Y39 Y48 800 610 4101 ActionRental com ...

Page 87: ...e tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve coil resistance specifications Description Specification Solenoid valve 2 position 2 way 29 31Ω 24V DC schematic items A B and C Proportional solenoid valve N C 31 5 to 33 5Ω 24V DC schematic item E So...

Page 88: ...e terminals Resistor 10W Genie part number 27287 3 Set a multimeter to read DC voltage The multimeter when set to read DC voltage should be capable of reading up to 800 mA a multimeter b 9V DC battery c 10W resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 4 Connect the negative lead to the other terminal on the coil If testing a single termina...

Page 89: ...ting 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 ...

Page 90: ... 7 Support and secure the axle assembly to an appropriate lifting device 8 Remove the axle mounting fasteners and remove the axle from the machine Crushing hazard The axle could become unbalanced and fall if not properly supported and secured when removed from the machine When the axle is installed the brakes should be bled Refer to the appropriate brake manufacturer s manual that was shipped with...

Page 91: ...r 84443 10 2 Parking Brake How to Adjust the Parking Brake ANSI models 1 Adjust the brakes Refer to the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 2 Chock the wheels 3 Release the parking brake 4 Loosen the set screw at the side of the parking brake handle 5 Adjust the handle just to the po...

Page 92: ...ve the pin 4 Gently tap the outrigger pivot pin towards the axle using a soft metal drift until the end of the pin is almost flush with the plastic outrigger switch guide 5 Place a rod through the hole in the pin and twist to remove the pin Remove the outrigger pivot pin from the machine Crushing hazard The outrigger may fall if not properly supported when the outrigger pivot pin is removed from t...

Page 93: ...ed from the machine Crushing hazard The outrigger cylinder could fall if not properly supported when the outrigger is removed from the machine 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 Fitti...

Page 94: ...ne 8 Raise the cylinder to a vertical position 9 Remove the pin retaining fasteners from the outrigger cylinder barrel end pivot pin 10 Place a rod through the hole in the outrigger cylinder barrel end pivot pin and twist to remove the pin Remove the outrigger cylinder barrel end pivot pin from the machine Crushing hazard The outrigger cylinder could fall if not properly supported when the pivot p...

Page 95: ...d burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this m...

Page 96: ...h the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process TROUBLESHOOTING FLOW CHARTS Malfunction discovered Identify symptoms Troubleshoot Perform repair Return to service problem solved problem still exists Inspect and test LED Diagnostic Readout A diagnostic display was incorporated into the side of t...

Page 97: ...Level machine OR repair or replace wire harness or connections OR replace outrigger switches OR consult Genie Industries Service Department 0010 ECM platform communications fault Machine functions inoperative Faulty control cable OR faulty circuit board Repair or replace control cable OR replace circuit boards 0011 Platform key pad fault Machine functions inoperative Platform controls has stuck or...

Page 98: ...032 Outrigger level coil fault Outrigger level valve coil shorted Short in wire harness OR faulty circuit board Repair faulty wiring OR replace circuit board 0033 Outrigger regen coil fault Outrigger regen valve coil open Coil not connected to wire harness OR open circuit OR faulty circuit board Restore connection OR replace circuit board 0034 Outrigger regen coil fault Outrigger regen valve coil ...

Page 99: ...ion OR replace circuit board 0046 Rotate right clockwise coil fault Rotate right valve coil shorted Short in wire harness OR faulty circuit board Repair faulty wiring OR replace circuit board 0047 Rotate left counterclockwise coil fault Rotate left valve coil open Coil not connected to wire harness OR open circuit OR faulty circuit board Restore connection OR replace circuit board 0048 Rotate left...

Page 100: ... VGIQY GTJ INKIQ URZGMK UT KGIN HGZZKX_ RKYY ZNGT NGXMK 58 INKIQ HGZZKX_ IUTJOZOUT H_ RUGJ ZKYZOTM HGZZKXOKY GTJ XKVRGIK 58 INKIQ LUX YNUXZ IOXI OZY 58 INKIQ HGZZKX_ IGHRKY 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ UX SUXK 8KVGOX UVKT OT Y VVR_ IGHRKY VUYOZO K GTJ TKMGZO K LXUS ZU 7 NKIQ URZGMK GZ OTV Z YOJK UL MXU TJ IUTZXUR SKXMKTI_ 9ZUV H ZZUT 6 8KVGOX UVKT OT OXK LXUS OTV Z YOJK UL 6 ZU IUTT...

Page 101: ...GZOTM ZNK IUTZGIZ HGJ 8KVGOX UX XKVRGIK 19 MUUJ 8KVRGIK MXU TJ IUTZXURY IUTZGIZ 58 XKLKX ZU XU TJ UTZXURY TUVKXGZO K NGXZ 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ XT QK_ Y OZIN ZU VRGZLUXS IUTZXUR VUYOZOUT GTJ INKIQ U ZV Z YOJK UL VRGZLUXS IUTZXURY IUTZGIZ MUUJ 8KVGOX UX XKVRGIK 19 HGJ 8KVRGIK VRGZLUXS IUTZXURY IUTZGIZ 58 XKLKX ZU 6RGZLUXS UTZXURY TUVKXGZO K NGXZ 58 IUTY RZ KTOK TJ YZXOKY 9KX O...

Page 102: ... XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 6XKYY GTJ NURJ G L TIZOUT KTGHRK H ZZUT GTJ INKIQ URZGMK UT ZKXSOTGR GZ ZNK SUZUX IUTZXURRKX 6XKYY GTJ NURJ ZNK NOMN YVKKJ L TIZOUT KTGHRK H ZZUT GTJ VXKYY ZNK VXOSGX_ HUUS V H ZZUT NKIQ URZGMK GZ ZKXSOTGR GZ NK URZGMK YNU RJ XGSV LXUS ZU URZY 8KVGOX UVKT OT OXK LXUS ZKXSOTGR GZ ZU ZKXSOTGR GZ IUTTKIZUX 0 UT ZNK OXK NGXTKYY IUTTKIZUX HUGXJ 58 XK...

Page 103: ...osition Be sure the hydraulic tank is full 8KSU K ZNK XKYKX UOX LXUS ZNK VU KX TOZ ZNKT XKSU K ZNK V SV LXUS ZNK V SV SUZUX 9KK 8KVGOX 9KIZOUT NKIQ ZNK IUTTKIZOUT HKZ KKT ZNK V SV SUZUX GTJ ZNK V SV H_ OY GRR_ OTYVKIZOTM ZNK IU VROTM UX QK_ LUX G VUYOZO K IUTTKIZOUT HGJ 8KVRGIK SUZUX UX V SV MUUJ KYZ ZNK V SV 9KK 8KVGOX 9KIZOUT HGJ 8KVRGIK ZNK V SV MUUJ 8K GJP YZ ZNK VXKYY XK XKROKL GR K OZKS 58 I...

Page 104: ...IZ _KY 8KVRGIK QK_ Y OZIN IUTZGIZ LUX MXU TJ IUTZXURY TU 8KVRGIK 19 8KVGOX UVKT OT OXK LXUS 19 ZU ZKXSOTGR UL IUTTKIZUX 0 GZ 8KVRGIK ZNK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ URZGMK GZ ZKXSOTGR UL IUTTKIZUX 0 GZ ZNK OXK NGXTKYY IUTTKIZUX HUGXJ 8KVGOX UVKT OT OXK LXUS ZKXSOTGR UL IUTTKIZUX 0 ZU OTV Z YOJK UL 19...

Page 105: ...GZOTM VRGZLUXS IUTZXUR IUTZGIZ _KY 8KVRGIK QK_ Y OZIN IUTZGIZ LUX VRGZLUXS IUTZXURY TU 8KVRGIK 19 8KVGOX UVKT OT OXK LXUS 19 ZU ZKXSOTGR UL IUTTKIZUX 0 GZ 8KVRGIK ZNK VRGZLUXS IUTZXURY QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ NKIQ URZGMK GZ ZNK OXK UT ZKXSOTGR UL IUTTKIZUX 0 GZ ZNK OXK NGXTKYY IUTTKIZUX HUGXJ 8KVGOX UVKT OT OXK LXUS...

Page 106: ...R K IUOR OZKS 6XKYY GTJ NURJ G L TIZOUT KTGHRK H ZZUT GTJ ZNK POH HUUS V H ZZUT UT ZNK MXU TJ VGTKR OT ZNK V JOXKIZOUT GTJ INKIQ URZGMK GIXUYY ZNK NZ GTJ HRQ OXKY GZ ZKXSOTGRY GTJ UL IUTTKIZUX 0 UT ZNK OXK NGXTKYY IUTTKIZUX IOXI OZ HUGXJ 8KVRGIK ZNK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ OYIUTTKIZ ZNK OXKY ZU ZNK PO...

Page 107: ...NK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ OYIUTTKIZ ZNK OXKY ZU ZNK POH HUUS ROLZ I_ROTJKX YURKTUOJ GR K IUOR GTJ ZKYZ ZNK XKYOYZGTIK UL ZNK GR K IUOR 9KK 8KVGOX 9KIZOUT UX OTLOTOZK UNSY ZU UNSY 8KVRGIK ZNK POH HUUS ROLZ I_ROTJKX YURKTUOJ GR K IUOR OZKS NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM POH HUUS JU T L TIZOUT...

Page 108: ...INKIQ URZGMK GIXUYY ZNK NZ GTJ HRQ OXKY GZ ZKXSOTGRY GTJ UL IUTTKIZUX 0 UT ZNK OXK NGXTKYY IUTTKIZUX IOXI OZ HUGXJ 8KVRGIK ZNK QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ 8KVGOX UVKT OT NZ GTJ HRQ OXKY LXUS ZKXSOTGRY GTJ UL IUTTKIZUX 0 GZ ZU ZNK VXUVUXZOUTGR YURKTUOJ GR K IUOR OZKS UTZOT KJ LXUS ZNK VXK OU Y VGMK 800 610 4101 ActionRen...

Page 109: ...OJ GR K IUOR OZKS 6XKYY GTJ NURJ G L TIZOUT KTGHRK H ZZUT GTJ ZNK VXOSGX_ HUUS V H ZZUT UT ZNK MXU TJ VGTKR OT ZNK V JOXKIZOUT GTJ INKIQ URZGMK GIXUYY ZNK NZ GTJ HRQ OXKY GZ ZKXSOTGRY GTJ UL IUTTKIZUX 0 UT ZNK OXK NGXTKYY IUTTKIZUX IOXI OZ HUGXJ 8KVRGIK ZNK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ OYIUTTKIZ ZNK OXKY Z...

Page 110: ...OXKY LXUS ZKXSOTGRY GTJ UL IUTTKIZUX 0 GZ ZU ZNK VXOSGX_ HUUS ROLZ I_ROTJKX YURKTUOJ GR K IUOR OZKS 6XKYY GTJ NURJ G L TIZOUT KTGHRK H ZZUT GTJ ZNK VXOSGX_ HUUS JU T H ZZUT UT ZNK MXU TJ VGTKR OT ZNK JU T JOXKIZOUT GTJ INKIQ URZGMK GIXUYY ZNK NZ GTJ HRQ OXKY GZ ZKXSOTGRY GTJ UL IUTTKIZUX 0 UT ZNK OXK NGXTKYY IUTTKIZUX IOXI OZ HUGXJ 8KVRGIK ZNK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 I...

Page 111: ... OZKS UTZOT KJ LXUS ZNK VXK OU Y VGMK NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM VXOSGX_ HUUS JU T L TIZOUT LXUS UVKXGZOTM 58 XKVGOX UX XKVRGIK ZNK I_ROTJKX 58 XKVGOX UX XKVRGIK ZNK YURKTUOJ GR K IGXZXOJMK OZKS UT ZNK I_ROTJKX 58 XKVRGIK ZNK VXUVUXZOUTGR GR K IGXZXOJMK OZKS UT ZNK N_JXG ROI VU KX TOZ 6XKYY GTJ NURJ G L TIZOUT KTGHRK H ZZUT GTJ ZNK VXOSGX_ HUUS JU T H ZZUT UT ZNK MXU TJ VGTKR OT ZNK ...

Page 112: ...KTUOJ GR K IUOR OZKS 6XKYY GTJ NURJ G L TIZOUT KTGHRK H ZZUT GTJ ZNK YKIUTJGX_ HUUS V H ZZUT UT ZNK MXU TJ VGTKR OT ZNK V JOXKIZOUT GTJ INKIQ URZGMK GIXUYY ZNK NZ GTJ HRQ OXKY GZ ZKXSOTGRY GTJ UL IUTTKIZUX 0 GZ ZNK OXK NGXTKYY IUTTKIZUX IOXI OZ HUGXJ 8KVRGIK ZNK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ OYIUTTKIZ ZNK O...

Page 113: ...OXKY LXUS ZKXSOTGRY GTJ UL IUTTKIZUX 0 GZ ZU ZNK YKIUTJGX_ HUUS ROLZ I_ROTJKX YURKTUOJ GR K IUOR OZKS 6XKYY GTJ NURJ G L TIZOUT KTGHRK H ZZUT GTJ ZNK YKIUTJGX_ HUUS JU T H ZZUT UT ZNK MXU TJ VGTKR OT ZNK JU T JOXKIZOUT GTJ INKIQ URZGMK GIXUYY ZNK NZ GTJ HRQ OXKY GZ ZKXSOTGRY GTJ UL IUTTKIZUX 0 GZ ZNK OXK NGXTKYY IUTTKIZUX IOXI OZ HUGXJ 8KVRGIK ZNK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK...

Page 114: ... OZKS UTZOT KJ LXUS ZNK VXK OU Y VGMK NKIQ LUX SKINGTOIGR XKYZXOIZOUTY QKKVOTM YKIUTJGX_ HUUS JU T L TIZOUT LXUS UVKXGZOTM 58 XKVGOX UX XKVRGIK ZNK I_ROTJKX 58 XKVGOX UX XKVRGIK ZNK YURKTUOJ GR K IGXZXOJMK OZKS UT ZNK I_ROTJKX 58 XKVRGIK ZNK VXUVUXZOUTGR GR K IGXZXOJMK OZKS UT ZNK N_JXG ROI VU KX TOZ 6XKYY GTJ NURJ G L TIZOUT KTGHRK H ZZUT GTJ ZNK YKIUTJGX_ HUUS JU T H ZZUT UT ZNK MXU TJ VGTKR OT ...

Page 115: ...RQ OXKY GZ ZKXSOTGRY GTJ UL IUTTKIZUX 0 GZ ZNK OXK NGXTKYY IUTTKIZUX IOXI OZ HUGXJ 8KVRGIK ZNK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ OYIUTTKIZ ZNK OXKY ZU ZNK Z XTZGHRK XUZGZK RKLZ YURKTUOJ GR K IUOR GTJ ZKYZ ZNK XKYOYZGTIK UL ZNK GR K IUOR 9KK 8KVGOX 9KIZOUT UX OTLOTOZK UNSY ZU UNSY 8KVRGIK ZNK Z XTZGHRK XUZGZK RK...

Page 116: ...UL IUTTKIZUX 0 GZ ZNK OXK NGXTKYY IUTTKIZUX IOXI OZ HUGXJ 8KVRGIK ZNK MXU TJ IUTZXUR QK_VGJ IOXI OZ HUGXJ 58 XKVRGIK ZNK 6 IOXI OZ HUGXJ 58 XKVRGIK 58 IUTY RZ KTOK TJ YZXOKY 9KX OIK KVGXZSKTZ OYIUTTKIZ ZNK OXKY ZU ZNK Z XTZGHRK XUZGZK XOMNZ YURKTUOJ GR K IUOR GTJ ZKYZ ZNK XKYOYZGTIK UL ZNK GR K IUOR 9KK 8KVGOX 9KIZOUT UX OTLOTOZK UNSY ZU UNSY 8KVRGIK ZNK Z XTZGHRK XUZGZK XOMNZ YURKTUOJ GR K IUOR U...

Page 117: ...es are properly connected and are in good condition SGINOTK SU KY JP YZ VGXQOTM HXGQK 9KK 8KVGOX 9KIZOUT VVR_ ZNK VGXQOTM HXGQK GTJ GZZKSVZ ZU V YN ZNK SGINOTK SGINOTK JUKY TUZ SU K NK VGXQOTM HXGQK OY UVKXGZOTM IUXXKIZR_ JP YZ ZNK HXGQKY 58 XKVRGIK HXGQK YNUKY 9KK HXGQK SGT LGIZ XKY SGT GR LUX VXUIKJ XKY UT JOYGYYKSHROTM ZNK HXGQKY 800 610 4101 ActionRental com ...

Page 118: ...Section 5 Troubleshooting Flow Charts June 2005 5 24 TMZ 34 19 Part No 52075 This page intentionally left blank 800 610 4101 ActionRental com ...

Page 119: ...ipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution 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 ca...

Page 120: ...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 LS 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 boo...

Page 121: ...om LS11 d structure retract limit switch LS1 from serial number T3498 001 to T3499 769 e outrigger deployed switch from serial number T3498 001 to T3499 769 left front SW13 SW13A right front SW14 SW14A left rear SW15 SW15A right rear SW16 SW16A e outrigger deployed switch after serial number T3499 769 left front SW13 right front SW14 left rear SW15 right rear SW16 800 610 4101 ActionRental com ...

Page 122: ... 2 5 5 1 1 6 6 4 3 4 3 L33 RIGHT REAR TAIL LIGHT L34 LEFT REAR TAIL LIGHT BN BN BK WH WH GN GN YL BK BN BK L36 LEFT SIDE MARKER 1 5 3 2 6 7 4 BN BK BN WH WH BN GN RD BL YL GN RD BL YL BN WH WH BK 5 5 7 7 3 3 2 6 1 2 6 1 4 4 2 BL 3 WH 1 YL 4 GN 5 BN 6 RD 7 BK 4 5 6 7 1 2 3 QD12 TRAILER PLUG TB TERMINAL BASE QD19 QUICK DISCONNECT L36 LEFT SIDE MARKER L35 RIGHT SIDE MARKER L33 RIGHT REAR TAIL LIGHT L...

Page 123: ...3 5V DC 24V DC 24V 5V S7 LEVEL SENSOR LS17 N O H C LS2 N C Emergency Stop button normally closed Circuit connection Circuits crossing no connection LED Button or switch Key switch Motor controller Horn or alarm Solenoid valve Limit switch Hour meter Fuse Circuit breaker Battery Motor DIP switch Voltage regulator Level sensor 800 610 4101 ActionRental com ...

Page 124: ...22 CPU DISPLAY BOARD J6 J3 34 PIN DUAL ROW RIBBON CABLE J2 J4 10 PIN RIBBON CABLE EN2 GROUND CONTROL BOX U21 CONNECTOR PC BOARD NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 10 20 PUMP ENABLE PUMP SPEED 24V LS1 STRUCTURE RETRACT N O LS1 N O H C 25 24 15 WH BK WH BK GROUND WH BK 3 4 H5 HORN 9 B 1 M T2 B 3 M5 MOTOR QD1 A1 D1 M5 U9 BATTERY CHARGER QD1 AC INPUT F6 2 A F 75 USE U6 MOTOR ...

Page 125: ...SPLAY BOARD J6 J3 34 PIN DUAL ROW RIBBON CABLE J2 J4 10 PIN RIBBON CABLE EN2 GROUND CONTROL BOX U21 CONNECTOR PC BOARD NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 10 20 PUMP ENABLE PUMP SPEED 24V LS1 STRUCTURE RETRACT N O LS1 N O H C 25 24 15 WH BK WH BK GROUND WH BK 3 4 H5 HORN 9 B 1 M T2 B 3 M5 MOTOR QD1 A1 D1 M5 U9 BATTERY CHARGER QD1 AC INPUT F6 2 A F 75 USE U6 MOTOR CONTROLLE...

Page 126: ... 1 G6 27 P3 OUTRIGGER NEGATIVE BOOM ANGLE N O LS17 LS17 N O H C 25 24 NEGATIVE BOOM ANGLE COM G8 DIAGNOSTIC DISPLAY OR RD BN BK 6 J4 5 4 2 3 1 G8 AVAILABLE AFTER SERIAL NUMBER T3402 115 LEFT REAR OUTRIGGER LED LEFT REAR OUTRIGGER LED L14 LEFT FRONT OUTRIGGER LED LEFT FRONT OUTRIGGER LED L12 LEFT REAR OUTRIGGER COM LEFT REAR OUTRIGGER N O SW15 LEFT FRONT OUTRIGGER COM LEFT FRONT OUTRIGGER N O SW13 ...

Page 127: ... OR WH GN BK RD BL P2 EMERGENCY STOP 1 3 2 6 4 5 QD4 7 3 1 5 9 8 24V DC 5V DC D7A VOLTAGE REGULATOR BN5 HORN 3 4 5 6 7 8 10 11 12 13 14 BN27 JIB UP BN28 JIB DOWN BN29 PRIMARY UP BN30 PRIMARY DOWN BN31 SECONDARY UP BN32 SECONDARY DOWN BN33 ROTATE LEFT BN34 ROTATE RIGHT BN12 FUNCTION ENABLE HIGH BN26 FUNCTION ENABLE MEDIUM BN13 FUNCTION ENABLE LOW ES0209D U21 CONNECTOR PC BOARD Y45 Y46 Y47 Y9 Y23 Y2...

Page 128: ...RONT OUTRIGGER COM RIGHT FRONT OUTRIGGER N C LS13 3 14 32 21 LS13 N C H O 29 17 LS12 N C H O 6 18 NOTE MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF B 1 M T2 B 3 M5 MOTOR QD1 A1 D1 M5 U9 BATTERY CHARGER QD1 AC INPUT P1 ENGINE F6 2 A F 75 USE U6 MOTOR CONTROLLER 1 2 17 PUMP ENABLE PUMP SPEED 24V CB2 30A CIRCUIT BREAKER BK RD P4 P5 B5 FOUR 6V BATTERIES GROUND CONTROLS MEMBRANE DECAL PANEL ...

Page 129: ...E DECAL PANEL J4 14 PIN RIBBON CABLE DATA DATA GND H2 HORN BK 2 1 RD J3 24V OR WH GN BK RD OR WH GN BK RD BL P2 EMERGENCY STOP 1 3 2 6 4 5 QD4 7 3 1 5 9 8 24V DC 5V DC D7A VOLTAGE REGULATOR BN5 HORN 3 4 5 6 7 8 10 11 12 13 14 BN27 JIB UP BN28 JIB DOWN BN29 PRIMARY UP BN30 PRIMARY DOWN BN31 SECONDARY UP BN32 SECONDARY DOWN BN33 ROTATE LEFT BN34 ROTATE RIGHT BN12 FUNCTION ENABLE HIGH BN26 FUNCTION E...

Page 130: ...Section 6 Schematics June 2005 6 12 TMZ 34 19 Part No 52075 This page intentionally left blank 800 610 4101 ActionRental com ...

Page 131: ...tor Fixed displacement pump Bi directional motor Shut off valve Relief valve Orifice with size Dual acting cylinder Single acting cylinder Solenoid operated 2 position 2 way directional valve Solenoid operated 2 position 3 way directional valve Proportional valve Solenoid operated 3 position 4 way directional valve Counterbalance valve Hydraulic power unit components Outrigger manifold components ...

Page 132: ...0 037 in 9 4 mm 0 037 in 9 4 mm PRIMARY BOOM LIFT CYLINDER B Y45 Y47 0 037 in 9 4 mm Y46 C A HYDRAULIC POWER UNIT P T T P 35 psi 2 4 bar M 1 5 gpm 5 7 L min D 3200 psi 220 6 bar G Y9 TEST 3 gpm 11 3 L min E F Y24 Y23 A B TURNTABLE ROTATE MANIFOLD T P 1200 psi 82 7 bar J I H 18 psi 1 2 bar SECONDARY BOOM LIFT CYLINDER JIB BOOM LIFT CYLINDER 800 610 4101 ActionRental com ...

Page 133: ... 037 in 9 4 mm 0 037 in 9 4 mm PRIMARY BOOM LIFT CYLINDER B Y45 Y47 0 037 in 9 4 mm Y46 C A HYDRAULIC POWER UNIT P T T P 35 psi 2 4 bar M 1 5 gpm 5 7 L min D 3200 psi 220 6 bar G Y9 TEST 3 gpm 11 3 L min E F Y24 Y23 A B TURNTABLE ROTATE MANIFOLD T P 1200 psi 82 7 bar J I H 18 psi 1 2 bar SECONDARY BOOM LIFT CYLINDER JIB BOOM LIFT CYLINDER 800 610 4101 ActionRental com ...

Page 134: ... BOOM LIFT CYLINDER B C A HYDRAULIC POWER UNIT P T T P M D G TEST E Y24 Y23 A B TURNTABLE ROTATE MANIFOLD T P J I H SECONDARY BOOM LIFT CYLINDER JIB BOOM LIFT CYLINDER 3200 psi 220 6 bar F 35 psi 2 4 bar 1 5 gpm 5 7 L min Y9 3 gpm 11 3 L min 18 psi 1 2 bar 1200 psi 82 7 bar 0 037 in 9 4 mm 0 037 in 9 4 mm Y45 Y47 0 037 in 9 4 mm Y46 800 610 4101 ActionRental com ...

Page 135: ...D 3200 psi 220 6 bar G Y9 TEST 3 gpm 11 3 L min E F Y24 Y23 A B TURNTABLE ROTATE MANIFOLD T P 1200 psi 82 7 bar J I H 18 psi 1 2 bar SECONDARY BOOM LIFT CYLINDER JIB BOOM LIFT CYLINDER 0 037 in 9 4 mm 0 037 in 9 4 mm 0 037 in 9 4 mm 0 037 in 9 4 mm 4000 psi 275 8 bar 3 1 2000 psi 137 9 bar 3 1 LEFT FRONT OUTRIGGER CYLINDER LEFT REAR OUTRIGGER CYLINDER RIGHT FRONT OUTRIGGER CYLINDER RIGHT OUTRIGGER...

Page 136: ...3200 psi 220 6 bar G Y9 TEST 3 gpm 11 3 L min E F Y24 Y23 A B TURNTABLE ROTATE MANIFOLD T P 1200 psi 82 7 bar J I H 18 psi 1 2 bar SECONDARY BOOM LIFT CYLINDER JIB BOOM LIFT CYLINDER 0 037 in 9 4 mm 0 037 in 9 4 mm 0 037 in 9 4 mm 0 037 in 9 4 mm 4000 psi 275 8 bar 3 1 2000 psi 137 9 bar 3 1 LEFT FRONT OUTRIGGER CYLINDER LEFT REAR OUTRIGGER CYLINDER RIGHT FRONT OUTRIGGER CYLINDER RIGHT OUTRIGGER C...

Page 137: ...569 65 98 480 775 65 67 533 544 81 3 3453 6082 81 3 3453 6083 82 25 587 267 82 25 583 910 55 11 41 665 755 55 11 41 665 754 31 183 581 102 31 183 581 566 Genie Scandinavia Genie France Genie Iberica Genie Germany Genie U K Genie Mexico City Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax Phone Fax 46 31 575100 33 0 2 37 26 09 99 33 0 2 37 26 09 98 34 93 579 5042 34 93 579 5059 49 0 4202 88520 49...

Page 138: ...Service Manual TMZ 34 19 Rev C Part No 52075 800 610 4101 ActionRental com ...

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