Genie TMZ 34 19 Service Manual en

Service Manual Part No.
52075
Rev C
June 2005
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.
Copyright © 1998 by Genie Industries

Contact Us:
52075 Rev C June 2005
PO Box 97030 First Edition, Third Printing
Redmond, WA 98073-9730 USA
"Genie" is a registered trademark of Genie
http://www.genieindustries.com Industries in the USA and many other countries.
"TMZ" is a trademark of Genie Industries.
e-mail: [email protected]
Printed on recycled paper
Printed in U.S.A.
ii TMZ-34/19 Part No. 52075

June 2005 Section 1 • Safety Rules
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
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance

Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 52075 TMZ-34/19 iii

Section 1 • Safety Rules June 2005
SAFETY RULES
Personal Safety Be sure to wear protective eye wear and

other protective clothing if the situation
Any person working on or around a machine must warrants it.
be aware of all known safety hazards. Personal
safety and the continued safe operation of the Be aware of potential crushing hazards
machine should be your top priority. such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert Workplace Safety
personnel to potential personal Be sure to keep sparks, flames and
injury hazards. Obey all safety lighted tobacco away from flammable and
messages that follow this symbol combustible materials like battery gases
to avoid possible injury or death. and engine fuels. Always have an approved fire
Red—used to indicate the extinguisher within easy reach.
presence of an imminently
hazardous situation which, if not
avoided, will result in death or Be sure that all tools and working areas
serious injury. are properly maintained and ready for use.
Orange—used to indicate the Keep work surfaces clean and free of
presence of a potentially debris that could get into machine components and
hazardous situation which, if not cause damage.
avoided, could result in death or
serious injury.
Be sure that your workshop or work area is
Yellow with safety alert symbol— properly ventilated and well lit.
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
Be sure any forklift, overhead crane or
minor or moderate injury.
other lifting or supporting device is fully
Yellow without safety alert capable of supporting and stabilizing the
symbol—used to indicate the weight to be lifted. Use only chains or straps that
presence of a potentially are in good condition and of ample capacity.
avoided, may result in property
damage. Be sure that fasteners intended for one
Green—used to indicate operation time use (i.e., cotter pins and self-locking
or maintenance information. nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or

other fluids. Use an approved container.
Please be environmentally safe .
iv TMZ-34/19 Part No. 52075

June 2005
Table of Contents
Introduction
Important Information ......................................................................................... ii
Section 1 Safety Rules

General Safety Rules ........................................................................................ iii
Section 2 Rev Specifications

C Machine Specifications ................................................................................ 2 - 1
C Performance Specifications ......................................................................... 2 - 1
C Hydraulic Specifications ............................................................................... 2 - 2
C Manifold Component Specifications ............................................................. 2 - 3
C Machine Torque Specifications .................................................................... 2 - 3
C Hydraulic Hose and Fitting Torque Specifications ......................................... 2 - 4
C SAE and Metric Fasteners Torque Charts .................................................... 2 - 5
Section 3 Rev Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................... 3 - 3
Maintenance Inspection Report .................................................................... 3 - 5
C Checklist A Procedures
A-1 Perform Pre-operation Inspection ........................................................ 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-9 Perform Axle Maintenance - CE Models ........................................... 3 - 10
A-10 Perform 30 Day Service .................................................................... 3 - 10
A-11 Grease the Turntable Rotation Bearing and Rotate Gear ................... 3 - 11
Part No. 52075 TMZ-34/19 v

June 2005
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued

C Checklist B Procedures
B-1 Inspect the Batteries ......................................................................... 3 - 12
B-2 Inspect the Electrical Wiring ............................................................. 3 - 13
B-3 Test the Emergency Stop ................................................................. 3 - 14
B-4 Test the Key Switch ......................................................................... 3 - 14
B-5 Test the Manual Lowering Operation ................................................. 3 - 15
B-6 Inspect the Tires and Wheels (including lug nut or lug bolt torque) .... 3 - 16
B-7 Service the Tongue Jack .................................................................. 3 - 16
B-8 Inspect the Parking Brake ................................................................. 3 - 17
B-9 Test the Horn .................................................................................... 3 - 18
B-10 Test the Flashing Beacon (if equipped) ............................................. 3 - 18
B-11 Test the Platform Rotation (if equipped) ............................................ 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 Checklist C Procedure
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 Checklist D Procedures
D-1 Check the Turntable Rotation Bearing Bolts ...................................... 3 - 24
D-2 Inspect for Turntable Bearing Wear ................................................... 3 - 25
D-3 Replace the Hydraulic Tank Return Filter .......................................... 3 - 26
D-4 Perform Axle Maintenance - ANSI Models ........................................ 3 - 27
D-5 Perform Hitch Maintenance - ANSI Models ....................................... 3 - 27
C Checklist E Procedure
E-1 Test or Replace the Hydraulic Oil ...................................................... 3 - 28
vi TMZ-34/19 Part No. 52075

June 2005
TABLE OF CONTENTS
Section 4 Rev Repair Procedures

Introduction .................................................................................................. 4 - 1
C Platform Controls
1-1 Circuit Board ....................................................................................... 4 - 2
1-2 Membrane Overlay ............................................................................. 4 - 3
C Platform Components
2-1 Platform .............................................................................................. 4 - 5
2-2 Platform Rotator (if equipped) ............................................................. 4 - 5
C Jib Boom Components
3-1 Jib Boom ............................................................................................ 4 - 8
3-2 Jib Boom Lift Cylinder ...................................................................... 4 - 10
B Boom Components
4-1 Boom ................................................................................................ 4 - 12
4-2 Lift Cylinders .................................................................................... 4 - 18
C Ground Controls
5-1 Ground Control Keypad Circuit Board ............................................... 4 - 20
5-2 CPU Circuit Board ............................................................................ 4 - 22
5-3 Connector Circuit Board .................................................................... 4 - 22
5-4 Software Configuration ...................................................................... 4 - 23
5-5 Membrane Overlay ........................................................................... 4 - 25
5-6 Level Sensor .................................................................................... 4 - 27
5-7 Interacter BatteryCharger .................................................................. 4 - 30
5-8 Lester Battery Charger ...................................................................... 4 - 32
B Hydraulic Power Unit
6-1 Hydraulic Power Unit Components .................................................... 4 - 34
6-2 Valve Adjustments - Hydraulic Power Unit ........................................ 4 - 36
6-3 Hydraulic Pump ................................................................................ 4 - 37
Part No. 52075 TMZ-34/19 vii

June 2005
TABLE OF CONTENTS
Section 4 Rev Repair, continued

C Manifolds
7-1 Turntable Rotation Manifold Components ......................................... 4 - 40
7-2 Valve Adjustments - Turntable Rotation Manifold ............................. 4 - 41
7-3 Outrigger Manifold Components ........................................................ 4 - 42
7-4 Valve Coils ....................................................................................... 4 - 43
B Turntable Rotation Components
8-1 Turntable Rotation Motor .................................................................. 4 - 45
B Axle Components
9-1 Axle .................................................................................................. 4 - 46
9-2 Hub and Bearings ............................................................................. 4 - 46
C Trailer Components
10-1 Trailer Brakes ................................................................................... 4 - 47
10-2 Parking Brake ................................................................................... 4 - 47
B Outriggers
11-1 Outrigger Components ...................................................................... 4 - 48
11-2 Outrigger Cylinder ............................................................................. 4 - 49
viii TMZ-34/19 Part No. 52075

June 2005
TABLE OF CONTENTS
Section 5 Rev Troubleshooting Flow Charts

Introduction .................................................................................................. 5 - 1
A Fault Code Chart (after serial number T3402-115) ......................................... 5 - 3
Chart Chart
Number Title
B 1 All Functions Will Not Operate
(before serial number T3400-001) ................................................. 5 - 6
B 2 Pump Motor Will Not Operate ....................................................... 5 - 8
B 3 All Functions Inoperative, Power Unit Starts and Runs ................. 5 - 9
B 4 Ground Controls Inoperative ....................................................... 5 - 10
B 5 Platform Controls Inoperative ..................................................... 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 Turntable Rotate Right Function Inoperative ............................... 5 - 22
A 14 Parking Brake Function Inoperative ............................................ 5 - 23
Part No. 52075 TMZ-34/19 ix

June 2005
TABLE OF CONTENTS
Section 6 Rev Schematics

Introduction .................................................................................................. 6 - 1
B Electrical Component and Wire Color Legends ............................................. 6 - 2
A Limit Switch Legend ..................................................................................... 6 - 3
A Trailer Lighting Wiring Diagram ..................................................................... 6 - 4
A Electrical Symbols Legend ........................................................................... 6 - 5
B Electrical Schematic - Models with Manual Outriggers
(from serial number T3498-001 to T3499-361) .............................................. 6 - 6
A Electrical Schematic - Models with Manual Outriggers
(from serial number T3499-362 to T3499-769) .............................................. 6 - 7
B Electrical Schematic - Models with Manual Outriggers
(from serial number T3400-001) .................................................................... 6 - 8
B Electrical Schematic - Models with Hydraulic Outriggers ............................ 6 - 10
A Hydraulic Symbols Legend and Component Reference ............................... 6 - 13
A Hydraulic Schematic - Models with Manual Outriggers
(from serial number T3498-001 to T3499-769) ............................................ 6 - 14
(from serial number T3400-001 to T3400-265) ............................................ 6 - 15
(after serial number T3400-265) .................................................................. 6 - 16
A Hydraulic Schematic - Models with Hydraulic Outriggers
(before serial number T3400-266) ............................................................... 6 - 14
A Hydraulic Schematic - Models with Hydraulic Outriggers
(after serial number T3400-265) .................................................................. 6 - 15
x TMZ-34/19 Part No. 52075

June 2005 Section 2 • Specifications
REV C
Specifications
Machine Specifications Performance Specifications
Batteries Boom function speeds, maximum
from ground controls (no weight in platform)
Type 6V DC
Jib boom up 10 to 15 seconds
Group T-105
Jib boom down 13 to 18 seconds
Quantity 4
Primary boom up 30 to 35 seconds
Battery capacity 225AH
Primary boom down 21 to 26 seconds
Reserve capacity @ 25A rate 447 minutes
Secondary boom up 15 to 20 seconds
Fluid capacities Secondary boom down 13 to 18 seconds
Hydraulic tank capacity 1.5 gallons Turntable rotate, 358 ° 55 to 60 seconds
5.7 liters
Airborne noise emissions 70 dB
Hydraulic system capacity 2.25 gallons Maximum sound level at normal operating workstations
(including tank) 8.5 liters (A-weighted)
Tires and wheels - ANSI, CSA
Tire size ST195/75-D14

For operational specifications, refer to the
Wheel lugs 5 @ 1/2 -20 Operator's Manual.
Lug nut torque, dry 90 to 120 ft-lbs
122 to 162 Nm
Continuous improvement of our products is a
Tire pressure (cold) 65 psi Genie policy. Product specifications are
4.5 bar subject to change without notice or obligation.
Tires and wheels - CE
Tire size 195/65R15 91T
Wheel lugs 5 @ 1/2 -20
Lug nut torque, dry 90 to 120 ft-lbs

122 to 162 Nm
Tire 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
Part No. 52075 TMZ-34/19 2-1

Section 2 • Specifications June 2005
REV C
SPECIFICATIONS
Hydraulic Specifications Hydraulic power unit
Hydraulic Oil Specifications Pump type: Gear
From serial number T3498-001 to T3402-375 Displacement 0.057 cu in

Hydraulic oil type Shell Donax TG (Dexron III) per revolution 0.93 cc
After serial number T3402-375 Flow rate @ 3000 psi / 207 bar 1.5 gpm
Hydraulic oil type Chevron Rykon MV equivalent 5.7 L/min
Approximate SAE grade 5W-20 System relief valve pressure 3200 psi
Viscosity index rating 200 220.6 bar
Chevron Rykon MV oil is fully compatible and Hydraulic tank 10 micron with
mixable with Shell Donax TG (Dexron III) oils. return filter 18 psi / 1.2 bar bypass
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic Turntable rotate manifold
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index Relief valve pressure 1200 psi
rating of 150. They should provide excellent antiwear, 82.7 bar
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada 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
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
2-2 TMZ-34/19 Part No. 52075

REV C SPECIFICATIONS
Manifold Component Machine Torque Specifications

Specifications
Turntable rotate motor
Plug torque M12 bolts, dry 60 ft-lbs
81 Nm
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
Valve coil resistance
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)
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)

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 Genie

policy. Product specifications are subject to change
without notice or obligation.
Part No. 52075 TMZ-34/19 2-3

SPECIFICATIONS REV C
Hydraulic Hose and Fitting Seal-Lok® fittings

Torque Specifications 1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken.
Your machine is equipped with Parker Seal-Lok® The O-ring cannot be re-used if the fitting or
fittings and hose ends. Genie specifications require hose end has been tightened beyond finger
that fittings and hose ends be torqued to tight.
specification when they are removed and installed
or when new hoses or fittings are installed. The O-rings used in the Parker
Seal Lok® fittings and hose ends
are custom-size O-rings. They are
SAE O-ring Boss Port not standard SAE size O-rings.
(tube fitting - installed into Aluminum) They are available in the O-ring
field service kit (Genie part
SAE Dash size Torque number 49612).
-4 11 ft-lbs / 14.9 Nm 2 Lubricate the O-ring before installation.
-6 23 ft-lbs / 31.2 Nm 3 Be sure that the face seal O-ring is seated and
retained properly.
-8 40 ft-lbs / 54.2 Nm
4 Position the tube and nut squarely on the face
-10 69 ft-lbs / 93.6 Nm
seal end of the fitting and tighten the nut finger
-12 93 ft-lbs / 126.1 Nm tight.
-16 139 ft-lbs / 188.5 Nm 5 Tighten the nut or fitting to the appropriate
torque per given size as shown in the table.
-20 172 ft-lbs / 233.2 Nm
6 Operate all machine functions and inspect the
-24 208 ft-lbs / 282 Nm hoses and fittings and related components to
confirm that there are no leaks.
SAE O-ring Boss Port Seal-Lok Fittings

®
(tube fitting - installed into Steel) (hose end)
SAE Dash size Torque SAE Dash size 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
-10 105 ft-lbs / 142.4 Nm -10 63 ft-lbs / 85.4 Nm
-12 140 ft-lbs / 190 Nm -12 90 ft-lbs / 122 Nm
-16 210 ft-lbs / 284.7 Nm -16 120 ft-lbs / 162.7 Nm
-20 260 ft-lbs / 352.5 Nm -20 140 ft-lbs / 190 Nm
-24 315 ft-lbs / 427.1 Nm -24 165 ft-lbs / 223.7 Nm
2-4 TMZ-34/19 Part No. 52075

REV C SPECIFICATIONS
SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
SIZE THREAD Grade 5 Grade 8
Black Oxide Bolts
LUBED DRY LUBED DRY LUBED
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
1/4 20 100 11.3 80 9 140 15.8 110 12.4 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
LUBED DRY LUBED DRY LUBED
f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm f t -lbs Nm
5/16 18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
3/8 16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
7/16 14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
1/2 13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
9/16 12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
5/8 11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
3/4 10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
7/8 9 320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
1 8 480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
1 1/8 7 590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
1 1/4 7 840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
1 1/2 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •
Size Class 4.6 4.6 Class 8.8 8.8 Class 10.9 10.9 Class 12.9 12.9
(m m ) LUBED DRY LUBED DRY LUBED DRY LUBED 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
5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
6 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
7 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
LUBED 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
8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4
12 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
Part No. 52075 TMZ-34/19 2-5

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2-6 TMZ-34/19 Part No. 52075

June 2005 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures

About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety

warnings and step-by-step instructions.
Observe and Obey: Symbols Legend
Maintenance inspections shall be completed by Safety alert symbol—used to alert

a person trained and qualified on the personnel to potential personal
maintenance of this machine. injury hazards. Obey all safety
messages that follow this symbol
Scheduled maintenance inspections shall be to avoid possible injury or death.
completed daily, quarterly and semi-annually as
Red—used to indicate the
specified on the Maintenance Inspection
presence of an imminently
Report.
Failure to perform each procedure avoided, will result in death or
as presented and scheduled could serious injury.
result in death, serious injury or
Orange—used to indicate the
substantial damage.
presence of a potentially
Immediately tag and remove from service a hazardous situation which, if not
damaged or malfunctioning machine. avoided, could result in death or
serious injury.
Repair any machine damage or malfunction
before operating the machine. Yellow with safety alert symbol—
used to indicate the presence of a
Keep records on all inspections for three years. potentially hazardous situation
which, if not avoided, may cause
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection. Yellow without safety alert
symbol—used to indicate the
Unless otherwise specified, perform each
maintenance procedure with the machine in the hazardous situation which, if not
following configuration: avoided, may result in property
· Machine disconnected from tow vehicle damage.
· Machine parked on a firm, level surface with Green—used to indicate operation
the boom stowed and both latches secured or maintenance information.
· Key switch in the off position with the
Indicates that a specific result is expected after
key removed
performing a series of steps.
· The red Emergency Stop button in the off
position at both ground and platform controls Indicates that an incorrect result has occurred
after performing a series of steps.
· Wheels chocked and parking brake applied
· All external AC power supply disconnected
from the machine
Part No. 52075 TMZ-34/19 3-1

Section 3 • Scheduled Maintenance Procedures June 2005
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend Pre-delivery Preparation Report

The following symbols have been The pre-delivery preparation report contains
used in this manual to help checklists for each type of scheduled inspection.
communicate the intent of the
instructions. When one or more of Make copies of the Pre-delivery Preparation report
the symbols appears at the to use for each inspection. Store completed forms
beginning of a maintenance as required.
procedure, it conveys the meaning Maintenance Schedule
below.
There are five types of maintenance inspections
that must be performed according to a schedule—
Indicates that tools will be required to daily, quarterly, semi-annually, annually, and
perform this procedure. 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
Indicates that new parts will be required
which group(s) of procedures are required to
to perform this procedure.
perform a scheduled inspection.
Indicates that a cold motor or pump will Inspection Checklist

be required to perform this procedure.
Daily or every 8 hours A
Quarterly or every 250 hours or

Indicates that dealer service will be every 3000 miles A+B
required to perform this procedure.
Semi-annually or every 500 hours or
every 6000 miles A+B+C
Annually or every 1000 hours or

every 12000 miles A+B+C+D
Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection Report
The maintenance inspection report contains

checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.
3-2 TMZ-34/19 Part No. 52075

Pre-Delivery Preparation
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and re-inspect it. After repair,
place a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.
Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Genie Industries USA Genie UK

18340 NE 76th Street The Maltings, Wharf Road
PO Box 97030 Grantham, Lincolnshire
Redmond, WA 98073-9730 NG31- 6BH England
(425) 881-1800 (44) 1476-584333
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie
Industries. Rev B
3-4 TMZ-34/19 Part No. 52075

Maintenance Inspection Report

Model Checklist A - Rev C Y N R Checklist B - Rev C Y N R
A-1 Pre-operation inspect B-1 Batteries
Serial number
A-2 Function tests B-2 Electrical wiring
Date A-3 Hitch maintenance - B-3 Emergency Stop
ANSI models B-4 Key switch
Hour meter A-4 Axle maintenance - B-5 Manual operation
ANSI models
Machine owner B-6 Tires and wheels
A-5 Axle maintenance -
B-7 Tongue jack
CE models
Inspected by (print) B-8 Parking brake
Perform after 100 km:
B-9 Horn
Inspector signature A-6 Axle maintenance -
CE models B-10 Flashing beacon
Inspector title (if equipped)
Perform after 200 miles:
B-11 Platform rotation
A-7 Axle maintenance -
Inspector company (if equipped)
ANSI models
B-12 Tank venting system
Perform weekly:
Instructions B-13 Hitch maintenance -
· Make copies of this report to use for A-8 Axle maintenance -
ANSI models
each inspection. ANSI models
B-14 Axle maintenance -
· Select the appropriate checklist(s) for Perform after 500 km:
ANSI models
the type of inspection to be A-9 Axle maintenance -
B-15 Hydraulic oil analysis
performed. CE models
Perform after 40 hours:
Daily or 8 hours Checklist C - Rev C Y N R
Inspection: A A-10 30 day service
C-1 Breather cap - models
Perform every 100 hours:
Quarterly or 250 hours or with optional oil
3000 mile Inspection: A+B A-11 Grease rotation bearing
C-2 Axle maintenance -
Semi-annually or ANSI models
500 hours or 6000 mile C-3 Hitch maintenance -
Inspection: A+B+C CE models
Annually or 1000 hours or
12000 mile
Checklist D - Rev C Y N R
Inspection: A+B+C+D
D-1 Turntable bearing bolts
Two year or 2000 hours
Inspection: A+B+C+D+E D-2 Turntable bearing wear
D-3 Hydraulic filter
· Place a check in the appropriate box
after each inspection procedure is D-4 Axle maintenance -
completed. ANSI models
· Use the step-by-step procedures in D-5 Hitch maintenance -
this section to learn how to perform ANSI models
these inspections.
· If any inspection receives an “N”, tag Checklist E - Rev C Y N R
and remove the machine from service, E-1 Hydraulic oil
repair and re-inspect it. After repair,
place a check in the “R” box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Part No. 52075 TMZ-34/19 3-5

Checklist A Procedures REV C
A-1 A-2
Perform Pre-operation Inspection Perform Function Tests
Completing a pre-operation inspection is essential Completing the function tests is essential to safe
to safe machine operation. The pre-operation machine operation. Function tests are designed to
inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The pre-operation inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
3-6 TMZ-34/19 Part No. 52075

REV C CHECKLIST A PROCEDURES
A-3 A-4
Perform Hitch Maintenance - Perform Axle Maintenance -
ANSI Models ANSI Models
Hitch specifications require that Axle specifications require that this

this procedure be performed daily. procedure be performed, initially
and following a wheel change,
Proper hitch maintenance, following the hitch
after the first 10, 25 and 50 miles.
manufacturer's maintenance schedule, is essential
to good hitch performance and service life. Failure Proper axle maintenance, following the axle
to perform the maintenance procedures can lead to manufacturer's maintenance schedule, is essential
poor hitch performance and component damage. to good axle performance and service life. Failure
to perform the maintenance procedures can lead to
Required maintenance procedures and additional poor axle performance and component damage.
hitch information is available in the
Atwood Model MPD84132 Surge Brake System Required maintenance procedures and additional
Operation/Maintenance Manual axle information is available in the Dexter Axle
(Atwood part number MPD85778) OR the Operation Maintenance Service Manual
Demco Model 91 Brake Actuators (Dexter part number LIT-001-00).
Owner/Operator Manual
(Demco part number BH20023). Dexter Axle Operation Maintenance Service Manual
Genie part number 84376
Atwood Model MPD84132 Owner/Operator Manual
Demco Model 91 Owner/Operator Manual

Part No. 52075 TMZ-34/19 3-7

CHECKLIST A PROCEDURES REV C
A-5 A-6
Perform Axle Maintenance - Perform Axle Maintenance -
CE Models CE Models
Axle specifications require that this Axle specifications require that this
procedure be performed initially procedure be performed initially
after the first 50 km, or 50 km after after the first 100 km.
a wheel change.
Proper axle maintenance, following the axle
Proper axle maintenance, following the axle manufacturer's maintenance schedule, is essential
manufacturer's maintenance schedule, is essential to good axle performance and service life. Failure
to good axle performance and service life. Failure to perform the maintenance procedures can lead to
to perform the maintenance procedures can lead to poor axle performance and component damage.
poor axle performance and component damage.
Required maintenance procedures and additional
Required maintenance procedures and additional axle information is available in the Knott Axle
axle information is available in the Knott Axle Service Manual (Knott part number P005).
Service Manual (Knott part number P005).
Knott Axle Service Manual
Knott Axle Service Manual Genie part number 84443
3-8 TMZ-34/19 Part No. 52075

A-7 A-8
Perform Axle Maintenance - Perform Axle Maintenance -
Axle specifications require that this Axle specifications require that this
procedure be performed initially at procedure be performed weekly.
200 miles.
Proper axle maintenance, following the axle
Proper axle maintenance, following the axle manufacturer's maintenance schedule, is essential
to good axle performance and service life. Failure to perform the maintenance procedures can lead to
poor axle performance and component damage.
Required maintenance procedures and additional axle information is available in the Dexter Axle
axle information is available in the Dexter Axle Operation Maintenance Service Manual
Operation Maintenance Service Manual (Dexter part number LIT-001-00).
(Dexter part number LIT-001-00).
Dexter Axle Operation Maintenance Service Manual
Dexter Axle Operation Maintenance Service Manual Genie part number 84376
Part No. 52075 TMZ-34/19 3-9

CHECKLIST A PROCEDURES REV C
A-9 A-10
Perform Axle Maintenance - Perform 30 Day Service
CE Models
The 30 day maintenance procedure is a one-time

Axle specifications require that this procedure to be performed after the first 30 days or
procedure be performed 500 km 40 hours of usage. After this interval, refer to the
after regreasing the wheel maintenance tables for continued scheduled
bearings. maintenance.
Proper axle maintenance, following the axle 1 Perform the following maintenance procedures:
manufacturer's maintenance schedule, is essential · A-11 Grease the Turntable Rotation
to good axle performance and service life. Failure Bearing and Rotate Gear
poor axle performance and component damage. · B-8 Inspect the Parking Brake
· D-1 Check the Turnable Rotation
Required maintenance procedures and additional Bearing Bolts
axle information is available in the Knott Axle
Service Manual (Knott part number P005). · D-3 Replace the Hydraulic Tank
Return Filter
3 - 10 TMZ-34/19 Part No. 52075

A-11
Grease the Turntable Rotation
Bearing and Rotate Gear
Genie specifications require that

this procedure be performed every
100 hours of operation.
Regular application of lubrication to the turntable
bearing and rotate gear is essential to good
machine performance and service life. Continued
use of an insufficiently greased bearing 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 greased.
3 Apply grease to each tooth of the drive gear
located under the turntable.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent
Part No. 52075 TMZ-34/19 3 - 11

Checklist B Procedures REV C
B-1 3 Be sure that the battery retaining fasteners are

in place and secure.
Inspect the Batteries
4 Remove the battery vent caps from all batteries
and check the specific gravity of each battery
cell with a hydrometer.
Proper battery condition is essential to good Result: If any battery cell displays a specific
machine performance and operational safety. A gravity of less than 1.026, the battery must be
faulty battery cell can result in poor machine replaced.
performance and improper fluid levels or damaged
5 Check the battery acid level of each battery. If
cables and connections can result in component
needed, replenish with distilled water to the
damage and hazardous conditions.
bottom of each battery fill tube. Do not overfill.
Bodily injury hazard. Batteries 6 Install the battery vent caps.
contain acid. Avoid spilling or
contacting battery acid. Neutralize 7 Check each battery pack and verify that the
battery acid spills with baking soda batteries are wired correctly. Refer to the
and water. Battery Connection Diagram decal on the
machine.
Electrocution hazard. Contact with
hot or live circuits could result in 8 Inspect the battery charger plug and pigtail for
death or serious injury. Remove all damage or excessive insulation wear. Replace
rings, watches and other jewelry. as required.
Perform this test after fully

charging the battery.
For a more accurate determination
of battery condition, fully charge
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 - 12 TMZ-34/19 Part No. 52075

REV C CHECKLIST B PROCEDURES
B-2 3 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on
Inspect the Electrical Wiring position at both the ground and platform
controls.
4 Raise the secondary boom until the platform is
approximately 10 feet / 3 m off the ground.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine 5 Inspect the boom storage area for burnt, chafed
performance. Failure to find and replace burnt, and pinched cables.
chafed, corroded or pinched wires could result in 6 Lower the boom to the stowed position and turn
unsafe operating conditions and may cause the machine off.
component damage.
7 Inspect the following areas for burnt, chafed,
Electrocution hazard. Contact corroded, pinched and loose wires:
with hot or live circuits could
result in death or serious injury. · Boom to platform cable harness
Remove all rings, watches and · Primary, secondary and jib booms
other jewelry.
1 Inspect the following areas for burnt, chafed,
corroded and loose wires:
· Turntable 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
Part No. 52075 TMZ-34/19 3 - 13

CHECKLIST B PROCEDURES REV C
B-3 B-4
Test the Emergency Stop Test the Key Switch
A properly functioning Emergency Stop is essential Proper key switch action and response is essential
for safe machine operation. An improperly to safe machine operation. The machine can be
operating red Emergency Stop button will fail to operated from the ground or platform controls and
shut off power and stop all machine functions, the activation of one or the other is accomplished
resulting in a hazardous situation. with the key switch. Failure of the key switch to
activate the appropriate control panel could cause
As a safety feature, selecting a hazardous operating situation.
and operating the ground controls
will override the platform controls, Perform this procedure from the
except the platform red ground using the platform controls.
Emergency Stop button. Do not stand in the platform.
1 Turn the key switch to ground control and pull 1 Pull out the red Emergency Stop button to the
out the red Emergency Stop button to the on on position at both the ground and platform
position at both the ground and platform controls.
controls.
2 Turn the key switch to platform control.
2 Push in the red Emergency Stop button at the
3 Check the platform up/down function from the
ground controls to the off position.
ground controls.
Result: No machine functions should operate.
Result: The machine functions should not
3 Turn the key switch to platform control and pull operate.
4 Turn the key switch to ground control.
position at both the ground and platform
controls. 5 Check the machine functions from the platform
controls.
4 Push down the red Emergency Stop button at
the platform controls to the off position. Result: The machine functions should not
Result: No machine functions should operate. operate.
6 Turn the key switch to the off position.
The red Emergency Stop button at
the ground controls will stop all Result: No function should operate.
machine operation without regard
to the position of the key switch.
3 - 14 TMZ-34/19 Part No. 52075

B-5 6 Locate the manual lowering valve at the base of

the secondary boom lift cylinder. Push and hold
Test the Manual Lowering the override knob until the secondary boom is
Operation fully lowered.
Testing the manual lowering operation for The override knob is protected by
malfunctions is essential for safe machine a black rubber cover.
operation. An unsafe working condition exists if the 7 Locate the manual lowering valve at the base of
manual lowering function does not operate in the the primary boom lift cylinder. Push and hold
event of a main power loss. the override knob until the secondary boom is
1 Raise the primary boom approximately fully lowered.
1 foot / 0.3 m. The override knob is protected by
2 Raise the secondary boom approximately a black rubber cover.
1 foot / 0.3 m. 8 Locate the manual lowering valve at the base of
3 Raise the jib boom approximately the jib boom lift cylinder. Push and hold the
1 foot / 0.3 m. override knob until the secondary boom is fully
lowered.
4 Push in the red Emergency Stop button to the
off position at both the ground and platform The override knob is protected by
controls. Turn the key switch to the off position. a black rubber cover.
5 From serial number T3498-001 to T3499-769: 9 From serial number T3498-001 to T3499-769:
Locate the proportional valve on the hydraulic Turn the thumbscrew at the proportional valve
power unit. Fully loosen the jam nut and turn fully in a counterclockwise direction. Tighten the
the thumbscrew fully in a clockwise direction to jamb nut against the proportional valve coil.
open the proportional valve. The boom will not function until the
The individual boom manual proportional valve is closed.
lowering valves will not function From serial number T3400-001 to date: Push
until the proportional valve is open. and turn the brass knob at the proportional
From serial number T3400-001 to date: valve in a counterclockwise direction to close
Locate the proportional valve on the hydraulic the valve.
power unit. Push and turn the brass knob in a The boom will not function until the
clockwise direction to open the proportional proportional valve is closed.
valve.
The individual boom manual
lowering valves will not function
until the proportional valve is open.
Part No. 52075 TMZ-34/19 3 - 15

B-6 B-7
Inspect the Tires and Wheels Service the Tongue Jack
(including lug nut or lug bolt
torque)
Maintaining the tongue jack in good condition is
essential to safe operation and good machine
performance. Failure to lubricate the internal gears
Maintaining the tires and wheels in good and bearings of the jack and axle bolt could result
condition is essential to safe operation and good in unsafe operating conditions and may cause
performance. Tire and/or wheel failure could result component damage.
in a machine tip-over. Component damage may
also result if problems are not discovered and 1 Using a needle nose applicator, pump a small
repaired in a timely fashion. amount of automotive grease through the
lubrication opening on the side of the jack.
1 Check the tire tread and sidewalls for cuts, Rotate the handle to evenly distribute the
cracks, punctures and unusual wear. lubricant to the internal gears.
2 Check each wheel for damage, bends and The lubrication opening is located
cracked welds. on the side of the jack, above the
3 Check each lug nut or lug bolt for proper torque. support plate.
Refer to Section 2, Specifications. 2 Lightly grease the inner tube of the jack with
4 Check the air pressure of each tire. Refer to automotive grease.
Section 2, Specifications. 3 Lubricate the handle at both sides of the tube
with a lightweight oil.
4 Lubricate the axle bolt and nut assembly with a
lightweight oil.
5 Check each tire with an air pressure gauge and
add air as needed. Refer to Section 2,
Specifications.
An over-inflated tire can explode
and could result in death or
serious injury.
3 - 16 TMZ-34/19 Part No. 52075

B-8 6 Loosen the set screw at the side of the parking

brake handle.
Inspect the Parking Brake
7 Turn the handle in a clockwise direction just to
the point where it is difficult to apply the parking
brake, then rotate the top of the parking brake
handle counterclockwise one full turn.
A properly functioning parking brake is essential to
safe machine operation. The parking brake is 8 Tighten the set screw. Do not overtighten.
manually activated. An improperly functioning 9 Repeat this procedure beginning with step 3.
parking brake will prevent the operator from
properly securing the machine when not in use.
Perform this procedure on a firm,
level surface.
1 Visually inspect the parking brake cables and
components for damage.
2 Visually inspect the parking brake cables to
ensure both are properly 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.
Part No. 52075 TMZ-34/19 3 - 17

B-9 B-10
Test the Horn Test the Flashing Beacon
A functioning horn is essential to safe machine (if equipped)
operation. The horn is activated at the ground, The flashing beacon is used to alert operators and
platform or drive controls and sounds at the ground ground personnel of machine proximity and
as a warning to ground personnel. An improperly motion. The flashing beacon is located on the
functioning horn will prevent the operator from upper (primary) boom.
alerting ground personnel of hazards or unsafe
conditions. 1 Turn the key switch to ground control and pull
1 Turn the key switch to platform control and position at both the ground and platform
pull out the Emergency Stop button to the controls. Pull out the red Emergency Stop
on position at both the ground and button to the on position at the drive controls (if
platform controls. equipped).
2 Push down the horn button at the platform Result: The beacons should flash.
controls.
2 Turn the key switch to platform controls.
Result: The horn should sound.
Result: The beacons should flash.
3 Push down the horn button at the ground
controls.
Result: The horn should not sound.
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.
3 - 18 TMZ-34/19 Part No. 52075

B-11 B-12
Test the Platform Rotation Inspect the Hydraulic Tank Cap
(if equipped) Venting System
Testing the platform rotation for malfunctions is
essential for safe machine operation. The platform
rotator is operated by manually turning the hand
crank in either a clockwise or counterclockwise Genie requires that this procedure
direction. be performed quarterly or every
250 hours, whichever comes first.
1 Turn the hand crank at the platform in the Perform this procedure more often
clockwise direction. if dusty conditions exist.
Result: The platform should rotate to the right A free-breathing hydraulic tank cap is essential for
and operate smoothly without any hesitation or good machine performance and service life. A dirty
binding. or clogged cap may cause the machine to perform
2 Turn the hand crank at the platform in the poorly. Extremely dirty conditions may require that
counterclockwise direction. the cap be inspected more often.
Result: The platform should rotate to the left 1 Remove the breather cap from the hydraulic
and operate smoothly without any hesitation or tank.
binding. 2 Check for proper venting.
Result: Air passes through the breather cap.
Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step 3.
When checking for positive tank
cap venting, air should pass freely
through the cap.
3 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat step 2.
4 Install the breather cap onto the hydraulic tank.
Part No. 52075 TMZ-34/19 3 - 19

B-13 B-14
Perform Hitch Maintenance - Perform Axle Maintenance -
Hitch specifications require that Axle specifications require that this

this procedure be performed procedure be performed quarterly
initially after 1000 miles of use, or every 3000 miles, whichever
and every 2000 miles of use comes first.
thereafter.
Proper axle maintenance, as specified in the axle
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.
Required maintenance procedures and additional axle information is available in the Dexter Axle
hitch information is available in the Atwood Model Operation Maintenance Service Manual
MPD84132 Brake Actuators Owner/Operator (Dexter part number LIT-001-00).
Manual (Atwood part number MPD85778).
Atwood Model MPD84132 Owner/Operator Manual Genie part number 84376
3 - 20 TMZ-34/19 Part No. 52075

B-15
Perform Hydraulic Oil Analysis
Replacement or testing of the hydraulic oil is

essential for good machine performance and
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and
continued use may cause component damage.
Extremely dirty conditions may require oil changes
to be performed more often.
Before replacing the hydraulic oil,
the oil may be tested by an oil
distributor for specific levels of
contamination to verify that
changing the oil is necessary. If
the hydraulic oil is not replaced
at the two year inspection, test
the oil quarterly. Replace the oil
when it fails the test. See E-1,
Test or Replace the Hydraulic Oil.
Part No. 52075 TMZ-34/19 3 - 21

Checklist C Procedures REV C
C-1 C-2
Replace the Perform Axle Maintenance -
Hydraulic Tank Breather Cap - ANSI Models
Models with Optional Hydraulic Oil
Axle specifications require that this

The hydraulic tank is a vented-type tank. The procedure be performed every 6
breather cap has an internal air filter that can months or 6000 miles, whichever
become clogged or, over time, can deteriorate. If comes first.
the breather cap is faulty or improperly installed, Required maintenance procedures and additional
impurities can enter the hydraulic system which axle information is available in the Dexter Axle
may cause component damage. Extremely dirty Operation Maintenance Service Manual
conditions may require that the cap be inspected (Dexter part number LIT-001-00).
more often.
1 Remove and discard the hydraulic tank breather Dexter Axle Operation Maintenance Service Manual
cap. Genie part number 84376
2 Install a new cap onto the tank.
3 - 22 TMZ-34/19 Part No. 52075

REV C CHECKLIST C PROCEDURES
C-3
Perform Hitch Maintenance -
CE Models
Hitch specifications require that

this procedure be performed semi-
annually.
manufacturer's maintenance schedule, is essential
to good hitch performance and service life. Failure
poor hitch performance and component damage.
axle information is available in the Knott Axle
Service Manual (Knott part number P005).

Part No. 52075 TMZ-34/19 3 - 23

Checklist D Procedures REV C
D-1 2 Working through the bearing bolt access, be

sure that each turntable rotation bearing
Check the Turntable Rotation mounting bolt above the turntable is torqued in
Bearing Bolts sequence to specification. See below.
The rotate bearing bolt access is
located next to the turntable rotate
motor.
Maintaining proper torque on the turntable bearing
bolts is essential to safe machine operation.
Improper bolt torque or torque sequence could
Tongue
result in an unsafe operating condition and
component damage.
1 Be sure that each turntable rotation bearing
mounting bolt securing the turntable to the
rotate bearing (above the turntable) is torqued 1
11 9
in sequence to specification. See below. 7
13
15 5
Tongue
4 3
6 16
1
11 9
8 14
13 7
10 12
5 2
Bearing-to-chassis bolt torque sequence
4 3
Turntable rotation bearing torque specifications
6 15 Bearing-to-turntable, dry 175 ft-lbs

237 Nm
8 14
Bearing-to-chassis, dry 105 ft-lbs
10 12 142 Nm
2
Bearing-to-turntable bolt torque sequence
3 - 24 TMZ-34/19 Part No. 52075

REV C CHECKLIST D PROCEDURES
D-2
a
Inspect for
Turntable Bearing Wear
b
Periodic inspection of turntable bearing wear is

essential to safe machine operation, good machine c
performance and service life. Continued use of a
worn turntable bearing could create an unsafe
operating condition, resulting in death or serious d
injury and component damage.
a turntable
Perform this procedure with the b dial indicator
machine on a firm, level surface c drive chassis
d turntable rotation bearing
and the boom in the stowed
position. 6 Lower the secondary boom to the stowed
1 Grease the turntable bearing. See A-11, Grease position and lower the primary boom to a
the Turntable Rotation Bearing and Rotate horizontal position. Fully extend the primary
Gear. boom.
2 Torque the turntable bearing bolts to 7 Note the reading on the dial indicator.
specification. See D-1, Check the Turntable Result: The measurement is less than
Rotation Bearing Bolts. 0.025 inch / 0.635 mm. The bearing is good.
3 Start the machine from the ground controls and Result: The measurement is more than
raise the primary and secondary booms to full 0.0249 inch / 0.634 mm. The bearing is worn
height. Do not extend the primary boom. and needs to be replaced.
4 Place a dial indicator between the drive chassis 8 Fully retract the primary boom. Raise the
and the turntable at a point that is directly primary and secondary booms to full height.
under, or inline with, the boom and no more Visually inspect the dial indicator to be sure the
than 1 inch / 2.5 cm from the bearing. needle returns to the "zero" position.
To obtain an accurate 9 Remove the dial indicator and rotate the
measurement, place the dial turntable 90°.
indicator no more than
1 inch / 2.5 cm from the turntable 10 Repeat steps 4 through 9 until the rotation
rotation bearing. bearing has been checked in at least four
equally spaced areas 90° apart.
5 At the dial indicator, adjust it to "zero" the
indicator. 11 Lower the primary and secondary booms to the
stowed position and turn the machine off.
12 Remove the dial indicator from the machine.
Part No. 52075 TMZ-34/19 3 - 25

CHECKLIST D PROCEDURES REV C
D-3 3 Apply a thin layer of fresh oil onto the gasket of

the new oil filter.
Replace the Hydraulic Tank
4 Install the filter and tighten it securely by hand.
Return Filter
5 Clean up any oil that may have spilled during
the replacement procedure. Properly discard
the used filter.
Replacement of the hydraulic tank return filter 6 Turn the key switch to ground controls and pull
element is essential for good machine performance out the red Emergency Stop button to the on
and service life. A dirty or clogged filter element position at both the ground and platform
may cause the machine to perform poorly and controls.
7 Move and hold the function enable toggle switch
Extremely dirty conditions may require that the
in the up direction and activate the platform up
filter element be replaced more often.
function.
Burn hazard. Beware of hot oil.
8 Inspect the filter and related components to
Contact with hot oil may cause
be sure that there are no leaks.
severe burns.
The hydraulic filter is mounted on
the function manifold next to the
hydraulic power unit.
1 Clean the area around the hydraulic oil filter.
Remove the filter with an oil 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 - 26 TMZ-34/19 Part No. 52075

REV C CHECKLIST D PROCEDURES
D-4 D-5
Perform Axle Maintenance - Perform Hitch Maintenance -
Axle specifications require that this Hitch specifications require that

procedure be performed every 12 this procedure be performed
months or 12000 miles, whichever annually.
comes first.
Required maintenance procedures and additional manufacturer's maintenance schedule, is essential
axle information is available in the Dexter Axle to good hitch performance and service life. Failure
Operation Maintenance Service Manual to perform the maintenance procedures can lead to
(Dexter part number LIT-001-00). poor hitch performance and component damage.
Dexter Axle Operation Maintenance Service Manual hitch information is available in the Atwood Model
MPD84132 Brake Actuators Owner/Operator
Manual (Atwood part number MPD85778).
Atwood Model MPD84132 Owner/Operator Manual

Part No. 52075 TMZ-34/19 3 - 27

Checklist E Procedure REV C
E-1 8 Apply thread sealant to the threads of the drain

plug. Install the drain plug into the tank and
Test or Replace the Hydraulic Oil torque to specification.
Torque specifications
Hydraulic tank drain plug, dry 250 in-lbs
Replacement or testing of the hydraulic oil is 28 Nm
essential for good machine performance and
service life. Dirty oil and suction strainers may Hydraulic tank drain plug, lubricated 188 in-lbs
cause the machine to perform poorly and 21 Nm
Extremely dirty conditions may require oil changes 9 Install the filter onto the pickup tube. Install the
to be performed more often. hydraulic tank onto the power unit and torque to
specification.
Before replacing the hydraulic oil,
the oil may be tested by an oil Be careful not to damage the
distributor for specific levels of O-ring when installing the
contamination to verify that hydraulic tank onto the power unit.
changing the oil is necessary. If
the hydraulic oil is not replaced Torque specifications
at the two year inspection, test
the oil quarterly. Replace the oil Hydraulic tank mounting fasteners, dry 40 in-lbs
when it fails the test. 4.5 Nm
Hydraulic tank mounting fasteners, lubricated 30 in-lbs
Perform this procedure with the
3.4 Nm
boom in the stowed position.
1 Disconnect the battery pack from the machine.
10 Install the hydraulic power unit onto the
2 Remove the drain plug from the hydraulic tank turntable. Securely install the fasteners.
and completely drain the tank into a suitable
11 Fill the tank with hydraulic oil until the oil is
container. Refer to Section 2, Specifications, for
visible in the sight gauge. Do not overfill. Refer
capacity information.
to Section 2, Specifications.
3 Disconnect the hydraulic oil return line from the
12 Activate the pump to fill the hydraulic system
manifold side of the hydraulic oil filter.
with oil and bleed the system of air.
4 Remove the mounting fasteners securing the
Component damage hazard. The
hydraulic tank to the turntable.
pump can be damaged if operated
5 Remove the mounting fasteners securing the without oil. Do not empty the
hydraulic tank to the power unit. Remove the hydraulic tank while in the process
tank from the machine. of filling the hydraulic system.
6 Remove the pick-up filter from hydraulic pump 13 Repeat steps 11 through 12 until the hydraulic
suction tube. system and tank are both full.
7 Clean the filter and tank using a mild solvent. 14 Retract the outriggers and return the boom to
the stowed position.
15 Clean up any oil that may have spilled. Properly
discard the used oil and filter.
3 - 28 TMZ-34/19 Part No. 52075

June 2005 Section 4 • Repair Procedures
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem. Perform disassembly procedures to
the point where repairs can be completed. Then to
Observe and Obey: re-assemble, perform the disassembly steps in
Repair procedures shall be completed by a reverse order.
person trained and qualified on the repair of this Symbols Legend
machine.
Safety alert symbol—used to alert
Immediately tag and remove from service a
personnel to potential personal
damaged or malfunctioning machine. injury hazards. Obey all safety
Repair any machine damage or malfunction messages that follow this symbol
before operating the machine. to avoid possible injury or death.
Red—used to indicate the
Before Repairs Start: presence of an imminently
Read, understand and obey the safety rules hazardous situation which, if not
and operating instructions in the Genie avoided, will result in death or
TMZ-34/19 Operator's Manual. serious injury.
Be sure that all necessary tools and parts are Orange—used to indicate the
available and ready for use. presence of a potentially
Read each procedure completely and adhere avoided, could result in death or
to the instructions. Attempting shortcuts may serious injury.
produce hazardous conditions.
Yellow with safety alert symbol—
Unless otherwise specified, perform each used to indicate the presence of a
repair procedure with the machine in the potentially hazardous situation
following configuration: which, if not avoided, may cause
· Machine disconnected from tow vehicle
· Machine parked on a firm, level surface with Yellow without safety alert
the boom stowed and both latches secured symbol—used to indicate the
· Key switch in the off position with the hazardous situation which, if not
key removed avoided, may result in property
· The red Emergency Stop button in the off damage.
position at both ground and platform controls
Green—used to indicate operation
· Wheels chocked and parking brake applied or maintenance information.
· All external AC power supply disconnected
Indicates that a specific result is expected after
from the machine
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
Part No. 52075 TMZ-34/19 4-1

Section 4 • Repair Procedures June 2005
Platform Controls REV C
Activating one or more buttons on the platform 1-1

controls first sends a signal to the platform controls
circuit board, then to the ground controls printed Circuit Board
circuit boards which ultimately activates a machine
function. Keeping the platform controls clean and How to
defect free is essential to safe machine operation.
Remove the Circuit Board
The platform controls contain a printed circuit
1 Tag and disconnect the platform controls wire
board, alarm, LEDs and push buttons or a
harness from the harness connector at the
membrane overlay decal. Models before serial
platform pivot.
number T3400-001 are equipped with push buttons
to activate machine functions while models after 2 Remove the platform controls from the
T3499-769 rely on a membrane overlay decal to machine. Release the clamp on the back of the
activate machine functions. All of the components platform controls and slide the controls up and
are replaceable. off of the platform. Place the control box on a
work bench.
For further information or assistance, consult the
Genie Industries Service Department.
J1 a
2
f OR POWER
a
POWER
N.C.
GN
WH
OR
BK
2 N.C. 1
WH
GN
OR
BK
RD
1
RD
BL
b
b U1
ALARM
c
J3
d
KEYPAD
c
ALARM
RD
BK
+ -
Models from serial number T3400-001 to date
e d
a red Emergency Stop button P2
b voltage regulator D7
c platform controls circuit board U3
d mounting fasteners
Models from serial number T3498-001 to T3499-769
a platform controls circuit board U3

b mounting fasteners
c voltage regulator D7
d horn H1
e control cable
f red Emergency Stop button P2
4-2 TMZ-34/19 Part No. 52075

REV C PLATFORM CONTROLS
3 From serial number T3498-001 to T3499-769: 1-2

Remove the back cover retaining fasteners
from the back of the platform controls and Membrane Overlay
remove the back cover.
From serial number T3400-001 to date: How to Replace the Overlay
Disconnect the retaining fasteners at the front
cover of the platform controls and open the Beginning with the 2000 model
platform control box. year (from serial number
T3400-001 to date), the platform
4 Tag and disconnect the wire connectors from control box was equipped with a
the circuit board. membrane overlay decal.
Component damage hazard. The following procedure will not
Electrostatic discharge (ESD) can apply for TMZ-34 models
damage printed circuit board manufactured in the 1998 and
components. Maintain firm contact 1999 model years (from serial
with a metal part of the machine number T3498-001 to T3499-769).
that is grounded at all times when 1 Remove the platform controls from the
handling printed circuit boards OR machine. Open the clamp on the back of the
use a grounded wrist strap. platform controls and slide the controls up and
5 Remove the circuit board mounting fasteners off of the platform.
and remove the circuit board from the box. 2 Tag and disconnect the platform control wire
harness from the harness connector at the
platform pivot and place the platform control
box on a work bench.
3 Loosen the platform control box lid retaining
fasteners and open the lid.
3 PLATFORM CONTROLS
4 MEMBRANE DECAL PANEL
5
RIBBON CABLE
6
7
14 PIN
8 BN29 PRIMARY UP
10
BN30 PRIMARY DOWN
11
12 BN31 SECONDARY UP
13
14 BN32 SECONDARY DOWN
BN27 JIB UP
BN28 JIB DOWN
BN34 ROTATE RIGHT
BN33 ROTATE LEFT
BN5 HORN
BN12 FUNCTION ENABLE HIGH
BN26 FUNCTION ENABLE MEDIUM
BN13 FUNCTION ENABLE LOW
Part No. 52075 TMZ-34/19 4-3

PLATFORM CONTROLS REV C
4 Disconnect the large blue connector from the 9 Remove all the brown backing material from the
circuit board at the connection marked new touch pad.
"KEYPAD" by sliding the connector parallel to
10 Insert the large blue connector from the new
the circuit board.
touch pad through the slot. Carefully align the
Component damage hazard. The low battery LED on the control box lid with the
circuit board will become damaged window in the new touch pad and lightly lay the
if the wire harness and connector touch pad onto the control box lid.
are disconnected without proper
Repositioning the touch pad is
care. Do not pull upwards on the
possible if the touch pad is lightly
connector.
adhered to the lid. Do not apply
Component damage hazard. The any pressure to the touch pad.
circuit board may become
11 When satisfied with the position of the touch
damaged if the weight from the
pad, firmly press down the entire surface of the
control box lid pulls on the wire
touch pad with your fingers.
harness. Do not put any weight or
strain on the wires. 12 Loosen the platform control box lid retaining
fasteners and open the lid.
Component damage hazard.
Electrostatic discharge (ESD) can 13 Using RTV-type sealant, completely seal the
damage printed circuit board opening in the slot of the control box lid around
components. Maintain firm contact the wire harness.
with metal that is grounded at all
times when handling printed circuit 14 Apply dielectric grease to the pins on the circuit
boards OR use a grounded wrist board at the connection marked "KEYPAD."
strap. 15 Install the large blue connector onto the circuit
5 Install the lid onto the control box. Finger-tighten board pins at the connection marked
the retaining fasteners. "KEYPAD," by sliding the connector parallel to
the circuit board, until the connector is pushed
6 Starting at the upper corners of the touch pad, onto the circuit board pins no less than
remove all layers of the key pad from the 0.2 inch / 5 mm.
control box lid.
Be sure all pins are in the
The wire harness and large blue connector.
connector will interfere if removing
the touch pad from the bottom. 16 Install the lid onto the control box and tighten
the retaining fasteners. Do not overtighten.
7 Pull the large blue connector through the slot in
the control box lid and discard the old touch 17 Install the platform controls onto the machine.
pad. Remove any remaining sealant from the 18 Connect the platform control wire harness to the
slot. harness connector at the platform pivot.
8 Using a mild solvent, clean the surface of the
control box lid. Allow the surface to dry.
circuit board will become damaged
if it comes in contact with solvent.
Do not allow solvent to contact the
circuit board.
4-4 TMZ-34/19 Part No. 52075

REV C
Platform Components
2-1 2-2
Platform Platform Rotator (if equipped)
How to The platform rotator is a manually-operated gear

assembly used to rotate the platform 160 degrees.
Remove the Platform
Models with Platform Rotate (option): How to
Remove the Platform Rotator
1 Support the platform with an appropriate lifting
device. 1 Remove the platform. See 2-1,
How to Remove the Platform.
2 Remove the fasteners securing the platform to
the platform mount on the platform rotator 2 Remove the platform controls from the platform
assembly. control box mount. Release the clamp on the
back of the platform control box and slide the
Crushing hazard. The platform
controls up and off of the mount. Lay the
may become unbalanced and fall
platform controls off to the side.
if not properly supported by a
lifting device when the fasteners Component damage hazard.
are removed. Cables can be damaged if they
are kinked or pinched.
3 Lift and remove the platform from the mount.
2 Support the platform rotator with an appropriate
Models without Platform Rotate:
lifting device.
1 Remove the platform controls from the platform 3 Remove the toggle pin securing the platform to
control box mount. Release the clamp on the the platform mount.
controls up and off of the mount. Crushing hazard. The platform
rotator may become unbalanced
2 Support the platform with an appropriate lifting and fall if not properly supported
device. when the toggle pin is removed.
3 Remove the toggle pin securing the platform to 4 Lift the platform rotator off the platform mount.
the platform mount.
Crushing 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.
Part No. 52075 TMZ-34/19 4-5

PLATFORM COMPONENTS REV C
How to How to
Adjust the Platform Rotator Service the Platform Rotator
The platform rotator is designed to allow the 1 Remove the platform. See 2-1,
platform to slip in the event of striking an object to How to Remove the Platform.
help prevent damage to the platform. If the
2 Remove the platform controls from the platform
platform rotator is too tight or seized, damage to
control box mount. Release the clamp on the
the platform may occur. If the platform rotator is
too loose, the platform may rotate side to side
controls up and off of the mount. Lay the
unexpectedly, resulting in a unsafe operating
platform controls off to the side.
condition.
1 Raise the primary boom approximately Cables can be damaged if they
3 feet / 1 m. are kinked or pinched.
2 Press the function enable button and the 3 Remove the fasteners securing the platform
platform level button in the down direction until control box mount and gearbox cover to the top
the platform is horizontal. Do not allow the of the gearbox case. Remove the mount and
platform to contact the ground. cover.
3 Remove the platform controls from the platform
4 Remove the four bolts securing the rotate
control box mount. Release the clamp on the handle shaft cover to the gearbox.
controls up and off of the mount. Lay the 5 Remove the rotate handle shaft and pinion from
platform controls off to the side. the gearbox case.
Component damage hazard. 6 Remove the gear assembly retaining nut from
Cables can be damaged if they the top of the shaft.
are kinked or pinched.
7 Disassemble the gear assembly.
4 Remove the fasteners securing the platform box
For ease of reinstallation, note the
mount and gearbox cover to the platform rotate
removal order of each gear
gearbox. Remove the mount and cover from
component.
the gearbox.
8 Visually inspect the inside of the platform rotator
5 Locate the gear assembly retaining nut on the
for the following items:
end of the platform pivot shaft. Loosen the nut
just enough to allow the handle to rotate. · Excessive wear
6 Tighten the locknut. Torque to specification. · Broken or damaged parts
· Rust or corrosion
Torque specification
· Binding
Gear assembly retaining nut, dry 180 ft-lbs ±5 ft-lbs If any parts are lightly rusted or
244 Nm ±7 Nm corroded, remove them and clean
rust or corrosion off with a wire
brush. If parts are worn, heavily
7 Thoroughly grease the entire mechanical rusted or corroded, replace them.
platform rotator assembly.
8 Operate the platform rotator and check for
smooth operation.
4-6 TMZ-34/19 Part No. 52075

REV C PLATFORM COMPONENTS
9 Thoroughly degrease and dry the gearbox case,

covers, all gear components and the platform
pivot shaft.
a 10 Install the gearbox case onto the platform pivot
shaft.
b 11 Install gear assembly onto the platform pivot
shaft in the reverse order of disassembly in
step 7.
12 Install the gear assembly retaining nut onto the
top of the shaft. Torque to specification.
c
Torque specification
Gear assembly retaining nut, dry 180 ft-lbs ±5 ft-lbs

d 244 Nm ±7 Nm
f 13 Thoroughly and heavily lubricate each tooth of

the gear using multipurpose grease. Rotate the
g gearbox case as required.
When lubricating the 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
h and poor rotator performance.
14 Install the rotate handle shaft, pinion and
i 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
securely tighten the fasteners. Do not over
tighten.
j
17 Install the platform control box mount and
gearbox cover onto the top of the gearbox.
Install and securely tighten the fasteners. Do
a control box mount
b gearbox top cover not over tighten.
c rotate gear assembly
d gearbox case
e pinion
f rotate handle shaft
g rotate handle shaft cover
h seal
i platform pivot shaft
j platform pivot
Part No. 52075 TMZ-34/19 4-7

Jib Boom Components REV C
3-1 How to
Jib Boom Remove the Jib Boom
a b c boom in the stowed position.
When removing a hose assembly
or fitting, the O-ring on the fitting
and/or hose end must be replaced
d
and then torqued to specification
during installation. Refer to
Section 2, Hydraulic Hose and
e
Fitting Torque Specifications.
1 Remove the platform. See 2-1, How to Remove
the Platform.
f
2 Disconnect the platform controls from the side
of the platform mount.
3 Disconnect the platform control cable plug from
the ground control box. Install the platform
g
controls into the outlet.
4 Raise the jib boom 4 to 5 feet / 1.2 to 1.5 m.
h
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.
i
6 Tag and remove the cable retaining plates from
the upper jib boom.
a primary boom
b primary linkage 7 Attach a lifting strap from an overhead crane to
c jib boom mount the rod end of the jib boom lift cylinder.
d upper jib boom
e jib boom cylinder barrel-end pivot pin 8 Remove the pin retaining fastener from the jib
f jib boom lift cylinder boom lift cylinder rod-end pivot pin.
g lower jib boom
h jib boom cylinder rod-end pivot pin
i platform mount
4-8 TMZ-34/19 Part No. 52075

REV C JIB BOOM COMPONENTS
9 Using a soft metal drift, remove the jib boom lift 16 Tag, disconnect and plug the hydraulic hoses at
cylinder rod-end pivot pin. the jib boom lift cylinder. Cap the fittings on the
cylinder.
Crushing hazard. The jib boom lift
cylinder could fall if not properly Bodily injury hazard. Spraying
supported when the rod-end pivot hydraulic oil can penetrate and
pin is removed from the machine. burn skin. Loosen hydraulic
10 Attach a lifting strap from an overhead crane to
the upper jib boom.
gradually. Do not allow oil to
11 Remove the pin retaining fastener from the squirt or spray.
upper jib boom pivot pin at the jib boom mount.
17 Tag and disconnect the wires from the jib boom
12 Using a soft metal drift, remove the upper jib lift cylinder solenoid valve.
pivot pin from the jib boom mount. Remove the
18 Support the jib boom lift cylinder with an
upper jib boom.
overhead crane or similar lifting device.
Crushing hazard. The upper jib
19 Support the lower jib boom with a overhead
boom could become unbalanced
crane or similar lifting device.
and fall if not properly supported
when the pivot pin is removed. 20 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
13 Support and secure the platform mounting
weldment. 21 Using a soft metal drift, remove the jib boom
lift cylinder barrel-end pivot pin. Remove the jib
14 Remove the pin retaining fastener from the
boom lift cylinder from the machine.
lower jib boom pivot pin at the platform mount.
Crushing hazard. The jib boom lift
15 Using a soft metal drift, remove the lower jib
cylinder could become unbalanced
boom pivot pin at the platform mount. Remove
the platform mount from the machine.
when the barrel-end pivot pin is
Crushing hazard. The platform removed.
mount could become unbalanced
Crushing hazard. The lower jib
when the pivot pin is removed.
Component damage hazard. Be
careful not to damage the solenoid
valve on the cylinder while
removing the cylinder.
Part No. 52075 TMZ-34/19 4-9

JIB BOOM COMPONENTS REV C
3-2 How to
Jib Boom Cylinder Remove the Jib Boom Cylinder
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 b c Section 2, Hydraulic Hose and
1 Raise the jib boom approximately 3 feet / 1 m.
2 Lower the jib boom until the platform mount
d rests on sawhorses or a work table of sufficient
capacity.
e
f 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
g the jib boom cylinder. Cap the fittings on the
cylinder.
h
i squirt or spray.
5 Tag and disconnect the wires from the jib boom
cylinder solenoid valve.
a primary boom
b primary linkage
c jib boom mount
d upper jib boom
e jib boom cylinder barrel-end pivot pin
f jib boom lift cylinder
g lower jib boom
h jib boom cylinder rod-end pivot pin
i platform mount
4 - 10 TMZ-34/19 Part No. 52075

REV C JIB BOOM COMPONENTS
6 Attach a lifting strap of suitable capacity from an

overhead crane to the jib boom lift cylinder.
Support the cylinder. Do not apply any lifting
pressure.
7 Remove the pin retaining fastener from the jib
boom cylinder rod-end pivot pin.
8 Using a soft metal drift, remove the jib boom
cylinder rod-end pivot pin.
Crushing hazard. The jib boom
cylinder could fall if not properly
supported when the rod-end pivot
pin is removed from the machine.
9 Attach a lifting strap of suitable capacity from 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.
cylinder could become unbalanced
when the barrel-end pivot pin is
removed from the machine.
Crushing hazard. The lower jib
when the pivot pin is removed
from the machine.
solenoid valve can be damaged.
Use caution when removing the
cylinder from the machine.
Part No. 52075 TMZ-34/19 4 - 11

Boom Components REV B
a b c d e f g h
m l k j i
a boom pivot h jib boom mount
b primary boom lift cylinder barrel-end pivot pin i secondary boom lift cylinder barrel-end pivot pin
c primary boom lift cylinder j secondary boom lift cylinder
d primary boom lift cylinder rod-end pivot pin k secondary boom lift cylinder rod-end pivot pin
e primary boom l secondary boom linkage
f primary boom linkage m secondary boom
g hold-down clamp
4 - 12 TMZ-34/19 Part No. 52075

REV B BOOM COMPONENTS
4-1 3 Tag and disconnect the wiring from the power

receptacle on the platform mounting weldment.
Boom
electrically charged circuits could
How to Disassemble the Boom result in death or serious injury.
This procedure in this section Remove all rings, watches and
requires specific repair skills, lifting other jewelry.
equipment and a suitable 4 Remove the quick disconnect plug assembly
workshop. Attempting this retaining fasteners from the platform mount.
procedure without these skills and
tools could result in death or Models from serial number T3400-001 to date:
serious injury and significant
5 Remove the jib boom limit switch (LS11) from
component damage. Dealer
the platform mount.
service is required.
6 Tag and disconnect the wiring from the jib boom
limit switch.
level surface.
All models:
boom in the stowed position. 7 Secure the primary boom with the hold-down
Follow the disassembly steps to the point required latch.
to complete the repair. Then re-assemble the 8 Remove the cable retaining plates from the
secondary boom by following the disassembly primary linkage.
steps in reverse order.
9 Place blocks between the primary boom and
When removing a hose assembly primary linkage.
and/or hose end must be replaced 10 Attach a lifting strap from an overhead crane to
and then torqued to specification the jib boom mount.
during installation. Refer to 11 Remove the pin retaining fasteners from the
Section 2, Hydraulic Hose and primary linkage pivot pin to the jib boom pivot.
12 Using a soft metal drift, remove the primary
1 Remove the platform. See 2-1, How to linkage pivot pin at the jib boom mounting
Remove the Platform. weldment.
2 Remove the jib boom and jib boom lift cylinder.
See 3-1, How to Remove the Jib Boom.
Part No. 52075 TMZ-34/19 4 - 13

BOOM COMPONENTS REV B
13 Remove the pin retaining fasteners from the 19 Remove the primary boom linkage from the
primary boom pivot pin at the jib boom mount. machine.
14 Using a soft metal drift, remove the primary Crushing hazard. The primary
boom pivot pin at the jib boom mount. boom linkage could become
unbalanced and fall if not properly
supported when removed from the
machine.
when the pivot pin is removed. 20 Carefully lay the hoses and cables over the
boom pivot.
15 Remove the jib boom mount from the machine.
Carefully pull the hoses and cables through the Component damage hazard.
jib mount while removing it. Cables and hoses can be
damaged if they are kinked or
pinched.
and fall if not properly supported 21 Support and secure the primary boom lift
when removed from the machine. cylinder to an appropriate lifting device.
Component damage hazard. 22 Tag, disconnect and plug the hydraulic hoses at
Cables and hoses can be the primary boom lift cylinder. Cap the fitting on
damaged if they are kinked or the cylinder.
pinched.
16 Attach a lifting strap from an overhead crane to hydraulic oil can penetrate and
the primary boom linkage. burn skin. Loosen hydraulic
17 Remove the pin retaining fasteners from the
primary boom linkage pivot pin at the boom
pivot.
or spray.
18 Using a soft metal drift, remove the primary
23 Tag and disconnect the wires from the primary
boom linkage pivot pin at the boom pivot.
boom lift cylinder.
Crushing hazard. The primary
boom linkage could become
primary boom lift cylinder rod-end pivot pin.
unbalanced and fall if not properly
supported when the pivot pin is
removed.
4 - 14 TMZ-34/19 Part No. 52075

25 Using a soft metal drift, remove the primary 34 Using a soft metal drift, remove the primary
boom lift cylinder rod-end pivot pin. boom lift cylinder barrel-end pivot pin.
Crushing hazard. The primary Crushing hazard. The primary
boom lift cylinder could fall if not boom lift cylinder could fall if not
properly supported when the pivot properly supported when the pivot
pin is removed. pin is removed.
26 Lower the cylinder onto the secondary boom. 35 Remove the primary boom lift cylinder from the
machine.
the primary boom. Crushing hazard. The lift cylinder
could become unbalanced and fall
28 Disconnect the primary boom hold-down latch.
if not properly supported when
29 Remove the pin retaining fasteners from the removed from the machine.
primary boom pivot pin at the boom pivot.
30 Using a soft metal drift, remove the primary solenoid valve can be damaged.
boom pivot pin at the boom pivot. Use caution when removing the
boom could become unbalanced 36 Tag and disconnect the limit switch wiring
and fall if not properly supported harness connector at the boom pivot.
37 Working at the male half of the connector,
31 Remove the primary boom from the machine. remove the cover from the end that inserts into
the female half of the connector.
boom could become unbalanced 38 Carefully depress the pin locks and remove the
and fall if not properly supported wires from the connector.
when removed from the machine.
Note the location of each wire
32 Attach a lifting strap from an overhead crane to before removing from the harness
the lug on the rod end of the primary boom lift connector.
cylinder. Raise the cylinder to a vertical
39 Remove the hose/cable retaining clamps from
position.
the inside of the boom pivot.
40 Remove the front cable guard from the
primary boom lift cylinder barrel-end pivot pin.
secondary boom.
Part No. 52075 TMZ-34/19 4 - 15

41 Place blocks between the secondary boom and 48 Remove the rear cable guard from the
secondary linkage. secondary boom.
Component damage hazard. Be 49 Place blocks across the turntable pivot plates,
careful not to damage the cables under the secondary boom lift cylinder.
or hoses.
50 Remove the pin retaining bolt from the
42 Attach a lifting strap from an overhead crane to secondary boom lift cylinder rod-end pivot pin.
the boom pivot.
51 Using a soft metal drift, remove the secondary
43 Remove the pin retaining fasteners from the boom lift cylinder rod-end pivot pin. Rest the
secondary boom pivot pin at the boom pivot. cylinder on the boom linkage.
44 Using a soft metal drift, remove the secondary 52 Attach a lifting strap from an overhead crane to
boom pivot pin at the boom pivot. the secondary boom.
Crushing hazard. The boom pivot 53 Remove the pin retaining fasteners from the
could fall if not properly supported secondary boom pivot pin at the turntable pivot.
45 Remove the pin retaining fastener from the boom pivot pin at the turntable pivot.
primary linkage pivot pin at the boom pivot.
55 Remove the secondary boom from the
46 Using a soft metal drift, remove the primary machine.
linkage pivot pin at the boom pivot.
Crushing hazard. The boom pivot
Crushing hazard. The boom pivot will fall if not properly supported
will fall if not properly supported when removed from the machine.
56 Carefully lay the hoses and cables over the
47 Slowly remove the boom pivot from the turntable pivot.
machine while pulling the cables and hoses
through it.
Cables and hoses can be
Crushing hazard. The boom pivot damaged if they are kinked or
will fall if not properly supported pinched.
57 Rotate the rod end lug of the secondary boom
Component damage hazard. lift cylinder until it can clear the secondary
Cables and hoses can be linkage during removal. Lower the cylinder
damaged if they are kinked or through the secondary boom linkage and rest it
pinched. on the block.
4 - 16 TMZ-34/19 Part No. 52075

58 Attach a lifting strap from an overhead crane to 66 Using a soft metal drift, remove the secondary
the secondary linkage. boom lift cylinder barrel-end pivot pin.
59 Remove the pin retaining fasteners from the Crushing hazard. If the overhead
secondary linkage pivot pin at the turntable crane or lifting device is not
pivot. properly attached, the primary
boom lift cylinder may become
unbalanced and fall when it is
linkage pivot pin at the turntable pivot.
61 Remove the secondary linkage from the
67 Remove the secondary boom lift cylinder from
machine.
the machine.
Crushing hazard. The secondary
Crushing hazard. The lift cylinder
linkage will fall if not properly
supported when removed from the
if not properly supported when
machine.
62 Support the secondary boom lift cylinder with an
overhead crane or similar lifting device.
63 Tag, disconnect and plug the secondary boom Use caution when removing the
lift cylinder hydraulic hoses at the secondary cylinder from the machine.
boom lift cylinder. Cap the fittings on the
cylinder.
or spray.
64 Tag and disconnect the wires from the
secondary boom lift cylinder.
secondary boom lift cylinder barrel-end pivot
pin at the turntable pivot.
Part No. 52075 TMZ-34/19 4 - 17

4-2 a b c d e
Lift Cylinders
The primary boom lift cylinder raises and lowers
the primary boom. The primary boom lift cylinder is
equipped with a bi-directional solenoid valve to
prevent movement in the event of a hydraulic line
failure.
How to Remove the Primary a primary boom lift cylinder barrel-end pivot pin
b primary boom lift cylinder
Boom Lift Cylinder c primary boom lift cylinder rod-end pivot pin
d primary boom
When removing a hose assembly e secondary boom
and/or hose end must be replaced 5 Using a soft metal drift, remove the primary
and then torqued to specification boom lift cylinder barrel-end pivot pin.
during installation. Refer to Crushing hazard. The lift cylinder
Section 2, Hydraulic Hose and will fall if not properly supported.
6 Lower the cylinder onto the secondary boom.
level surface. Component damage hazard. The
solenoid valve on the lift cylinder
1 Tag, disconnect and plug the hydraulic hoses can be damaged if allowed to
on the primary boom lift cylinder. Cap the come in contact with the boom.
fittings on the cylinder.
Bodily injury hazard. Spraying primary boom lift cylinder rod-end pivot pin.
burn skin. Loosen hydraulic 8 Using a soft metal drift, remove the primary
connections very slowly to allow boom lift cylinder rod-end pivot pin.
the oil pressure to dissipate Crushing hazard. The lift cylinder
gradually. Do not allow oil to squirt will fall if not properly supported.
or spray.
9 Carefully remove the cylinder from the machine.
2 Tag and disconnect the wiring from the solenoid
valve on the cylinder. Crushing hazard. The lift cylinder
3 Support the primary boom lift cylinder with an if not properly supported when
overhead crane or similar lifting device. removed from the machine.
4 Remove the pin retaining fastener from the Component damage hazard. The
primary boom lift cylinder barrel-end pivot pin. solenoid valve can be damaged.
4 - 18 TMZ-34/19 Part No. 52075

How to Remove the Secondary a b c d e
Boom Lift Cylinder

Fitting Torque Specifications. a boom pivot
b secondary boom
Perform this procedure on a firm, c secondary boom lift cylinder rod-end pivot pin
level surface. d secondary boom lift cylinder
e secondary boom lift cylinder barrel-end pivot pin
1 Tag, disconnect and plug the hydraulic hoses
on the secondary boom lift cylinder. Cap the 9 Support the secondary boom lift cylinder with an
fittings on the cylinder. appropriate lifting device.
Bodily injury hazard. Spraying 10 Rotate the rod end lug of the secondary boom
hydraulic oil can penetrate and lift cylinder until it can clear the secondary
burn skin. Loosen hydraulic linkage during removal.
connections very slowly to allow 11 Remove the pin retaining fastener from the
the oil pressure to dissipate secondary boom lift cylinder barrel-end pivot
gradually. Do not allow oil to squirt pin.
or spray. 12 Using a soft metal drift, remove the secondary
2 Tag and disconnect the wiring from the solenoid boom lift cylinder barrel-end pivot pin.
valve on the cylinder. Crushing hazard. The lift cylinder
3 Support the rod end of the cylinder with an will fall if not properly supported.
appropriate lifting device. 13 Carefully remove the cylinder from the machine.
4 Remove the pin retaining fastener from the Crushing hazard. The lift cylinder
secondary boom lift cylinder rod-end pivot pin. could become unbalanced and fall
5 Using a soft metal drift, remove the secondary if not properly supported when
boom lift cylinder rod-end pivot pin. removed from the machine.
Crushing hazard. The lift cylinder Component damage hazard. The

will fall if not properly supported. solenoid valve can be damaged.
6 Lower the cylinder onto the secondary linkage. cylinder from the machine.
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.
Part No. 52075 TMZ-34/19 4 - 19

Ground Controls REV C
TMZ-34 models manufactured in the 1998 and

1999 model years (from serial number T3498-001
to T3499-769) were originally equipped with
ground controls boxes containing three printed
circuit boards. Machine functions are activated
using push buttons on the exterior of the box.
Beginning with the 2000 model year (from serial
number T3400-001 to date), the ground control box
was changed to a two-board configuration. The
push buttons used to activate machine functions
on earlier models were replaced with a membrane
overlay decal, mounted on the exterior of the box.
a b c a b c
D7
VOLTAGE
REGULATOR
8 7 6 54 3 2 1 8 7 6 54 3 2 1
SW25A SW25
DIP SWITCH DIP SWITCH
N.O. KS1
N.C.
D7
N.O.
N.O.
P1 KS1 P1 KEY
VOLTAGE
KEY EMERGENCY
N.C. EMERGENCY
STOP
N.O. SWITCH STOP
REGULATOR SWITCH
f e d g f e d
From serial number T3498-001 to T3499-769 From serial number T3400-001 to date
a voltage regulator D7 a DIP switch SW25A

b CPU circuit board U17 b DIP switch SW25
c connector circuit board U21 c connector circuit board U21
d key switch KS1 d key switch KS1
e Emergency Stop button P2 e CPU/display circuit board U22
f key pad circuit board U15 f voltage regulator D7
g Emergency Stop button P2
4 - 20 TMZ-34/19 Part No. 52075

REV C GROUND CONTROLS
5-1 2 Remove the four lid retaining fasteners from the

ground control box. Open the lid.
Ground Control Keypad
3 Tag and disconnect the ribbon cables from the
Circuit Board ground control circuit board.
The ground control keypad circuit board controls Component damage hazard.
the machine functions from the ground. The Electrostatic discharge (ESD) can
ground control circuit board is connected to the damage printed circuit board
CPU circuit board via a ribbon cable. components. Maintain firm contact
with a metal part of the machine
TMZ-34 models manufactured in the 1998 and that is grounded at all times when
1999 model years (from serial number T3498-001 handling printed circuit boards OR
to T3499-769) were originally equipped with use a grounded wrist strap.
circuit boards. Machine functions are activated 4 Remove the circuit board mounting fasteners
using push buttons on the exterior of the box. and remove the circuit board from the ground
control box lid.
number T3400-001 to date), the ground control box Component damage hazard. Be
was changed to a two-board configuration. The sure not to pinch the wires or
push buttons used to activate machine functions ribbon cable when installing the lid
on earlier models were replaced with a membrane onto the ground control box.
overlay decal, mounted on the exterior of 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
other jewelry.
Part No. 52075 TMZ-34/19 4 - 21

GROUND CONTROLS REV C
5-2 5-3
CPU Circuit Board Connector Circuit Board
The CPU circuit board controls all machine The connector circuit board connects the wire
functions. harness to the CPU circuit board using several
cables. From serial number T3498-001 to
How to Remove T3499-769, the connector circuit board is equipped
the CPU Circuit Board with a replaceable 5 amp fuse.
1 Disconnect the battery pack from the machine. How to Remove

Electrocution hazard. Contact with the Connector Circuit Board
Remove all rings, watches and Electrocution hazard. Contact with
other jewelry. electrically charged circuits could
2 Remove the four lid retaining fasteners from the
other jewelry.
3 Tag and disconnect all wiring from the CPU
2 Tag and disconnect the wire harness
circuit board.
connectors from the ground control box.
3 Remove the four lid retaining fasteners from the
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact 4 Tag and disconnect all wiring from the
with a metal part of the machine connector circuit board.
that is grounded at all times when
handling printed circuit boards OR
Electrostatic discharge (ESD) can
use a grounded wrist strap.
damage printed circuit board
4 Remove the CPU circuit board mounting components. Maintain firm contact
fasteners and remove the CPU circuit board. 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.
4 - 22 TMZ-34/19 Part No. 52075

5-4 How to Determine

Software Configuration the DIP Switch Configuration
A diagnostic display was
TMZ-34 models manufactured in the 1998 and
incorporated into the ground
1999 model years (from serial number T3498-001
controls after serial number
to T3499-769) were originally equipped with
T3402-115. The following
procedure will not apply to
circuit boards. Machine functions are activated
machines before serial number
using push buttons on the exterior of the box.
T3402-116.
1 Turn the key switch to platform control and pull
number T3400-001 to date), the ground control box
was changed to a two-board configuration. The
push buttons used to activate machine functions
controls.
on earlier models were replaced with a membrane
overlay decal, mounted on the exterior of the box. 2 Press and hold both the secondary down button
and the turntable rotate counterclockwise
Programming for all configurations of the the 1998 button at the ground controls.
and 1999 model years (from serial number
T3498-001 to T3499-769) is contained in the Result: The DIP switch settings will appear in
EPROM, which is installed into the CPU circuit the diagnostic display.
board.
The display will show each toggle
Beginning with the 2000 model year, the machine of the DIP switch in numerical
can be configured by changing the combination of order from 1 through 16, and
toggles of the DIP switch mounted on the CPU whether the toggle is in the on
circuit board. position (01) or off position (00).
For example, 0401 shown in the
The following procedures will not diagnostic display indicates that
apply for machines manufactured the fourth toggle is in the on
in the 1998 and 1999 model years. position.
a secondary down
b turntable rotate counterclockwise
Part No. 52075 TMZ-34/19 4 - 23

How to a b c d
Set the DIP Switch

KS1 P1
N.O.
N.O.
N.C.
KEY EMERGENCY
1 Turn the key switch to the off position and push SWITCH STOP
in the red Emergency Stop button to the off

D7
position at both the ground and platform VOLTAGE
REGULATOR
controls.
SW25 SW25A
2 Remove the fasteners securing the top to the DIP SWITCH DIP SWITCH
K K
J
ON ON
ground controls box and open the ground 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
control box.
e e
3 Rotate the top of the ground control box to the
position shown in the following illustration to a key switch KS1
correctly identify the configuration of the DIP b ground control lid
switch settings. c CPU/display circuit board U22
d Emergency Stop P1
4 Locate the DIP switch on the circuit board. e DIP switch SW25A
Move the DIP switch settings to correspond f DIP switch SW25
with the configuration of the machine options as
illustrated below.
5 Close the lid and install the fasteners.
K K
J
J
ON ON
DIP Switch Legend
Toggle Description Position 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
1 All models On models with manual outriggers
2 Hour meter/flashing beacon On
3 Not used Off K K

J
J
ON ON
4 Outriggers
hydraulic Off 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
manual On
models with hydraulic outriggers
5 - 16 Not used
4 - 24 TMZ-34/19 Part No. 52075

5-5 3 Disconnect the large blue connector from the

circuit board at the connection marked KEYPAD
Membrane Overlay by sliding the connector parallel to the circuit
board.
The following procedures will not
apply for machines manufactured Component damage hazard. The
in the 1998 and 1999 model years. circuit board will become damaged
if the wire harness and connector
How to are disconnected without proper
care. Do not pull upwards on the
Replace the Overlay connector OR put any weight or
1 Disconnect the battery pack from the machine. strain on the wires.
Electrocution hazard. Contact with Component damage hazard.
electrically charged circuits could Electrostatic discharge (ESD) can
result in death or serious injury. damage printed circuit board
Remove all rings, watches and components. Use a grounded
other jewelry. wrist strap at all times when
handling printed circuit boards.
2 Loosen the control box lid retaining fasteners
and open the lid. 4 Install the lid onto the control box. Finger-tighten
the retaining fasteners.
GROUND CONTROLS MODELS WITH

MEMBRANE DECAL PANEL HYDRAULIC OUTRIGGERS
SECONDARY DOWN BN41 BN49 OUTRIGGER AUTO LEVEL
LEFT FRONT OUTRIGGER BN52 BN47 OUTRIGGER EXTEND
PRIMARY UP BN38 BN48 OUTRIGGER RETRACT
PRIMARY DOWN BN39 BN43 ROTATE RIGHT
RIGHT FRONT OUTRIGGER BN53 BN42 ROTATE LEFT
HORN BN35 BN50 LEFT REAR OUTRIGGER
FUNCTION ENABLE HIGH BN44 BN36 JIB BOOM UP
FUNCTION ENABLE MEDIUM BN45 BN37 JIB BOOM DOWN
FUNCTION ENABLE LOW BN46 BN51 RIGHT REAR OUTRIGGER
BN40 SECONDARY UP
16
15
14
13
12
10
11
8
7
6
5
2
1
16 PIN RIBBON CABLE
GROUND CONTROLS MODELS WITH

MEMBRANE DECAL PANEL MANUAL OUTRIGGERS
NOTE PRIMARY UP BN38
THE RANDOM ORDER OF THE 16-PIN
RIBBON CONNECTOR IS DONE ONLY TO PRIMARY DOWN BN39 BN43 ROTATE RIGHT
SHOW THE WIRE CIRCUITS. ON THE
MACHINE, THE WIRES OF THE RIBBON HORN BN35 BN42 ROTATE LEFT
CABLE, WHERE THEY CONNECT WITH
THE CIRCUIT BOARD ARE IN NUMERIC FUNCTION ENABLE HIGH BN44 BN36 JIB BOOM UP
ORDER FROM 1 TO 16.
THE CIRCUIT BOARD IS MARKED AT ONE FUNCTION ENABLE MEDIUM BN45 BN37 JIB BOOM DOWN
END OF THE BOARD-TO-CABLE BN40 SECONDARY UP
FUNCTION ENABLE LOW BN46
CONNECTION WITH THE NUMBER “1.”
CAREFULLY INSPECT THE CIRCUIT BN41 SECONDARY DOWN
BOARD TO LOCATE THE NUMBER 1
16
15
14
13
12
10
WIRE OF THE RIBBON CABLE.

8
7
6
5
16 PIN RIBBON CABLE
Part No. 52075 TMZ-34/19 4 - 25

5 Starting at the upper corners of the touch pad, 11 Loosen the control box lid retaining fasteners
remove all layers of the touch pad from the and open the lid.
control box lid.
12 Using RTV-type sealant, completely seal the
The wire harness and large blue opening in the slot of the control box lid around
connector will interfere if removing the wire harness.
the touch pad from the bottom.
13 Apply dielectric grease to the pins on the circuit
6 Pull the large blue connector through the slot in board at the connection marked KEYPAD.
the control box lid and discard the old touch
14 Install the large blue connector onto the circuit
pad. Remove any remaining sealant from the
board pins at the connection marked KEYPAD.
slot.
Slide the connector parallel to the circuit board
7 Using a mild solvent, clean the surface of the until the connector is pushed onto the circuit
control box lid. Allow the surface to dry. board pins no less than 0.2 inch / 5 mm.
Component damage hazard. The Be sure all pins are in the
circuit board will become damaged connector.
if it comes in contact with solvent.
15 Install the lid onto the control box and tighten
Do not allow solvent to contact the
the retaining fasteners. Do not overtighten.
circuit board.
8 Remove all the brown backing material from the
new touch pad.
9 Insert the large blue connector from the new
touch pad through the slot. Carefully align the
battery power LED on the 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.
4 - 26 TMZ-34/19 Part No. 52075

5-6 Models with hydraulic outriggers:

Level Sensor 3 Push and hold the auto level button. Push and
hold the extend outrigger button.
One level sensor monitors the incline of the
Result: The outriggers will lower and adjust to
turntable after the outriggers are deployed and the
level the machine and raise the wheels slightly
machine is level. The Electronic Control Module
off the ground. Use a digital level to confirm that
(ECM) is programmed to deactivate lift functions
the machine is level.
and activate an alarm when a signal is received
from the level sensor, making the operator aware Models with manual outriggers:
of a potentially hazardous situation.
4 Lower and lock into place each outrigger.
The tilt alarm sounds when the incline of the
5 Adjust the outriggers to level the machine and
chassis exceeds 1.5° in any direction. The tilt level
raise the wheels slightly off the ground.
sensor is located below the ground control box.
Result: The corresponding interlock display
How to Install and Calibrate the lights will be on. If the light is flashing, continue
Tilt Level Sensor adjusting the outrigger until the light remains
on.
Tip-over hazard. Failure to install
or calibrate the level sensor as All models:
instructed could result in the 6 Turn the key switch to the off position.
machine tipping over causing
death or serious injury. Do not 7 Locate the tilt level sensor next to the ground
install or calibrate the level sensor control box.
other than specified in this
procedure.
1 Perform this procedure with the machine on a
firm, level surface that is free of obstructions.
a
2 Turn the key switch to ground control and pull
controls.
Result: The power light should be on.
X
c
Y
a battery charger
b ground control box
c level sensor
Part No. 52075 TMZ-34/19 4 - 27

If you are not installing a new level sensor, Adjust the side-to-side axis:
proceed to step 13.
14 Set a multimeter to read DC voltage.
8 Tag and disconnect the wire harness from the
15 Without disconnecting the wire harness from
tilt level sensor.
the level sensor, connect the negative lead of
9 Remove the fasteners securing the level sensor the multimeter to the black wire at the level
to the machine. Remove the level sensor from sensor.
the machine.
16 Without disconnecting the wire harness from
10 Install the new level sensor onto the machine the level sensor, connect the positive lead of
with the "X" on the level sensor housing closest the multimeter to the yellow wire at the level
to the ground control box, as shown in the sensor.
illustration on the previous page. Install and
17 Adjust the "Y" axis (side-to-side) to 2.5V DC.
securely tighten the level sensor retaining
Tap the top of the level sensor lightly with
fasteners.
fingers after each turn of an adjusting nut.
Tip-over hazard. The level sensor
Tip-over hazard. Do not adjust the
must be installed with the "X" on
potentiometers on the bottom of
the level sensor base closest to
the level sensor or calibrate the
the ground control box. Failure to
level sensor other than specified in
install the level sensor as
this procedure. Failure to calibrate
instructed could result in the
the tilt level sensor as instructed
machine tipping over causing
will cause the machine to tip over
death or serious injury.
resulting in death or serious injury.
11 Connect the wire harness to the level sensor.
Be sure there are threads showing
12 Tighten the level sensor adjusting fasteners through the top of each adjusting
until the bubble in the top of the level sensor is nut.
centered in the calibration circles.
18 Disconnect the positive lead.
4 - 28 TMZ-34/19 Part No. 52075

Adjust the front-to-back axis: Test the machine:

19 Without disconnecting the wire harness from 23 Raise the primary, secondary and jib booms
the level sensor, connect the positive lead of approximately 12 inches / 30 cm.
the multimeter to the blue wire at the level
Result: The tilt sensor alarm should not sound.
sensor.
24 Press down one side of the tilt sensor and place
20 Adjust the "X" axis (front-to-back) to 2.5V DC.
the tilt sensor test tool under one of the posts.
Tap the top of the level sensor lightly with
fingers after each turn of an adjusting nut. Result: The alarm, located in the platform,
should sound at 180 beeps per minute after 1
second. The interlock display light should flash.
potentiometers on the bottom of
the level sensor or calibrate the 25 Test all machine functions.
level sensor other than specified in
this procedure. Failure to calibrate Result: The primary boom up, secondary boom
the tilt level sensor as instructed up and jib boom up functions should not
will cause the machine to tip over operate. The primary boom down, secondary
resulting in death or serious injury. boom down, jib boom down and turntable rotate
functions should operate normally.
Be sure there are threads showing
through the top of each adjusting 26 Turn the key switch to platform control.
nut. 27 Test all machine functions.
21 Disconnect the positive and negative leads. Result: The primary boom up, secondary boom
22 Apply Sentry Seal to the adjusting nuts. up and jib boom up functions should not
operate. The primary boom down, secondary
boom down, jib boom down and turntable rotate
functions should operate normally.
Part No. 52075 TMZ-34/19 4 - 29

5-7 Callout LED Description

Interacter Battery Charger 20-25A Red Illuminates when charge current
is 80% of chargers nominal rating.
The Interacter 24/25 battery charger, used on
15-20A Red Illuminates when charge current
machines before serial number T3403-131, is a is 60% of chargers nominal rating.
three-stage, microprocessor-controlled 24V 25A
charger, with short circuit and reverse battery 10-15A Red Illuminates when charge current
protection, constant current, and constant voltage is 40% of chargers nominal rating.
with temperature compensated charging voltage.
5-10A Red Illuminates when charge current
There is no need to switch off the charger once the is 20% of chargers nominal rating.
batteries are charged, as the charger senses the
NOTE: If the batteries are fully
condition of the batteries and automatically discharged, all of the above listed
switches into a float or standby mode. LEDs will illuminate at the same
time; if the batteries are not fully
The charger is protected with a 10A slow blowing discharged, not all will illuminate.
fuse, located behind a small panel just below the
AC input connector. Charge Red Illuminates when battery is
connected correctly and AC power
There are 7 LEDs on the front panel, any is present. LED turns off when
combination of which indicates the state of battery battery reaches first voltage limit.
charge or charger operating condition. Listed in the
next column, in order from top to bottom as seen 80% Yellow Illuminates during charging when
on the charger case, is an explanation of what timer is running; battery voltage is
these LEDs indicate. held constant at this while this LED
is on, minimum one hour OR one
When using the charger, be sure the AC supply hour plus half time required to
circuit is grounded. reach first voltage limit.
Ready Green Illuminates at end of charging

cycle, indicating batteries are
charged and ready for use, and
will remain on as long as AC power
A
-25
20 20A
-
15 15A
and batteries remain connected,
-
10 0A
a 5-1ARG
E maintaining charger in float or
CH
R E
%
80 DY
A standby mode.
b NOTE: If the Green LED flashes
ON constantly at the end of the charge,
c this indicates an override timeout
T
fault condition, which happens if
SE
RE
the charge cycle is not completed
within 18 hours of charge start,
d
after which the charger will not
output any current. This is caused
a LEDs by a charger low output current
b on/off switch fault OR a shorted cell in a battery.
c AC input connector
d fuse panel Current settings Normal Liquid Gel
First voltage limit 29V 31V 28V

Float / Standby 27.6V 27.7V 27.5V
4 - 30 TMZ-34/19 Part No. 52075

How to
Install a Circuit Board
Battery Charger DIP Switch
1 Disconnect the battery pack from the machine. Circuit Board
1
2
other jewelry.
DIP switch location
2 Disconnect all external AC power supply from
the machine. 8 Install the cover onto the battery charger. Install
and securely tighten the fasteners. Do not over
3 Remove the fasteners securing the cover to the tighten.
top of the battery charger. Remove the cover.
DIP settings Normal Liquid Gel
4 Locate the circuit board. Tag and disconnect all
Toggle 1 OFF OFF ON
circuit board wiring.
Toggle 2 ON OFF OFF
5 Remove the circuit board.
6 Install the new circuit board into the battery
charger. Securely install all circuit board wiring. If not operating correctly, check
7 Set the DIP switch. Determine the type of the following:
batteries being used on the machine. Then,
using the following chart, set the toggles of the · Good power supply at the AC power source
DIP switch accordingly. · Use only #12 AWG heavy-duty extension cord
Component damage hazard. · Power cable firmly connected to the AC input
Incorrectly setting the DIP switch plug or fitted into the AC input connector
may result in decreased battery · Faulty fuse (120V models) or
life. Use caution when faulty circuit breakers (230V models)
programming the circuit board. · Correct wiring at the batteries:
'Gel' setting will increase battery · Red charger wire to battery positive
life while decreasing the amount of · Black charger wire to battery negative
cycles for the machine.
'Normal' setting will decrease the
battery life, while increasing the Component damage hazard. This
amount of cycles for the machine. charger is designed to sense
battery condition and automatically
switch off when the batteries are
fully charged. To avoid
overcharging and possible battery
damage should the charger fail to
turn off, disconnect the AC supply
from the charger if the machine
will be unattended for more than
24 hours.
Part No. 52075 TMZ-34/19 4 - 31

5-8 If not operating correctly, check

Lester Battery Charger the following:
· Good power supply at the AC power source
North America models: The Lester 19740 battery
charger, used on machines after serial number · Use only #12 AWG heavy-duty extension cord
T3403-130, is a 24V 25A charger. Designed for · Power cable firmly connected to the AC input
use with wet (liquid filled) batteries, this self- plug or fitted into the AC input connector
regulating charger is equipped with built-in line · Faulty fuse (19740 models) or
voltage compensation which supplies consistent faulty circuit breakers (22310 models)
DC output even when the AC supply voltage varies
by as much as 10%. · Correct wiring at the batteries
This 120V AC charger is equipped with and · Red or White charger wire to battery positive
· Black charger wire to battery negative
protected by a 30A fuse, located on the charger
face plate next to the AC input plug.
Worldwide models: The Lester 22310 battery
These chargers are designed to
charger, used on machines after serial number
sense battery condition and
T3403-130, is a 24V 20A charger. Designed for
automatically switch off when the
use with wet (liquid filled) batteries, this self-
batteries are fully charged. To
regulating charger is equipped with built-in line
avoid overcharging and possible
voltage compensation which supplies consistent
battery damage should the
DC output even when the AC supply voltage varies
charger fail to turn off, disconnect
by as much as 10%.
the AC supply from the charger if
This charger, which automatically adjusts to
the machine will be unattended for
operate on 110V or 220V AC, is equipped with and
more than 24 hours.
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.
a c
b d
a North America model c Worldwide model

b 30A fuse (output) d 45A circuit breaker (output)
e AC input connector
4 - 32 TMZ-34/19 Part No. 52075

Part No. 52075 TMZ-34/19 4 - 33

Hydraulic Power Unit 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 Schematic
No. Description Item Function Torque
1 Hydraulic return filter ........................................ Filters oil returning to the tank
2 Diagnostic nipple ............................... D ........... Testing .................................................. 155 in-lbs / 17.5 Nm
3 Proportional valve, N.C. with
manual over ride knob ....................... E ........... Allows lowering 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 ................................................................ Tank to pump seal
11 Sight gauge ...................................................... Hydraulic fluid level
12 Tank .................................................................. 6 quarts / 5.7 liters ..................................... 40 in-lbs / 4.5 Nm
13 Drain plug ......................................................... Drains tank ............................................... 250 in-lbs / 28 Nm
14 Breather cap ..................................................... Vent tank
15 Check valve ....................................... G ........... One way valve for pump output ............ 155 in-lbs / 17.5 Nm
4 - 34 TMZ-34/19 Part No. 52075

REV B HYDRAULIC POWER UNIT
1 2 3 4
15
G 5
6
14
13 12 11 10 9 8 7
Part No. 52075 TMZ-34/19 4 - 35

HYDRAULIC POWER UNIT REV B
6-2 4 Press and hold the high speed function enable

button and press and hold the primary boom up
Valve Adjustments - button and observe the pressure reading on the
Hydraulic Power Unit pressure gauge. Turn the machine off.
5 Hold the relief valve adjusting screw and loosen
How to the lock nut.
Adjust the System Relief Valve 6 Adjust the relief valve screw. Turn it clockwise
to increase the pressure or counterclockwise to
1 Connect a 0 to 5000 psi / 0 to 350 bar pressure decrease the pressure. Refer to Section 2,
gauge to the test port on the hydraulic power Specifications.
unit.
2 Turn the key switch to ground controls and pull relief valve higher than specified.
position at both the ground and platform 7 Hold the relief valve screw and tighten the lock
controls. nut. Be sure the relief valve screw does not
turn.
3 Fully raise the primary boom.
8 Repeat steps 2 through 4 to confirm the relief
a b c valve pressure.
9 Bleed the hydraulic system by raising the
platform to full height. If the pump cavitates or
platform fails to reach full height, add hydraulic
oil until the pump is functioning correctly. Do not
overfill the hydraulic tank.
Component damage hazard. Do
not continue to operate the
machine if the hydraulic pump is
cavitating.
d
a hydraulic tank
b test port
c pump motor
d pump
e lock nut
f relief valve adjusting screw
4 - 36 TMZ-34/19 Part No. 52075

6-3 4 Activate a function enable button and any lift

function button at the ground controls.
Hydraulic Pump
Result: If the pressure gauge reads
3000 psi / 207 bar, immediately stop. The pump
How to is good.
Test the Hydraulic Pump Component damage hazard. If the
When removing a hose assembly pressure exceeds
or fitting, the O-ring on the fitting 3000 psi / 207 bar, see 6-2, How
and/or hose end must be replaced to Adjust the System Relief Valve.
and then torqued to specification Result: If pressure fails to reach
3000 psi / 207 bar, the internal relief valve
setting is incorrect OR the proportional valve is
faulty OR the pump is faulty and will need to be
Perform this procedure with the serviced or replaced.
manual override knob turned fully
5 Remove the pressure gauge and reconnect the
counterclockwise to the closed
hydraulic hose.
position.
1 Tag, disconnect and plug the hydraulic hose
from the high pressure port at the top of the
main function pump.
or spray.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the high pressure port on the pump.
controls.
Part No. 52075 TMZ-34/19 4 - 37

HYDRAULIC POWER UNIT REV B
How to Remove 4 Tag and disconnect the power cables from the
hydraulic power unit motor.
the Hydraulic Power Unit
When removing a hose assembly electrically charged circuits may
or fitting, the O-ring on the fitting result in death or serious injury.
and/or hose end must be replaced Remove all rings, watches and
and then torqued to specification other jewelry.
Section 2, Hydraulic Hose and 5 Remove the power unit mounting fasteners and
Fitting Torque Specifications. remove the power unit from the machine.
1 Disconnect the battery pack from the machine. If a new power unit is installed, the
pressure relief valve must be
Electrocution hazard. Contact with properly adjusted. See 6-2, How to
electrically charged circuits may Adjust the System Relief Valve.
other jewelry.
2 Tag, disconnect and plug the hydraulic hoses.
Cap the fittings on the power unit.
or spray.
3 Tag and disconnect the electrical wiring from
the valve coil.
4 - 38 TMZ-34/19 Part No. 52075

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.
Improper alignment during
assembly can damage the
pump-to-motor seal. Use caution
when installing the pump onto the
motor.
Part No. 52075 TMZ-34/19 4 - 39

Manifolds REV C
7-1
Turntable Rotation Manifold Components
The turntable rotation manifold is located on the power unit side of the machine.
Index Schematic
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
1
Y24
Y23
I
2
J 3
4 - 40 TMZ-34/19 Part No. 52075

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.
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.
Part No. 52075 TMZ-34/19 4 - 41

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 Schematic
— 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 Y41
1
Y39
L Y48
2
4 - 42 TMZ-34/19 Part No. 52075

REV C MANIFOLDS
7-4 Valve coil resistance specifications

Valve Coils Description Specification
How to Test a Coil Solenoid valve, 2 position 2 way 29 - 31Ω

24V DC (schematic items A, B and C)
A properly functioning coil provides an
electromotive force which operates the solenoid Proportional solenoid valve, N.C. 31.5 to 33.5Ω
valve. Critical to normal operation is continuity 24V DC (schematic item E)
within the coil that provides this force field.
Electrocution hazard. Contact with 20V DC (schematic item H)
result in death or serious injury. Solenoid valve, 2 position 3 way 23 to 25Ω
Remove all rings, watches and 20V DC (schematic item K)
other jewelry.
1 Tag and disconnect the wire harness from the
20V DC (schematic item L)
coil to be tested.
2 Test the coil resistance. Solenoid valve, 2 position 2 way 29 - 31Ω
24V DC (schematic items M, N, O and P)
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.
Part No. 52075 TMZ-34/19 4 - 43

MANIFOLDS REV C
How to Test a Coil Diode

Genie incorporates spike suppressing diodes in all COIL
a
of its coils. Properly functioning coil diodes protect d
MULTI
METER
the electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current c -
to a coil. Faulty diodes can fail to protect the
+
b
electrical system, resulting in a tripped circuit 10 W 9V
breaker or component damage. RESISTOR BATTERY
Electrocution hazard. Contact with c

b
+
-
Remove all rings, watches and a multimeter
other jewelry. b 9V DC battery
c 10W resistor
1 Test the coil for resistance. See 7-4 How to d coil
Test a Coil. Note: Dotted lines in illustration indicate a
reversed connection as specified in step 6
2 Connect a 10W resistor to the negative terminal
of a known good 9V DC battery. Connect the 4 Connect the negative lead to the other terminal
other end of the resistor to a terminal on the on the coil.
coil.
If testing a single-terminal coil,
The battery should read 9V DC or connect the negative lead to the
more when measured across the internal metallic ring at either end
terminals. of the coil.
5 Momentarily connect the positive lead from the
Resistor, 10W
Genie part number 27287 multimeter to the positive terminal on the 9V
battery. Note and record the current reading.
6 At the battery or coil terminals, reverse the
3 Set a multimeter to read DC voltage. connections. Note and record the current
reading.
The multimeter, when set to read
DC voltage, should be capable of Result: Both current readings are greater than
reading up to 800 mA. 0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings are
0 mA, or if the two current readings do not differ
by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
4 - 44 TMZ-34/19 Part No. 52075

REV B
Turntable Rotation Components
8-1
Turntable Rotation Motor
How to Remove the Turntable

Rotation Motor
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.
Part No. 52075 TMZ-34/19 4 - 45

Axle Components REV B
9-1 9-2
Axle Hub and Bearings
How to Remove the Axle How to Remove the Hub and

1 Lower the outriggers and adjust to level the Bearings
machine and raise the wheels off the ground. Repair procedures and additional axle information
2 Disconnect the parking brake cable at the are available in the Dexter Axle
tension equalizer. Operation Maintenance Service Manual
3 Pull the parking brake cable through the
mounting hole on the trailer.
4 Tag, disconnect and plug the brake line from Genie part number 84376
the back of the hub. Cap the fitting.
5 Clean up any brake fluid that may have spilled.
6 Repeat steps 2 through 5 for the other side.
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 the axle is installed, the
brakes should be bled. Refer to
the appropriate brake
manufacturer's manual that was
shipped with your Genie TMZ.
4 - 46 TMZ-34/19 Part No. 52075

REV C
Trailer Components
10-1 10-2
Trailer Brakes Parking Brake
Hydraulic Brake System - How to Adjust the Parking Brake

ANSI Models ANSI models:
Repair procedures and additional axle information 1 Adjust the brakes. Refer to the Dexter Axle
is available in the Dexter Axle Operation Operation Maintenance Service Manual
Maintenance Service Manual (Dexter part number LIT-001-00).
Dexter Axle Operation Maintenance Service Manual Genie part number 84376
2 Chock the wheels.

Electrical Brake System - 3 Release the parking brake.
ANSI Models 4 Loosen the set screw at the side of the parking
Repair procedures and additional axle information brake handle.
is available in the Dexter Axle Operation
5 Adjust the handle just to the point where it is
Maintenance Service Manual
difficult to apply the parking brake, then rotate
the top of the parking brake handle
counterclockwise one full turn.
Genie part number 84376 6 Tighten the set screw. Do not over tighten.
7 Engage the parking brake. Attempt to move the
machine.
Mechanical Brake System - Result: The parking brake should prevent the
CE Models machine from moving. If the parking brake does
not prevent the machine from moving, repeat
Repair procedures and additional axle information
this procedure beginning with step 1.
is available in the KNOTT Axle Service Manual
(KNOTT part number P005). CE models:

KNOTT Axle Service Manual
axle information is available in the KNOTT Axle
Service Manual (KNOTT part number P005).
KNOTT Axle Service Manual

Part No. 52075 TMZ-34/19 4 - 47

Outrigger Components REV B
11-1 Models with manual outriggers, tongue end:

Outrigger Components 1 Attach a lifting strap from an overhead crane to
the pad end of the outrigger. Do not apply any
How to Remove an Outrigger lifting pressure.
2 Remove the external snap ring and washer
Outriggers are essential to safe machine operation
from the outrigger pivot pin.
and machine stability. Operating a machine with a
damaged or improperly operating outrigger will 3 Remove the pin retaining fastener from the
result in death or serious injury. outrigger pivot pin. Do not remove the pin.
Perform this procedure with the 4 Use a soft metal drift to remove the outrigger
parking brake applied, outriggers pivot pin. Remove the outrigger from the
in the stowed position and the machine.
machine disconnected from the Crushing hazard. The outrigger
tow vehicle. may fall if not properly supported
Models with manual outriggers, platform end: when the outrigger pivot pin is
the pad-end of the outrigger. Do not apply any
lifting pressure.
2 Remove the external snap ring and washer
from the outrigger pivot pin.
outrigger pivot pin. Do not remove 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
4 - 48 TMZ-34/19 Part No. 52075

REV B OUTRIGGER COMPONENTS
Models with hydraulic outriggers: 11-2

1 Attach a lifting strap from an overhead crane to Outrigger Cylinder
the pad end of the outrigger. Do not apply any
lifting pressure. How to Remove an Outrigger
2 Tag and disconnect the wire harness from the Cylinder
outrigger limit switch.
outrigger pivot pin. Do not remove the pin.
4 Remove the pin retaining fasteners from the and then torqued to specification
outrigger cylinder rod-end pivot pin. during installation. Refer to
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 1 Extend the outrigger until the pad just touches
pivot pin from the machine. the ground. Do not rest the weight of the
machine on the outrigger.
6 Secure the rod-end of the cylinder to the
chassis. 2 Remove the cylinder guard mounting fasteners
from the rod end of the outrigger cylinder and
remove the cylinder guard from the machine.
pivot pin and twist to remove the pin. Remove
the outrigger pivot pin from the machine. 3 Tag and disconnect the wire harness from the
outrigger cylinder valve coil.
could fall if not properly supported 4 Tag, disconnect and plug the hydraulic hoses
when the pivot pin is removed from the outrigger cylinder. Cap the fittings on
from the machine. the cylinder.
Crushing hazard. The outrigger Bodily injury hazard. Spraying
cylinder could fall if not properly hydraulic oil can penetrate and
supported when the outrigger is burn skin. Loosen hydraulic
removed from the machine. connections very slowly to allow
or spray.
Part No. 52075 TMZ-34/19 4 - 49

OUTRIGGER COMPONENTS REV B

the lug on the rod end of the cylinder.
a
6 Remove the pin retaining fasteners from
outrigger cylinder rod-end pivot pin.
b
cylinder rod-end pivot pin and twist to remove
the pin. Remove the outrigger cylinder rod-end
pivot pin from the machine.
8 Raise the cylinder to a vertical position.
outrigger cylinder barrel-end pivot pin.
a valve coil (hidden from view)
10 Place a rod through the hole in the outrigger b outrigger cylinder
cylinder barrel-end pivot pin and twist to
remove the pin. Remove the outrigger cylinder
barrel-end pivot pin from the machine.
cylinder could fall if not properly
supported when the pivot pin is
4 - 50 TMZ-34/19 Part No. 52075

June 2005 Section 5 • Troubleshooting Flow Charts
Troubleshooting Flow Charts

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.
Observe and Obey:
Read each appropiate flow chart thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each
from movement.
repair procedure with the machine in the
following configuration: Electrocution hazard. Contact
· Machine disconnected from tow vehicle with electrically charged circuits
could result in death or serious
· Machine parked on a firm, level surface with injury. Remove all rings, watches
the boom stowed and both latches secured and other jewelry.
· Key switch in the off position with the
key removed
· The red Emergency Stop button in the off burn skin. Loosen hydraulic
position at both ground and platform controls connections very slowly to allow
· Wheels chocked and parking brake applied the oil pressure to dissipate
· All external AC power supply disconnected squirt or spray.
from the machine
Perform all troubleshooting on a
firm, level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.
Part No. 52075 TMZ-34/19 5-1

Section 5 • Troubleshooting Flow Charts June 2005
TROUBLESHOOTING FLOW CHARTS
About This Section

When a malfunction is discovered, the flow charts
in this section will help a service professional
pinpoint the cause of the problem. To use this
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. LED Diagnostic Readout
The location of terminals mentioned in this section A diagnostic display was incorporated into the side
can be found on the appropriate electrical or of the ground controls after serial number
hydraulic schematics provided in Section 6, T3402-115.
Schematics.
The diagnostic readout displays numerical codes
Since various degrees of a particular function that provide information about the machine
loss may occur, selecting the appropriate flow operating status and about malfunctions. The
chart may be troublesome. When a function will not numbers will blink with fault codes and the 4
operate with the same speed or power as a dashes will remain on during normal operation.
machine in good working condition, refer to the
flow chart which most closely describes the The codes listed in the Fault Code Chart describe
problem. malfunctions and can aid in troubleshooting the
machine by pinpointing the area or component
General Repair Process affected.
Malfunction Identify Troubleshoot

discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
5-2 TMZ-34/19 Part No. 52075

REV A
Fault Code Chart
(after serial number T3402-115)
Fault Code Fault Condition Possible Cause Solution
– – – – Normal operation
Outriggers up, no Faulty switches OR Repair or replace

0001 Safety circuit fault retract structure faulty harness OR switches or harness
switches faulty circuit board OR replace CPU board
Faulty switch OR faulty Repair or replace
Negative angle boom Outrigger up, no
0002 switch fault negative angle switch
harness OR faulty switch or harness OR
circuit board replace CPU board
Level machine OR
Machine out of level OR charge batteries OR
Lift and rotate functions low battery voltage OR replace outrigger
0003 Down only mode
disabled faulty outrigger switches OR consult
switches Genie Industries
Service Department
Level machine OR
repair or replace wire
Machine out of level OR
harness or connections
faulty wire harness OR
0009 Level sensor fault Machine out of level
faulty level sensor OR
OR replace outrigger
switches OR consult
faulty circuit board
Genie Industries
Service Department
Repair or replace
ECM/platform Machine functions Faulty control cable OR
0010 communications fault inoperative faulty circuit board
control cable OR
replace circuit boards
Replace platform key
Machine functions Platform controls has
0011 Platform key pad fault
inoperative stuck or faulty button
pad or touch pad OR
Open or short in control Repair or replace
ECM/drive
0012 communications fault
No drive communication cable OR faulty circuit control cable OR
boards replace circuit boards
Replace ground key
Machine functions Ground controls has
0015 Ground keypad fault
inoperative stuck or faulty button
pad or touch pad OR
Coil not connected to
Secondary up valve coil wire harness OR open Restore connection OR
0021 Lower boom up coil fault
open circuit OR faulty circuit replace circuit board
board
Secondary up valve coil Short in wire harness Repair faulty wiring OR
0022 Lower boom up coil fault
shorted OR faulty circuit board replace circuit board
Continued on next page
Part No. 52075 TMZ-34/19 5-3

FAULT CODE CHART (AFTER SERIAL NUMBER T3402-115) REV A

Primary up valve coil wire harness OR open Restore connection OR
0025 Upper boom up coil fault
board
Primary up valve coil Short in wire harness Repair faulty wiring OR
0026 Upper boom up coil fault
Outrigger up valve coil wire harness OR open Restore connection OR
0029 Outrigger up coil fault
board
Outrigger up valve coil Short in wire harness Repair faulty wiring OR
0030 Outrigger up coil fault
Outrigger level valve wire harness OR open Restore connection OR
0031 Outrigger level coil fault
coil open circuit OR faulty circuit replace circuit board
board
Outrigger level valve Short in wire harness Repair faulty wiring OR
0032 Outrigger level coil fault
coil shorted OR faulty circuit board replace circuit board
Outrigger regen coil Outrigger regen valve wire harness OR open Restore connection OR
0033 fault coil open circuit OR faulty circuit replace circuit board
board
Outrigger regen coil Outrigger regen valve Short in wire harness Repair faulty wiring OR
0034 fault coil shorted OR faulty circuit board replace circuit board
Left front outrigger coil LF outrigger valve coil wire harness OR open Restore connection OR
0035 fault open circuit OR faulty circuit replace circuit board
board
Left front outrigger coil LF outrigger valve coil Short in wire harness Repair faulty wiring OR
0036 fault shorted OR faulty circuit board replace circuit board
Right front outrigger coil RF outrigger valve coil wire harness OR open Restore connection OR
board
Right front outrigger coil RF outrigger valve coil Short in wire harness Repair faulty wiring OR
5-4 TMZ-34/19 Part No. 52075

REV A FAULT CODE CHART (AFTER SERIAL NUMBER T3402-115)

Left rear outrigger coil LR outrigger valve coil wire harness OR open Restore connection OR
board
Left rear outrigger coil LR outrigger valve coil Short in wire harness Repair faulty wiring OR
Right rear outrigger coil RR outrigger valve coil wire harness OR open Restore connection OR
board
Right rear outrigger coil RR outrigger valve coil Short in wire harness Repair faulty wiring OR
Rotate right (clockwise) Rotate right valve coil wire harness OR open Restore connection OR
0045 coil fault open circuit OR faulty circuit replace circuit board
board
Rotate right (clockwise) Rotate right valve coil Short in wire harness Repair faulty wiring OR
0046 coil fault shorted OR faulty circuit board replace circuit board
Rotate left
Rotate left valve coil wire harness OR open Restore connection OR
0047 (counterclockwise) coil
fault
board
Rotate left
Rotate left valve coil Short in wire harness Repair faulty wiring OR
0048 (counterclockwise) coil
fault
wire harness OR open Restore connection OR
0049 Jib up coil fault Jib up valve coil open
circuit OR faulty circuit replace circuit board
board
Short in wire harness Repair faulty wiring OR
0050 Jib up coil fault Jib up valve coil shorted
OR faulty circuit board replace circuit board
Proportional valve coil Proportional valve coil wire harness OR open Restore connection OR
board
Proportional valve coil Proportional valve coil Short in wire harness Repair faulty wiring OR
Part No. 52075 TMZ-34/19 5-5

Chart 1 REV B
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serial number HGZZKX_IGHRKY58
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5-6 TMZ-34/19 Part No. 52075

REV B CHART 1
)NKIQ\URZGMKGZOTV[Z < 8KVGOXUVKTOT]OXKLXUS

)UTZOT[KJLXUSZNK
YOJKULQK_Y]OZIN19 ZKXSOTGR ULIUTTKIZUX
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0GZZNK]OXKNGXTKYY
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ZNKOTV[ZYOJKUL19
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<
HGJ
:[XTQK_Y]OZIN19ZU )NKIQZUYKKOLIGSUT 8KVGOXUXXKVRGIK19
<
MXU[TJIUTZXURVUYOZOUT QK_Y]OZINOYGIZO\GZOTM
GTJINKIQU[ZV[ZYOJKUL ZNKIUTZGIZ
MXU[TJIUTZXURYIUTZGIZ
MUUJ
8KVRGIKMXU[TJIUTZXURY
IUTZGIZ58XKLKXZU
-XU[TJ)UTZXURY
< /TUVKXGZO\K)NGXZ58
9KX\OIK*KVGXZSKTZ
MUUJ
:[XTQK_Y]OZINZU )NKIQZUYKKOLIGSUT 8KVRGIKVRGZLUXS
<
VRGZLUXSIUTZXURVUYOZOUT QK_Y]OZINOYGIZO\GZOTM IUTZXURYIUTZGIZ58
GTJINKIQU[ZV[ZYOJKUL ZNKIUTZGIZ XKLKXZU6RGZLUXS
VRGZLUXSIUTZXURY )UTZXURY/TUVKXGZO\K
IUTZGIZ )NGXZ58IUTY[RZ
HGJ
-KTOK/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
8KVGOXUXXKVRGIK19
<
:XU[HRKYNUUZROLZGTJ
JXO\KY_YZKSY
YKVGXGZKR_58XKVRGIK
)6;IOXI[OZHUGXJ;
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Part No. 52075 TMZ-34/19 5-7

Chart 2 REV B
Pump Motor 6XKYYGTJNURJG 8KVGOXUVKTOT]OXKLXUS
Will Not L[TIZOUTKTGHRKH[ZZUT
GTJINKIQ\URZGMKUT
<
ZKXSOTGR
ZKXSOTGR
GZ;ZU
GZ
Operate ZKXSOTGR GZZNKSUZUX
IUTZXURRKX;
IUTTKIZUX0UTZNK]OXK
NGXTKYYIUTTKIZUX
HUGXJ;58XKVRGIK
Be sure the batteries ZNKQK_VGJIOXI[OZHUGXJ
are properly connected. ;58XKVRGIKZNK
)6;IOXI[OZHUGXJ;
58XKVRGIK;58
Be sure the batteries
< IUTY[RZ-KTOK/TJ[YZXOKY
are fully charged. 9KX\OIK*KVGXZSKTZ
6XKYYGTJNURJZNKNOMN 8KVGOXUVKTOT]OXKLXUS
YVKKJL[TIZOUTKTGHRK ZKXSOTGR GZ;ZU
H[ZZUTGTJVXKYYZNK ZKXSOTGR GZ
VXOSGX_HUUS[VH[ZZUT < IUTTKIZUX0UTZNK]OXK
)NKIQ\URZGMKGZ NGXTKYYIUTTKIZUX
ZKXSOTGR GZ;:NK HUGXJ;58XKVRGIK
\URZGMKYNU[RJXGSV ZNKQK_VGJIOXI[OZHUGXJ
LXUSZU\URZY ;58XKVRGIKZNK
)6;IOXI[OZHUGXJ;
58XKVRGIK;58
9KX\OIK*KVGXZSKTZ
<
RKYY
)NKIQ\URZGMKGZZNK 8KVGOXUVKTOT<
ZNGT<
VUYOZO\KZKXSOTGRUTZNK VU]KXY[VVR_IGHRKLXUS
V[SVSUZUX3 HGZZKXOKYZU(ZKXSOTGR
GZ;ZUVUYOZO\K
ZKXSOTGRGZ3
<
<
)NKIQIUTJOZOUTUL 6XKYYGTJNURJZNKNOMN 8KVRGIK;
MUUJ
MXU[TJIGHRKLXUS3ZU YVKKJL[TIZOUTKTGHRK
ZNK3ZKXSOTGRGZ; H[ZZUTGTJVXKYYZNK
VXOSGX_HUUS[VH[ZZUT
)NKIQ\URZGMKGZ3
HGJ
ZKXSOTGRGZ;
8KVRGIKMXU[TJIGHRK RKYYZNGT
LXUS3ZU;58XKVGOX <
UVKTOTMXU[TJIGHRK
LXUSHGZZKXOKY(ZU; 8KVRGIK3
5-8 TMZ-34/19 Part No. 52075

REV B
Chart 3
All Functions 8KSU\KZNKXKYKX\UOX
HGJ
8KVRGIKSUZUXUXV[SV
Inoperative, LXUSZNKVU]KX[TOZ
ZNKTXKSU\KZNKV[SV
Power Unit LXUSZNKV[SVSUZUX
9KK8KVGOX9KIZOUT
Starts and Runs )NKIQZNKIUTTKIZOUT
HKZ]KKTZNKV[SV
Be sure that the manual SUZUXGTJZNKV[SVH_
\OY[GRR_OTYVKIZOTMZNK
override knob on the IU[VROTMUXQK_LUXG
proportional valve on VUYOZO\KIUTTKIZOUT
the power unit is turned

counterclockwise in the MUUJ
closed position. HGJ

:KYZZNKV[SV9KK 8KVRGIKZNKV[SV
8KVGOX9KIZOUT
Be sure the hydraulic
tank is full.
MUUJ
8KGJP[YZZNKVXKYY[XK
XKROKL\GR\KOZKS,58
9KX\OIK*KVGXZSKTZ
Part No. 52075 TMZ-34/19 5-9

Chart 4 REV B
Ground :[XTQK_Y]OZINZU )NKIQ\URZGMKGZ 8KVGOXUVKTOT]NOZK
Controls MXU[TJIUTZXURGTJV[RR
U[ZZNK+SKXMKTI_9ZUV
< ZKXSOTGR ULIUTTKIZUX
0GZZNK]OXKNGXTKYY
< ]OXKLXUSZKXSOTGR(GZ
SUZUXIUTZXURRKX;ZU
Inoperative H[ZZUTYZUZNKUTVUYOZUT
GZHUZNZNKMXU[TJGTJ
IUTTKIZUXHUGXJ; ZKXSOTGR
0GZ;
ULIUTTKIZUX
VRGZLUXSIUTZXURY)NKIQ
Be sure the key \URZGMKUTZNKOTV[ZYOJK
<
switch is turned to ULZNKMXU[TJIUTZXURY
IUTZGIZGZQK_Y]OZIN 8KVGOXUVKTOT]OXKLXUS
ground control. 19 ZKXSOTGR ULIUTTKIZUX
0ZUOTV[ZYOJKUL19
58XKVRGIK;
<
)NKIQ\URZGMKGZU[ZV[Z < )NKIQOLQK_Y]OZIN 8KVRGIKQK_Y]OZIN

_KY
YOJKULIUTZGIZGZ19 OTZKXTGRIGSOYGIZO\GZOTM IUTZGIZLUXMXU[TJ
MXU[TJIUTZXURIUTZGIZ IUTZXURY
TU
<
8KVRGIK19
)NKIQ\URZGMKGZ 8KVGOXUVKTOT]OXKLXUS
ZKXSOTGR ULIUTTKIZUX < 19ZUZKXSOTGR UL
0GZZNK]OXKNGXTKYY IUTTKIZUX0GZ;
IUTTKIZUXIOXI[OZHUGXJ
;
<
)NKIQZUYKKOLGRRXOHHUT ;TVR[MZNKXOHHUT
IGHRKYGXKVXUVKXR_ HGJ IGHRKYGTJXKIUTTKIZ
IUTTKIZKJZUZNKIOXI[OZ ZNKSZUZNKIOXI[OZHUGXJ
HUGXJY SGQOTMY[XKZNGZZNK_
GXKIUTTKIZKJYZXGOMNZ
GTJHKMOT
MUUJ
ZXU[HRKYNUUZOTMLXUSZNK
HKMOTTOTMULZNKINGXZ
8KVRGIKZNKMXU[TJ
IUTZXURQK_VGJIOXI[OZ
HUGXJ;58XKVRGIK
ZNK)6;IOXI[OZHUGXJ
;58XKVRGIK;
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 10 TMZ-34/19 Part No. 52075

REV B
Chart 5
Platform :[XTQK_Y]OZINZU )NKIQ\URZGMKGZZNK 8KVGOXUVKTOT]NOZK
Controls VRGZLUXSIUTZXURGTJV[RR
U[ZZNK+SKXMKTI_9ZUV
<
]OXKUTZKXSOTGR UL
IUTTKIZUX0GZZNK]OXK
<
]OXKLXUS(ZKXSOTGRUL
SUZUXIUTZXURRKX;ZU
Inoperative H[ZZUTZUZNKUTVUYOZUT
GZHUZNZNKMXU[TJGTJ
NGXTKYYIUTTKIZUX
HUGXJ;
ZKXSOTGR
0GZ;
ULIUTTKIZUX
VRGZLUXSIUTZXURY)NKIQ
Be sure all \URZGMKUTZNKOTV[ZYOJK
<
cables from ULZNKVRGZLUXSIUTZXURY
IUTZGIZGZZNKQK_Y]OZIN
turntable through 19 8KVGOXUVKTOT]OXKLXUS
the boom linkage ZKXSOTGR ULIUTTKIZUX
are in good 0ZUOTV[ZYOJKUL19
58XKVRGIK;
condition with no <
kinks or abrasions.
Be sure the key

)NKIQ\URZGMKGZU[ZV[Z < )NKIQOLQK_Y]OZIN 8KVRGIKQK_Y]OZIN
switch is turned to YOJKULIUTZGIZGZ19 OTZKXTGRIGSOYGIZO\GZOTM
_KY
IUTZGIZLUXVRGZLUXS
platform control. VRGZLUXSIUTZXURIUTZGIZ IUTZXURY
TU
<
8KVRGIK19
)NKIQ\URZGMKGZZNK 8KVGOXUVKTOT]OXKLXUS
<
]OXKUTZKXSOTGR UL 19ZUZKXSOTGR UL
IUTTKIZUX0GZZNK]OXK IUTTKIZUX0GZ;
NGXTKYYIUTTKIZUX
IOXI[OZHUGXJ;
<
)NKIQZUYKKOLGRRXOHHUT ;TVR[MZNKXOHHUT
IGHRKYGXKVXUVKXR_ IGHRKYGTJXKIUTTKIZ
HGJ
IUTTKIZKJZUZNKIOXI[OZ ZNKSZUZNKIOXI[OZHUGXJ
HUGXJYGZZNKMXU[TJ SGQOTMY[XKZNGZZNK_
GTJVRGZLUXSIUTZXURY GXKIUTTKIZKJYZXGOMNZ
GTJHKMOT
ZXU[HRKYNUUZOTMLXUSZNK
MUUJ
HKMOTTOTMULZNKINGXZ
8KVRGIKZNKVRGZLUXS
IUTZXURYQK_VGJIOXI[OZ
HUGXJ;58XKVRGIK
ZNK)6;IOXI[OZHUGXJ
;58XKVRGIK;
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Part No. 52075 TMZ-34/19 5 - 11

Chart 6 REV B
Jib Boom Up =OZNQK_Y]OZINZ[XTKJ 6XKYYGTJNURJG 8KVGOXUVKTOT]NZGTJ
Function ZUMXU[TJIUTZXURGTJ
ZNK+SKXMKTI_9ZUV
L[TIZOUTKTGHRKH[ZZUT
GTJZNKPOHHUUS[V
HRQ]OXKYLXUSZKXSOTGRY
GTJ ULIUTTKIZUX
<
Inoperative H[ZZUTV[RRKJU[ZZUZNK
UTGZHUZNMXU[TJGTJ
H[ZZUTUTZNKMXU[TJ
VGTKROTZNK[VJOXKIZOUT
0GZ;ZUZNKPOH
HUUSROLZI_ROTJKX
VRGZLUXSIUTZXURYVXKYY < GTJINKIQ\URZGMK YURKTUOJ\GR\KIUOR

Be sure all other GTJNURJGL[TIZOUT GIXUYYZNK]NZGTJHRQ OZKS'
functions operate KTGHRKH[ZZUTGTJZNKPOH ]OXKYGZZKXSOTGRY
HUUS[VH[ZZUTUTZNK GTJ ULIUTTKIZUX0

normally. MXU[TJVGTKROTZNK[V UTZNK]OXKNGXTKYY
JOXKIZOUTGTJINKIQ IUTTKIZUXIOXI[OZHUGXJ
\URZGMKGIXUYYZNK]OXKY ;
GZZNKPOHHUUSI_ROTJKX
YURKTUOJ\GR\KIUOR
<
OZKS'
8KVRGIKZNKMXU[TJ
HUGXJ58XKVRGIKZNK
)6;IOXI[OZHUGXJ;
58XKVRGIK;58
<
9KX\OIK*KVGXZSKTZ
UX
*OYIUTTKIZZNK]OXKYZU
OTLOTOZK
ZNKPOHHUUSROLZI_ROTJKX 8KVRGIKZNKPOHHUUSROLZ
UNSY
YURKTUOJ\GR\KIUORGTJ I_ROTJKXYURKTUOJ\GR\K
ZKYZZNKXKYOYZGTIKULZNK IUOROZKS'
\GR\KIUOR9KK8KVGOX
9KIZOUT
ZU
UNSY
)NKIQLUXSKINGTOIGR
XKYZXOIZOUTYQKKVOTMPOH
HUUS[VL[TIZOUTLXUS
UVKXGZOTM58XKVGOXUX
XKVRGIKZNKI_ROTJKX58
XKVGOXUXXKVRGIKZNK
YURKTUOJ\GR\KIGXZXOJMK
OZKS'UTZNKI_ROTJKX
5 - 12 TMZ-34/19 Part No. 52075

REV B
Chart 7
Jib Boom Down =OZNQK_Y]OZINZ[XTKJ 6XKYYGTJNURJG 8KVRGIKZNKMXU[TJ
Function ZUMXU[TJIUTZXURGTJ
ZNK+SKXMKTI_9ZUV
GTJZNKPOHHUUSJU]T
HUGXJ;58XKVRGIK
UTVUYOZOUTGZHUZN
H[ZZUTUTZNKMXU[TJ
VGTKROTZNKJU]T
< ZNK)6;IOXI[OZHUGXJ
;58XKVRGIK;
MXU[TJGTJVRGZLUXS < JOXKIZOUTGTJINKIQ 58IUTY[RZ-KTOK

Be sure all other IUTZXURYVXKYYGTJNURJ \URZGMKGIXUYYZNK]NZ /TJ[YZXOKY9KX\OIK
functions operate GL[TIZOUTKTGHRKH[ZZUT GTJHRQ]OXKYGZ *KVGXZSKTZ
GTJZNKPOHHUUSJU]T ZKXSOTGRY GTJ UL

normally. H[ZZUTUTZNKMXU[TJ IUTTKIZUX0UTZNK]OXK
VGTKROTZNKJU]T NGXTKYYIUTTKIZUX
JOXKIZOUTGTJINKIQ IOXI[OZHUGXJ;
\URZGMKGIXUYYZNK]OXKY
GZZNKPOHHUUSI_ROTJKX
<
YURKTUOJ\GR\KIUOR
OZKS'
8KVGOXUVKTOT]NZGTJ
GTJ ULIUTTKIZUX
0GZ;ZUZNKPOH
HUUSROLZI_ROTJKX
YURKTUOJ\GR\KIUOR
<
OZKS'
*OYIUTTKIZZNK]OXKYZU UX
ZNKPOHHUUSROLZI_ROTJKX OTLOTOZK
8KVRGIKZNKPOHHUUSROLZ
YURKTUOJ\GR\KIUORGTJ UNSY
I_ROTJKXYURKTUOJ\GR\K
ZKYZZNKXKYOYZGTIKULZNK
IUOROZKS'
\GR\KIUOR9KK8KVGOX
9KIZOUT
ZU
UNSY
6XKYYGTJNURJG *OYIUTTKIZZNK]OXKYZU )NKIQLUXSKINGTOIGR

ZU
L[TIZOUTKTGHRKH[ZZUT ZNKVXUVUXZOUTGRYURKTUOJ XKYZXOIZOUTYQKKVOTMPOH
< UNSY
GTJZNKPOHHUUSJU]T \GR\KIUORGTJZKYZZNK HUUSJU]TL[TIZOUT
H[ZZUTUTZNKMXU[TJ XKYOYZGTIKULZNK\GR\K LXUSUVKXGZOTM58
VGTKROTZNKJU]T IUOR9KK8KVGOX9KIZOUT XKVGOXUXXKVRGIKZNK
JOXKIZOUTGTJINKIQ I_ROTJKX58XKVGOXUX
\URZGMKGIXUYYZNK]NZ UXOTLOTOZK XKVRGIKZNKYURKTUOJ
GTJHRQ]OXKYGZZNK UNSY \GR\KIGXZXOJMKOZKS'
VXUVUXZOUTGRYURKTUOJ UTZNKI_ROTJKX58
\GR\KOZKS+UTZNK 8KVRGIKZNKVXUVUXZOUTGR XKVRGIKZNKVXUVUXZOUTGR
N_JXG[ROIVU]KX[TOZ YURKTUOJ\GR\KIUOR \GR\KIGXZXOJMKOZKS+
OZKS+ UTZNKN_JXG[ROIVU]KX
[TOZ
<
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52075 TMZ-34/19 5 - 13

CHART 7 REV B
6XKYYGTJNURJG 8KVGOXUVKTOT]NZGTJ
)UTZOT[KJLXUSZNK
L[TIZOUTKTGHRKH[ZZUT HRQ]OXKYLXUSZKXSOTGRY
VXK\OU[YVGMK
GTJZNKPOHHUUSJU]T < GTJ UL
H[ZZUTUTZNKMXU[TJ IUTTKIZUX0GZ;ZU
VGTKROTZNKJU]T ZNKVXUVUXZOUTGRYURKTUOJ
JOXKIZOUTGTJINKIQ \GR\KIUOROZKS,
\URZGMKGIXUYYZNK]NZ
GTJHRQ]OXKYGZ
ZKXSOTGRY GTJ
ULIUTTKIZUX0UTZNK
]OXKNGXTKYYIUTTKIZUX
IOXI[OZHUGXJ;
<
8KVRGIKZNKQK_VGJ
IOXI[OZHUGXJ;58
XKVRGIKZNK)6;IOXI[OZ
HUGXJ;58XKVRGIK
;58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 14 TMZ-34/19 Part No. 52075

REV B
Chart 8
Primary Boom =OZNQK_Y]OZINZ[XTKJ 6XKYYGTJNURJG 8KVGOXUVKTOT]NZGTJ
Up Function ZUMXU[TJIUTZXURGTJ
ZNK+SKXMKTI_9ZUV
GTJZNKVXOSGX_HUUS
GTJ ULIUTTKIZUX
<
UTVUYOZOUTGZHUZN
[VH[ZZUTUTZNKMXU[TJ
VGTKROTZNK[VJOXKIZOUT
0GZ;ZUZNKVXOSGX_
HUUSROLZI_ROTJKX
MXU[TJGTJVRGZLUXS < GTJINKIQ\URZGMK YURKTUOJ\GR\KIUOR

Be sure all other IUTZXURYVXKYYGTJNURJ GIXUYYZNK]NZGTJHRQ OZKS(
functions operate GL[TIZOUTKTGHRKH[ZZUT ]OXKYGZZKXSOTGRY
GTJZNKVXOSGX_HUUS GTJ ULIUTTKIZUX0

normally. [VH[ZZUTUTZNKMXU[TJ UTZNK]OXKNGXTKYY
VGTKROTZNK[VJOXKIZOUT IUTTKIZUXIOXI[OZHUGXJ
GTJINKIQ\URZGMK ;
GIXUYYZNK]OXKYGZZNK
VXOSGX_HUUSI_ROTJKX
<
YURKTUOJ\GR\KIUOR
OZKS(
8KVRGIKZNKMXU[TJ
HUGXJ;58XKVRGIK
ZNK)6;IOXI[OZHUGXJ
;58XKVRGIK;
58IUTY[RZ-KTOK
<
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
*OYIUTTKIZZNK]OXKYZU )NKIQLUXSKINGTOIGR
ZNKVXOSGX_HUUSROLZ ZU XKYZXOIZOUTYQKKVOTM
I_ROTJKXYURKTUOJ\GR\K UNSY VXOSGX_HUUS[V
IUORGTJZKYZZNK L[TIZOUTLXUSUVKXGZOTM
XKYOYZGTIKULZNK\GR\K 58XKVGOXUXXKVRGIKZNK
IUOR9KK8KVGOX9KIZOUT I_ROTJKX58XKVGOXUX
XKVRGIKZNKYURKTUOJ
UXOTLOTOZK \GR\KIGXZXOJMKOZKS(
UNSY UTZNKI_ROTJKX
8KVRGIKZNKVXOSGX_
HUUSROLZI_ROTJKX
YURKTUOJ\GR\KIUOR
OZKS(
Part No. 52075 TMZ-34/19 5 - 15

Chart 9 REV B
Primary Boom =OZNQK_Y]OZINZ[XTKJ 6XKYYGTJNURJG 8KVRGIKZNKMXU[TJ
Down Function ZUMXU[TJIUTZXURGTJ
ZNK+SKXMKTI_9ZUV
GTJZNKVXOSGX_HUUS
HUGXJ;58XKVRGIK
UTVUYOZOUTGZHUZNZNK
JU]TH[ZZUTUTZNK
MXU[TJVGTKROTZNK
;58XKVRGIK;
MXU[TJGTJVRGZLUXS < JU]TJOXKIZOUTGTJ 58IUTY[RZ-KTOK

Be sure all other IUTZXURYVXKYYGTJNURJ INKIQ\URZGMKGIXUYY /TJ[YZXOKY9KX\OIK
functions operate GL[TIZOUTKTGHRKH[ZZUT ZNK]NZGTJHRQ]OXKYGZ *KVGXZSKTZ
GTJZNKVXOSGX_HUUS ZKXSOTGRY GTJ UL

normally. JU]TH[ZZUTUTZNK IUTTKIZUX0UTZNK]OXK
MXU[TJVGTKROTZNK NGXTKYYIUTTKIZUX
JU]TJOXKIZOUTGTJ IOXI[OZHUGXJ;
INKIQ\URZGMKGIXUYY
ZNK]OXKYGZZNKVXOSGX_
<
HUUSI_ROTJKXYURKTUOJ
\GR\KIUOROZKS(
8KVGOXUVKTOT]NZGTJ
GTJ ULIUTTKIZUX
0GZ;ZUZNKVXOSGX_
HUUSROLZI_ROTJKX
< YURKTUOJ\GR\KIUOR
OZKS(
ZNKVXOSGX_HUUSROLZ OTLOTOZK
8KVRGIKZNKVXOSGX_
I_ROTJKXYURKTUOJ\GR\K UNSY
HUUSROLZI_ROTJKX
IUORGTJZKYZZNK
YURKTUOJ\GR\KIUOR
XKYOYZGTIKULZNK\GR\K
OZKS(
IUOR9KK8KVGOX9KIZOUT
ZU
UNSY
)UTZOT[KJUTZNKTK^Z
VGMK
5 - 16 TMZ-34/19 Part No. 52075

REV B CHART 9

)UTZOT[KJLXUSZNK ZU
L[TIZOUTKTGHRKH[ZZUT ZNKVXUVUXZOUTGRYURKTUOJ XKYZXOIZOUTYQKKVOTM
VXK\OU[YVGMK < UNSY
GTJZNKVXOSGX_HUUS \GR\KIUORGTJZKYZZNK VXOSGX_HUUSJU]T
JU]TH[ZZUTUTZNK XKYOYZGTIKULZNK\GR\K L[TIZOUTLXUSUVKXGZOTM
MXU[TJVGTKROTZNK IUOR9KK8KVGOX9KIZOUT 58XKVGOXUXXKVRGIKZNK
JU]TJOXKIZOUTGTJ I_ROTJKX58XKVGOXUX
INKIQ\URZGMKGIXUYY UXOTLOTOZK XKVRGIKZNKYURKTUOJ
ZNK]NZGTJHRQ]OXKYGZ UNSY \GR\KIGXZXOJMKOZKS(
ZNKVXUVUXZOUTGRYURKTUOJ UTZNKI_ROTJKX58
[TOZ
<
GTJZNKVXOSGX_HUUS < GTJ UL
JU]TH[ZZUTUTZNK IUTTKIZUX0GZ;ZU
MXU[TJVGTKROTZNK ZNKVXUVUXZOUTGRYURKTUOJ
JU]TJOXKIZOUTGTJ \GR\KOZKS+
INKIQ\URZGMKGIXUYY
ZNK]NZGTJHRQ]OXKYGZ
ZKXSOTGRY GTJ
ULIUTTKIZUX0GZZNK
IOXI[OZHUGXJ;
<
8KVRGIKZNKQK_VGJ
IOXI[OZHUGXJ;58
HUGXJ;58XKVRGIK
;58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
Part No. 52075 TMZ-34/19 5 - 17

Chart 10 REV B
Secondary =OZNQK_Y]OZINZ[XTKJ 6XKYYGTJNURJG 8KVGOXUVKTOT]NZGTJ
Boom Up ZUMXU[TJIUTZXURGTJ
ZNK+SKXMKTI_9ZUV
GTJZNKYKIUTJGX_
GTJ ULIUTTKIZUX
<
Function H[ZZUTV[RRKJU[ZZUZNK
UTVUYOZOUTGZHUZNZNK
HUUS[VH[ZZUTUTZNK
MXU[TJVGTKROTZNK[V
0GZ;ZUZNK
YKIUTJGX_HUUSROLZ
Inoperative MXU[TJGTJVRGZLUXS
IUTZXURYVXKYYGTJNURJ
< JOXKIZOUTGTJINKIQ
\URZGMKGIXUYYZNK]NZ
IUOROZKS)
GL[TIZOUTKTGHRKH[ZZUT GTJHRQ]OXKYGZ
Be sure all other GTJZNKYKIUTJGX_ ZKXSOTGRY GTJ UL
functions operate HUUS[VH[ZZUTUTZNK IUTTKIZUX0GZZNK]OXK
MXU[TJVGTKROTZNK[V NGXTKYYIUTTKIZUX
normally.
GZZNKYKIUTJGX_HUUS
<
IUOROZKS)
8KVRGIKZNKMXU[TJ
HUGXJ;58XKVRGIK
ZNK)6;IOXI[OZHUGXJ
;58XKVRGIK;
58IUTY[RZ-KTOK
<
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
*OYIUTTKIZZNK]OXKYZU )NKIQLUXSKINGTOIGR
ZU
ZNKYKIUTJGX_HUUSROLZ XKYZXOIZOUTYQKKVOTM
UNSY
I_ROTJKXYURKTUOJ\GR\K YKIUTJGX_HUUS[V
IUORGTJZKYZZNK L[TIZOUTLXUSUVKXGZOTM
XKYOYZGTIKULZNK\GR\K 58XKVGOXUXXKVRGIKZNK
IUOR9KK8KVGOX9KIZOUT I_ROTJKX58XKVGOXUX
XKVRGIKZNKYURKTUOJ
UXOTLOTOZK \GR\KIGXZXOJMKOZKS)
UNSY UTZNKI_ROTJKX
8KVRGIKZNKYKIUTJGX_
HUUSROLZI_ROTJKX
YURKTUOJ\GR\KIUOR
OZKS)
5 - 18 TMZ-34/19 Part No. 52075

REV B
Chart 11
Secondary =OZNQK_Y]OZINZ[XTKJ 6XKYYGTJNURJG 8KVRGIKZNKMXU[TJ
Boom Down ZUMXU[TJIUTZXURGTJ
ZNK+SKXMKTI_9ZUV
GTJZNKYKIUTJGX_
HUGXJ;58XKVRGIK
Function H[ZZUTV[RRKJU[ZZUZNK
UTVUYOZOUTGZHUZNZNK
HUUSJU]TH[ZZUTUT
ZNKMXU[TJVGTKROTZNK
;58XKVRGIK;
< JU]TJOXKIZOUTGTJ
INKIQ\URZGMKGIXUYY
58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
GL[TIZOUTKTGHRKH[ZZUT ZNK]NZGTJHRQ]OXKYGZ *KVGXZSKTZ

Be sure all other GTJZNKYKIUTJGX_ ZKXSOTGRY GTJ UL
functions operate HUUSJU]TH[ZZUTUT IUTTKIZUX0GZZNK]OXK
ZNKMXU[TJVGTKROTZNK NGXTKYYIUTTKIZUX
normally.
JU]TJOXKIZOUTGTJ IOXI[OZHUGXJ;
INKIQ\URZGMKGIXUYY
ZNK]OXKYGZZNK
<
YKIUTJGX_HUUS
IUOROZKS) 8KVGOXUVKTOT]NZGTJ
GTJ ULIUTTKIZUX
0GZ;ZUZNK
YKIUTJGX_HUUSROLZ
<
IUOROZKS)
ZNKYKIUTJGX_HUUSROLZ OTLOTOZK
8KVRGIKZNKYKIUTJGX_
I_ROTJKXYURKTUOJ\GR\K UNSY
HUUSROLZI_ROTJKX
IUORGTJZKYZZNK
YURKTUOJ\GR\KIUOR
XKYOYZGTIKULZNK\GR\K
OZKS)
IUOR9KK8KVGOX9KIZOUT
ZU
UNSY
)UTZOT[KJUTZNKTK^Z
VGMK
Part No. 52075 TMZ-34/19 5 - 19

CHART 11 REV B

)UTZOT[KJLXUSZNK ZU
L[TIZOUTKTGHRKH[ZZUT ZNKVXUVUXZOUTGRYURKTUOJ XKYZXOIZOUTYQKKVOTM
VXK\OU[YVGMK < UNSY
GTJZNKYKIUTJGX_ \GR\KIUORGTJZKYZZNK YKIUTJGX_HUUSJU]T
HUUSJU]TH[ZZUTUT XKYOYZGTIKULZNK\GR\K L[TIZOUTLXUSUVKXGZOTM
ZNKMXU[TJVGTKROTZNK IUOR9KK8KVGOX9KIZOUT 58XKVGOXUXXKVRGIKZNK
JU]TJOXKIZOUTGTJ I_ROTJKX58XKVGOXUX
INKIQ\URZGMKGIXUYY UXOTLOTOZK XKVRGIKZNKYURKTUOJ
ZNK]NZGTJHRQ]OXKYGZ UNSY \GR\KIGXZXOJMKOZKS)
ZNKVXUVUXZOUTGRYURKTUOJ UTZNKI_ROTJKX58
[TOZ
<
GTJZNKYKIUTJGX_ < GTJ UL
HUUSJU]TH[ZZUTUT IUTTKIZUX0GZ;ZU
ZNKMXU[TJVGTKROTZNK ZNKVXUVUXZOUTGRYURKTUOJ
JU]TJOXKIZOUTGTJ \GR\KOZKS+
INKIQ\URZGMKGIXUYY
ZNK]NZGTJHRQ]OXKYGZ
ZKXSOTGRY GTJ
ULIUTTKIZUX0UTZNK
IOXI[OZHUGXJ;
<
8KVRGIKZNKQK_VGJ
IOXI[OZHUGXJ;58
HUGXJ;58XKVRGIK
;58IUTY[RZ-KTOK
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
5 - 20 TMZ-34/19 Part No. 52075

REV B
Chart 12
Turntable =OZNZNKQK_Y]OZIN 6XKYYGTJNURJG 8KVGOXUVKTOT]NZGTJ
Rotate Left Z[XTKJZUMXU[TJIUTZXUR
GTJZNK+SKXMKTI_
GTJZNKZ[XTZGHRKXUZGZK
GTJ UL
<
Function 9ZUVH[ZZUTV[RRKJU[ZZU
ZNKUTVUYOZOUTGZHUZN
RKLZH[ZZUTUTZNKMXU[TJ
VGTKROTZNKRKLZJOXKIZOUT
IUTTKIZUX0GZ;ZU
ZNKZ[XTZGHRKXUZGZKRKLZ
< GTJINKIQ\URZGMK
GIXUYYZNK]NZGTJHRQ
YURKTUOJ\GR\KIUOR
OZKS.
GL[TIZOUTKTGHRKH[ZZUT ]OXKYGZZKXSOTGRY
Be sure all other GTJZNKZ[XTZGHRKXUZGZK GTJ ULIUTTKIZUX0
functions operate RKLZH[ZZUTUTZNKMXU[TJ GZZNK]OXKNGXTKYY
VGTKROTZNKRKLZJOXKIZOUT IUTTKIZUXIOXI[OZHUGXJ
normally.
GTJINKIQ\URZGMK ;
GIXUYYZNK]OXKYGZZNK
Be sure the needle Z[XTZGHRKXUZGZKRKLZ
<
valve is not in the open YURKTUOJ\GR\KIUOR
position. OZKS.
8KVRGIKZNKMXU[TJ
HUGXJ;58XKVRGIK
ZNK)6;IOXI[OZHUGXJ
;58XKVRGIK;
58IUTY[RZ-KTOK
<
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
UX
OTLOTOZK
ZNKZ[XTZGHRKXUZGZKRKLZ 8KVRGIKZNKZ[XTZGHRK
UNSY
YURKTUOJ\GR\KIUORGTJ XUZGZKRKLZYURKTUOJ\GR\K
ZKYZZNKXKYOYZGTIKULZNK IUOR
\GR\KIUOR9KK8KVGOX
9KIZOUT
ZU
UNSY
)UTTKIZGZUVYO )NKIQLUXSKINGTOIGR
ZUHGXVXKYY[XK XKYZXOIZOUTYQKKVOTM
MG[MKZUZNKW[OIQ Z[XTZGHRKXUZGZKRKLZ
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
Part No. 52075 TMZ-34/19 5 - 21

Chart 13 REV B
Turntable =OZNZNKQK_Y]OZIN 6XKYYGTJNURJG 8KVGOXUVKTOT]NZGTJ
Rotate Right Z[XTKJZUMXU[TJIUTZXUR
GTJZNK+SKXMKTI_
GTJZNKZ[XTZGHRKXUZGZK
GTJ ULIUTTKIZUX
<
Function 9ZUVH[ZZUTV[RRKJU[ZZU
ZNKUTVUYOZOUTGZHUZN
XOMNZH[ZZUTUTZNK
MXU[TJVGTKROTZNKXOMNZ
0GZ;ZUZNK
Z[XTZGHRKXUZGZKXOMNZ
< JOXKIZOUTGTJINKIQ
\URZGMKGIXUYYZNK]NZ
YURKTUOJ\GR\KIUOR
OZKS.
GL[TIZOUTKTGHRKH[ZZUT GTJHRQ]OXKYGZ
Be sure all other GTJZNKZ[XTZGHRKXUZGZK ZKXSOTGRY GTJ UL
functions operate XOMNZH[ZZUTUTZNK IUTTKIZUX0GZZNK]OXK
MXU[TJVGTKROTZNKXOMNZ NGXTKYYIUTTKIZUX
normally.
GZZNKZ[XTZGHRKXUZGZK
<
RKLZYURKTUOJ\GR\KIUOR
OZKS.
8KVRGIKZNKMXU[TJ
HUGXJ;58XKVRGIK
ZNK)6;IOXI[OZHUGXJ
;58XKVRGIK;
58IUTY[RZ-KTOK
<
/TJ[YZXOKY9KX\OIK
*KVGXZSKTZ
UX
OTLOTOZK
ZNKZ[XTZGHRKXUZGZKXOMNZ 8KVRGIKZNKZ[XTZGHRK
UNSY
YURKTUOJ\GR\KIUORGTJ XUZGZKXOMNZYURKTUOJ
ZKYZZNKXKYOYZGTIKULZNK \GR\KIUOR
\GR\KIUOR9KK8KVGOX
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 Part No. 52075

REV A
Chart 14
Parking Brake 'JP[YZVGXQOTMHXGQK
SGINOTK
'JP[YZZNKHXGQKY58
Function 9KK8KVGOX9KIZOUT
'VVR_ZNKVGXQOTMHXGQK
SU\KY
XKVRGIKHXGQKYNUKY
9KKHXGQKSGT[LGIZ[XKY
Inoperative GTJGZZKSVZZUV[YNZNK
SGINOTK
SGT[GRLUXVXUIKJ[XKY
UTJOYGYYKSHROTMZNK
HXGQKY
Be sure that the parking SGINOTK
brake cables are JUKYTUZ
SU\K
properly connected and
are in good condition. :NKVGXQOTMHXGQKOY
UVKXGZOTMIUXXKIZR_
Part No. 52075 TMZ-34/19 5 - 23

5 - 24 TMZ-34/19 Part No. 52075

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
Observe and Obey: Electrocution hazard. Contact with

Troubleshooting and repair procedures shall be result in death or serious injury.
completed by a person trained and qualified on Remove all rings, watches and
the repair of this machine. other jewelry.
Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine.
Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
Read, understand and obey the safety rules gradually. Do not allow oil to squirt
and operating instructions in the appropriate or spray.
operator's manual on your machine. General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Malfunction Identify Troubleshoot
discovered symptoms
problem
still exists
Return to Inspect Perform

service problem and test repair
solved
Part No. 52075 TMZ-34/19 6-1

Section 6 • Schematics June 2005
Electrical Component and Wire Color Legends

REV B
ABBREVIATION LEGEND ABBREVIATION LEGEND

Item Description Item Description
B5 Four 6V batteries L Light or LED
BN Button L5 = Power (ground)
BN5 = Horn L12 = Left front outrigger
BN12 = Function enable high L13 = Right front outrigger
BN13 = Function enable low L14 = Left rear outrigger
BN26 = Function enable medium L15 = Right rear outrigger
BN27 = Jib boom up L18 = Emergency Stop (platform)
BN28 = Jib boom down L19 = Power (platform)
BN29 = Primary up L33 = Right rear tail light
BN30 = Primary down L34 = Left rear tail light
BN31 = Secondary up L35 = Right side marker
BN32 = Secondary down L36 = Left side marker
BN33 = Rotate left L45 = Emergency Stop (ground)
BN34 = Rotate right LS Limit switch
BN35 = Horn LS1 = Structure retract
BN36 = Jib boom up LS2 = Primary boom up
BN37 = Jib boom down LS11 = Jib boom down
BN38 = Primary up LS12 = Left front outrigger
BN39 = Primary down LS13 = Right front outrigger
BN40 = Secondary up LS14 = Left rear outrigger
BN41 = Secondary down LS15 = Right rear outrigger
BN42 = Rotate left LS17 = Negative boom angle
BN43 = Rotate right LS27 = Turntable
BN44 = Function enable high M5 Hydraulic power unit
BN45 = Function enable medium N.C. Normally closed
BN46 = Function enable low N.C.H.O. Normally closed held open
CB2 30A Circuit breaker, controls N.O. Normally open
D7 Voltage regulator N.O.H.C. Normally open held closed
EN Enclosure P Power switch
EN1 = Platform control box P1 = Emergency Stop button at ground controls
EN2 = Ground control box P2 = Emergency Stop button at platform controls
F Fuse QD Quick disconnect
F6 = 275A, Function QD1 = Primary battery disconnect
F10 = 5A, System power QD3 = Control cable at platform
FB Flashing beacons (option) QD4 = Control cable at ground
G Gauge QD12 = Trailer connector
G6 = Hour meter QD19 = Trailer harness connector
G7 = Battery charge indicator (option) S7 Level sensor
G8 = Diagnostic display SW Switch
H Horn or alarm SW13 = Left front outrigger
H1 = Horn SW14 = Right front outrigger
H5 = Multifunction alarm SW15 = Left rear outrigger
KS1 Key switch SW16 = Right rear outrigger
SW25 = DIP switch
TB Terminal base
U Electronic component
U3 = Platform controls circuit board
U6 = Motor controller
U9 = Battery charger
WIRE COLOR LEGEND U15 = Key pad circuit board
U21 = Connector circuit board
Color Description U22 = CPU/display circuit board
BK Black Y Valve coil
BL Blue Y9 = Proportional (function)
Y23 = Turntable rotate left
GN Green Y24 = Turntable rotate right
OR Orange Y39 = Outrigger up (retract)
RD Red Y41 = Outrigger regen
Y45 = Primary boom
WH White Y46 = Secondary boom
YL Yellow Y47 = Jib boom
Y48 = Outrigger level
6-2 TMZ-34/19 Part No. 52075

Limit Switch Legend

REV A
a b c
Limit Switch Legend
a secondary boom up limit switch LS4

b primary boom up limit switch LS2
c jib boom LS11
d structure retract limit switch LS1
(from serial number T3498-001 to T3499-769)
e outrigger deployed switch
• left front SW13, SW13A
• right front SW14, SW14A
• left rear SW15, SW15A
• right rear SW16, SW16A
e outrigger deployed switch
• left front SW13
• right front SW14
• left rear SW15
• right rear SW16
Part No. 52075 TMZ-34/19 6-3

Trailer Lighting Wiring Diagram

REV A
ANSI, CSA Models L35

RIGHT SIDE MARKER
BK GN
QD19
BN QUICK DISCONNECT
BN1
1 BN BN
7 7
WH WH
1
WH 2 WH WH
5 5
2 QD12
TRAILER BK
PLUG 2 2
3 BN2 3 BN L33
RIGHT REAR TAIL LIGHT
GN GN
4 4 6 6
5
6 L34
1 GN LEFT REAR TAIL LIGHT
YL YL
2 YL 7 1 1
3 BN1
WH
3 BN2
4 WH TB TERMINAL BASE
RD RD
3 3
BK BN
BK
BL BL
L36 4 4
LEFT SIDE MARKER GN
YL
CE Models L35
RIGHT SIDE MARKER
QD19
QUICK DISCONNECT
BN GN
BN
1 BN
5 5
WH WH
QD12
TRAILER PLUG WH 2 WH
3 3
BK
L33
BK 3 BN
7 7 RIGHT REAR TAIL LIGHT
GN GN
4 4 4
RD RD
5
1 BL BL 6 6 L34
6 LEFT REAR TAIL LIGHT
YL YL
6 2 7 2 2
7 TB TERMINAL BASE
1 1 YL
5 3
L36
LEFT SIDE MARKER
1 YL 4
2 BL 5 BN
3 WH 6 RD
4 GN 7 BK
6-4 TMZ-34/19 Part No. 52075

Electrical Symbols Legend

REV A
GROUND
LS2
M5
LS17 N.C.
PLATFORM N.O.H.C.
Emergency Stop button
normally closed Motor
Limit switch
KS1 KEY SWITCH
Key switch
M- B+
G6 8 7 6 5 4 3 2 1
A2 1
B- 3 DIP switch
Circuit connection Hour meter
Motor controller
24V DC 5V DC
Fuse
Horn or alarm Voltage regulator
Circuits crossing
no connection
24V
Circuit breaker
5V
Solenoid valve
LED
S7
LEVEL SENSOR
Level sensor
-
+
Button or switch
Battery
Part No. 52075 TMZ-34/19 6-5

Electrical Schematic
Models with Manual Outriggers REV B
EN2 EN1
GROUND CONTROL BOX PLATFORM CONTROL BOX
BN35 BN36 BN37 BN38 BN39 BN40 BN41 BN42 BN43 BN44 BN45 BN46 BN5 BN27 BN28 BN29 BN30 BN31 BN32
U3
24V DC 5V DC
U15 PLATFORM D7A

KEYPAD PC BOARD CONTROLS VOLTAGE
PRINTED REGULATOR
CIRCUIT
BOARD
G7
L5 L45 L12 L13 L14 L15 BN33 BN34 BN12 BN13 BN26
U15 J2 J2
KEYPAD PC BOARD
4 3 2 1 1 2
OR
BK
RD
34 PIN
F10 L18 L19
+
DUAL-ROW
P1 5A FUSE
RIBBON CABLE H1
EMERGENCY
STOP
- HORN
P2 EMERGENCY STOP
WH
GN
OR
24V DC 5V DC
RD
BK
U22
D7 CPU / DISPLAY BOARD
VOLTAGE REGULATOR QD3
J4 J3
BK 1 QD4
BK J1 10 PIN
RIBBON CABLE
34 PIN
DUAL-ROW
2 RIBBON CABLE
BASE BK 1
KS1 BK 2 J9
J2 J6 U21
7 1 2 3 6
KEY CONNECTOR PC BOARD

SWITCH BK 3
PLATFORM J7 J8 J5 J4
POWER OUT - LEFT OUT - RIGHT LIFT STRUCTURE
6 18 12 13 4 3 15 9 20 10 24 25 22 18 21 16 24 20 1 5 4 9 2 7 22 18 21 16 24 20 1 5 4 9 2 7 3 2 15 9 5 10 22 21 12 18 13 7
WH
WH
WH
BK
BK
BK
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
LS1
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
4 1 2 3
STRUCTURE RETRACT N.O.
N.O.H.C.
+
+
LEVEL SENSOR 24V+
PUMP ENABLE
PUMP SPEED
LEVEL SENSOR -
GROUND
+
X-AXIS (0-5V)
Y-AXIS (0-5V)
24V +
H5
RD
RD
RD
RD
HORN
S7
SW14A RIGHT FRONT SWITCH 2 N.O.
24V
SW16A RIGHT REAR SWITCH 2 N.O.

SW13A LEFT FRONT SWITCH 2 N.O.
SW14 RIGHT FRONT SWITCH 1 N.O.

SW15A LEFT REAR SWITCH 2 N.O.
SW16 RIGHT REAR SWITCH 1 N.O.

SW13 LEFT FRONT SWITCH 1 N.O.
LEVEL
LS1
SW15 LEFT REAR SWITCH 1 N.O.
SENSOR
5V
Y9 PROPORTIONAL VALVE
Y46 SECONDARY BOOM
L13 RIGHT FRONT LAMP
L12 LEFT FRONT LAMP
L15 RIGHT REAR LAMP

L14 LEFT REAR LAMP
Y45 PRIMARY BOOM
Y24 ROTATE RIGHT
QD1 (+)
Y23 ROTATE LEFT
Y47 JIB BOOM
F6 D1
U9 275A
B5 BATTERY FUSE M5
FOUR 6V CHARGER
BATTERIES M5
- MOTOR A1
T2
+
M- B+
24V+
-
1
- NOTE -
0-5V
+
B- 3 MACHINE SHOWN
- IN THE STOWED
AC INPUT U6 POSITION WITH
+
MOTOR
- CONTROLLER THE POWER OFF
+
QD1 (-) ES0061C
6-6 TMZ-34/19 Part No. 52075

REV A Models with Manual Outriggers
EN2 EN1
GROUND CONTROL BOX PLATFORM CONTROL BOX
BN35 BN36 BN37 BN38 BN39 BN40 BN41 BN42 BN43 BN44 BN45 BN46 BN5 BN27 BN28 BN29 BN30 BN31 BN32
U3
24V DC 5V DC
U15 PLATFORM D7A

KEYPAD PC BOARD CONTROLS VOLTAGE
PRINTED REGULATOR
CIRCUIT
BOARD
G7
L5 L45 L12 L13 L14 L15 BN33 BN34 BN12 BN13 BN26
U15 J2 J2
KEYPAD PC BOARD
4 3 2 1 1 2
OR
BK
RD
34 PIN
F10 L18 L19
+
DUAL-ROW
P1 5A FUSE
RIBBON CABLE H1
EMERGENCY
STOP
- HORN
P2 EMERGENCY STOP
WH
GN
OR
24V DC 5V DC
RD
BK
U22
KS1 VOLTAGE REGULATOR QD3
KEY SWITCH
J4 J3
BK 1 QD4
GROUND BK J1 10 PIN
RIBBON CABLE
34 PIN
DUAL-ROW
2 RIBBON CABLE
BK 1 7 1 2 3 6
BK J2 J6 U21
2 J9
BK CONNECTOR PC BOARD
3
PLATFORM J7 J8 J5 J4
POWER OUT - LEFT OUT - RIGHT LIFT STRUCTURE
6 18 12 13 4 3 15 9 20 10 24 25 22 18 21 16 24 20 1 5 4 9 2 7 22 18 21 16 24 20 1 5 4 9 2 7 3 2 15 9 5 10 22 21 12 18 13 7
WH
WH
WH
BK
BK
BK
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
WH
LS1
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
4 1 2 3
STRUCTURE RETRACT N.O.
N.O.H.C.
+
+
LEVEL SENSOR 24V+
PUMP ENABLE
PUMP SPEED
LEVEL SENSOR -
GROUND
+
X-AXIS (0-5V)
Y-AXIS (0-5V)
24V +
H5
RD
RD
RD
RD
HORN
S7
SW14A RIGHT FRONT SWITCH 2 N.O.
24V
SW16A RIGHT REAR SWITCH 2 N.O.

SW13A LEFT FRONT SWITCH 2 N.O.
SW14 RIGHT FRONT SWITCH 1 N.O.

SW15A LEFT REAR SWITCH 2 N.O.
SW16 RIGHT REAR SWITCH 1 N.O.

SW13 LEFT FRONT SWITCH 1 N.O.
LEVEL
LS1
SW15 LEFT REAR SWITCH 1 N.O.
SENSOR
5V
Y9 PROPORTIONAL VALVE
Y46 SECONDARY BOOM
L13 RIGHT FRONT LAMP
L12 LEFT FRONT LAMP
L15 RIGHT REAR LAMP

L14 LEFT REAR LAMP
Y45 PRIMARY BOOM
Y24 ROTATE RIGHT
QD1 (+)
Y23 ROTATE LEFT
Y47 JIB BOOM
F6 D1
U9 275A
B5 BATTERY FUSE M5
FOUR 6V CHARGER
BATTERIES M5
- MOTOR A1
T2
+
M- B+
24V+
-
1
- NOTE -
0-5V
+
B- 3 MACHINE SHOWN
- IN THE STOWED
AC INPUT U6 POSITION WITH
+
MOTOR
- CONTROLLER THE POWER OFF
+
ES0061D QD1 (-)
Part No. 52075 TMZ-34/19 6-7

Models with Manual Outriggers REV B
(from serial number T3400-001)
G8 AVAILABLE
AFTER
SERIAL NUMBER
T3402-115
GROUND CONTROLS MEMBRANE DECAL PANEL
PRIMARY UP BN38
HORN BN35 BN42 ROTATE LEFT G8

DIAGNOSTIC
DISPLAY
+
FUNCTION ENABLE LOW BN46 BN40 SECONDARY UP
BN41 SECONDARY DOWN

H5
16
15
14
13
12
10
HORN
8
7
6
5
L12 L13 L14 L15

16 PIN
OR
RD
BN
BK
RIBBON CABLE
GROUND
4 3 1 2 3 4 5 6
EN2 1
SW25 J4
GROUND 24V DC 5V DC 8 7 6 54 3 2 1 DIP SWITCH
2
CONTROL 3 4
4 J7 U22
BOX
PLATFORM SW25A
3
8 7 6 54 3 2 1 DIP SWITCH
J8
KS1 KEY SWITCH 2 1
VOLTAGE REGULATOR
J6 J9 J2 J3
7 PIN 11 PIN 26 PIN 40 PIN
JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE
BK
RD
P1 EMERGENCY STOP G7
J2 J1 J3 J4 1 2
BK
P5 U21 J8
RD
P4 P1 CONNECTOR PC BOARD P3
CB2 30A ENGINE OUTRIGGER 19
23
17
21
16
20
30
33
14
18
29
32
24
22
27
25
10
15
17
27
CIRCUIT BREAKER
4
3
8
6
1
LS17 LS11 SW16 SW14

PUMP ENABLE
PUMP SPEED
N.O.H.C. N.O.H.C.
N.O. N.O.
LS2
24V +
N.O.H.C.
1 SW15 SW13
N.O. N.O.
2
G6 LS27
N.C. RIGHT FRONT OUTRIGGER LED +
RIGHT FRONT OUTRIGGER LED -
SW14 RIGHT FRONT OUTRIGGER COM
3
FLASHING BEACONS + (OPTION)
RIGHT REAR OUTRIGGER LED +
RIGHT FRONT OUTRIGGER N.O.

LEFT FRONT OUTRIGGER LED +
RIGHT REAR OUTRIGGER LED -
LEFT FRONT OUTRIGGER LED -
SW13 LEFT FRONT OUTRIGGER COM

SW16 RIGHT REAR OUTRIGGER COM
LEFT FRONT OUTRIGGER N.O.

LEFT REAR OUTRIGGER LED +
RIGHT REAR OUTRIGGER N.O.

LEFT REAR OUTRIGGER LED -
NEGATIVE BOOM ANGLE COM
SW15 LEFT REAR OUTRIGGER COM

LS17 NEGATIVE BOOM ANGLE N.O.
LEFT REAR OUTRIGGER N.O.

LS2 PRIMARY BOOM UP N.O.H.C.
LIMIT SWITCH CIRCUIT COM
QD1 (+)
FLASHING BEACONS -
F6
LS11 JIB BOOM N.O.H.C.
D1
LS27 TURNTABLE N.C.
U9 275A
B5 BATTERY
FUSE M5
FOUR 6V CHARGER
BATTERIES M5
- MOTOR A1
T2
+
M- B+
L14
L15
L12
L13
-
FB
1
24V+
+
-
B- 3
0-5V - NOTE -
AC INPUT U6 MACHINE SHOWN
+
MOTOR
- CONTROLLER IN THE STOWED
POSITION WITH
THE POWER OFF
+
QD1 (-)
ES0209D
ES0209F
6-8 TMZ-34/19 Part No. 52075

REV B Models with Manual Outriggers
(from serial number T3400-001)
U3 3 PLATFORM CONTROLS
PLATFORM 4 MEMBRANE DECAL PANEL
CONTROLS 5
RIBBON CABLE
PRINTED
6
CIRCUIT
7
14 PIN
BOARD
8 BN29 PRIMARY UP
10
J4 BN30 PRIMARY DOWN
11
13
24V DC 5V DC
D7A BN27 JIB UP
VOLTAGE
REGULATOR
BN28 JIB DOWN
L46 BN34 ROTATE RIGHT

J2 J3
4 3 2 1 1 2 BN33 ROTATE LEFT
BN5 HORN
BK
RD

+
H2
DATA +
DATA -
- BN26 FUNCTION ENABLE MEDIUM

24V +
HORN
GND
P2
EMERGENCY
STOP
EN1 PLATFORM CONTROL BOX

WH
OR
GN
RD
BK
BL
QD3
7 1 3 5 9 8
QD4
EN2
GROUND CONTROL
BOX
J5 1 2 3 6 4 5
P2
LIFT / DRIVE
U21
CONNECTOR PC BOARD
31
21
35
33
32
34
10
14
22
30
23
13
8
4 1 2 3
+
LEVEL SENSOR 24V+

LEVEL SENSOR -
+
X-AXIS
Y-AXIS
24V
PROPORTIONAL VALVE
SECONDARY BOOM
5V
PRIMARY BOOM
ROTATE RIGHT
ROTATE LEFT
JIB BOOM
S7
LEVEL SENSOR
Y45
Y46
Y47
Y23
Y24
Y9
- NOTE -
MACHINE SHOWN
IN THE STOWED
POSITION WITH
ES0209D THE POWER OFF
ES0209F
Part No. 52075 TMZ-34/19 6-9

Models with Hydraulic Outriggers REV B
GROUND CONTROLS MEMBRANE DECAL PANEL
G8 AVAILABLE
AFTER
SERIAL NUMBER
SECONDARY DOWN BN41 BN49 OUTRIGGER AUTO LEVEL T3402-115
LEFT FRONT OUTRIGGER BN52 BN47 OUTRIGGER EXTEND
PRIMARY UP BN38 BN48 OUTRIGGER RETRACT
RIGHT FRONT OUTRIGGER BN53 BN42 ROTATE LEFT
HORN BN35 BN50 LEFT REAR OUTRIGGER G8

DIAGNOSTIC
DISPLAY
+
FUNCTION ENABLE LOW BN46 BN51 RIGHT REAR OUTRIGGER
BN40 SECONDARY UP
H5
16
15
14
13
12
10
11
HORN
8
7
6
5
2
1
L12 L13 L14 L15

16 PIN
OR
RD
BN
BK
RIBBON CABLE
GROUND
4 3 1 2 3 4 5 6
EN2 1
SW25 J4
GROUND 24V DC 5V DC 8 7 6 54 3 2 1 DIP SWITCH
2
CONTROL 3 4
4 J7 U22
BOX
PLATFORM SW25A
3
8 7 6 54 3 2 1 DIP SWITCH
J8
KS1 KEY SWITCH 2 1
VOLTAGE REGULATOR
J6 J9 J2 J3
7 PIN 11 PIN 26 PIN 40 PIN
JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE
BK
RD
P1 EMERGENCY STOP G7
J2 J1 J3 J4 1 2
BK
P5 U21 J8
RD
P4 P1 CONNECTOR PC BOARD P3
CB2 30A ENGINE OUTRIGGER
24
22
25
27
10
20
19
18
17
15
16
33
23
14
32
21
30
29
17
27
CIRCUIT BREAKER
1
3
8
6
LS17 LS11 LS15 LS13
PUMP ENABLE
N.C.H.O. N.C.H.O.
PUMP SPEED
N.O.H.C. N.O.H.C.
LS2 LS14 LS12

24V +
N.O.H.C. N.C.H.O. N.C.H.O.

+
+
1
2
G6 LS27
N.C. RIGHT FRONT OUTRIGGER COIL +
RIGHT FRONT OUTRIGGER COIL -
RIGHT REAR OUTRIGGER COIL +
LEFT FRONT OUTRIGGER COIL +
3
FLASHING BEACONS + (OPTION)
LS13 RIGHT FRONT OUTRIGGER COM

RIGHT REAR OUTRIGGER COIL -
LEFT FRONT OUTRIGGER COIL -
RIGHT FRONT OUTRIGGER N.C.

LEFT REAR OUTRIGGER COIL +
LS15 RIGHT REAR OUTRIGGER COM
LEFT FRONT OUTRIGGER COM

LEFT REAR OUTRIGGER COIL -
RIGHT REAR OUTRIGGER N.C.
LS12 LEFT FRONT OUTRIGGER N.C.

NEGATIVE BOOM ANGLE COM
LEFT REAR OUTRIGGER COM

LS17 NEGATIVE BOOM ANGLE N.O.
LS14 LEFT REAR OUTRIGGER N.C.

LS2 PRIMARY BOOM UP N.O.H.C.
LIMIT SWITCH CIRCUIT COM
QD1 (+)
FLASHING BEACONS -
F6
LS11 JIB BOOM N.O.H.C.
D1
LS27 TURNTABLE N.C.
U9 275A
B5 BATTERY
FUSE M5
FOUR 6V CHARGER
BATTERIES M5
- MOTOR A1
T2
+
M- B+
Y33
Y34
Y35
Y36
-
FB
1
24V+
+
-
B- 3
0-5V - NOTE -
AC INPUT U6 MACHINE SHOWN
+
MOTOR
- CONTROLLER IN THE STOWED
POSITION WITH
THE POWER OFF
+
QD1 (-)
ES0210D
ES0210E
6 - 10 TMZ-34/19 Part No. 52075

REV B Models with Hydraulic Outriggers
U3 3 PLATFORM CONTROLS
PLATFORM 4 MEMBRANE DECAL PANEL
CONTROLS 5
RIBBON CABLE
PRINTED
6
CIRCUIT
7
14 PIN
BOARD
8 BN29 PRIMARY UP
10
J4 BN30 PRIMARY DOWN
11
13
24V DC 5V DC
D7A BN27 JIB UP
VOLTAGE
REGULATOR
BN28 JIB DOWN
L46 BN34 ROTATE RIGHT

J2 J3
4 3 2 1 1 2 BN33 ROTATE LEFT
BN5 HORN
BK
RD

+
H2
DATA +
DATA -
- BN26 FUNCTION ENABLE MEDIUM

24V +
HORN
GND
P2
EMERGENCY
STOP
EN1 PLATFORM CONTROL BOX

WH
OR
GN
RD
BK
BL
QD3
7 1 3 5 9 8
QD4
EN2
GROUND CONTROL
BOX
J5 1 2 3 6 4 5
P2
LIFT / DRIVE
U21
CONNECTOR PC BOARD
31
21
35
33
32
21
34
10
14
22
30
23
13
8
2
3
4
5
4 1 2 3
+
+
LEVEL SENSOR 24V+
LEVEL SENSOR -
+
+
X-AXIS
Y-AXIS
OUTRIGGER LEVEL (EXTEND) COIL

OUTRIGGER UP (RETRACT) COIL
24V
OUTRIGGER REGEN COIL

PROPORTIONAL VALVE
ROTATE RIGHT COIL

SECONDARY BOOM
5V
GROUP A GROUND
ROTATE LEFT COIL

PRIMARY BOOM
ROTATE RIGHT
ROTATE LEFT
JIB BOOM
S7
LEVEL SENSOR
Y39
Y48
Y41
Y24
Y23
Y45
Y46
Y47
Y23
Y24
Y9
- NOTE -
MACHINE SHOWN
IN THE STOWED
POSITION WITH
ES0210D THE POWER OFF
ES0210E
Part No. 52075 TMZ-34/19 6 - 11

6 - 12 TMZ-34/19 Part No. 52075

Hydraulic Symbols Legend and

REV A Component Reference
Y41
Filter Bi-directional motor Dual acting cylinder Solenoid operated

2 position 3 way
directional valve
Y9
Check valve Shut off valve Single acting cylinder Proportional valve
Y24 Y23
M
Y45
Motor Relief valve Solenoid operated Solenoid operated

2 position 2 way 3 position 4 way
directional valve directional valve
0.037 in
9.4 mm
4000 psi 2000 psi

275.8 bar 137.9 bar
Fixed displacement pump Orifice with size 3:1 3:1
Counterbalance valve
D
Hydraulic power unit

Y9 components
Y23
Y24
F
I
K Y41
Turntable manifold
components
Y39
L Y48 Outrigger manifold

components
Part No. 52075 TMZ-34/19 6 - 13

Hydraulic Schematic
Models with Manual Outriggers REV A
PRIMARY SECONDARY JIB

BOOM BOOM BOOM
LIFT LIFT LIFT
CYLINDER CYLINDER CYLINDER
B C A
Y45 Y46 Y47
0.037 in 0.037 in 0.037 in

9.4 mm 9.4 mm 9.4 mm
P D TEST T
E Y9 A B
3 gpm 1200 psi

11.3 L/min 82.7 bar
F I
3200 psi T
G 220.6 bar
35 psi
2.4 bar
J
M
1.5 gpm
5.7 L/min
Y24 Y23
18 psi
1.2 bar
TURNTABLE
H ROTATE
P
MANIFOLD
T
HYDRAULIC POWER UNIT
HS00007A
6 - 14 TMZ-34/19 Part No. 52075

Hydraulic Schematic
REV A Models with Manual Outriggers

BOOM BOOM BOOM
LIFT LIFT LIFT
B C A
Y45 Y46 Y47
0.037 in 0.037 in 0.037 in

9.4 mm 9.4 mm 9.4 mm
P D TEST T
E Y9 A B
3 gpm
J
11.3 L/min
F
3200 psi 1200 psi
T
G 220.6 bar 82.7 bar
35 psi
2.4 bar
I
M
1.5 gpm
5.7 L/min
Y24 Y23
18 psi
1.2 bar
TURNTABLE
H ROTATE
P
MANIFOLD
T
HS0132A
Part No. 52075 TMZ-34/19 6 - 15

Hydraulic Schematic
Models with Manual Outriggers REV A

BOOM BOOM BOOM
LIFT LIFT LIFT
B C A
Y45 Y46 Y47
0.037 in 0.037 in 0.037 in

9.4 mm 9.4 mm 9.4 mm
P D TEST T
E Y9 A B
3 gpm
J
11.3 L/min
F
1200 psi
3200 psi T 82.7 bar
G 220.6 bar
35 psi
2.4 bar I
M
1.5 gpm
5.7 L/min
Y24 Y23
18 psi
1.2 bar
TURNTABLE
H ROTATE
P
MANIFOLD
T
HS0132B
6 - 16 TMZ-34/19 Part No. 52075

Hydraulic Schematic
REV A Models with Hydraulic Outriggers
(before serial number T3400-266)
LEFT FRONT RIGHT FRONT

OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
O P
Y35 Y36
0.037 in 0.037 in
9.4 mm 9.4 mm
LEFT REAR RIGHT REAR

OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
M N
Y33 Y34
0.037 in 0.037 in
9.4 mm 9.4 mm
PRIMARY SECONDARY JIB C2 C1

BOOM BOOM BOOM
4000 psi 2000 psi
LIFT LIFT LIFT 275.8 bar 137.9 bar
CYLINDER CYLINDER CYLINDER 3:1 3:1
V2 V1
B C A
Y45 Y46 Y47 K
Y41
0.037 in 0.037 in 0.037 in
9.4 mm 9.4 mm 9.4 mm
Y39 Y48
P
L
OUTRIGGER MANIFOLD
P D TEST T
T
P
E Y9 A B
J
3 gpm
11.3 L/min
F 1200 psi
82.7 bar
3200 psi T
G 220.6 bar
35 psi
I
2.4 bar
M
1.5 gpm
5.7 L/min
Y24 Y23
18 psi
1.2 bar
TURNTABLE
H ROTATE
P
MANIFOLD
T
HS0133A
Part No. 52075 TMZ-34/19 6 - 17

Hydraulic Schematic
Models with Hydraulic Outriggers REV A
LEFT FRONT RIGHT FRONT

OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
O P
Y35 Y36
0.037 in 0.037 in
9.4 mm 9.4 mm
LEFT REAR RIGHT REAR

OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
M N
Y33 Y34
0.037 in 0.037 in
9.4 mm 9.4 mm
PRIMARY SECONDARY JIB C2 C1

BOOM BOOM BOOM
4000 psi 2000 psi
LIFT LIFT LIFT 275.8 bar 137.9 bar
CYLINDER CYLINDER CYLINDER 3:1 3:1
V2 V1
B C A
Y45 Y46 Y47 K
Y41
0.037 in 0.037 in 0.037 in
9.4 mm 9.4 mm 9.4 mm
Y39 Y48
P
L
OUTRIGGER MANIFOLD
P D TEST
T
P
E Y9 A B
J
3 gpm
11.3 L/min
F 1200 psi
82.7 bar
3200 psi T
G 220.6 bar
I
35 psi
2.4 bar
M
1.5 gpm
5.7 L/min
Y24 Y23
18 psi
1.2 bar TURNTABLE
H ROTATE
P
MANIFOLD
T
HS0133B
6 - 18 TMZ-34/19 Part No. 52075

Genie North America
Phone 425.881.1800
Toll Free USA and Canada
Distributed By:
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.

Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie Scandinavia
Phone +46 31 575100 Genie China
Fax +46 31 579020 Phone +86 21 53852570
Fax +86 21 53852569
Genie France
Phone +33 (0)2 37 26 09 99 Genie Malaysia
Fax +33 (0)2 37 26 09 98 Phone +65 98 480 775
Fax +65 67 533 544
Genie Iberica
Phone +34 93 579 5042 Genie Japan
Fax +34 93 579 5059 Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Germany
Phone 0800 180 9017 Genie Korea
Phone +49 422 149 1818 Phone +82 25 587 267
Fax +49 422 149 1820 Fax +82 25 583 910
Genie U.K. Genie Brasil

Phone +44 (0)1476 584333 Phone +55 11 41 665 755
Fax +44 (0)1476 584334 Fax +55 11 41 665 754
Genie Mexico City Genie Holland

Phone +52 55 5666 5242 Phone +31 183 581 102
Fax +52 55 5666 3241 Fax +31 183 581 566
Part No.
52075
Rev C
Service Manual TMZ-34/19

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Service Manual Part No.

Copyright © 1998 by Genie Industries

ii TMZ-34/19 Part No. 52075

Do Not Perform Maintenance

Part No. 52075 TMZ-34/19 iii

Personal Safety Be sure to wear protective eye wear and

Be sure to properly dispose of old oil or

iv TMZ-34/19 Part No. 52075

Section 1 Safety Rules

Section 2 Rev Specifications

Section 3 Rev Scheduled Maintenance Procedures

Part No. 52075 TMZ-34/19 v

Section 3 Rev Scheduled Maintenance Procedures, continued

vi TMZ-34/19 Part No. 52075

Section 4 Rev Repair Procedures

Part No. 52075 TMZ-34/19 vii

Section 4 Rev Repair, continued

viii TMZ-34/19 Part No. 52075

Section 5 Rev Troubleshooting Flow Charts

Part No. 52075 TMZ-34/19 ix

Section 6 Rev Schematics

x TMZ-34/19 Part No. 52075

Tires and wheels - ANSI, CSA

Tire size ST195/75-D14

Tire size 195/65R15 91T

Wheel lugs 5 @ 1/2 -20

Lug nut torque, dry 90 to 120 ft-lbs

Tire pressure (cold) 44 psi

Tongue jack jockey wheels

Tire size - pneumatic tire 4.00 / 3.50-4

Tire pressure, maximum (cold) 50 psi

Part No. 52075 TMZ-34/19 2-1

Hydraulic Specifications Hydraulic power unit

Hydraulic Oil Specifications Pump type: Gear

From serial number T3498-001 to T3402-375 Displacement 0.057 cu in

Biodegradable Petro Canada Premium ECO 46

Fire resistant UCON Hydrolube HP-5046

Mineral based Shell Tellus T32

Use Chevron Aviation A hydraulic

2-2 TMZ-34/19 Part No. 52075

Manifold Component Machine Torque Specifications

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

Valve coil resistance

Solenoid valve, 2 position 2 way 29 - 31Ω

Proportional solenoid valve, N.C. 31.5 to 33.5Ω

Solenoid valve, 3 position 4 way N.C. 23 to 25Ω

Solenoid valve, 2 position 3 way 23 to 25Ω

Solenoid valve, 3 position 4 way N.C. 23 to 25Ω

Solenoid valve, 2 position 2 way 29 - 31Ω

Continuous improvement of our products is a Genie

Part No. 52075 TMZ-34/19 2-3

Hydraulic Hose and Fitting Seal-Lok® fittings

SAE O-ring Boss Port Seal-Lok Fittings

(tube fitting - installed into Steel) (hose end)

SAE Dash size Torque SAE Dash size Torque