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Service Manual - Genie Industries

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1. Section 6 Schematics June 2005 Hydraulic Schematic Engine only Models with Drive Option REV B before serial number T5000 91 Part 1 of 2 OUTRIGGERS FRONT LEFT RIGHT RIGHT DRIVE DRIVE BRAKE CYLINDER CYLINDER RELEASE L CYLINDER ef LEFT 4 4 x DRIVE DRIVE imm FM doma 1 MOTOR MOTOR 8 8 1 M2 c M3 M4 mas LQ u i TTT DRIVE MANIFOLD 5 a REAR va X Yea X Yesa LEFT RIGHT tan igi ZEE ZEE SLAVE e uras Qu 1 0 046 inch 0 046 inch 19 44 70 psi 117mm 117mm iF D1 D2 3 F t ALT cal C1 AUXILIARY oom T Oot POWER 275 8 Tl 177 7 137 9 bar MASTER UNIT
2. M M r H L al DRIVE lua 1 PLATFORM CONTROLS OPTION PLATFORM 2 MEMBRANE DECAL PANEL contROLs 3 1 PRINTED y 4 DRIVE CONTROLS m 5 MEMBRANE DECAL PANEL BOARD mms 5 BN78 OUTRIGGER EXTEND 3 foe 29 PRIMARY UP 192 s 2 5 BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 40 e BN80 OUTRIGGER RETRACT 12vDbO sv oc 1 BN31 SECONDARY UP Xp D7A Ju 12 a li BN81 HORN 4 Eus VOLTAGE 1 EC SECONDARY DOWN l 1 BN82 DRIVE ENABLE 1l REGULATOR 14 T l 4 BN27 JIBUP cae ni 7 o BN28 JIB DOWN 6 PIN v2 J3 L3 RIBBON CABLE us JC5 4324 1 2 s4 BN34 ROTATE RIGHT J3 U24 JOYSTICK m m BN33 ROTATE LEFT DRIVE CONTROLS 2288 B PRINTED CIRCUIT BOARD 33 H2 BN74 BOOM RET
3. Section 6 Schematics June 2005 Hydraulic Schematic DC Models with Drive Option REV B before serial number T5000 91 Part 1 of 2 DRIVE OUTRIGGERS OPTION i FRONT FRONT LEFT RIGHT RIGHT CYLINDER omen BRAKE RELEASE I A CYLINDER io LEFT 4 4 21 x li e E B 1 B 1 M2 M4 lare DRIVE MANIFOLD el TNT REAR REAR Yea oe Y64A LEFT RIGHT DEVS XW nit tb an i ome Ce tem 4 FF Ex celu E LO i Lop i pwn Mh po eed cal E AUXILIARY oop r T uc PUMP 1 2758 T1 T 137 9 MASTER ME S COUNTER LA PS LB OLT BALANCE od y VALVE _ MANIFOLD v2 vi GA D1 D2 T2 AUX T3 1 B1 TEST A2 B2 EAA ee ee r a 42 6 GN
4. T OUTRIGGER AUTO LEVEL BN49 PRIMARY UP T T ENGINE START BN68 gt PRIMARY DOWN T T OUTRIGGER EXTEND BN47 e RIGHT FRONT OUTRIGGER ES Ed OUTRIGGER RETRACT BN48 SECONDARY UP T T PLATFORM LEVEL DOWN BN70 n SECONDARY DOWN fic m PLATFORM LEVEL UP BN69 ar LEFT FRONT OUTRIGGER T 2 3 BOOM RETRACT BN72 AT io JIB BOOM UP T T BOOM EXTEND BN71 e gt JIB BOOM DOWN G8 DIAGNOSTIC HORN BN35 o e e RIGHT REAR OUTRIGGER DISPLAY FUNCTION ENABLE HIGH BN44 e gt ROTATE RIGHT gt FUNCTION ENABLE MEDIUM BN45 te ROTATE LEFT T T FUNCTION ENABLE LOW BN46 5 I LEFT REAR OUTRIGGER HORN 112 L13 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 85 z 1 EN2 5 SW25 GROUND I 12 24V DC 5V DC 8765432 DIPSWITCH CONTROL 12g 4 ROX PLATFORM D7 W CPU DISPLAYBOARD 111111444 SW25A 87654321 DIP SWITCH KS1 8 VOLTAGE REGULATOR CN
5. GROUND CONTROLS MEMBRANE DECAL PANEL a o OUTRIGGER AUTO LEVEL BN49 E BN38 PRIMARY UP T T ENGINE START BN68 BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER ES Ed OUTRIGGER RETRACT BN48 oe gt BN40 SECONDARY UP T T PLATFORM LEVEL DOWN 70 BN41 SECONDARY DOWN fic PLATFORM LEVEL UP BN69 52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 36 JIB BOOM UP p End G8 BOOMEXTEND BN71 BN37 JIB BOOM DOWN DIAGNOSTIC HORN BN35 o e e 51 RIGHT REAR OUTRIGGER DISPLAY FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 BN50 LEFT REAR OUTRIGGER H5 O 0 HORN L12 113 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 4 123456 1 EN2 Irt 5 SW25
6. ee L al DRIVE lua 1 PLATFORM CONTROLS OPTION PLATFORM 2 MEMBRANE DECAL PANEL controts 3 1 PRINTED y 4 E DRIVE CONTROLS 5 MEMBRANE DECAL PANEL BOARD mms 5 BN78 OUTRIGGER EXTEND z foe 29 PRIMARY UP 192 s 2 5 BN79 OUTRIGGER AUTO LEVEL BN30 PRIMARY DOWN XP 9 e m 40 e BN80 OUTRIGGER RETRACT BN31 SECONDARY UP Xp 1 12vDbO sv oc D7A Ju 12 a li BN81 HORN MP 4 VOLTAGE 1 EC SECONDARY DOWN l 1 BN82 DRIVE ENABLE 1l REGULATOR 14 T BN27 JIB UP cae ni 7 o BN28 JIB DOWN 6 PIN v2 J3 L3 RIBBON CABLE us JC5 s4 BN34 ROTATE RIGHT J3 U24 JOYSTICK 2 1 4324 m m BN33 ROTATE LEFT DRIVE CONTROLS 2288 PRINTED CIRCUIT BOARD 33 H2 BN74 BOOM RETRACT ID7B 5 E 12V DC 5v D
7. Section 6 Schematics June 2005 Hydraulic Schematic DC Models with Drive Option REV after serial number T5000 90 Part 1 of 2 OUTRIGGERS DRIVE i FRONT FRONT LEFT RIGHT J OPTION LEET DRIVE DRIVE BRAKE CYLINDER CYLINDER RELEASE E CYLINDER ef LEFT 4 4 x DRIVE DRIVE vem 1 FM dew U MOTOR MOTOR 1 M2 C BOR l 4 a TTT DRIVE MANIFOLD E X Yea NT X Yesa 327 LEFT RIGHT Y tly f amp 0 ME i SLAVE 3850 psi e T 3850 psi s S i or o 3 ak j a rien 2 Di pel bi BON bom eU M E 2 1 E AUXILIARY on j uc PUMP ba o MASTER s 1 tii COUNTER BALANCE I od VALVE __ MANIFOLD 2 vi NEP AA D1 D2 T2 AUX T3 Al __ B1 __ E _ A2 B2 pee D
8. Section 6 Schematics June 2005 Hydraulic Schematic DC Models without Drive Option REV B before serial number T5000 91 Part 1 of 2 OUTRIGGERS FRONT FRONT LEFT RIGHT er ier ELE IX mmm i EXE ew AE REAR LEFT RIGHT me ll Hh poc eme cal C1 E AUXILIARY PUMP koei mE MASTER I A ITP Ta COUNTER eil Nt E BALANCE y VALVE l MANIFOLD I 2 Vi ode toate tel 64 EN AME ee D E ect UR m c eu ue 3 rd M 3 1 T Y41 I SD tr Y xx c8 3 e u PUMP MANIFOLD FUNCTION MANIFOLD P1 po T 1 DC 3 gpm 69 11 4 L min HYDRAULIC TANK HS0124B 6 52 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics E Hydraulic Schematic DC Models without Drive Option
9. GROUND CONTROLS MEMBRANE DECAL PANEL a o OUTRIGGER AUTO LEVEL BN49 HE 6 BN38 PRIMARY UP T T ENGINE START BN68 BN39 PRIMARY DOWN TE T OUTRIGGER EXTEND BN47 E BN53 RIGHT FRONT OUTRIGGER T T OUTRIGGER RETRACT BN48 oe o BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN7O oe BN41 SECONDARY DOWN T T PLATFORM LEVELUP 9 BN52 LEFT FRONT OUTRIGGER p cle BOOM RETRACT BN72 BN36 JIB BOOM UP dp BOOMEXTEND BN71 BN37 JIB BOOM DOWN T HORN BN35 oe BN51 RIGHT REAR OUTRIGGER T Im FUNCTION ENABLE HIGH BN44 e gt BN43 ROTATE RIGHT Mrd E FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT Ed FUNCTION ENABLE LOW BN46 BN50 LEFT REAR OUTRIGGER H5 _ o xowoor cono HORN P1 LM 7 112 113 114 115 EMERGENCY e e 16 PIN SOMEONE stop 9 RIBBON CABLE OQ Ct Aa EN2 GROUND H III SW25 e 42 12V DC 5V DC U22 87654321 DIP SWITCH m J7 ROX I PLATFORM 13 D7 UU CPU DISPLAY BOARD 55553515 SW25A i 87654321 DIP SWITCH 1 VOLTAGE REGULATOR I J6 J9 J2 J3 Lo L
10. i 1 SS SS SS SS SS SS 4 BEC Sask on u s 28 WOO ASHAAZH 1431 v9A Su EO gt Q lt 9 4 8 T annows 5 3 8 GHVMYOS 1431 OSA 5 0 gt 5 k Du 9 E 7 2 2 fF WOOsSHaAaH HOI WHOA nez Qua de Ss d 9 x a a 5 1109 1 VOSA 5 ul lt 28 s a Ini E gt I WAS 5 ZEA r9u 2 E or ogou g 9 uz 1643 332 8 11985 314 lt lt E e m Jo dee 29 2 E o mk 05555 83 q a a AS 0 SIXV A A x 25 68 amp amp g Ilo 3 20 u 25 gt epa 9 0 SIXV X 2 m CITIT 58 LE a a 15 help women 5 d d d d d a 5 g qd ole lo 1 Av HOSN3S 13 31 Al ES 1 gt amp gt FT ano i ze M 1 rel S ou iz 5 CT viva or 8 j NO OF _ E m E wo Me Je 14 709 10vHl3HWOOS SZA Fac px iue ra 5 3 g gt 1 Ly 109 aNaix3WoO8 92A t sete ce ce ee CO tr tt L a xd 1 1 SI
11. i 1 4 s on a 28 _ WOO3SH3A3Hld3l POA Sup o eos 1491 OSA o c CAS gt E o 3 k 5 h ul ez ASO 2 5 2 ooasudAdH1HOld WHOA or zz Qua de co m 9 x a a 5 109 1 VOSA oo 5 og eg E gas g u 2 ZweO Li 8 5F Zu E or ogou g 9 lt 20 uz 15258 8 E 1984 Sik S205 E m lt ea arent gt 2 fg eggy je qt 3 8 x OD ae Co ZZ E 98 d Ia 8 hepte AS 0 SIXWA A ao 256 5 gt epa AS 0 SIXV X m r m i T i IT odd dp g LE kaj ona ann E le 4 H H H H H m z 8 ol lo 1 Av HOSN3S 13 31 Al ES t T gt TONS i M ra ns iz 5 CT viva or 8 j aod rv HM x n m lt E uo Je 14 709 10vHl3HWOOS SZA Fac px iue ra 5 ou gt 9L e 109 aNaix3WoO8 92A ee o a xd 1100 1 1 09 with Nt dn GNAL
12. eter a ae as gras ny S a meh i PLATFORM CONTROLS PME MEMBRANE DECAL PANEL CONTROLS Pi PRINTED 4 DRIVE CONTROLS 5 5 an gos MEMBRANE DECAL PANEL 92 BN78 OUTRIGGER EXTEND 3 z BN29 PRIMARY UP 44 192 9 4 BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 e BN80 OUTRIGGER RETRACT 24V DC 5V DC TA i BN31 SECONDARY UP BIBT HOAN MP VOLTAGE 13 t 2 BN32 SECONDARY DOWN BN82 DRIVE ENABLE 1l 14 REGULATOR 1 BN27 JIB UP illl VE PIN Ww v2 J3 P m di Md RIBBON CABLE JC5 4324 1 2 s4 BN34 ROTATE RIGHT J3 JOYSTICK E U24 p BN33 ROTATE LEFT DRIVE CONTROLS 2288 A B PRINTED CIRCUIT BOARD 33 H2 BN74 BOOM RETRACT ID7B 5 22 ivottace ov De sv oc 28 585 STAY HORN p BN73 BOOM EXTEND 31 6 6 4 6 e BN76 PLATFORM LEVEL DOWN L 4321 3 B a cs P2 oe BN75 PLATFORM LEVEL UP 2 EMERGENCY STOP EMERGENCY a E e e fj SOP BN77 ENGINE
13. i 1 SS SS Q 4 s BEC on a 28 OSL f9A Sup o eos 1491 OSA x TIS gt 3 k 5 h ul 9 T 55 2 2 fF ooasudAdH1HOld WHOA nez O m d 9 S 3 a 5 109 1 VOSA u nO oog eg E gas g u 2 ZweO Li 8 5F ZuE E rezu g 48 o 9 gt uzi amp zaaes Bs 219 sim s2 lt E m lt ea arent zel Seegs 31 5 4 3 Z P A l Co ZZ E 98 d Ia 8 hepte AS 0 SIXWA A ao 256 5 gt epa AS 0 SIXV X m r m i T i DITIT dp g LE Ld al 15 eeel onsin 5 d d d d d a 5 g qd ole lo 1 AFZ38OSN3SJ3A31 I ah NS 1 gt amp 1 ze 1 rel D ou iz 5 CT viva or 8 j aod rv HM x n m lt E 4 tt 1109 10VHl3H WOOS SZA Fac px iue ra 5 ou gt 9L e aN31X3 W009 92A Enc c o si Wr 1 xd 1100 1 1 09 r mE dn 1 19A To c _ I ae mi
14. Electrical Schematic Diesel Bi Fuel Models after serial number TMZ5003 228 Part 2 of 2 Tm 4 l us 1 PLATFORM CONTROLS MEMBRANE DECAL PANEL CONTROLS PAINTED 5 4 p DRIVE CONTROLS BOARD d li ds MEMBRANE DECAL PANEL BN78 OUTRIGGER EXTEND Sut hu BN29 PRIMARY UP 4 22 8 gt tat BNT9 OUTRIGGER AUTO LEVEL B 9 oe BN30 PRIMARY DOWN 2 m 10 4 E BN80 OUTRIGGER RETRACT 24vDC Sv DC oe 4 BN31 SECONDARY UP D7A 12 3 li BN81 HORN voutace 13 Vices BN32 SECONDARY DOWN l BN82 DRIVE ENABLE 1l REGULATOR 14 BN27 JIB UP 1 5 4321 E 6 PIN S 22 J3 Pp ER LM RIBBON CABLE 148 5 4323 BN34 ROTATE RIGHT J3 U24 JOYSTICK 4 E BN33 ROTATE LEFT DRIVE CONTROLS 3 2 3 9 B PRINTED CIRCUIT BOARD 33 t H2 BN74 BOOM RETRACT 107
15. Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a a OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 ee BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER ES Ed OUTRIGGER RETRACT BN48 oe gt BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN7O oe oe BN41 SECONDARY DOWN fic PLATFORM LEVEL UP BN69 BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 BN36 JIB BOOM UP p End G8 BOOMEXTEND BN71 BN37 JIB BOOM DOWN E E DIAGNOSTIC HORN BN35 e 51 RIGHT REAR OUTRIGGER DISPLAY FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 I BN50 LEFT REAR OUTRIGGER H5 O 0 HORN L12 113 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 ett 123456 71 EN2 pe 5 SW25 4 GROUND li 12V DC 5V DC 87654321 DIP SWITCH CONTROL 2 J7 U22 4 BOX ME PLATFORM D7 UJ CPU DISPLAY BOARD SW25A 3 87654321 DIP SWITCH KS1 8 VOLTAGE REGULATOR a KEY SWITCH 21 J6 J9 J2 J3
16. Electrical Schematic Diesel Models after serial number TMZ5003 228 Part 2 of 2 ater M a as rs ee en M i PLATFORM CONTROLS pM PLATFORM 2 MEMBRANE DECAL PANEL I controts 3 gt gt gt gt PRINTED 4 DRIVE NTROL CIRCUIT 2 E CONTROLS an gos MEMBRANE DECAL PANEL BN78 OUTRIGGER EXTEND 5 BN29 PRIMARY UP 4 QZ 8 e BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 e BN80 OUTRIGGER RETRACT 12V DC 5V DC TA i BN31 SECONDARY UP BIBT HOAN voutace 19 TA SECONDARY DOWN l BN82 DRIVE ENABLE 1l REGULATOR 14 T BN27 JIB UP cae ni T O e BN28 JIB DOWN 6 PIN v 22 J3 ue E RIBBON CABLE yy 148 JC5 adem mm mE a BN34 ROTATE RIGHT J3 U24 JOYSTICK m 4 BN33 ROTATE LEFT l DRIVE CONTROLS 2288 x s PRINT
17. Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL o OUTRIGGER AUTO LEVEL BN49 J BN38 PRIMARY UP T T ENGINE START BN68 E BN39 PRIMARY DOWN TE T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER EJ nd OUTRIGGER RETRACT BN48 oe gt BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN70 oe BN41 SECONDARY DOWN T T PLATFORM LEVELUP BN69 oe BN52 LEFT FRONT OUTRIGGER p cle BOOM RETRACT BN72 BN36 JIB BOOM UP dp BOOM EXTEND BN71 e BN37 JIB BOOM DOWN T HORN BN35 BN51 RIGHT REAR OUTRIGGER FUNCTION ENABLE HIGH BN44 e BN43 ROTATE RIGHT Mrd E FUNCTION ENABLE MEDIUM BN45 e BN42 ROTATE LEFT Ed FUNCTION ENABLE LOW BN46 I BN50 LEFT REAR OUTRIGGER H5 er P1 e sr 2777 qim 114 115 ado EMERGENCY e e 16 PIN SOMEONE stop S l RIBBON CABLE OQ Ct Puer SW25 GROUND E lo 12V DC 5V DC 87654321 DIP SWITCH 022 ovo 1 SW25A BOX 13 D7 UU CPU DISPLAYBOARD DIE SWITCH VOLTAGE REGULATOR KS key smrten J6 J9 J2 J3 Lo Lo P Lo 7 PIN 11 PIN 26 PIN 40 PIN ea ORNA JUMPER CABLE JUMPER CABLE
18. Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a o 1 OUTRIGGER AUTO LEVEL BN49 o oe BN38 PRIMARY UP T T ENGINE START BN68 BN39 PRIMARY DOWN m T OUTRIGGER EXTEND BN47 oe BN53 RIGHT FRONT OUTRIGGER T T OUTRIGGER RETRACT BN48 TE BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN70 n gt 4 BN41 SECONDARY DOWN T T PLATFORM LEVEL UP BN69 e 52 LEFT FRONT OUTRIGGER T T BOOM RETRACT BN72 oe BN36 JIB BOOM UP T BOOMEXTEND BN71 4 37 JIB BOOM DOWN T HORN BN35 n BN51 RIGHT REAR OUTRIGGER T T FUNCTION ENABLE HIGH BN44 e BN43 ROTATE RIGHT T FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT TT T FUNCTION ENABLE LOW BN46 te I BN50 LEFT REAR OUTRIGGER H5 raat eS S m S nono HORN P1 di 112 113 114 115 EMERGENCY Re OR Me ae stop 1 RIBBON CABLE OQ Ct pesce EN2 GROUND H III SW25 CONTROL 42 DC U22 87654321 DIP SWITCH yl JT BOX 3 SW25A PLATFORM D7 CPU DISPLAY BOARD 87659821 DIP SWITCH 1 VOLTAGE REGULATOR 1 J6 J9 J2 J3 Loy Lo P Lo 7 PIN 11 PIN 26 PIN 40 PIN l KS1 KEY SWITCH UU gt JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE
19. Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a o OUTRIGGER AUTO LEVEL BN49 HE 6 BN38 PRIMARY UP T T ENGINE START BN68 BN39 PRIMARY DOWN E3 OUTRIGGER EXTEND BN47 E BN53 RIGHT FRONT OUTRIGGER EJ ES OUTRIGGER RETRACT BN48 oe gt o BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN70 oe BN41 SECONDARY DOWN T T PLATFORM LEVELUP BN69 BN52 LEFT FRONT OUTRIGGER p cle BOOM RETRACT BN72 BN36 JIB BOOM UP dp BOOM EXTEND BN71 e BN37 JIB BOOM DOWN T HORN BN35 oe BN51 RIGHT REAR OUTRIGGER FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT Mrd E FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT TE oe FUNCTION ENABLE LOW BN46 BN50 LEFT REAR OUTRIGGER H5 raat m mono HORN P1 112 113 114 115 EMERGENCY e e 16 PIN Re UNCLE NE stop S l RIBBON CABLE OQ Ct ENS 11 5 MM SW25 GROUND hear lo 12V DC 5V DC 87654321 DIP SWITCH 022 ovo 1 SW25A BOX 13 D7 UU CPU DISPLAY BOARD 2 51321 DIP SWITCH VOLTAGE REGULATOR KS key smrten J6 J9 J2 J3 Lo Lo P Lo 7 PIN 11 PIN 26 PIN 40 PIN MIC JUMPER CABLE JUMPERCABLE RIBB
20. ater r as ae RN i PLATFORM CONTROLS PUE PLATFORM 2 MEMBRANE DECAL PANEL contROLs 3 P 1 PRINTED y 4 E DRIVE CONTROLS BOARD I li MEMBRANE DECAL PANEL OR BN78 OUTRIGGER EXTEND 5 BN29 PRIMARY UP e 4 QZ 8 e BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 BN80 OUTRIGGER RETRACT 24V DC 5V DC 11 T e BN31 SECONDARY UP BN84 HORN MP voutace 19 1 SECONDARY DOWN l BN82 DRIVE ENABLE REGULATOR 14 sd BN27 JIB UP T rab 6 PIN BN28 JIB DOWN 22 J3 ue E RIBBON CABLE yy 148 JC5 JOYSTICK 4321 1 2 BN34 ROTATE RIGHT J3 U24 m 4 oe BN33 ROTATE LEFT DRIVE CONTROLS 2288 x s PRINTED CIRCUIT BOARD 555 H2 BN74 BOOM RETRACT ID7B 5 JH VOLTAGE o24VDC 5 0 28 HORN BN73 BOOM EXTEND m e 3 4555 JA 648K e BN76 PLATFORM LEVEL DOWN L 14 321 IE a cs P2 oe BN75 PLATFORM LEVEL UP 2 EMERGENCY STOP EMERGENCY a E e e fj SOP BN77 ENGINE START EN7 588582 E 4 BN5 HORN i mimm DRIVE CONTROL amp ox _ se
21. Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a o OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 ee BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER ES Ed OUTRIGGER RETRACT BN48 gt E BN40 SECONDARY UP T T PLATFORM LEVEL DOWN 70 BN41 SECONDARY DOWN fic PLATFORM LEVEL UP BN69 E BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 36 JIB BOOM UP p End G8 BOOMEXTEND BN71 BN37 JIB BOOM DOWN E E DIAGNOSTIC HORN BN35 BN51 RIGHT REAR OUTRIGGER FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 e BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 I 50 LEFT REAR OUTRIGGER H5 O 0 HORN L12 113 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 ett 123456 71 EN2 5 SW25 GROUND 12V DC 5V DC 87654321 DIP SWITCH CONTROL 2 J7 U22 4 ROX PLATFORM D7 UJ CPU DISPLAY BOARD SW25A 87654321 DIP SWITCH KS1 8 VOLTAGE REGULATOR CN KEY SWITCH 21 J6 J9 J2 J3 e ix x a Ly a F F J 7 PIN 11 PI
22. Electrical Schematic Gasoline Bi Fuel Models after serial number TMZ5003 228 Part 2 of 2 ater M a as rs ee en M i PLATFORM CONTROLS pM PLATFORM 2 MEMBRANE DECAL PANEL gt 2 DRIVE CONTROLS an gos MEMBRANE DECAL PANEL 92 BN78 OUTRIGGER EXTEND 3 e z BN29 PRIMARY UP 44 192 9 5 BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 e BN80 OUTRIGGER RETRACT 24V 5V DC 11 T T e BN31 SECONDARY UP BN84 HORN voutace 19 1 SECONDARY DOWN BN82 DRIVE ENABLE 1l 14 REGULATOR 1 BN27 JIB UP illl A PIN v o2 J3 I ow BNE DROWN RIBBON CABLE poy JC5 4 21 1_2 me BN34 ROTATE RIGHT J3 U24 JOYSTICK ol m 4 oe BN33 ROTATE LEFT DRIVE CONTROLS 2288 A B PRINTED CIRCUIT BOARD 33 H2 BN74 BOOM RETRACT ID
23. a secondary boom hold down latch m secondary boom link b secondary boom link pivot pin n secondary boom lift cylinder rod end pivot pin secondary boom pivot pin o secondary boom lift cylinder d mid pivot p primary boom hold down latch e platform level master cylinder q platform level slave cylinder barrel end pivot pin f platform level master cylinder rod end pivot pin hidden from view g primary boom pivot pin r extension boom h extension cylinder barrel end pivot pin S platform level slave cylinder i primary boom t jib mount pivot pin j primary boom lift cylinder u jib mount k primary boom lift cylinder rod end pivot pin v platform level slave cylinder rod end pivot pin secondary boom w turntable TEREX COMPANY 4 12 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 4 1 Cable Track The boom cable track guides cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire boom cable track may be necessary when performing major repairs that involve removing the boom How to Remove the Cable Track When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to S
24. e 0 6 gpm T 2 27 L min REV B before serial number T5000 91 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER 1 E 1 mT i AE mo ow 3000 psi 3000 psi 2500 ni y gee ps 206 8 bar 206 8 bar 1724 bar 206 8 bar S1 A3 A57 BS A4 A6 A75 B7 O gt GK 68 SHA e G Nc Y23 Y22 Y19 Y53 ti Y52 Y26 Y61 Y60 DR FUNCTION MANIFOLD HS0124B Part No 65162 TMZ 50 30 6 53 Section 6 Schematics June 2005 Hydraulic Schematic DC Models without Drive Option REV after serial number T5000 90 Part 1 of 2 OUTRIGGERS FRONT FRONT LEFT RIGHT er ier RIT 0 046 inch 0 046 inch 1 17 mm 1 17mm ew AE s PLATFORM ee SLAVE SII EL TO OME MN poc eme 2 C1 E AUXILIARY gs uc PUMP 1S8 bar MASTER OL COUNTER 4 BALANCE r gt VALVE
25. Electrical Schematic Diesel Models from serial number T5002 25 to TMZ5003 228 Part 2 of 2 ee i 1 3 lus i PLATFORM CONTROLS pM PLATFORM 2 MEMBRANE DECAL PANEL A m _ CONTROLS 3 m 1 PRINTED 4 DRIVE CONTROLS CIRCUIT 2 E an 2 MEMBRANE DECAL PANEL op BN78 OUTRIGGER EXTEND 5 BN29 PRIMARY UP J4 QZ L BN79 OUTRIGGER AUTO LEVEL 9 T 9 m 10 e BNO PRIMARY DOWN 4 BN80 OUTRIGGER RETRACT 12V DC 5V DC TA i BN31 SECONDARY UP BIBT HOAN voutace 19 TA SECONDARY DOWN l BN82 DRIVE ENABLE 1l REGULATOR 14 T 4 BN27 JIBUP T 6 PIN s BN28 JIBDOWN 22 J3 ue RIBBON CABLE yy 148 JC5 adem mm mE a BN34 ROTATE RIGHT J3 U24 JOYSTICK Aa DRIVE CONTROLS 2229 4 e BNOS ROTATE LEFT PRINTED CIRCUITBOARD 8 lt 5 H2 BN74 BOOM RETRACT ID7B 5 12V DC 5v DC 211 BL l HORN VOLTAGE age
26. Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a o OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 E BN39 PRIMARY DOWN TE T OUTRIGGER EXTEND BN47 E BN53 RIGHT FRONT OUTRIGGER OUTRIGGER RETRACT BN48 gt BN40 SECONDARY UP T T PLATFORM LEVEL DOWN 70 m BN41 SECONDARY DOWN T T PLATFORM LEVEL BN69 s BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 BN36 JIB BOOM UP dp BOOM EXTEND BN71 A Lr BN37 JIB BOOM DOWN HORN BN35 zs 4 BN51 RIGHT REAR OUTRIGGER Im FUNCTION ENABLE HIGH BN44 e gt E BN43 ROTATE RIGHT Mrd FUNCTION ENABLE MEDIUM BN45 e oa BN42 ROTATE LEFT Ed FUNCTION ENABLE LOW BN46 I BN50 LEFT REAR OUTRIGGER H5 aore HORN L12 113 114 115 EMERGENCY e e 16 PIN SOMEONE stop S l RIBBON CABLE OQ Ct pee 1 ENE GROUND __ T 13133323 SW25 E lo 12V DC 5V DC U22 87654321 DIP SWITCH D J7 BOX ii D7 17 U CPU DISPLAY BOARD NIMM i SW25A DIP SWITCH VOLTAGE REGULATOR IKS1 key J6 J9 J2 J3 Lod Lo Lod Lo Lied 7 PIN 11 PIN 26 PIN 40 PIN JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE L G7 6 BK J2 Ji J3 J4 1 2 JB yf RD P4 U21
27. Electrical Schematic Gasoline Bi Fuel Models from serial number T5002 25 to TMZ5003 228 Part 2 of 2 eter a E ears gras t eh i PLATFORM CONTROLS Pd PLATFORM 2 MEMBRANE DECAL PANEL controts 3 PRINTED y 4 E DRIVE CONTROLS BOARD Es I li MEMBRANE DECAL PANEL 92 BN78 OUTRIGGER EXTEND Jaloz BN29 PRIMARY UP li e yz e 1 BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 BN80 OUTRIGGER RETRACT 24V 5V DC 11 T T e BN31 SECONDARY UP BN84 HORN voutace 19 1 SECONDARY DOWN l BN82 DRIVE ENABLE REGULATOR 14 fe 27 JIB UP 321 O e BN28 JIB DOWN 6 PIN v 22 J3 ue E RIBBON CABLE yy 148 JC5 4324 1 2 s4 BN34 ROTATE RIGHT J3 JOYSTICK ae ee 024 m m BN33 ROTATE LEFT DRIVE CONTROLS 2288 ES s PRINTED CIRCUI
28. DRIVE U3 1 PLATFORM CONTROLS OPTION PLATFORM 2 MEMBRANE DECAL PANEL controts 3 1 PRINTED ED NL DRIVE CONTROLS BOARD d li ds MEMBRANE DECAL PANEL BN78 OUTRIGGER EXTEND 92 BN29 PRIMARY UP li 4153 Im Ea BN79 OUTRIGGER AUTO LEVEL 8 52 B 9 oe BN30 PRIMARY DOWN 2 m 10 4 BN80 OUTRIGGER RETRACT a ip 12v DC sv DC n bra w BN31 SECONDARY UP Soll EREN HORN pace VOLTAGE 19 e BN32 SECONDARY DOWN l 1 BN82 DRIVE ENABLE i REGULATOR 14 BN27 JIB UP BN28 JIB DOWN 6 PIN Li JC5 O46 AA RIBBON CABLE TX 52 4321l 1 2 Ta BN34 ROTATE RIGHT J3 U24 JOYSTICK 4 T BN33 ROTATE LEFT DRIVE CONTROLS 2 2 2 o ES s PRINTED CIRCUIT BOARD 555 tL uo s4 BN74 BOOM RETRACT 1D7B THER 5 HORN lt llvorragz ot2vec sv oc 21 EEEE Pers BN73 BOOM EXTEND 6 S J4 6 HBK amp e BN76 PLATFORM LEVEL DOWN s 14 321 Ed E DE a P2 oe BN75 PLATFORM LEVEL UP EMERGENCY STOP E EMERGENCY SEO e stop T a en E BN77 ENGINE START a DRIVE CONTROL BOX 554 ME cssc E Pm BN5 HORN BN12 FUNCTION ENABLE HI
29. Gasoline Models REV A from serial number T5000 91 to T5002 24 Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a a OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 t gt BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER ES Ed OUTRIGGER RETRACT BN48 4 BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN7O BN41 SECONDARY DOWN ES pi PLATFORM LEVEL UP BN69 t BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 gt 36 JIB BOOM UP p End BOOM EXTEND BN71 BN37 JIB BOOM DOWN m P HORN BN35 TE BN51 RIGHT REAR OUTRIGGER FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 E 42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 5 os BN50 LEFT REAR OUTRIGGER H5 O 0 HORN ne 112 113 114 115 EMERGENCY So Guo tuy ey stop RIBBON CABLE Ct 1 EN2 GROUND T 13133323 SW25 GROUND LEN lo 12V DC 5V DC 87654321 DIP SWITCH CONTROL i J7 U22 SW25A BOX PIAFO 3 D7 CPU DISPLAY BOARD M VOLTAGE REGULATOR I KS1 J6 J9 J2 J3 Lo Lod Lo 7 PIN 11 PIN 26 PIN 40 PIN V JUMPER CABLE JUMPER CABLE RIBBON CA
30. Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a a OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 t gt BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 TE BN53 RIGHT FRONT OUTRIGGER ES Ed OUTRIGGER RETRACT BN48 4 BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN7O BN41 SECONDARY DOWN fic PLATFORM LEVEL UP BN69 t BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 gt 36 JIB BOOM UP p End G8 BOOM EXTEND BN71 BN37 JIB BOOM DOWN DIAGNOSTIC HORN BN35 o e e 51 RIGHT REAR OUTRIGGER DISPLAY FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 E 2 ROTATE LEFT T FUNCTION ENABLE LOW BN46 5 os BN50 LEFT REAR OUTRIGGER H5 O 0 HORN 112 L13 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 4 123456 1 EN2 Irt 5 SW25 GROUND lli EUR l2 24V DC 5V DC 87654321 DIP SWITCH CONTROL 3 74 117 U22 PLATFORM D7 0 PU DISPLAY BOARD 13343333 SW25A l J8 VOLTAGE REGULATOR ee KS1 51 J6 J9 J2 03 Lo Lo P Lo 7 PIN 11 PIN 26 PIN 40 PIN UU JUMPER CABLE JUMPERCABLE RIBBON CABLE RIBBON CABLE
31. Electrical Schematic Diesel Models before serial number T5000 91 Part 2 of 2 eter ee s aaa as rs ee an M us i PLATFORM CONTROLS pM PLATFORM 2 MEMBRANE DECAL PANEL controts 3 PRINTED y 4 B DRIVE CONTROLS B 5 ARD gos MEMBRANE DECAL PANEL 92 BN78 OUTRIGGER EXTEND x E e 92 8 A ENEO PRIMARY UP m 79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 BN80 OUTRIGGER RETRACT 12V 5V DC 11 T e BN31 SECONDARY UP BN84 HORN VOLTAGE 13 t 2 BN32 SECONDARY DOWN BN82 DRIVE ENABLE 1l 14 REGULATOR e o BN27 JIB UP 584321 T O e BN28 JIB DOWN 6 PIN v 22 J3 ue E RIBBON CABLE yy 148 JC5 4324 1 2 s4 BN34 ROTATE RIGHT J3 JOYSTICK m gt o BN33 ROTATE LEFT DRIVE CONTROLS 5558 ES s PRINTED CIRCUIT BOARD 555 H2 BN74 BOOM RETRACT ID7B 5
32. 3 23 Genie A TEREX COMPANY vi TMZ 50 30 Part No 65162 June 2005 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued B Checklist C Procedure C 1 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 25 C 2 Perform Axle Maintenance ANSI Models 3 25 C 3 Perform Hitch Maintenance CE Models 3 25 B Checklist D Procedures D 1 Check the Boom Wear Pads sse 3 26 0 2 Check the Turntable Rotation Bearing Bolts 3 27 D 3 Inspectfor Turntable Bearing 3 28 D 4 Replace the Hydraulic Tank Return Filter 3 29 0 5 Perform Axle Maintenance ANSI Models 3 30 D 6 Perform Engine Maintenance Hatz Models if equipped 3 30 B Checklist E Procedures 1 Testor Replace the Hydraulic Oil 3 31 E 2 Perform Engine Maintenance Honda Models if equipped 3 32 Section 4 Rev Repair 4 1 B Platform Controls 1 1 Circ itBOard uite Drei eie nt ei EE HORE 4 2 1 2 Membrane Overlay esses nennen nennen 4 3 B Platform Components SEM Sul 4 5
33. HA Testing 2 Flow regulator valve 0 6 2 27 L min Turntable rotate circuit 18 20 ft lbs 24 27 Nm 3 Orifice Plug 0 025 inch 0 64mm HC Turntable rotate circuit 4 Pilot operated check valve HD Outrigger down circuit 30 35 ft lbs 41 47 Nm 5 Solenoid valve 2 position 3 way HE Primary boom extension 18 20 ft lbs 24 27 Nm 6 Solenoid valve 2 position 3 way with manual over ride HF Primary boom retract 18 20 ft lbs 24 27 Nm 7 Solenoid valve 3 position 4 way with manual over ride HG Jib boom 18 20 ft lbs 24 27 Nm 8 Solenoid valve 3 position 4 way with manual over ride HH Primary upper boom up down 18 20 ft lbs 24 27 Nm 9 Solenoid valve 3 position 4 way with manual over ride Secondary lower boom up down 18 20 ft lbs 24 27 Nm 10 Solenoid valve 2 position 3 way Regenerative circuit for outriggers 18 20 ft lbs 24 27 Nm 11 Counterbalance valve HK Platform level up 30 35 ft lbs 41 47 Nm 12 Shuttle valve
34. Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a o OUTRIGGER AUTO LEVEL BN49 E BN38 PRIMARY UP T T ENGINE START BN68 BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER S OUTRIGGER RETRACT BN48 oe gt BN40 SECONDARY UP T T PLATFORM LEVEL DOWN 70 BN41 SECONDARY DOWN ES pi PLATFORM LEVEL UP BN69 BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 gt 36 JIB BOOM UP p End G8 BOOM EXTEND BN71 e BN37 JIB BOOM DOWN E E DIAGNOSTIC HORN BN35 o e e 51 RIGHT REAR OUTRIGGER DISPLAY FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 I BN50 LEFT REAR OUTRIGGER H5 O 0 HORN L12 113 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 4 123456 71 EN2 Irt 5 SW25 GROUND li 24V DC 5V DC 87654321 DIP SWITCH CONTROL 2 J7 U22 ROX PLATFORM 4 D7 UJ CPU DISPLAY BOARD SW25A J8 VOLTAGE REGULATOR KS1 21 J6 J9 J2 J3 Lo Lo P Lo 7 PIN 11 PIN 26 PIN 40 PIN JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE P1 EMERGENCY J2 Ji J3 J
35. GO Turntable rotate left right 18 20 ft los 24 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie TEREX COMPANY 4 54 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on GA the hydraulic schematic C cn Bg en D A is 25 GD Y26 Genie Part No 65162 TMZ 50 30 4 55 Section 4 Repair Procedures June 2005 p M mer MANIFOLDS REV B 9 8 Function Manifold Components DC Models after serial number T5000 90 The function manifold is located next to the engine under the engine side cover Index Schematic No Description Item Function Torque Coil nut items HE HF HG HH HI i ie iom m umu tuk Eh 4 5 ft lbs 5 7 Nm Coil nut item Hu a ii ea al ee Se nee RUE NE ee 5 7 ft los 7 9 Nm Diagnostic nipple
36. MANIFOLD v2 Vi eae acer alte fA x AUX 1 B1 TEST A2 B2 TT e o oe 66 lo f O eee 5 9 6 wan pal 9 e amm 3 1 E e Lem E XE ue 1 P2 T1 DC 1 M am S L min 11 4 HYDRAULIC TANK HS0134C A TEREX COMPANY 6 54 TMZ 50 30 Part No 65162 Section 6 Schematics June 2005 HydraulicSchematic REVA DC Models without Drive Option after serial number T5000 90 Part 2 of 2 0 6 gpm 2 27 L min TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER 1 E 1 mT i AE mo ow 3000 psi 3000 psi 7 2500 ps i gee ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 3 1 3 1 3 1 3 1 1 B3 A5 B5 A4 B4 A6 B6 AT B7 x u c 7 use oH z HG ae im Y23 v22 T t Yes T 7 pee Yel H Patt ale ARA LAM N FUNCTION MANIFOLD HS0134C Genie Part No 65162 TMZ 50 30 6 55
37. O 0 HORN 112 113 114 115 EMERGENCY e e 16 PIN ee ee strop e RIBBON CABLE Ct 80 11 5 MM SW25 GROUND oa lo 24V DC 5V DC 87654321 DIP SWITCH CONTROL J7 U22 SW25A BOX 13 D7 UU CPU DISPLAY BOARD 2 51321 DIP SWITCH VOLTAGE REGULATOR IKS1 key J6 J9 J2 J3 Lo Lo P Lo 7 PIN 11 PIN 26 PIN 40 PIN qu MN dT JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE 7 8 P5 J2 J1 J3 J4 1 5 7v RD U21 5 4 P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER 1172 FEY MS 5 Se Sa g2 gg pea LL 1 TII TN ul 28 4 6 LS15 zu di T o N C H O BE z gt 2 lt ES 55 3 2 a D7C 5 H HE 5 LS14 Le T N C H O NEC H4 U23 t ge Ll sis ENGINE pan CIRCUIT QD1 D1 KS3 BOARD lo ong E 2 SWITCH jf 22 88 89 28 88 U9 ce cc oo FUSE 15 OG I 22 go 66 99 gg aes M5 LM 22 EE EE 55 55 ge lt 25 88 99 55 3 oo Cc lt lt lt lt 4 6V A G5 crc L2 e F9 cra 96 P i 24V 10A HIGH FUEL 2 FE 99 99 FUSE IDLE CUTOFF aa a osv cmi 4
38. ZSA 1 5 al Oz z B l 0L Lot 709 dN AO 1411 amp amp Su 8 die T 709 TAS 1311 H3MO1 LZA 2 E yyy gt lt 6x 2 aaa 85 2 7109 dn TAD 13ITH3MO1 ZZA 2 0 gt gt j lt lt lt O i D x Br ZZ z 22 21 zz e 7 a gt ao Q G z Lb Kk gt 2 2 211 7109 103138 SA E amp Sup 6 y 9 9 9 bd ez s s 9 k z z E E2266 6 n No 7109 1437 SLVLOH ECA lt o 9 5 5 9 9 s lt 9 5 2 gt 2 ES lt EEUU S 24 QO OQ os 9 R GG 9 P P wi 9 1100 LHDIH EA m E zu Tn 9 8 58 S ES 8 S 8 2 E elle 100 ad aaiWuO4Ivid GLA oz m m m m m m m mn m m m m m m v Dell 1109 AM3 dn d3A31WHOdlvld OZA 5 a 2 zr 4 7109 N3O3H H395lH1nO LYA T TL u 7109 ON31X3 14A31u399IH1nO OFA T P lt z sos n 4 MP ol ES N QovHi3u dnuaoomino BEA Eu a x e d d d dere eee of of of of of of e gl dnouo x 12 Q oe z 109 IVNOLLHOdOUd oz 12 e i 7109 3AVA 4 a 12 o pb w cn B z S qp 2 lu u a3 WOO8 AuvWIHd 257 1 25115 OHO NWOOS LLST orang 9 lez WOO HOLI
39. capacity AWARNING primary boom primary linkage jib boom mount upper jib boom lower jib boom Q p m O platform mount cylinder AWARNING When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Raise the jib boom approximately 3 feet 1 m Lower the jib boom until the platform mount rests on sawhorses or a work table of sufficient 3 Disconnect the battery pack from the machine Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 4 Tag disconnect and plug the hydraulic hoses at the jib boom cylinder Cap the fittings on the Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Tag and disconnect the wires from the jib boom cylinder solenoid valve jib boom cylinder barrel end pivot pin jib boom lift cylinder jib boom cylinder rod end pivot pin Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B JIB BOOM COMPONENTS 6 Attach a lifting strap of suitable capacity from an
40. Type 2 section pressure balanced gear pump Displacement per revolution 0 488 cu in 8 cc Flow rate 5 6 gpm 21 2 L min Hydraulic tank return line filter 10 micron Auxiliary pump engine powered models Type single section pressure balanced gear pump Displacement per revolution 0 032 cu in 0 52 cc Flow rate 2500 psi 172 bar 0 6 gpm 2 27 L min Relief valve pressure 3700 psi 255 bar Auxiliary pump DC powered models Type single section hand pump Displacement per stroke 0 6 cu in 9 8 cc G Part No 65162 A TEREX COM TMZ 50 30 Flow regulator 6 gpm 22 7 L min Section 2 Specifications June 2005 SPECIFICATIONS Manifold Component REV B Valve Coil Resistance Specifications Description Specification Plug torque Solenoid valve 2 position 3 way 6 to 8Q 10V DC engine models schematic item BD SAE No 2 50 in Ibs 6 Nm Solenoid valve 2 position 3 way 26 to 280 SAE No 4 13 ft lbs 18Nm 20V DC DC models schematic item BD SAE No 6 18 ft lbs 24 Nm Solenoid valve 2 position 3 way 6 to 82 10V DC schematic items ED EE SAE No 10 55 ft lbs 75 Nm Solenoid valve 2 position way 4 to 6Q SAE No 12 75 ft lbs 102 Nm 10 DC schematic item FJ Solenoid valve 2 position 3 way 26 to 280 20V DC schematic item HE Valve Coil Resistance E Solenoid valve 2 position
41. FIDE M C LOTO D1 D2 T x I E F 4000 psi C 20 31 ic m mE MASTER CAT TV Tq COUNTER H BALANCE 1 V VALVE _ 1 MANIFOLD v2 v1 EA D1 D2 T2 AUX T3 B1 we A2 B2 SR Si ee ee 42 EJ Ud or EN S ae El 3000 psi I HA aval 206 8 bar wy AB 3000 pat ED Ld a SEED RTA mz t E 09 XY em FUNCTION MANIFOLD E ce 1 P2 P4 P3 2 1 DC 3 gpm 3 gpm m 11 4 L min 11 4 L min 908 11 1921 RUNI i e HYDRAULIC TANK HS0127C 6 64 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Hydraulic Schematic Bi Fuel Models with Drive Option REV B before serial number T5000 91 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER I rue i w Te M Q m i E 3000 psi 3000 psi p ps y I T 3000 ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 3 1 3 1 3 1 3 1 1 B3 A5 B5 A
42. HL Turntable rotate brake circuit 4 5 ft Ibs 5 7 Nm 13 Solenoid valve 3 position 4 way HM Outriggers up down 18 20 ft lbs 24 27 Nm 14 Solenoid valve 3position 4 way HN Platform level up down 18 20 ft lbs 24 27 Nm 15 Counterbalance valve HO Platform level down 30 35 ft lbs 41 47 Nm 16 Solenoid valve 3 position 4 way with manual over ride AP Turntable rotate left right 18 20 ft lbs 24 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie TEREX COMPANY 4 56 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on HA the hydraulic schematic U O HB B 9 e pow HK p 6 ON HD e lt t H
43. TN D7A 12 T L 4 Eus VOLTAGE 18 JA BN32 SECONDARY DOWN oo BNB DEVEREKE REGULATOR 14 2 5 4 BN27 JIBUP cae ni 7 o BN28 JIB DOWN 6 PIN v2 J3 L3 RIBBON CABLE us JC5 A32 2 e s4 BN34 ROTATE RIGHT J3 U24 JOYSTICK E ol m 4 oe BN33 ROTATE LEFT DRIVE CONTROLS 22 z B PRINTED CIRCUIT BOARD 33 to uo 74 BOOM RETRACT 1D7B THE 5 E VOLTAGE o 12V DC 5 DC 211 BL JE l s HORN BN73 age Zu BOOM EXTEND ligneus 3 S S J4 6 HBK e BN76 PLATFORM LEVEL DOWN n 14 321 T a adr A cs P2 oe BN75 PLATFORM LEVEL UP sage P3 EMERGENCY STOP EMERGENCY a EEE e Us e fj SOP BN77 ENGINE START Ed 2859 e _ 4 BN5 HORN DRIVE CONTROL BOX a ee BN12 FUNCTION ENABLE HIGH QD9B BN26 FUNCTION ENABLE MEDIUM apal ME QD9A 1113598 J i BN13 FUNCTION ENABLE LOW 2i PLATFORM CONTROL BOX GROUND CONTROL SS BOX LLILLLA J5 12 364 5 P3 CONNECTOR PC BOARD P2 412356 J6 OUTRIGGER U21 LIFT DRIVE Zo gras Ve 28a o on So of rz 89 t 9888 rti LI t Hl Lo 15137 LS11 4 4 N C H O oss 41 2 7 2 X X I X X X I X 1 X 1 X X I ista 0 LS2 S N O H C jc ix iW Ja gt x X x x
44. 11 4 L min 11 Eis HYDRAULIC TANK HS0124B 6 68 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Hydraulic Schematic Bi Fuel Models without Drive Option REV B before serial number T5000 91 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER I TON T uec i ii 124 pe M o m HSN pe Q 3000 psi 3000 psi p E y I T 3000 ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 3 1 3 1 3 1 3 1 1 B3 A5 B5 A4 B4 A6 B6 7 B7 eres lt O E amp ERAS t Y26 S Ch 22 k I L X X19 Y H X x H X Y60 s 1 0 6 2 27 Limin FUNCTION MANIFOLD HS0124B Part No 65162 TMZ 50 30 6 69 Section 6 Schematics June 2005 Hydraulic Schematic Bi Fuel Models without Drive Option REVA after serial number T5000 90 Part 1 of 2 OUTRIG
45. TEREX COMPANY Part No 65162 TMZ 50 30 6 21 Section 6 Schematics June 2005 E D Electrical Schematic Gasoline Bi Fuel Models REV B before serial number T5000 91 Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a a 1 OUTRIGGER AUTO LEVEL BN49 E BN38 PRIMARY UP T T ENGINE START BN68 BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER S T OUTRIGGER RETRACT BN48 oe BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN7O oe oe BN41 SECONDARY DOWN fic PLATFORM LEVEL UP BN69 52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 36 JIB BOOM UP p End BOOM EXTEND BN71 BN37 JIB BOOM DOWN m P HORN BN35 oe BN51 RIGHT REAR OUTRIGGER T T FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE
46. BN73 BOOM EXTEND Teves 31 G G 4 6 e BN76 PLATFORM LEVEL DOWN n 4321 P2 aa all sa Op CN se BN75 PLATFORM LEVEL UP EMERGENCY STOP EMERGENCY a EEE e Us e fj SOP BN77 ENGINE START EN7 m 888582 Ed 2859 Box _ Hu BN5 HORN DRIVE CON on X r exi um ss am n a BN12 FUNCTION ENABLE HIGH QD9B p BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 713598 BN13 FUNCTION ENABLE LOW D 855 pee eee 7 2 2 2 2 EN2 E PLATFORM CONTROL BOX EGU CONTROL fa ee ee BOX H j L Ll J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE gran RN NE SRh o on o FI EE t S835 L Jaee bet 1137 is n Bu NE X X I X X X G X X I X X 5 LS12 VA LS2 Tj 8 N O H C c n 9 9 c HN x X x x X 2 2 X 41527 i i 1 i 1 i 1 i N C Ee d g i 88 28 88 8 4 88 SU 90 OZ rr K 8 5 8 EZ as E I o tu a a a2 a i uu uu 66 66 o lt x o i 00 60 60 E 9 Ty 8 88 85 a L 24 99 99 rr rr 99 3 22 6 52358 2 Za 29 82 g 95 zr cr EE ZZ 9 55
47. BOOM RETRACT BN72 BN36 JIB BOOM UP p End G8 BOOMEXTEND BN71 BN37 JIB BOOM DOWN E E DIAGNOSTIC HORN BN35 oe BN51 RIGHT REAR OUTRIGGER FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 I BN50 LEFT REAR OUTRIGGER H5 O 0 HORN L12 113 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 ett 123456 71 EN2 5 SW25 GROUND 24V DC 5V DC 87654321 DIP SWITCH CONTROL 2 J7 U22 BOX PLATFORM 1 D7 UJ CPU DISPLAY BOARD SW25A 87654321 DIP SWITCH KS1 8 VOLTAGE REGULATOR CN KEY SWITCH 21 J6 J9 J2 J3 Lo Lo P Lo 7 PIN 11 PIN 26 PIN 40 PIN T poco qr s JUMPER CABLE JUMPERCABLE RIBBON CABLE RIBBON CABLE P1 EMERGENCY STOP J2 J1 J3 J4 1 2 P5 J8 RD U21 P4 P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER 14172 a e 3 18 5 3 89 82 88 s s A ksi x i s LI 1 ul a EI M 5 LS15 zu E T o N C H O E x 2 z gg 15 5 3 z r 2 7 E b I ne 5 5 LS14 Le T N C H O la 8 rape U23 EIC H15 ENGINE fee ka CIRCUIT QD1 D1 KS3 BOARD lo ong
48. 13 Thoroughly and heavily lubricate each tooth of the gear using multipurpose grease Rotate the 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 and poor rotator performance 14 Install the rotate handle shaft pinion and associated components into the gearbox 15 Thoroughly and heavily lubricate each tooth of the pinion using multipurpose grease 16 Install the rotate handle shaft cover Install and securely tighten the fasteners Do not over tighten 17 Install the platform control box mount and gearbox cover onto the top of the gearbox Install and securely tighten the fasteners Do not over tighten Genie Part No 65162 TEREX COMPANY TMZ 50 30 4 7 Section 4 Repair Procedures June 2005 Jib Boom Components 3 1 Jib Boom primary boom primary linkage jib boom mount upper jib boom jib boom cylinder barrel end pivot pin jib boom lift cylinder lower jib boom jib boom cylinder rod end pivot pin platform mount REV B How to Remove the Jib Boom 7 Perform this procedure with the 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 and then torqued to specification during installation R
49. BN41 SECONDARY DOWN P End PLATFORM LEVEL UP BN69 gee BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 BN36 JIB BOOM UP T Ed BOOM EXTEND BN71 BN37 JIB BOOM DOWN XR HORN BN35 TE BN51 RIGHT REAR OUTRIGGER a E FUNCTION ENABLE HIGH BN44 e gt BN43 ROTATE RIGHT ES T FUNCTION ENABLE MEDIUM BN45 E 42 ROTATE LEFT A T FUNCTION ENABLE LOW BN46 5 I BN50 LEFT REAR OUTRIGGER H5 anes 8F990Se worn EMERGENCY 38 EN L12 113 114 115 sop t b RIBBON CABLE ESS leg 1 EN2 z 33333333 SW25 oa 24V DC 5V DC 87654321 DIP SWITCH CONTROL 2 U22 ji BOK 13 D7 UU CPU DISPLAY BOARD M SOR WITCH J8 VOLTAGE REGULATOR IKS1 key switch J6 J9 J2 J3 Lo Lod Lod Lo 7 PIN 11 PIN 26 PIN 40 PIN c JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE P5 J2 J1 J3 J4 M RD 021 P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER i 1172 ET am 3229 LI 1 t TIL TII T 1 GY ulo 5 ree mu E z o H O lt u u 5 210 oc n a 2 u z o 215 LS14 gt 212 amp lt H 9 gg N C H O rT 6 6 6 oon 1 1 IKS3 SOM KEY SWITCH wH U33 001 VOLTAGE Fai WH RD BK REGULATOR
50. Gl 3000 psi 8 709 L Ju 20668 or i t 1 DE T 9 lt WY PUMP MANIFOLD FUNCTION MANIFOLD LLL ee ee ee P1 P2 P4 P3 Ti 2 1 DC 3 gpm 3 gpm 11 4 L min 11 4 L min e HYDRAULIC TANK HS0127C 6 48 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics ss O Hydraulic Schematic DC Models with Drive Option REV B before serial number T5000 91 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER 1 E 1 mT i AE mo ou 3000 psi 3000 psi 2500 ni y T 3000 ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 3 1 3 1 3 1 3 1 1 B3 A5 B5 A4 B4 A6 B6 AT B7 J G o gt GK 69 GB 65 Y24 H Y23 Y22 Y19 Y53 ti Y52 Y26 Y61 Y60 DR __ 0 0 6 gpm T 2 27 Limin FUNCTION MANIFOLD HS0127C Part No 65162 TMZ 50 30 6 49
51. 29 8 g IGF EE 55 55 8 5 ub gg Bg 595 55 85 28 8 12 88 55 55 30 366 99 S 2230 gg 59 U ge R 15 Qu og 22925 f FF Hoo oo o2 lt ES zr fo EE 22 522 fa GL 6k k o of 152 gu a CO E uu uj E 4 gt SO FEE fe O99 zz EE lt G 203 35 54 Ex amp gt EE Ef eR eR 22 5529 990 er ge EHX E 97 150 EE BE kk ge gg 22 522 amp 590E EE EE EE FSF FH B EB B 188 LE qu ee rr Pg 53 ttoo oo 569 85 55 Sg 8 e o N e oo o Ar AH HO ON A D 2 5 49 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0217B THE POWER OFF ES0222B TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics U n Electrical Schematic Diesel Models from serial number T5000 91 to T5002 24 June 2005
52. P1 EMERGENCY J2 Ji J3 J4 1 2 5 J8l _ RD oN P4 P1 U21 P3 CB2 ENGINE CONNECTOR PC BOARD OUTRIGGER CIRCUIT BREAKER i 17 2 9 19 Qo 82 88 E a SS SS tht 727 n LS15 N C H O tui 5 MESES SLSt4 gt 2 2 N C H O X m mm s oz il B5 oo gt 8 8 8 EIGHT 6V BATTERIES QD1 EE 5 5 5 5 MODELS WITH DRIVE rs 22 Sc ae en F6 SiG EE 5 U9 275A 55 25 25 OO FOUR 6V BATTERIES BATTERY FUSE 66 22 ee E gE MODELS WITHOUT DRIVE CHARGER EE lt lt occ Qd OG pe EE ao m ee Ek eg z qu fe fe uo S 5 8 1 24V gt gt 2 M gt A G6 0 5V NOTE Uo MACHINE SHOWN D remm INTHE STOWED POSITION WITH THE POWER OFF ES0230B ES0235B 6 12 A TEREX COMPANY TMZ 50 30 Part No 65162 DC Models Part 2 of 2 Section 6 Schematics after serial number TMZ5003 228 Electrical Schematic June 2005 REV
53. 8 B m qm s START 3 Tar 185 bas 87A 85 gt gt b gt Lt AC INPUT o 4 L QD7 CONTROLLER b h SW2 SW28 Qa NOTE ENGINE ENGINE oz b CYLINDER 5E MACHINE SHOWN PRESSURE HEAD TMP Zz IN THE STOWED 175A FUSE ets Jt lt gt POSITION WITH 20 Q3 Q8 zd THE POWER OFF 4 HIGH IDLE FUEL SOLENOID CUTOFF ES0219C ec ES0224B 6 40 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic Diesel Bi Fuel Models from serial number T5000 91 to T5002 24 Part 2 of 2 eter ee ce a as rs ay oy ne i PLATFORM CONTROLS Pal PLATFORM 2 MEMBRANE DECAL PANEL contROLs 3 p gt gt gt gt PRINTED 4 SOL gt 2 DRIVE CONTROLS an gos MEMBRANE DECAL PANEL
54. AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed 9 Lower the cylinder onto the secondary boom REV B 10 Remove the pin retaining fasteners from the platform level master cylinder rod end pivot pin 11 Using a soft metal drift remove the platform level master cylinder rod end pivot pin 12 Attach a lifting strap of suitable capacity from an overhead crane to the primary boom Support the boom Do not apply any lifting pressure Component damage hazard The CAUTION cable track can be damaged if not protected when lifting the boom 13 Remove the pin retaining fasteners securing the primary boom pivot pin 14 Using a soft metal drift remove the primary boom pivot pin ADANGER Crushing hazard The primary boom could become unbalanced and fall if not properly supported when the pin is removed 15 Release the latch at the turntable end of the machine 16 Remove the primary boom from the machine ADANGER Crushing hazard The primary boom could become unbalanced and fall if not properly supported when removed from the machine Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 4 3 Boom Extension How to Remove the Boom Extension AWARNING This procedure in this section requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without
55. BN78 OUTRIGGER EXTEND 5 BN29 PRIMARY UP e 4 QZ 8 ut BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 e BN80 OUTRIGGER RETRACT oz22ved Jsvoe BN31 SECONDARY UP D7A 35 E HORN voutace 19 1 SECONDARY DOWN l BN82 DRIVE ENABLE REGULATOR 14 BN27 JIB UP 54321 CO L46 BN28 JIB DOWN 6 PIN Lag JCS v2 lv A RIBBON CABLE ro 4321l 1 2 4a 4 ROTATE RIGHT J3 U24 JOYSTICK E v m 4 oe BN33 ROTATE LEFT DRIVE CONTROLS 2288 B PRINTED CIRCUIT BOARD 33 H2 BN74 BOOM RETRACT ID7B 5 24V 5V DC ot BL HORN VOLTAGE 585 BN73 BOOM EXTEND ali 4555 J4 BK e BN76 PLATFORM LEVEL DOWN MM 14 321 IE EBD a cs P2 oe BN75 PLATFORM LEVEL UP zzi P3 EMERGENCY STOP EMERGENCY SES e e 97 STOP BN77 ENGINE START EN7 BN5 HORN DRIVE CONTROL BOX E a 4 BN12 FUNCTION ENABLE HIGH QD9B T BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 1113598 J BN13 FUNCTION ENABLE LOW 2 2 2 2 EN2 LEN1 PLATFORM CONTROL BOX II __ __ __ __ __ __ __ GROUND CONTROL a ee ee
56. SECONDARY DOWN l BN82 DRIVE ENABLE 1l REGULATOR 14 T BN27 JIB UP 54321 EX O e BN28 JIB DOWN 6 PIN v o2 J3 3 RIBBON CABLE 2 148 JC5 4321l 1 2 4a 4 ROTATE RIGHT J3 U24 JOYSTICK A E m 4 BN33 ROTATE LEFT DRIVE CONTROLS 2 2 lg ES s PRINTED CIRCUIT BOARD 555 H2 BN74 BOOM RETRACT ID7B Tt 5 4d HORN 22 1 I vortace o12vec sv oc at EEEE Hr BN73 BOOM EXTEND al Yt amp amp 6 JA 648K e BN76 PLATFORM LEVEL DOWN n 14 321 P2 aa all sa C CN BN75 PLATFORM LEVEL UP EMERGENCY STOP is 2 L BN77 ENGINE START EN7 a cm BN5 HORN 9 aea DRIVE CONTROL BOX E a BN12 FUNCTION ENABLE HIGH QD9B p BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 1113598 BN13 FUNCTION ENABLE LOW ee ees M p d EN2 LEN1 PLATFORM CONTROL BOX __ __ __ __ __ __ __ __ GROUND CONTROL Bir ccr dicen occum ee ee urs s BOX J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE BES RE NE SSR wo vv on So of 99 t BAB L r bet 1137 is ES Eu 7 2 X X I X X X I X X I X X I i Sts12 x LS2 i i S N CH O N O H C EN c x X x
57. U24 DRIVE CONTROLS PRINTED CIRCUIT BOARD J3 6 PIN RIBBON CABLE 12345 6 BN78 OUTRIGGER EXTEND BN79 OUTRIGGER AUTO LEVEL BN80 OUTRIGGER RETRACT BN81 HORN i BN82 DRIVE ENABLE DRIVE CONTROLS MEMBRANE DECAL PANEL Ps ee IA Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005 DRIVE COMPONENTS OPTION 4 Disconnect the blue connector from the circuit board at the connection marked KEYPAD by sliding the connector parallel to the circuit board CAUTION Component damage hazard The circuit board will become damaged if the wire harness and connector are disconnected without proper care Do not pull upwards on the connector Component damage hazard The circuit board may become damaged if the weight from the control box lid pulls on the wire harness Do not put any weight or strain on the wires CAUTION Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when handling printed circuit boards CAUTION 5 Install the lid onto the control box Finger tighten the retaining fasteners 6 Starting at the lower corners of the touch pad remove all layers of the key pad from the control box lid The wire harness and blue connector will interfere if removing the
58. 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Gasoline engine models Turn the manual fuel shutoff knob to the off position Diesel engine models Hold the manual fuel shutoff lever in the closed position 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Pull out the red Emergency Stop button to the on position at the drive controls if equipped 5 Engine models Observe the pressure gauge while cranking the engine using the key switch at the engine DC models Observe the pressure gauge while activating any boom function from the ground controls Result If the pressure gauge reads 3000 psi 207 bar immediately stop The pump is good W Result If the pressure fails to reach 3000 psi 207 bar the pump or the coupling is bad and will need to be serviced or replaced Component damage hazard The CAUTION hydraulic pump can be damaged if the pressure exceeds 3000 psi 207 bar 6 Remove the pressure gauge and reconnect the hydraulic hose Torque to specification AWARNING injury hazard Spraying ydraulic 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 Genie A TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Sec
59. 88 98 EE 55 55 SSoe uy 8g 525 85 589 28 12 O8 22 55 DO 00 G z 2250 go OG 5 BO LS gH a oo oo 55 6 z zx055 63 25 O U 119 n gu EE r 2 2 2 Go HO o o2 rz T 0 EE 66 55 99 EE 24 ust S E LI l a 6 66 66 EE 99 22 989 gt 55 56 fx u 10 Of E gt EE ge 3822 S838 88 ge ge 57 158 ce oe Ek EE 568 58 44 En 2 SO oE EE RE EE Eos z Ha cB LEVELSENSOR gt FE ee ee ttoo 88 20 569 85 55 Sg 8 e o e Q0 9 o Ar AH HO ON A D 494 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0233B THE POWER OFF ES0238B TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics E Sn Electrical Schematic Diesel Models before serial number T5000 91 June 2005
60. AH HO ON A D 2 5 49 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0219C THE POWER OFF ES0224B TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics Electrical Schematic Diesel Bi Fuel Models from serial number T5002 25 to TMZ5003 228 June 2005 Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a o OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 ee BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER ES Ed OUTRIGGER RETRACT BN48 oe gt BN40 SECONDARY UP T T PLATFORM LEVEL DOWN 70 oe BN41 SECONDARY DOWN fic PLATFORM LEVEL UP BN69 BN52 LEFT FRONT OUTRIGGER
61. CA All functions 25 27 ft lbs 34 36 Nm 2 Relief valve 3000 psi 206 8 CB System relief 18 20 ft Ibs 24 27 Nm 3 Check valve CC Prevents flow from DC power unit to engine pump 18 20 ft los 24 27 Nm 4 Check vaklve CD us Prevents flow from engine pump to DC power unit 18 20 ft los 24 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie TEREX COMPANY 4 46 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha callouts refer to corresponding notes on the hydraulic schematic CA D Note alpha numeric callouts refer to corresponding notes on the electrical schematic 4 EY E E NG amp cc lt 3 L CY lt 4 Nas 4 Genie A TEREX TMZ 50 30 Part No 65162 Section 4 Repair Procedures June 2005 p a s x r1 MANIFOLDS REV B 9 4 Pump Man
62. E gt Zu OO c sk Lz lt 09 99 fe 22 zz 0 feito OO 3 2035 35 56 10 E gt EE SosS 99 00 EE fae bz 57 zu ee kk 55 55 82 S22 99295 EE 55 BE fE 58 B teversenson gg 55 uu 84 ce SSP 260 oo 3569 95 55 5 8 A 66 e o o e DNDN o Ar QW sS AH HO ON QW 1D 3 3 94 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0234A THE POWER OFF ES0239A TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics Electrical Schematic Diesel Bi Fuel Models after serial number TMZ5003 228 Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL June 2005 m T T O
63. Hydraulic Schematic Engine only Models with Drive Option REVA after serial number T5000 90 Part 1 of 2 DRIVE OUTRIGGERS OPTION i FRONT FRONT LEFT RIGHT RIGHT DRIVE DRIVE BRAKE CYLINDER CYLINDER RELEASE E CYLINDER ef LEFT 4 4 x DRIVE DRIVE vem 1 FM dew U MOTOR MOTOR B 1 M2 C BOR l 4 Sl Sp a seda ima mm DRIVE MANIFOLD PONE mas PLATFORM n yw A xi e Y LEFT RIGHT LEVEL Y tly I d f amp 0 i SLAVE 3850 psi e T 3850 psi amp i Sian gio Yi 0 046 inch 0 046 inch M 1 jem HF x E D1 D2 Tip Oo N oss ee cll ae 3 gt EE TEES T p AUXILIARY A a POWER 275 8 ber yr MASTER PUNI OR
64. L12 113 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 4 123456 71 EN2 Irt 5 SW25 GROUND li 12V DC 5V DC 87654321 DIP SWITCH CONTROL 2 J7 U22 4 BOX 3 PLATFORM D7 cpu DISPLAY BOARD 33333413 SW25A I 3 87654321 DIP SWITCH KS1 8 VOLTAGE REGULATOR a KEY SWITCH 21 J6 J9 J2 J3 Lo 4 x Y Lx xl x x x 7 PIN 11 PIN 26 PIN 40 PIN T JUMPER CABLE JUMPER CABLE RIBBONCABLE RIBBON CABLE i P1 EMERGENCY STOP B J2 Ji J3 J4 5 mu dp U21 x P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER EE 6 4 16 1 5 919 389 82 8 amp 8 H L T 1 GY C i u a LS15 M z N C H O 2 ola SEE IT z 2 N C H O SF a i 7 KS3 1 1 BA KEY SWITCH wH Bkm Be 033 VOLTAGE i WH Roek REGULATOR at ais d dd gt gt x oo zo oo OZ BK gt O0 OO oq G 22 OG L 95 990 EE EE rast e LO L 12 99 90 ge cc tr c ce lt lt lt lt r3 Er gg gp ss co cao FUSE CR4 55 kt EE tz HIGH uk bb IDLE aa aj CE EE 30 486 t E o gt gt 4 gt REC 85 SW26 NOTE ENGINE Zu I OIL d Sz MACHINE SHOWN 11 L
65. Note alpha callouts refer to corresponding notes on EA the hydraulic schematic U EB g en D CA lt 25 er _ ED Y26 Genie Part No 65162 TMZ 50 30 4 51 Section 4 Repair Procedures June 2005 MANIFOLDS 9 6 Function Manifold Components REV B Engine and Bi Fuel Models after serial number T5000 90 The function manifold is located next to the engine under the engine side cover Index Schematic No Description Item Function Coil nut items FE FF FG FH FI EM EN UE Coil nut item Fd psp Torque usine as 4 5 ft lbs 5 7 Nm varies 5 7 ft lbs 7 9 Nm Diagnostic nipple FA Testing 2 Flow regulator valve 0 6 2 27 L min Turntable rotate circuit 18 20 ft lbs 24 27 Nm 3 Orifice Plug 0 025 inch 0 64 mm FC Turntable rotate circuit 4 Pilot operated check valve FD Outrigger down circuit 30 35 ft Ibs 41 47 Nm 5 Solenoid valve 2 position 3 way FE Primary boom extension 18 20 ft los 24 27 Nm 6 Solenoid valve 2 position 3 way EF ausus Primary boom retract 18 20 ft los 24 27 Nm
66. REI ME AOX 0 6 gpm _ 2 27 L min FUNCTION MANIFOLD HS0139D Part No 65162 TMZ 50 30 6 59 Section 6 Schematics June 2005 Hydraulic Schematic Engine only Models without Drive Option REV B before serial number T5000 91 Part 1 of 2 OUTRIGGERS FRONT FRONT LEFT RIGHT r r ITF SITE 0 046 inch 0 046 inch 1 17 mm 1 17mm Vm Km man uus p LEFT RIGHT LEVEL SLAVE SII et mE LO eae M pen AUXILIARY 5 POWER 275 8bar 1 T 137 9 bar MASTER UNIT Er 8 COUNTER 1 Sd BALANCE F1 E y MANIFOLD tll V2 12088 1 EA d Al Je Ae BEDS Ir n e la wo HW E F a Po ct Y39 Y20 M S TTD xv CB 1 CO L PUMP MANIFOLD FUNCTION MANIFOLD pps k J s u Espuma P1 T1 2 a CO 11 Eis K min e HYDRAULIC TANK
67. when the pivot pin is removed 9 Remove the pin retaining fasteners from the platform level slave cylinder barrel end pivot pin 10 Using a soft metal drift remove the platform level slave cylinder barrel end pivot pin Remove the cylinder AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed 11 Remove the pin retaining fasteners from the extension cylinder rod end pivot pins 12 Using a soft metal drift remove the extension cylinder rod end pivot pins Remove the cylinder AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 4 4 Primary Boom Lift Cylinder How to Remove the Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Rem
68. 10 Pull out and hold the knob at the center of the secondary boom valve stem Operate the hand pump with a push pull motion Result The secondary boom down function should operate 11 Release the knob 12 Locate the jib boom valve on the function manifold Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures REV B 13 Pull out and hold the knob at the center of the jib boom valve stem Operate the hand pump with a push pull motion Result The jib boom down function should operate 14 Locate the turntable rotate valve on the function manifold 15 Pull out and hold the knob at the center of the turntable rotate valve stem Operate the hand pump with a push pull motion Result The turntable should rotate in a clockwise direction 16 Push in and hold the knob at the center of the turntable rotate valve stem Operate the hand pump with a push pull motion Result The turntable should rotate in a counterclockwise direction Bi Fuel and Engine Models 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Pull out the red Emergency Stop button to the on position at the drive controls if equipped Start the engine Result The engine power light should be on 2 Raise the primary secondary and jib booms approximately 12 inches 30 cm
69. 22 BB Si 25 S 5 57 198 PB Ba we EE EE 55 CES 2052 ee ER GE Eg bz gt EE bE EE 55 44 sar 8225 55 Eee FF Eo gg B EVELSENSOR g kk uu uu ce LE 55 260 oo 3569 95 55 5 8 cc e o N e oo o Ar AH HO ON A D 2 5 49 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0218C THE POWER OFF ES0223C TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics June 2005 E 1t Electrical Schematic Gasoline Bi Fuel Models REVA from serial number T5002 25 to TMZ5003 228 Part 1 of 2 GROUND CONTROLS MEMBRANE DE
70. 4 5 1 mM 3 1 Tox COUNTER 7 1 7 BALANCE a ae y VALVE alid wwrop Tao psi 7 V2 V1 1 1 EA D1 D2 T2 AUX T3 At B TEST __ jns im Ch gt lt El 3000 psi 709 Me Ha 2 6 a SEED RTA uii t 69 T 9 rS x xy PUMP MANIFOLD FUNCTION MANIFOLD EL ee ee ee ee s i ee 1 P2 P4 P3 T1 2 S08 11 Eis i HYDRAULIC TANK HS0129E 6 56 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Hydraulic Schematic Engine only Models with Drive Option REV before serial number T5000 91 Part 2 of 2 TURNTABLE PRIMARY EXTENSION JIB ROTATE CYLINDER CYLINDER BOOM UPPER 1 i ME o ou 3000 psi DH y TE isi 206 8 bar 172 4 bar 206 8 bar 3 1 3 1 3 1 1 B3 A5 B5 A6 B6 7 B7 NEUE 2 SI RED BE lt o E B evar EO Y23 Y22 ES Y19 Y26 Y61 Y60 re MBI ALAS rm s 1 0 6 2 27 L min FUNCTION MANIFOLD 0129 Genie Part No 65162 TMZ 50 30 6 57 Section 6 Schematics June 2005
71. 4 Tag and disconnect the wire connectors from the circuit board Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when handling printed circuit boards 5 Remove the circuit board mounting fasteners and remove the circuit board from the box Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 1 2 Membrane Overlay How to PLATFORM CONTROLS 4 Disconnect the large blue connector from the circuit board at the connection marked KEYPAD by sliding the connector parallel to the circuit board CAUTION Component damage hazard The Replace the Overlay circuit board will become damaged if the wire harness and connector 1 Tag and disconnect the platform controls wire are disconnected without proper ae ee harness connector at the care Do not pull upwards on the PIANO pivot connector 2 Remove the controls from the machine Open Component damage hazard The the clamp on the back of the controls and slide CAUTION circuit board may become damaged he weight rom the control box lid pulls on the wire 3 Loosen the control box lid retaining fasteners harness Do not put any weight or and open the lid strain on the wires CAUTION Component damage hazard El
72. E See a 5 BN12 FUNCTION ENABLE HIGH QD9B BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 1113598 J BN13 FUNCTION ENABLE LOW MEG n s EN2 LEN1 PLATFORM CONTROLBOX II __ __ __ __ __ __ is GROUND CONTROL BOX J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE Ve SER o on No of FE 22 t 9838 m bet 1137 is ES Eu 7 O gt 2 all B X Xe ee ee Xp N C H O N O H C 5 5 c PK PX G 212 ie CX 5 uu i z dd 9 a 223 22 35 95 55 acB 2 88 x oo QS 20 OO E s Sica CO E RAS r F 4 4 i OZ rr 8 55 as gt I ff 68 58 9 5 So 9 Es a B ES oO OO i ang 9 E 90 99 22 22 29 5 2 32 k 2 sz 29 Ba x 85 22 rr FE FE ZZ xxoU 29 2 5285 455 8 8 t o FE 55 55 EOS gt gt Lu 3 OF oz 5 00 59 0 2 S 22 55 99 BIS 3250 g OQ 5 22 15 of 00 OO FE EE Z08 305 GG doo o2 ES F gE ED 66 55 55 Bzg 9955 Sh kk ko SE E ES 86 6 66 zg gg oo ES FE Dal 55 b2 k b 5 ES 65 55 EE 98 Bic
73. GROUND li 12V DC 5V DC 87654321 DIP SWITCH CONTROL 2 J7 U22 I 4 BOX 3 PLATFORM D7 cpu DISPLAY BOARD 33333413 SW25A I 3 87654321 DIP SWITCH KS1 8 VOLTAGE REGULATOR a KEY SWITCH 21 J6 J9 J2 J3 ele Lo Lo P Lo 7 PIN 11 PIN 26 PIN 40 PIN JUMPER CABLE JUMPER CABLE RIBBONCABLE RIBBON CABLE i P1 EMERGENCY STOP B J2 Ji J3 J4 5 mu dp U21 x P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER EE 6 4 16 1 5 919 389 82 8 amp 8 H L T 1 GY C i u a LS15 M z N C H O 2 ola SEE IT z 2 N C H O SF a i 7 KS3 1 1 BA KEY SWITCH wH Bkm Be 033 VOLTAGE i 2 WH Roek REGULATOR at ais d dd gt gt x oo zo oo 3 QQ OO OZ Lge ae cu 29 88 38 g me G64 gt gt 55 88 G8 95 990 Er EE east pe Loe 12 99 90 ge cc tr c ce lt lt lt lt g gg 20 22 co co FUSE CR4 55 EE tz HIGH uk bh IDLE aa aj CE EE 30 486 t E 9 m gt gt 4 gt REC 85 SW26 NOTE ENGINE zu I OIL d 62 MACHINE SHOWN 11 LEVEL B 2 IN THE STOWED 175A FUSE tae de POSITION WITH M3 103 Q7 019 Y U20 THE POWER OFF UI AH HIGH IDLE CHOKE IGNITION SPARK 2
74. HS0126D 6 60 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics REV B TURNTABLE PRIMARY ROTATE CYLINDER UPPER Hydraulic Schematic Engine only Models without Drive Option before serial number T5000 91 1 we 3000 psi 206 8 bar S1 A3 B3 A5 BS EO oer lt Q Y23 Y22 qT T 0 6 gpm T 2 27 L min lt P HS0126D Part No 65162 Part 2 of 2 EXTENSION JIB CYLINDER BOOM w Te E M 9 m i E 87 172 4 bar 206 8 bar 3 1 3 1 qM OMA he Bl p AP eae amp IAB E TMZ 50 30 6 61 Section 6 Schematics June 2005 Hydraulic Schematic Engine only Models without Drive Option REVA after serial number T5000
75. Remove the return filter mounting fasteners Lay the filter off to the side Remove the hydraulic tank mounting fasteners and remove the hydraulic tank from the machine Part No 65162 TMZ 50 30 4 67 Section 4 Repair Procedures June 2005 Axle Components 11 1 Axle How to Remove the Axle ANSI models 1 Lowerthe outriggers and adjust to level the machine and raise the wheels off the ground Disconnect the secondary brake cables at the tension equalizer Pull the cables free of the trailer Hydraulic brakes Tag disconnect and plug the hydraulic brake line and brake hose assembly from the back of the hub Cap the fitting Clean up any brake fluid that may have spilled Electric brakes Remove the parking brake cable and the electric brake cable from the back of the hub Repeat step 4 for the other side Support and secure the axle assembly to an appropriate lifting device Remove the axle mounting fasteners and remove the axle from the machine AWARNING Crushing hazard The axle could REV B CE models 1 Lower the outriggers and adjust to level the machine and raise the wheels off the ground Disconnect the secondary brake cables at the tension equalizer Support and secure the axle assembly to an appropriate lifting device Remove the axle mounting fasteners and remove the axle from the machine AWARNING Crushing hazard The axle could become unbalanced and fall if not p
76. Repair Procedures June 2005 SECONDARY BOOM COMPONENTS 10 Remove the cable supports securing the cables and hoses to the mid pivot Pull the cables through the mid pivot and lay them off to the side of the secondary boom Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched For ease of assembly pay close attention to how the cables and hoses are routed when removed from the cable support 11 Attach a lifting strap of suitable capacity from an overhead crane to the mid pivot Support the mid pivot Do not apply any lifting pressure REV B 12 Attach a lifting strap of suitable capacity from an overhead crane to the secondary boom Support the boom Do not apply any lifting pressure 13 Remove the pin retaining fasteners from the secondary boom pivot pin at the mid pivot 14 Using a soft metal drift remove the secondary boom pivot pin Crushing hazard The secondary AWARNING boom could become unbalanced and fall if not properly supported when the pin is removed 15 Remove the pin retaining fasteners from the secondary link pivot pin at the mid pivot a secondary boom hold down latch m secondary boom link b secondary boom link pivot pin n secondary boom lift cylind
77. Required maintenance procedures and additional engine information is available in the Honda GX340 Engine Owner Manual Honda part number 31ZH9603 Honda GX340 Owner s Manual Genie part number 97361 Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Genie TMZ 50 30 Operator s Manual Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Id Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine disconnected from tow vehicle Machine parked on a firm level surface with the boom stowed and both latches secured Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked and parking brake applied All external AC power supply disconnected from the machine Rep
78. SECONDARY BOOM COMPONENTS 5 2 Secondary Boom Lift Cylinder How to Remove the Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom to a horizontal position 2 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Attach a lifting strap of suitable capacity from an overhead 5 ton 5000 kg crane to the mid pivot 4 Attach a lifting strap of suitable capacity from an overhead crane to the rod end of the secondary boom lift cylinder 5 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin REV B 6 Use a soft metal drift to remove the lift cylinder rod end pivot pin Crushing hazard The cylinder AWARNING d may fall if not properly supported when the pivot pin is removed 7 Lower the cylinder onto the turntable 8 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the
79. TMZ 50 30 REV B Torque 4 5 ft lbs 5 7 Nm 5 7 ft lbs 7 9 Nm 12 14 ft lbs 17 19 Nm 25 27 ft lbs 34 36 Nm 25 27 ft lbs 34 36 Nm 18 20 ft lbs 24 27 Nm 12 14 ft lbs 17 19 Nm 12 14 ft lbs 17 19 Nm 25 27 ft lbs 34 36 Nm Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS LEFT REV FWD Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on the hydraulic schematic Part No 65162 Genie TMZ 50 30 4 59 Section 4 Repair Procedures June 2005 p M mer MANIFOLDS REV B 9 10 Drive Manifold Components after serial number T5000 90 The drive manifold is located on the axle at the ground controls side of the machine Index Schematic No Description Item Function Torque t item KD he t a a a 4 5 ft Ibs 5 7 Nm Coil nut items KB and KG 3 2 a e Ratte tate t e e teatri etur 5 7 ft los 7 9 Nm 1 Counterbalance valve KA Ground controls left side drive motor 30 35 ft lbs 41 47 Nm 2 Solenoid valve 3 position 4 way Controls the ground controls side drive motor in forward and reverse 25 27 ft lbs 34 36 Nm 3 Solenoid valve 3 position 4 way Contr
80. j O O6 rr rr 3 Z xz 52 eae Zao 29 Of O Lx 4 89 62 rr 65 9065 Egor 1 o2 695 65 60 119 22 22 QQ EO z S50 oo 2 a 26 i 2 90 22 55 OO gt gt 42 gt gt St GSE 5 5 oo oo 55 209z 305 Sc FEF BS FS RQR ilo lt 2 cy EE ZZ zz 5 r rcr 2 2 E ME amp lt zz zz 58 Zz uu EE ES Q rc O02 gt zu oo OO 99 gt ti o Kd 203 35 5 gt cc uu zz lt uu c S7 o te rr Pog QOS2 kt 65h Gk Gs gt 5 LE 33 ga 22 5218 EE EE SE Ege EE 118 e EE ii kh uu 55 260 oo 3569 95 55 5 o omen HH N e lt lt to T NN sr N 0 onm N ot e o e DNDN o sx NF NN S S AH DH ON A gt de v gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0234B THE POWER OFF ES0239B Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 6 Schematics June 2005 E This pa
81. 1 jf 36 ge zz zz 990 Go E a uu ss w St EE ES Q rc 4 O2 C gt go gg EE 22 22 99 EE 22 22 30 EG E S7 ilog OOS ac ce i a ve re Ek 55 EBS Sse FE EE Sse Hu amp 2 2 evecsenson 28 FE EE 560 O90 4 Sag 9995 55 lt lt 55 EQS t Fa a9 8 2 506 uu uu gg 55a ee 369 95 55 58 N lt lt o 89 o S AN AB BS BSE 523 xU SE 4 4 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR DRIVE FUNCTIONS NOTE MODELS WITH DRIVE MACHINE SHOWN IN THE STOWED POSITION WITH ES0198C THE POWER OFF ES0203A G enie Part No 65162 A TEREX COMPANY TMZ 50 30 Section 6 Schematics June 2005 Electrical Schematic DC Models REV A from serial number T500
82. 24 27 Nm 5 Solenoid valve 2 position 3 way with manual over ride GE 25343 Primary boom retract 18 20 ft los 24 27 Nm 6 Solenoid valve 3 position 4 way with manual over ride Jib boom up down 18 20 ft lbs 24 27 Nm 7 Solenoid valve 3 position 4 way with manual over ride GG Primary upper boom up down 18 20 ft los 24 27 Nm 8 Solenoid valve 3 position 4 way with manual over ride GH Secondary lower boom up down 18 20 ft lbs 24 27 Nm 9 Solenoid valve 2 position 3 way Gl Regenerative circuit for outriggers 18 20 ft lbs 24 27 Nm 10 Counterbalance valve GJ iiu Platform level up 30 35 ft lbs 41 47 Nm 11 Shuttle valve ous Turntable rotate brake circuit 4 5 ft Ibs 5 7 Nm 12 Solenoid valve 3 position 4 way Gb assu Outriggers up down 18 20 ft lbs 24 27 Nm 13 Solenoid valve 3 position 4 way GM Platform level up down 18 20 ft lbs 24 27 Nm 14 Counterbalance valve Platform level down 30 35 ft lbs 41 47 Nm 15 Solenoid valve 3 position 4 way with manual over ride
83. 7 5 Level Sensor One level sensor monitors the incline of the turntable after the outriggers are deployed and the machine is level The Electronic Control Module ECM is programmed to deactivate lift functions and activate an alarm when a signal is received from the level sensor making the operator aware of a potentially hazardous situation The tilt alarm sounds when the incline of the chassis exceeds 1 5 in any direction The tilt level sensor is located below the ground control box How to Install and Calibrate the Tilt Level Sensor A DANGER Tip over hazard Failure to install or calibrate the level sensor as instructed could result in the machine tipping over causing death or serious injury Do not install or calibrate the level sensor other than specified in this procedure 1 Perform this procedure with the machine on a firm level surface that is free of obstructions Genie 4 34 A TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B GROUND CONTROLS 2 Turn the key switch to ground control and pull If you are not installing a new level sensor out the red Emergency Stop button to the on position at both the ground and platform controls Pull out the red Emergency Stop button to the on position at the drive controls if equipped Result The power light should be on proceed to step 11 6 Tag and disconnect the wire harness from the tilt
84. 7 Solenoid valve 3 position 4 way FG unu Jib boom up down 18 20 ft lbs 24 27 Nm 8 Solenoid valve 3 position 4 way FH Primary upper boom up down 18 20 ft los 24 27 Nm 9 Solenoid valve 3 position 4 way EL sss Secondary lower boom up down 18 20 ft lbs 24 27 Nm 10 Solenoid valve 2 position 3 way EJ Regenerative circuit for outriggers 25 27 ft los 34 36 Nm 11 Counterbalance valve FK Platform level up 30 35 ft lbs 41 47 Nm 12 Shuttle valve Eb uu Turntable rotate brake circuit 4 5 ft Ibs 5 7 Nm 13 Solenoid valve 3 position 4 way FM Outriggers up down 18 20 ft lbs 24 27 Nm 14 Solenoid valve 3 position 4 way Platform level up down 18 20 ft lbs 24 27 Nm 15 Counterbalance valve FQ Platform level down 30 35 ft lbs 41 47 Nm 16 Solenoid valve 3 position 4 way Turntable rotate left right 18 20 ft lbs 24 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install th
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86. Extend the primary boom approximately 12 inches 30 cm 3 Turn the engine off Push in the red Emergency Stop button to the off position at the ground controls Genie TEREX COMPANY TMZ 50 30 3 17 Part No 65162 CHECKLIST B PROCEDURES Pull out the red Emergency Stop button to the on position at the ground controls Result The battery power light should be on Activate the lower function for the primary secondary and jib booms and lower each boom approximately 6 inches 15 cm Result The boom lower functions should operate Activate the retract function for the boom extension and retract the boom approximately 6 inches 15 cm Result The boom retract function should operate Activate the turntable rotate function in both directions Result The turntable rotate function should operate in both directions Turn the key switch to platform controls Result The battery power light should be on Repeat steps 5 through 7 from the platform controls Section Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 6 Inspect the Tires and Wheels including lug nut or lug bolt torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion 1 Check the tire
87. Part No 65162 June 2005 Section 4 Repair Procedures REV B 4 2 Primary Boom How to Shim the Primary Boom 1 Extend the boom until the wear pads are accessible 2 Loosen the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Securely tighten the mounting fasteners Do not over tighten 5 Extend and retract the boom through an entire cycle Check for tight spots that could cause binding or scraping Always maintain squareness between the outer and inner boom tubes PRIMARY BOOM COMPONENTS How to Remove the Primary Boom AWARNING This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib See 3 1 How to Remove the Jib Boom 2 Remove the cable track See 4 1 How to Remove the Cable Track 3 Remove the supports securing the cables to the bottom
88. RIBBON CABLE RIBBON CABLE ll 7 J2 J1 J3 J4 1 2 BK 5 38 M RD 021 P1 CONNECTOR PC BOARD P3 30A ENGINE OUTRIGGER 2 CIRCUIT BREAKER 17 4 1 3 18 5 2x Qo 82 8 amp 8 i pawak LL 1 TII 1 u a Zo LS15 E uj 2 5 B N C H O iu E z 8 3 lt 2 7 E b 5 5 i814 I T ry 24 U23 1 H15 ENGINE 7 l CIRCUIT BOARD N lo o 223 oz I Ii 21021 a8 99 99 B6 Oz 29 00 4 g SE 55 mg t gt gt O5 GO GG co SO O0 re aa EE EE E zz 88 38 a 6 ce ee SS SS Te re mm LM oo CR4 406 EE EE HIGH FUEL 5 gg gg gg IDLE CUTOFF 232 30 je6 730 86 e m ur 85 E 87A E g 4 gt Diis SW2 SW28 NOTE ENGINE ENGINE gt OIL CYLINDER MACHINE SHOWN 11 PRESSURE PED Zz IN THE STOWED AES se X dye i E POSITION WITH Q3 Q8 gt THE POWER OFF tu HIGH IDLE FUEL ao SOLENOID CUTOFF 0217 n i rS ES0222C 6 32 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic Diesel Models from
89. X 2 2 CX i2 EEE 1514 pe BB N C zi due 28 dg aa 25 98 65 6 a X 88 3 3 px 88 82 29 0 gt Gg 22 8 a2 laa 85 Go BB BB 5 8 88 2 8 dd 2 s 99 x 5 2 P e 25 8 8 88 8 LE a 90 00 rr 909 2 32 0 52 56 2 Za 29 OF Q Is i 89 rr FE 55 ssor jJ o2 695 65 60 1 So 890 33 33 oz gt 0 m OQ usa 25 j 20 Loe Soa OO x z 3322 gt gt FO 2 gt gt FR ABA o i 1 2 Qu oo oO GH groz 2202 f Fe WOO oo o2 lt Sel fH EE ZZ ZZ mm ozOQ0u rc 22 64 mc zu 00 990 Go E ay uu gu EE ES Q rc 4 K gt 99 99 fr 98 lt 2035 35 5 2 EE 0059 99 00 HH ee rk ES S7 Ef Of Ek 55 22 En 2 5995 EE RE EE EZ Eu LEVELSENSOR kk PUR Q a tc qu rr ere gg SEP 22 569 85 8 8 amp 8 8 3 3 94 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS MODELS WITH DRIVE IN THE STOWED POSITION WITH ES0231B THE POWER OFF ES0236B
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91. a2 l E gt gt x i 88 8 g 8 8 8 bk G o 3 88 OO OZ Fe rc U9 LIN icu ce 88 88 55 88 4 gt gt OG L Pn sm 91 88 32 88 22 gg zz 55 55 88 B5 Fg O Fo 66 05 55 gg ds A CR49 te gg fe aw CR4 ENGINE ee EE HIGH STOP eg EL 55 89 24V 30 se FE uu uu SS wee PE d oo 33 cc t N 0 5V CR1 S iid sg 8 Z 85 7 O e START 20 87 86 gt gt ee eb gt AC INPUT eum Us En QD7 SW26 oo NOTE ENGINE Oll d Sz MACHINE SHOWN LEVEL B 2 IN THE STOWED 1 E 175A FUSE dt amp POSITION WITH l y N M3 Q3 U19 Y U20 2 a THE POWER OFF gt HIGH IDLE IGNITION SPARK O SOLENOID COIL plus 02 ES0218C ES0223C a 6 24 2 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic Gasoline Bi Fuel Models from serial number T5000 91 to T5002 24 Part 2 of 2
92. cylinder Bodily injury hazard Spraying AWARNING 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 9 Remove the fasteners securing the ground control box to the control box mount 10 Lay the ground control box off to the side CAUTION Component damage hazard Use caution when removing the ground control box so as not to damage the wire harness or connectors 11 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin 12 Place a rod through the barrel end pivot pin and twist to remove the pin Remove the cylinder from the machine Crushing hazard The lift cylinder AWARNING may become unbalanced and fall if not properly supported when removed from the machine Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 6 1 RPM Adjustment Refer to Maintenance Procedures B 14 Check and Adjust the Engine RPM 6 2 Pump Coupler The pump coupler connects the engine crankshaft to the hydraulic pump How to Remove the Pump Coupler Do not damage the crankshaft key or the rubber spacer when disassembling the pump coupler 1 Remove the fasteners securing the hydraulic pump to the engine bell housing 2 Pullthe hydraulic pump assembly away from the bell housing to access the pump coupler 3 Locate th
93. damage or excessive insulation wear Replace as required Section Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Turntable area Ground controls Function manifold wiring Power unit wiring DC and Bi Fuel models Engine wiring 2 Inspect for a liberal coating of dielectric grease in the following locations Between the ground and platform controls Between the ground and drive controls if equipped All harness connectors Level sensor 3 14 TMZ 50 30 REV B Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Raise the secondary boom until the platform is approximately 10 feet 3 m off the ground Inspect the boom storage area for burnt chafed and pinched cables Lower the boom to the stowed position and turn the machine off Inspect the following are
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96. lt 1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER E 4 16 3 18 5 919 es Go 82 BA t TIL TIU T 1 ul GY C i a LS15 z 5 N C H O uj ib amp TN z i N C H O o iu 7 lt ne mE U33 1A X KEY SWITCH WH BKYL VOLTAGE ae WH Roek REGULATOR at 11 g5 dg 3 x 55 zo 99 cr cr GG GE 5 mr uu OG BK WH G64 99 gg d aa Tr EE ce p gt EE 55 p B x 6 E 2 co ctc F9 CR49 EE d 15 5 5 uu aca mm FUSE CR4 ENGINE 2 TT HIGH STOP 99 tt 55 oo IDLE NES uu uu ee ee m te B e 2 87 85 86 gt 2 4 9 2 B1 P ONE 12V Peg QD7 SW26 P NOTE ENGINE 5 En OIL H BE MACHINE SHOWN LLL LEVEL 9 amp B 2 IN THE STOWED Er ppm amp POSITION WITH a M3 Q3 U19 7 U20 jeg THE POWER OFF v HIGH IDLE IGNITION SPARK 8 solenon con rue 02 ES0216B ES0221B 6 14 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic REV B Gasoline Models before serial number T5000 91 Part 2 of 2
97. n 7 P5 J2 Ji J3 J4 1 B Lcd XQ BD P4 P1 U21 P3 CB2 ENGINE CONNECTOR PC BOARD OUTRIGGER CIRCUIT BREAKER i 1172 9 19 3 go 2 28 SS EE I a LS15 i U 1 4 u a N C H O 24V 12V Zu VOLTAGE amp b5 DIVIDER Hala 1514 z 5 5 N C H O N vd 50 gt amp fA H 85 87 E s Gz i 5 aa 55 28 88 oz EIGHT 6V BATTERIES QD1 cc oo MODELS WITH DRIVE gt gt O0 99 gg Za E SSO O0 fe BE 09 13 EE ZE 88 35 FOUR 6V BATTERIES BATTERY FUSE 55 99 99 zc ae MODELS WITHOUT DRIVE CHARGER EE lt lt lt lt Go OG Vic ads asss co co 3 oO ic 55 tt tt 5 usu uu rr gc Ut re 1 S 50 5 8 24V 3 G6 gt 4 4 NOTE ACINPUT y6 a MACHINE SHOWN INTHE STOWED QD1 POSITION WITH THE POWER OFF ES0198C ES0203A 6 6 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics REV B Electrical Schematic DC Models before serial number T5000 91 Part 2 of 2
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99. 120 ft lbs 162 7 Nm 20 140 ft Ibs 190 Nm 24 165 ft lbs 223 7 Nm SAE O ring Boss Port tube fitting installed into Steel REV B Torque Procedure Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal LokQ fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 11 ft lbs 14 9 Nm 6 35 ft Ibs 47 5 Nm 6 23 ft lbs 31 2 Nm 8 60 ft Ibs 81 3 Nm 8 40 ft lbs 54 2 Nm 10 105 ft lbs 142 4 Nm 10 69 ft lbs 93 6 Nm 12 140 ft lbs 190 Nm 12 93 ft lbs 126 1 Nm 16 210 ft lbs 284 7 Nm 16 139 ft lbs 188 5
100. 2 Pos Za 25 82 D g I 85 gg zr cr EE ZZ 9 55 g 555 85 26 290 8 8 f EE 22 22 EOD gt gt 25 Yo Jg oo 225 a i z 90 22 22 00 00 QQ gt 2220 SS LO 435 x b5 i T 2 aw oO GH groz 2202 f u Fe WOO oo o2 lt Sel fH EE ZZ ZZ bb 53 0 u 22 k ME Su zc 86 55 22 22 co FES Bd ees 5E Eg t b 198 5g EE EE kk oe 22 5210 60 For rt 197 em Du kk g gg 39 50E EE kk EE EOS sb EU vB B 92 EE qu ee ee ttoo 88 20 569 85 55 Sg 8 e o e Q0 9 o Ar AH HO ON A D 494 gt gt gt gt Se Ss gt gt X gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0232B THE POWER OFF ES0237B TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics June 2005 _ Electrical Schematic Diesel Bi Fuel Models REV B before serial number T5000 91 Part 1 of 2
101. 22 55 99 BIS 3250 g OQ 5 22 15 of 55 PE EE 395 doo 55 55 Se Q 116 gu EE 66 66 29 P28 6555 zz Sh CGE EE ko 9B E 16 6 9g ge EE 22 382 99 55 hu gee 25 I6 28 B 198 8 58 fr LL fe kL FF BBE 9059 99 00 EE GSE ge ck bz S7 u Ek 38 38 33 S225 55 kk BE Eo g8 8 iet 8 uu gg 55 oo amp amp 369 95 55 5 8 lt ec nu lt lt lt to b Tf Cv O N N 6D Nr te N ot e o N e oo o Qr QW N OO GN D 2 5 49 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0217C THE POWER OFF ES0222C TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics D 1 Electrical Schematic Diesel Models from serial number T5002 25 to TMZ5003 228 June 2005
102. 90 Part 1 of 2 OUTRIGGERS FRONT FRONT LEFT RIGHT r OH ITF SITE Ete EXE ew AE ma D py LEFT RIGHT LEVEL SLAVE SII er NP O OME eae T pen AUXILIARY 2 a POWER 275 8 ber yr MASTER UNIT COUNTER BALANCE F3 E i l MANIFOLD E v2 Vi a x AUX T3 Al 5 Bi TEST A2 _ 2 __ l 3 s TI 5 ER E To bd XxX i I m _ ES 3 6 3000 psi AD F Y41 3 1 206 8 bar 1__ Y40 Ll Y39 Y20 om Went tt LX BRL Iz LORS LE H een PUMP MANIFOLD FUNCTION MANIFOLD ee ee 1 2 Ti e ic 11 Pie min e HYDRAULIC TANK HS0136C 6 62 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Hydraulic Schematic Engine only Models without Drive Option REVA after serial number T5000 90 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER T Wi Lene i w 124 M 9 m H
103. BREAKER i 1172 4 d POS 38 p LL 1 TII 1 ul a EI M 5 LS15 zu E a N C H O El 2 2 E Elo r 55 3 2 7 El b m EE LS14 Le E N C H O la art E H24 U23 l ELT 5 ENGINE rem rni CIRCUIT QD1 D1 KS3 l BOARD B M SZ SwiTcH 8 2 EE ai 55 8 28 88 ft 88 00 OZ Fe cc U9 FUSE fao 15 uu OG I 22 00 OO CHARGER 950 EE SS O90 mc 5 23 B5 Il 55 2 99 EX 4 6V A cr mm Es F9 Go 8 BB 24V 10A HIGH FUEL uu uu 99 99 FUSE IDLE CUTOFF oo HH cc I Xf t 0 5V CR1 80 ro IE B6 2 9 i START Ter 185 185 gt gt 3 3 9 fer AC INPUT pass 29 4 mem TNT 87 MOTOR 1 QD7 CONTROLLER L k SW2 SW28 2T NOTE ENGINE ENGINE oz CYLINDER MACHINE SHOWN F11 STARTER PRESSURE PEE 2 E IN THE STOWED P X i 175A FUSE lt Jt lt gt POSITION WITH Oe gt e gt 0 03 Q8 zd THE POWER OFF 4 HIGHIDLE FUEL SOLENOID CUTOFF ze ES0234B mom ES0239B a mer 6 44 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics REVA
104. COUNTER Lt BALANCE 5 VALVE __ _ MANIFOLD tll 206 7 a D1 02 T2 AUX T3 1 B1 TEST A2 B2 pee p E SE I 4238 iue FJ 3000 psi du 69 N 206 8 bar sod Ld TE EN EN RN ic j Y40 i 11 X vao i X vio Hd i Y Eh UPS ae GP Y Y6 69 Y v ER PUMP MANIFOLD FUNCTION MANIFOLD Een es cer onu sep P1 P2 P4 P3 Ti 2 11 ae um i HYDRAULIC TANK HS0139D Genie A TEREX COMPANY 6 58 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Hydraulic Schematic Engine only Models with Drive Option REVA after serial number T5000 90 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER T Wi Lene i w 124 M 9 m HSN MW 3000 psi 3000 psi p ps y T 3000 ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 31 31 31 3 1 S1 A3 A5 B5 A4 B4 A6 B6 A7 B7 ee o gt Nu Y23 Y22 om Y53 ti om Y26 Y61 om a
105. Coil The battery should read 9V DC or more when measured across the terminals Resistor 100 Genie part number 27287 3 Setamultimeter to read DC amperage The multimeter when set to read DC amperage should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil REV B COIL A MULTI 2 1 l 100 9V RESISTOR E le d VERI v V tla Y V a multimeter b 9V DC battery C 100 resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 2096 The coil is good W 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 Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair
106. E 12V DC 5v DC 211 BL lt o HORN VOLTAGE u EEEE neus BN73 BOOM EXTEND le i 3 G G 4 6 e BN76 PLATFORM LEVEL DOWN n 4321 IE EBD a cs P2 oe BN75 PLATFORM LEVEL UP EMERGENCY STOP EMERGENCY a EEE e Us e fj SOP BN77 ENGINE START EN7 s assa S a cm BN5 HORN 9 aea DRIVE CONTROL BOX E a BN12 FUNCTION ENABLE HIGH QD9B p BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 1113598 J BN13 FUNCTION ENABLE LOW 2 2 2 2 EN2 LEN1 PLATFORM CONTROL BOX __ __ __ __ __ __ __ __ GROUND CONTROL Bir ccr dicen occum ee ee urs s BOX J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE Ve SER o on No of FE 22 t 9838 m ga r bet 15137 N C H O oss 41 2 7 2 X X I X X X I X X I X X I i ista 0 LS2 i S PS CN Note eS Hs x X x x X 2125 X 5 al a gt 23 gg dB 8 883 88 95 59 zo E G du 9 8 UD OZ rr 55 E 2 as 2 I BG 89 88 8 3 S9 2 x ES Q x o Q E IDE OO OO c Q E 90 99 22 22 29 5 2 253 b 2 5Z
107. Electrical Symbols Legend sss 6 5 B Electrical Schematic DC Models before serial number T5000 91 6 6 A Electrical Schematic DC Models from serial number T5000 91 to T5002 24 6 8 A Electrical Schematic DC Models from serial number T5002 25 to TMZ5003 228 6 10 A Electrical Schematic DC Models after serial 25003 228 6 12 B Electrical Schematic Gasoline Models before serial number T5000 91 6 14 A Electrical Schematic Gasoline Models from serial number T5000 91 to T5002 24 6 16 A Electrical Schematic Gasoline Models from serial number T5002 25 to TMZ5003 228 6 18 A Electrical Schematic Gasoline Models after serial number TMZ5003 228 6 20 B Electrical Schematic Gasoline Bi Fuel Models before serial number T5000 91 6 22 A Electrical Schematic Gasoline Bi Fuel Models from serial number T5000 91 to T5002 24 6 24 Genie A TEREX COMPANY x TMZ 50 30 PartNo 65162 June 2005 Section6 Rev TABLE OF CONTENTS Schematics continued Electrical Schematic Gasoline Bi Fuel Models from serial number T5002 25 to TMZ5003 228 6 26 Electrical Schematic Gasoline Bi Fu
108. Engine start Y20 Platform up CR4 High idle Y21 Lower lift cylinder down CR8 Ignition fuel cutoff Y22 Lower lift cylinder up CR50 Power supply to converter U14 Y23 Turntable rotate left D Power supply Y24 Turntable rotate right D1 Alternator Y25 Boom retract D7 Voltage regulator Y26 Boom extend EN Enclosure Y32 Drive EN1 Platform control box Y33 Left rear outrigger EN2 Ground control box Y34 Right rear outrigger EN7 Drive control box Y35 Left front outrigger F Fuse Y36 Right front outrigger F6 275A Function Y39 Outrigger retract F9 Alternator Y40 Outrigger extend F11 175A Engine starter Y41 Outrigger regen FB1 Flashing beacons option Y42 Lift drive select G Gauge Y50 Drive forward G6 Hour meter Y52 Upper lift inder down G7 Battery charge indicator option E pi ipn up H gr alarm Y61 Jib boom extend d Y64 Drive reverse H5 Multifunction alarm Y65 Proportional drive JC5 Drive joystick KS Key switch KS1 Main KS3 Engine Genie 6 2 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Limit Switch Legend REVA Limit Switch Legend a outrigger limit switch left front LS12 right front LS13 left rear LS14 right rear LS15 turntable rotate limi
109. MEDIUM BN45 BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 os BN50 LEFT REAR OUTRIGGER 5 _ oxowoor ers HORN DAMES E s 112 113 114 115 EMERGENCY e e 16 PIN ee ee stop RIBBON CABLE Ct Ee EN2 nouo H III SW25 Ld e 42 12V DC 5V DC U22 87654321 DIP SWITCH J7 n 33333 SW25A PLATFORM D7 UU CPU DISPLAY BOARD 17655521 DIB SWITCH 1 VOLTAGE REGULATOR lg J6 J9 J2 J3 IKS1 F a a Ly a F Ly A 7 PIN 11 PIN 26 PIN 40 PIN LASY KEY SWITCH qi JUMPER JUMPERCABLE RIBBON CABLE RIBBON CABLE x G7 o Bk P5 J2 J1 J3 J4 1 5 M RD 021 CB2 P1 CONNECTOR PC BOARD P3 30A ENGINE OUTRIGGER CIRCUIT BREAKER i 1 17 4 16 18 5 2x Qo 82 88 1 t TIL TII 1 12 i U14 ula 1 5 N C H O LES S aviv 2 uj 2 5 VOLTAGE 2 Tm 2 DIVIDER L o 9 3 N CHO 6 VERAS O T 30 1 CR50 gt IKS3 KEY SWITCH wH U33 QD1 9 rm VOLTAGE REGULATOR iile gt gt x oo O9 26 3 OZ Fe rc U9 BK AN nim Go ng BATTERY l 206 22 GG GG CHARGER p 65 gg gg EE E 55 88 88 B5 M M 55 00 99 ca aa F9 oo cc CE lt lt
110. TMZ 50 30 5 9 Section 5 Troubleshooting Flow Charts June 2005 E This page intentionally left blank A TEREX COMPANY 5 10 TMZ 50 30 PartNo 65162 June 2005 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING 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 General Repair Process Be sure that all necessary tools and test equipment are available and ready for use Malfunction Identity Troubleshoot discovered symptoms problem still exists
111. The bearing is worn and needs to be replaced 8 Fully retract the primary boom Raise the primary and secondary booms to full height Visually inspect the the dial indicator to be sure the needle returns to the zero position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the primary and secondary booms to the stowed position and turn the machine off 12 Remove the dial indicator from the machine Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures REV B D 4 Replace the Hydraulic Tank Return Filter Replacement of the hydraulic return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns The hydraulic filter is located at the hydraulic tank 1 Clean the area around the hydraulic oil filter Remove the filter with an oil filter wrench AWARNING ae injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate graduall
112. The drive controls consists of a printed circuit board Emergency Stop button joystick and an overlay membrane decal All of the components are replaceable Keeping the drive controls clean and defect free is essential to safe machine operation For further information or assistance consult the Genie Industries Service Department How to Remove the Circuit Board 1 Tag and disconnect the drive controls wire harness from the ground control box 2 Remove the controls from the machine Open the clamp on the back of the controls and slide the controls up and off of the platform Place the control box on a work bench 3 Remove the fasteners securing the cover to the control box Open the box 4 Tag and disconnect the wire connectors from the circuit board Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when handling printed circuit boards 5 Remove the circuit board mounting fasteners and remove the circuit board from the box DRIVE COMPONENTS OPTION 14 3 Membrane Overlay How to Replace the Overlay 1 Tagand disconnect the drive controls wire harness from the ground control box Remove the controls from the machine Open the clamp on the back of the controls and slide the controls up and off of the platform Place the control box on a work bench Loosen the control box lid retaining fasteners and open the lid
113. a registered trademark of Genie Industries in the USA and many other countries TMZ is a trademark of Genie Industries 3 Printed on recycled paper Printed in U S A A TEREX COMPANY ii TMZ 50 30 Part No 65162 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 M 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 A TEREX COMPANY PartNo 65162 TMZ 50 30 lii Section 1 Safety Rules June 2005 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority 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 personnelto potential
114. boom lift cylinder rod end pivot pin 13 Using a soft metal drift remove the jib boom lift cylinder rod end pivot pin Crushing hazard The jib boom lift AWARNING cylinder could fall if not properly supported when the rod end pivot pin is removed from the machine 14 Attach a lifting strap of suitable capacity from an overhead crane to the upper jib boom 15 Remove the pin retaining fastener from the upper jib boom pivot pin at the jib boom mount 16 Using a soft metal drift remove the upper jib pivot pin from the jib boom mount Remove the upper jib boom AWARNING Crushing hazard The upper jib boom could become unbalanced and fall if not properly supported when the pivot pin is removed 17 Support and secure the platform mount 18 Remove the pin retaining fastener from the lower jib boom pivot pin at the platform mount 19 Using a soft metal drift remove the lower jib boom pivot pin at the platform mount Remove JIB BOOM COMPONENTS 20 Tag disconnect and plug the hydraulic hoses at the jib boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 21 Tag and disconnect the wires from the jib boom lift cylinder solenoid valve 22 Attach a lifting strap of suitable capacity from an overhead crane t
115. ft lbs 24 27 Nm 9 Check vakve Al Prevents flow from pump section 2 from entering pump section 1 18 20 ft lbs 24 27 Nm 10 Check AJ Prevent flow from pump section 1 from entering pump section 2 How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie 18 20 ft lbs 24 27 Nm A TEREX COMPANY 4 42 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic BACK S lt Q S S S e C AD C AE O AF 6 O S fos p AG 7 Genie Part No 65162 TMZ 50 30 4 43 Section 4 Repair Procedures p M p O m t MANIFOLDS 9 2 Pump Manifold Components Models with Drive option after serial number T5000 90 June 2005 REV B The pump manifold is located next to the function manifold under the function manifold side cover Index Schema
116. ft lbs Nm 36 5 23 6 32 31 4 42 6 2 467 62 3 81 108 129 172 202 269 278 371 394 535 536 1233 682 E K O1 o wo O N ATO Go Cay Cop cd cor Iv e O OA N Of po v COTO Q OF OT po e A SIO 583 8 1055 Part No 65162 TMZ 50 30 2 9 Section 2 Specifications May 2005 This page intentionally left blank A TEREX COMPANY 2 10 TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly and semi annually as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Keep records on all inspections for three years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each main
117. g 555 85 26 290 8 8 f EE 22 22 EOD gt gt 25 Yo Jg oo 225 a i z 90 22 22 00 00 QQ gt 2220 SS LO 435 x b5 i T 2 Co Ay oO GH groz 229 ac DOO oo o2 z X Sel fH EE ZZ ZZ bb 53 0 u 22 k ao 52 2 1 su SC zz zz EZ uu zz gu ES c gu Pe pg Ek EE 22 3822 FESS 98 55 Efe cg s EG E 198 BU Ez 99g cr oc I i amp EE E Ir 5 Soor EE EE Sas B dB B LEVELSENSOR 18 tk 1 tc w ox uu 22 22 go SE FESS 88 cs 22 5898 85 8 8B 8 1155 gg 44 8 3 2 8 508 o ROS 8 RD 65 28 B s 83 8 gt o9 Ww 9 6 9 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND i MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0232A THE POWER OFF ES0237A TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics mam Electrical Schematic Diesel Models after serial number TMZ5003 228 June 2005
118. hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based 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 Part No 65162 June 2005 Section 2 Specifications REV B Function pump models without drive SPECIFICATIONS Pump manifold Type single section gear pump System 3000 psi relief valve pressure 206 8 bar Displacement per revolution 0 244 cu in 4cc Function manifold Flow rate 2 8 gpm Flow regulator 0 6 gom 10 6 L min 2 27 L min Hydraulic tank return line filter 10 micron Drive manifold before serial number TMZ5000 91 Function pump models with drive option
119. i 1172 18 9 19 82 88 1 SS SS SSS 77 1 1515 a N C H O tui EE MESES gt 5 N C H O HX k x E dz 22 en s 20 5 55 88 Sz 29 99 EIGHT 6V BATTERIES re uu MODELS WITH DRIVE 22 co OO F6 55 ge EE EE 5 U9 275A zz 55 55 88 38 FOUR 6V BATTERIES BATTERY FUSE 66 o E E rr rc MODELS WITHOUT DRIVE CHARGER lt lt lt lt OD ER pe TRE eR EE 55 qu uu fe fe ite 1 S 50 5 8 mE 24V 3 G6 gt gt zd dr gt 1 I 4 N 0 5V 2 it AC INPUT U6 MACHINE SHOWN L ili E FOR DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH THE POWER OFF ES0215B ES0220B enie A TEREX COMPANY 6 8 TMZ 50 30 Part No 65162 DC Models Part 2 of 2 Section 6 Schematics from serial number T5000 91 to T5002 24 Electrical Schematic June 2005 REV
120. in death or serious injury 1 Lower the outrigger to be removed just until it touches the ground Do not rest the entire weight of the outrigger on the ground Outriggers at the Platform end 2 Tag and disconnect the electrical wiring at the tail light 3 Remove the tail light mounting fasteners Remove the tail light from the machine All outriggers 4 Remove the outrigger limit switch mounting fasteners at the foot pad Do not disconnect the wiring 5 Remove the limit switch and cable assembly from the chassis end of the outrigger 6 Remove the pin retaining fasteners from the outrigger pivot pin 7 Attach a lifting strap of suitable capacity from an overhead crane to the pivot end of the outrigger Outriggers 8 Place a 2 x 4x 10 inch 5 x 10 x 25 cm wooden block between the outrigger cylinder rod and the outrigger mounting arm 9 Remove the pin retaining fasteners from the outrigger cylinder rod end pivot pin 10 Use a soft metal drift pin to remove the rod end pivot pin Rest the cylinder on the block 11 Use a soft metal drift pin to remove the outrigger pivot pin Crushing hazard The outrigger ACAUTION may fall when the outrigger pivot pin is removed if it is not properly supported 12 Remove the outrigger from the machine Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005 OUTRIGGERS 13 2 5 Outrigger Cylinder How to i Remove an Outrig
121. level sensor 7 Remove the fasteners securing the level sensor to the machine Remove the level sensor from the machine 3 Push and hold the auto level button Push and hold the extend outrigger button 8 Install the new level sensor onto the machine with the X on the level sensor housing closest Result The outriggers will lower and adjust to to the ground control box as shown in the level the machine and raise the wheels slightly illustration below Install and securely tighten off the ground Use a digital level to confirm that the level sensor retaining fasteners the machine is level 4 Turn the key switch to the off position Locate the tilt level sensor behind the ground control box hydraulic tank battery charger if equipped ground control box voltage converter if equipped motor controller if equipped level sensor ADANGER Tip over hazard The level sensor must be installed with the X on the level sensor base closest to the ground control box Failure to install the level sensor as instructed could result in the machine tipping over causing death or serious injury 3 6 wy a hydraulic tank b ground control box C level sensor Genie Part No 65162 TEREX COMPANY TMZ 50 30 4 35 Section 4 Repair Procedures June 2005 GROUND CONTROLS 9 Connect the wire harness to the level sensor 10 Tighten
122. lt lt 46V CR49 re mm BATTERY XA DE CR4 ENGINE 20 kk f 10 24 HIGH 86 EE Rr gg gg zi cc caca t 2 a c D Pd 0 5 CRI 8 8 5 5 START 20 ter 195 joo gt LEE E BEI AC INPUT L LI MOTOR II ra 007 CONTROLLER SW26 PR NOTE ENGINE Zu Oll d Sz MACHINE SHOWN 11 LEVEL B 2 IN THE STOWED 175A FUSE da POSITION WITH 1 0 M3 x Q3 U19 U20 gd THE POWER OFF 4 HIGH IDLE IGNITION SPARK O SOLENOID COIL PLUG O ES0218B ES0223B a enie A TEREX COMPANY 6 22 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic Gasoline Bi Fuel Models before serial number T5000 91 Part 2 of 2 eter E M us 1 PLATFORM CONTROLS Pal PLATFORM 2 MEMBRANE
123. numbers will blink with fault codes and the 4 dashes will remain on during normal operation pon The codes listed in the Fault Code Chart describe pinea malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected Genie A TEREX COMPANY 5 2 TMZ 50 30 PartNo 65162 June 2005 Section 5 Troubleshooting Flow Charts Fault Code Chart after serial number T5002 24 REVA Fault Code Fault Condition Possible Cause Solution Safety circuit fault 0001 0003 0007 0008 0009 Down only mode Level sensor always high Level sensor always low Level sensor fault ECM platform communications fault Platform key pad fault ECM drive communications fault Drive controls fault Outriggers up no retract structure switches Lift and rotate functions disabled Control box receiving too much voltage from level sensor Control box receiving too little voltage from level sensor Machine out of level Machine functions inoperative Machine functions inoperative Faulty switches OR faulty harness OR faulty circuit board Machine out of level OR low battery voltage OR faulty outrigger switches Faulty level sensor Open or short in level sensor circuit Machine out of level OR faulty wire harness OR faulty level sensor OR faulty circuit board Faulty control cable OR faulty circuit board Platfor
124. numeric callouts refer to corresponding notes on the electrical schematic 9 m Genie TEREX COMPANY Part No 65162 TMZ 50 30 4 49 Section 4 Repair Procedures June 2005 p M R rss MANIFOLDS REV B 9 5 Function Manifold Components Engine and Bi Fuel Models before serial number T5000 91 The function manifold is located next to the engine under the engine side cover Index Schematic No Description Item Function Torque Coil nut items ED EE EF EG El EL EM apd E O i i RO RI e atc census 4 5 ft lbs 5 7 Nm Diagnostic EA Testing 2 Flow regulator valve 0 6 2 27 L min EB asin Turntable rotate circuit 18 20 ft lbs 24 27 Nm 3 Orifice Plug 0 025 inch 0 64mm EC Turntable rotate circuit 18 20 ft lbs 24 27 Nm 4 Solenoid valve 2 position 3 way us Primary boom extension 18 20 ft lbs 24 27 Nm 5 Solenoid valve 2 position 3 way EE Primary boom retract 18 20 ft los 24 27 Nm 6 Solenoid valve 3 position 4 way EP auus Jib boom up down 18 20 ft los 24 27 Nm 7 Solenoid valve 3 position 4 way EG aitek Primary upper boom up down 18 20 ft los 24 27 Nm 8 Solenoid valve 3 position 4 way EH
125. 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 AWARNING 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 AWARNING Crushing hazard The jib boom cylinder could become unbalanced and fall if not properly supported when the barrel end pivot pin is removed from the machine Crushing hazard The lower jib AWARNING boom could become unbalanced and fall if not properly supported when the pivot pin is removed from the machine Component damage hazard The CAUTION solenoid valve can be damaged Use caution when removing the cylinder from the machine Genie TEREX COMPANY Part No 65162 TMZ 50 30 4 11 Section 4 Repair Procedures June 2005 Primary Boom Components REV B
126. personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING O an9e used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green usedto indicate operation ormaintenance information A TEREX CON iv TMZ 50 30 other protective clothing if the situation e Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes j Be aware of potential crushing hazards Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfac
127. s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING injury hazard Spraying ydraulic 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 Section 5 Troubleshooting Flow Charts June 2005 FAULT CODES About This Section When a malfunction is discovered the fault code 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 General Repair Process A diagnostic display was incoportated into the side of the ground controls after serial number T5002 24 Malfunction Identify Troubleshoot discovered symptoms The diagnostic readout displays numerical codes that provide information about the machine problem operating status and about malfunctions The still exists
128. service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Perform this procedure with the machine on firm level surface and the boom in the stowed position 1 Grease the turntable bearing See A 13 Grease the Turntable Rotation Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 2 Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and raise the primary and secondary booms to full height Do not extend the primary boom 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing 5 Atthe dial indicator adjust it to zero the indicator REV B turntable dial indicator drive chassis turntable rotation bearing 6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom 7 Note the reading on the dial indicator Result The measurement is less than 0 025 inch 0 635 mm The bearing is good W Result The measurement is more than 0 0249 inch 0 634 mm
129. the fitting on the filter head Remove the return filter mounting fasteners Lay the filter off to the side Remove the hydraulic tank mounting fasteners and remove the hydraulic tank from the machine Remove the suction strainer and clean it using a mild solvent at the two year inspection test 8 the oil quarterly Replace the oil when it fails the test Clean the inside of the tank using a mild solvent 9 Install the suction strainer into the tank and When removing a hose assembly securely tighten or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 10 Install and tighten the hydraulic tank drain plug using a thread sealant on the threads Torque to specification Torque specifications Perform this procedure with the Hydraulic tank drain plug dry 75 in lbs boom in the stowed position 8 5 Nm 1 Disconnect the battery pack from the machine Hydraulic tank drain plug lubricated 56 in lbs 6 3 Nm AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Genie Part No 65162 TMZ 50 30 3 31 Section Scheduled Maintenance Procedures June 2005 CHECKLIST E PROCEDURES 11 Install the hydraulic tank and install and tighten the hydrau
130. touch pad from the top 7 Pullthe blue connector through the slot in the control box lid and discard the old touch pad Remove any remaining sealant from the slot 8 Using a mild solvent clean the surface of the control box lid Allow the surface to dry CAUTION Component damage hazard The circuit board will become damaged if it comes in contact with solvent Do not allow solvent to contact the circuit board REV B 9 Remove all the brown backing material from the new touch pad 10 Insert the blue connector from the new touch pad through the slot Carefully align the AUTOMATIC LEVELING 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 11 When satisfied with the position of the touch pad firmly press down the entire surface of the touch pad with your fingers 12 Loosen the control box lid retaining fasteners and open the lid 13 Using RTV type sealant completely seal the opening in the slot of the control box lid around the wire harness 14 Apply dielectric grease to the pins on the circuit board at the connection marked KEYPAD 15 Install the blue connector onto the circuit board pins at the connection marked Keypa Slide the connector parallel to the circuit board until the connector is fully pushed onto the ci
131. x X 2 12 gt X 5 ici ME x a B zu gt gt 23 z5 98 55 5 acB 2 88 x QQ zo OO E Sica CO E RAS OO OZ Fe 55 E 2 as 2 i GE 89 88 8 oo 2 Es x ES Q x o Q E IDE OO OO c Q E 90 99 22 22 29 5 2 253 b 2 5Z 29 8 g IGF 88 22 zr EE 22 9 55 SSN 290 5a 59 s 28 95 8 ia 9o EE 55 55 00 EOD SS oe aa 0872 95 50 20 O 119 22 55 99 BIS 3250 g OQ 5 22 15 of 55 PE EE 395 doo 55 55 Se Q 116 gu EE 66 66 29 P28 6555 zz Sh CGE EE ko 9B E 16 6 9g ge EE 22 382 99 55 hu gee 25 I6 28 B 198 8 58 fr LL fe kL FF BBE 9059 99 00 EE GSE ge ck bz S7 u Ek 38 38 33 S225 55 kk BE Eo g8 8 iet 8 uu gg 55 oo amp amp 369 95 55 5 8 lt ec nu lt lt lt to b Tf Cv O N N 6D Nr te N ot e o N e oo o Qr QW N OO GN D 2 5 49 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0219B THE POWER OFF ES0224
132. 0 046 inch E 17mm 17 Dil E T mE bo BON bom eU M E deo Be 3 1 yr MASTER COUNTER Le BALANCE VALVE _ _ __ __ MANIFOLD v2 vi FA D1 02 T2 AUX T3 A Bt E _ A ags p Howe I 1536 f vLiE C T EJ 3000 psi A H H 69 w JF 2068 bar 81 3000 psi Ld EN bar Y40 Ll Y39 Y20 Y19 my ETUR va pd zn Se He I t GP Y Y6 69 Y v ER PUMP MANIFOLD FUNCTION MANIFOLD Een es P1 P2 P4 P3 1 2 1 DC 3 gpm 3 gpm 11 4 L min 11 4 L min I 2 11 pen i HYDRAULIC TANK HS0138D Genie 6 66 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Hydraulic Schematic REVA Bi Fuel Models with Drive Option after serial number T5000 90 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER 1 E 1 mT i AE mo ow 3000 psi 3000 psi 2500 ni y T 3000 ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 3 1 3 1 3 1 3 1 1 A
133. 0 91 to T5002 24 Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a OUTRIGGER AUTO LEVEL BN49 J BN38 PRIMARY UP T T ENGINE START BN68 BN39 PRIMARY DOWN T T OUTRIGGER EXTEND BN47 JE E BN53 RIGHT FRONT OUTRIGGER dp ES OUTRIGGER RETRACT BN48 2 BN40 SECONDARY UP P came PLATFORM LEVEL DOWN BN7O re BN41 SECONDARY DOWN cS PLATFORM LEVELUP BN69 oe BN52 LEFT FRONT OUTRIGGER T Ed BOOM RETRACT BN72 BN36 JIB BOOM UP T T BOOM EXTEND BN71 e BN37 JIB BOOM DOWN T ind HORN BN35 BN51 RIGHT REAR OUTRIGGER Fa FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT T FUNCTION ENABLE MEDIUM BN45 e BN42 ROTATE LEFT Ap m FUNCTION ENABLE LOW BN46 I 50 LEFT REAR OUTRIGGER H5 raat C e m s s S nono HORN P1 Me 112 113 114 115 EMERGENCY ee Saa Xue stop 1 RIBBON CABLE OQ Cn aaron z 1 1 EN2 GROUND T C MM SW25 pd lo 24V DC 5V DC U22 87654321 DIP SWITCH BOX t l 13 MASS SW25A D7 J U CPU DISPLAYBOARD 2522253 VOLTAGE REGULATOR I KS1 key switcn J6 J9 J2 J3 Lod Lod 7 PIN 11 PIN 26 PIN 40 PIN 5702 JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE L 7 8 J2 J J3 J4 1 2 BK P5 M RD oN P4 P1 U21 P3 CB2 ENGINE CONNECTOR PC BOARD OUTRIGGER CIRCUIT BREAKER
134. 10 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual TMZ 50 30 Part No 65162 Rev B QIR A TERI
135. 2 2 Platform Rotator if equipped 4 5 B Jib Boom Components 3 1 lese ME 4 8 3 2 Boom Lift Cylinder 4 10 PartNo 65162 TMZ 50 30 vii June 2005 TABLE OF CONTENTS Section 4 Rev B Repair continued Primary Boom Components vill 4 1 Cable Track sea n aa aay 4 12 4 2 Primary 4 15 4 3 Boom EXt6nsion REN bade 4 17 4 4 Primary Boom Lift 4 19 4 5 Extension Cylinder sss 4 20 4 6 Platform Leveling Cylinders a 4 21 Secondary Boom Components 5 1 Secondary Boom 4 23 5 2 Secondary Boom Lift Cylinder 4 26 Engines 6 1 BPM Adjustment L u me eter eu x dr ta eS 4 27 62 1 nennen ennt rennen nnne 4 27 Ground Controls 7 1 CPU Circuit Board a 4 28 7 2 Connector Circuit Board sass 4 29 7 3 Software Configuration 4 30 7 4 Membrane Overlay 1 nennen nennen nennen 4 33 7 5 Level9Sensor a 4 34 7 6 4 37 7 7 Leste
136. 2 22 00 00 990 0T 2250 gu 09 USN ge a 5 15 ag 2202 f Fe DOS oo o2 lt Sel fH EE EE ZZ zz mo 5z9 685r 22 6k c dm es 115 36 ge 00 990 Go E a uu EE ES Q rc 4 mc xu 55 rE EE 99 Ek lt 6 oo T3 2035 35 56 fx gg tt EE EE 288 9559 99 HH Eag Er gk S7 E 66 55 99 22 995 EE FOS se ED D LEVELSENSOR D gt Li PUR Q a a tc w ox uu uu gr ee gg 5535 E amp amp 0 oo ze S68 85 55 2 amp 8 B ec e o o e o sx Vr NN S A AH DH ON A 1D gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS MODELS WITH DRIVE IN THE STOWED POSITION WITH ES0216B THE POWER OFF ES0221B TEREX COMPANY Part No 65162 TMZ 50 30 6 15 Section 6 Schematics June 2005 Sg Electrical Schematic
137. 3 A5 B5 4 4 B6 A7 B7 ee FL 25 Nu Y23 Y22 om Y53 ti om Y26 Y61 om a REI ME AOX 0 6 gpm __ 2 27 L min FUNCTION MANIFOLD HS0138D Part No 65162 TMZ 50 30 6 67 Section 6 Schematics June 2005 Hydraulic Schematic Bi Fuel Models without Drive Option REV B before serial number T5000 91 Part 1 of 2 OUTRIGGERS FRONT FRONT LEFT RIGHT r r SIT IX mmm i EXE ES REAR REAR LEFT RIGHT LEVEL Ome me ll ot Mi LO cal je Papi p H 20psi 81 275 8 an mE 137 9 bar MASTER 4 5 1 1 3 1 A 1 CB COUNTER BALANCE v VALVE _ _ _ _ MANIFOLD V2 V1 X AUX T3 At _ B1 TEST A2 _ 2 __ Ir E Fe a 2 Ins aE NIFI X x G DE d CB eO xe PUMP MANIFOLD FUNCTION MANIFOLD EIL T a k wA P1 P2 T1 1 DC cm
138. 3 way 18 to 200 Description Specification 20 DC schematic item HJ Proportional valve 12V DC 4 to 6Q Solenoid valve 3 position 4 way 10V DC 6 to 82 schematic items AB AC CA and DA schematic items EF EG EH EL EM EO FG FH FM FN and FP Proportional valve 12V DC engine models 4to6Q Solenoid valve position 4 way 26 to 280 24V DC DC models 18102190 20 DC schematic items HM and HN schematic items BA and BB Solenoid valve 3 position 4 way 4 to 60 Solenoid valve 2 position 2 way 6to8Q 10V DC schematic items JB and JC 10V DC schematic item JD Solenoid valve 3 position 4 way Solenoid valve 2 position 2 way 10V DC engine models RS Sa 4 to 60 10V DC engine models 6to8Q 20V DC DC models sss 18 to 200 20V DC models 26to28Q schematic items KB and KC schematic item KD Solenoid valve 2 position 3 way 6 to 8Q 10V DC with manual over ride schematic item GE Solenoid valve 2 position 3 way 26 to 280 20V DC with manual over ride schematic item HF Solenoid valve 3 position 4 way 6 to 8Q 10V DC with manual over ride schematic items GF GG GH and GO Solenoid valve 3 position 4 way 26 to 280 20V DC with manual over ride schematic items HG HH HI and HP Genie A TEREX COMI TMZ 50 30 Part No 65162 June 2005 Section 2 Speci
139. 30 Day Service a 3 11 A 12 Perform Engine Maintenance Honda Models if equipped 3 11 A 13 Grease the Turntable Rotation Bearing and Rotate Gear 3 12 A 14 Perform Engine Maintenance Honda Models if equipped 3 12 B Checklist B Procedures B 1 Inspect the Batteries u uu 3 13 B 2 Inspect the Electrical Wiring uuu 3 14 B 3 Test the Emergency Stop 3 15 B 4 Test the Key Switch sss 3 15 B 5 Testthe Auxiliary Lowering eeen 3 16 B 6 Inspect the Tires and Wheels including lug nut or lug bolt torque 18 B 7 Service the Tongue Jack sss sss 3 18 B 8 Inspect the Parking 3 19 B 9 Test the Horn eas 3 20 B 10 Test the Flashing Beacon if equipped 3 20 B 11 Test the Platform Rotation if equipped 3 21 B 12 Inspect the Hydraulic Tank Cap Venting System 3 21 B 13 Perform Axle Maintenance ANSI Models 3 22 B 14 Perform Hydraulic Oil Analysis 3 22 B 15 Check and Adjust the Engine RPM
140. 4 1 2 5 J8l _ RD oN P4 P1 U21 P3 CB2 ENGINE CONNECTOR PC BOARD OUTRIGGER CIRCUIT BREAKER 1172 18 9 19 Qo 82 88 le ee 1 ris SS tr ac i LS15 Zz a N C H O E MESES SLSt4 gt 2 2 N C H O X M s M B5 oo gt 8 8 8 EIGHT 6V BATTERIES QD1 9 5 zz occ MODELS WITH DRIVE f 22 co OO F6 58 EE EE EE EE 5 U9 275A zz 55 55 38 38 FOUR 6V BATTERIES BATTERY FUSE 55 ce 55 EE MODELS WITHOUT DRIVE CHARGER lt lt lt lt pe EE m EE p kk tk 55 l qu fe fe uo Lge 8 2 3 O 1 24V 3 G6 gt 8 S T AZ 0 5V Mrz i AC INPUT U6 MACHINE SHOWN MOTOR ous IN THE STOWED POSITION WITH THE POWER OFF ES0230A ES0235A enie 6 10 A TEREX COMPANY TMZ 50 30 Part No 65162 DC Models Part 2 of 2 Section 6 Schematics from serial number T5002 25 to TMZ5003 228 Electrical Schematic June 2005 REV
141. 4 B4 A6 B6 7 B7 O lt O E B evar L g Y26 24 i t1 Xe Yes k I L X X19 Y L x x H X Y60 s 0 6 gpm T 2 27 L min FUNCTION MANIFOLD HS0127C Part No 65162 TMZ 50 30 6 65 Section 6 Schematics June 2005 Hydraulic Schematic Bi Fuel Models with Drive Option REVA after serial number T5000 90 Part 1 of 2 OUTRIGGERS DRIVE FRONT FRONT LEFT RIGHT fene LEFT RIGHT DRIVE DRIVE H BRAKE CYLINDER CYLINDER RELEASE E CYLINDER ef LEFT 4 4 x DRIVE DRIVE vem 1 FM dew U MOTOR MOTOR B e Me DRIVE MANIFOLD al oD REAR REAR Yea Y64A LEFT RIGHT ERE p XW MU XW zlim an f amp 0 ME i SLAVE 3850 psi e T 3850 psi s S i Sian gio Yi 0 046 inch
142. 4 P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER 1172 4 uS S BE Se go S2 88 H t TIL TII T 1 GY i T u LS15 N C H O 8 5 210 oc a z 2 5 1514 gt Q lt H 5 N CH O b rT 665 IKS3 Term QD1 4 KEY SWITCH wH U33 i we e WH RDK A5 oF 22 55 8d 28 88 88 OZ Fe rc U9 R BK mc su BB 55 35 33 BATTERY BINH g9 88 99 CHARGER 55 188 88 08 88 5 F9 eg co ce lt lt XH 4 6V A Eu cr CE BATTERY o cr rece nw FUSE CR4 55 FE EE i 7 24V co uu A oo fe ce Ti 0 5V CR1 J o Z P lt o N e E Sanma gt a m gt 2 AC INPUT tg qw m 4 007 6 2g NOTE Sz MACHINE SHOWN B 2 IN THE STOWED 4 175A FUSE a Lz POSITION WITH T 20 M3 107 019 Y U20 jeg THE POWER OFF 4 HIGH IDLE CHOKE IGNITION SPARK O SOLENOID COIL PLUG O ES0233A ES0238A TEREX COMPANY 6 26 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics
143. 6 JIB BOOM UP T Ea BOOM EXTEND BN71 BN37 JIB BOOM DOWN ark Zant HORN BN35 BN51 RIGHT REAR OUTRIGGER cies T FUNCTION ENABLE HIGH BN44 t o BN43 ROTATE RIGHT T T FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT P p FUNCTION ENABLE LOW BN46 t BN50 LEFT REAR OUTRIGGER Do OO N o eO 10 Ae BIN NOTE 1 A RIBBON CABLE I THE RANDOM ORDER OF THE 16 PIN RIBBON CONNECTORIS DONE ONLY TO SHOW THE WIRE CIRCUITS ON THE MACHINE THE WIRES J OF THE RIBBON CABLE WHERE THEY CONNECT WITH THE CIRCUIT q L BOARD ARE IN NUMERIC ORDER FROM 1 TO 16 1 1 THE CIRCUIT BOARD IS MARKED AT ONE END OF THE BOARD TO CABLE li CONNECTION WITH THE NUMBER 1 CAREFULLY INSPECT THE CIRCUIT BOARD TO LOCATE THE NUMBER 1 WIRE OF THE RIBBON CABLE Part No 65162 TMZ 50 30 4 33 Section 4 Repair Procedures June 2005 GROUND CONTROLS 5 Starting at the upper corners of the touch pad remove all layers of the touch pad from the control box lid The wire harness and large blue connector will interfere if removing the touch pad from the bottom 6 Pullthe large blue connector through the slot in the control box lid and discard the old touch pad Remove any remaining sealant from the slot 7 Using a mild solven
144. 62 June 2005 Section Scheduled Maintenance Procedures Checklist C Procedures REV B C 1 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install a new cap onto the tank C 2 Perform Axle Maintenance ANSI Models Axle specifications require that this procedure be performed every 6 months or 6000 miles whichever comes first Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 C 3 Perform Hitch Maintenance CE Models Hitch specifications require that this procedure be performed semi annually Proper hitch maintenance following the hitch manufacturer s maintenance schedule is essential to good hitch performance and service life Failure to perform the maintenance procedures can lead to poor hitch performance and component damage Required maintenance procedures and additio
145. 7B 5 22 ivottace ov De sv oc 28 EEEE S HORN BN73 BOOM EXTEND die cds al Yt 44 6 J4 BK e BN76 PLATFORM LEVEL DOWN L 14 321 a cs P2 oe BN75 PLATFORM LEVEL UP 2 EMERGENCY STOP EMERGENCY a E e e fj SOP BN77 ENGINE START EN7 Z z r Z z x o j S 3 BN5 HORN 9 ze DRIVE CONTROL BOX E a 5 BN12 FUNCTION ENABLE HIGH QD9B BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 1113598 J BN13 FUNCTION ENABLE LOW 2 2 2 2 EN2 LEN1 PLATFORM CONTROL BOX __ __ __ __ __ __ __ __ GROUND CONTROL BOX J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 4 12 98 56 6 i OUTRIGGER U21 LIFT DRIVE Ve 8 o on So of X 2 9888 m et es bet tt et 15137 N C H O oss 41 2 7 2 X 1 X X X I X 1 X X 1 X X I Mise A W PS CN Notte A x X x x X 2 2 CX 41827 i i 1 i 1 i i i N C m m er 2 28 38 Bo 95 66 6 ae X 88 x 99 OZ Ge re 2 g 55 2 as EUM GE 58 ba 9 8 co 9 Es Bg d E SE 28 88 98 c 5 vu 8855 8 8 88 D m SS EE rr 29 2g4 u 32 56 2 Za zQ 02
146. 8 SOLENOID COIL PLUG O ES0231A ES0236A TEREX COMPANY 6 18 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic REVA Gasoline Models from serial number T5002 25 to TMZ5003 228 Part 2 of 2 ee es i L al DRIVE lua 1 PLATFORM CONTROLS OPTION PLATFORM 2 MEMBRANE DECAL PANEL contROLs 3 P 1 PRINTED y 4 E DRIVE CONTROLS 5 MEMBRANE DECAL PANEL 1 BOARD S 92 BN78 OUTRIGGER EXTEND z BN29 PRIMARY UP 44192 8 m 79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 e BN80 OUTRIGGER RETRACT 12v pci BN31 SECONDARY UP BIBT HOAN D7A 2 A MP voutace 19 TA SECONDARY DOWN BN82 DRIVE ENABLE 1l 14 T REGULATOR 1 BN27 JIB UP illi L Ea p P BN28 JIB DOW
147. A TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics June 2005 Electrical Schematic Diesel Bi Fuel Models from serial number T5000 91 to T5002 24 Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a a OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 ee BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER ES Ed OUTRIGGER RETRACT BN48 BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN7O oe oe BN41 SECONDARY DOWN ES pi PLATFORM LEVEL UP BN69 BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 BN36 JIB BOOM UP p End BOOMEXTEND BN71 BN37 JIB BOOM DOWN m P HORN BN35 oe BN51 RIGHT REAR OUTRIGGER FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 e BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 I BN50 LEFT REAR OUTRIGGER H5
148. B O 9 98 die 2 Q i uu uu gt lt KO EE 5 958 6 E bat 99 s E 5 gos Oa z YL E a _ 90 00 rr 909 2 32 0 52 56 2 Za 29 OF Q Is i 89 zr cr EE EE 55 065 soc 62 685 85 69 59 5 48 a9 88 EE 55 28 DO mE 221245 gt 60 0445 45 LS Z0 p i 5 Qu oreo 3322 gt gt FO 2 gt gt FR ABA o i Co Aw oO GH groz 2202 f u Fe WOO oo o2 lt Sel fH EE ZZ ZZ mm ozOQ0u rc 22 64 mc zu zz zz OO OO E 2 y gu EE ES Q rc 4 l 62 gt gt 99 909 EE 99 gt gt lt 2035 35 5 2 su gg EE EE LE EEE S509 99 OO Bar ge EX Ge gt S7 u EE kk kk 39 S228 8806 EE kk EE E Og B LEVELSENSOR LE ee Q a w ox uu fr yr gg SEP dd 22 369 85 58 8R B 66 e o o e DNDN o Ar AH HO ON A 1D 3 3 94 gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS MODELS WITH DRIVE IN THE STOWED POSITION WITH ES0231A THE POWER OFF ES0236A TEREX COMPANY Part No 65162 TMZ 50 30 6 19 Section 6 Schematics June 2005 Sg Ele
149. BLE RIBBON CABLE L 8 J2 J1 J3 J4 121 BK 5 Ea RD 021 1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER 7 4 16 3 18 5 919 es Go 82 8 amp 8 1 t TIL T 1 ul GY C i a LS15 M N C H O a amp 2 2 25 lt N C H O p r F4 T E o 6 hr s 1 Lay IKS3 BRN l A KEY SWITCH wH U33 VOLTAGE i WH RDIBK REGULATOR i amp d el QS dd gt gt x oo zo o OZ Fe ce l INT BK O0 OO me G64 gt gt O0 66 Ed O00 gr FE r gt 33 55 33 ae l5 OO rer ee F9 CR49 EE lt lt 15 mE r m CR4 ENGINE TT LE FUSE STOP 99 tt EL 55 55 30 o d uu ee 87A o i 2 4 NOTE 62 MACHINE SHOWN amp B 2 IN THE STOWED Lz POSITION WITH L we U19 U20 E THE POWER OFF HIGH IDLE IGNITION SPARK 8 SOLENOID COIL PLUG O ES0216C ES0221C TEREX COMPANY 6 16 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic REVA Gasoline Models from serial number T5000 91 to T5002 24 Part 2 of 2
150. C 211 BL HORN VOLTAGE B age BN73 BOOM EXTEND 565 J4 BK e BN76 PLATFORM LEVEL DOWN n 14 321 T a adr a cs P2 oe BN75 PLATFORM LEVEL UP sage P3 EMERGENCY STOP EMERGENCY ele STOP BN77 ENGINE START EN7 TIMES x a cm BN5 HORN 9 aea DRIVE CONTROL BOX a ee BN12 FUNCTION ENABLE HIGH QD9B BN26 FUNCTION ENABLE MEDIUM apal ME QD9A 713598 713598 E a BN13 FUNCTION ENABLE LOW 1 1713598 PLATFORM CONTROL BOX EGU CONTROL Rire e ur BOX ee J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE Zo 9o RS Qe 28a o or 9 o9 99 amp 8838 et Ls13 is LS41 EN N C H O N O H C 7 X 1 X X I X 1 X X I X I X X i ista 0 LS2 i S N O H C jc ix iW Ja PA PAI PAI A gE PA did 2 iB BB 28 88 9 55 88 BRL 3 22 E gt g 22 98 laa 0 29 82 88 E 3 me 1 823 88 2 Ez z 5 x 5 2 P e 25 8 8 88 8 LE a 99 rr rr 3 Z 5254 2 Za O
151. CAL PANEL a o OUTRIGGER AUTO LEVEL BN49 E BN38 PRIMARY UP T T ENGINE START BN68 BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER S OUTRIGGER RETRACT BN48 oe BN40 SECONDARY UP T T PLATFORM LEVEL DOWN 70 BN41 SECONDARY DOWN fic PLATFORM LEVEL UP BN69 52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 gt 36 JIB BOOM UP p End G8 BOOMEXTEND BN71 BN37 JIB BOOM DOWN DIAGNOSTIC HORN BN35 oe BN51 RIGHT REAR OUTRIGGER FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 BN50 LEFT REAR OUTRIGGER H5 O 0 HORN L12 113 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 4 123456 1 EN2 5 IN SW25 GROUND 24V DC 5V DC 87654321 DIP SWITCH CONTROL 2 J7 U22 BOX PLATFORM 1 D7 UJ CPU DISPLAY BOARD SW25A 3 87654321 DIP SWITCH KS1 8 VOLTAGE REGULATOR CN KEY SWITCH 21 J6 J9 J2 J3 Lo Lod Lo 7 PIN 11 PIN 26 PIN 40 PIN S es JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE P1 EMERGENCY STOP Ei 6 BK J2 Ji J3 J4 1 2 5 J8 M RD U21 P
152. CIFICATIONS Performance Specifications Boom function speeds maximum from ground controls no weight in platform DC and Bi fuel Models Jib boom up 10 to 15 seconds Jib boom down 13 to 18 seconds Primary boom up 20 to 25 seconds Primary boom down 15 to 20 seconds Primary boom extend 15 to 20 seconds Primary boom retract 15 to 20 seconds Secondary boom up 20 to 25 seconds Secondary boom down 13 to 18 seconds Turntable rotate 358 Engine Models 55 to 60 seconds Jib boom up 5 to 8 seconds Jib boom down 4 to 7 seconds Primary boom up 10 to 15 seconds Primary boom down 8 to 13 seconds Primary boom extend 10 to 15 seconds Primary boom retract 10 to 15 seconds Secondary boom up 12 to 17 seconds Secondary boom down 9 to 14 seconds Turntable rotate 358 30 to 40 seconds Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMI TMZ 50 30 REV B Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type ISO viscosity grade Chevron Rykon MV equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron oils Genie specifications require
153. DECAL PANEL controts 3 PRINTED y 4 B DRIVE CONTROLS BOARD Es I li MEMBRANE DECAL PANEL BN78 OUTRIGGER EXTEND 5 BN29 PRIMARY UP e 4 QZ 8 e BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 BN80 OUTRIGGER RETRACT tunel BN31 SECONDARY UP D7A 12 E A HORN voutace 19 TA SECONDARY DOWN l BN82 DRIVE ENABLE 1l REGULATOR 14 T BN27 JIB UP 54321 EX O e BN28 JIB DOWN 6 PIN v o2 J3 3 RIBBON CABLE 2 148 JC5 4321l 1 2 4a 4 ROTATE RIGHT J3 U24 JOYSTICK A E m 4 BN33 ROTATE LEFT DRIVE CONTROLS 2 2 lg ES s PRINTED CIRCUIT BOARD 555 H2 BN74 BOOM RETRACT ID7B Tt 5 4d HORN 22 1 I vortace o12vec sv oc at EEEE Hr BN73 BOOM EXTEND al Yt amp amp 6 JA 648K e BN76 PLATFORM LEVEL DOWN n 14 321 P2 aa all sa C CN BN75 PLATFORM LEVEL UP EMERGENCY STOP is 2 L BN77 ENGINE START EN7 a cm BN5 HORN 9 aea DRIVE CONTROL BOX E a BN12 FUNCTION ENABLE HIGH QD9B p BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 1113598 BN13 FUNCTION ENABLE LOW ee ees M p d EN2 LEN1 PLATFORM CONTROL BOX __ __ __ __
154. ED CIRCUIT BOARD 33 H2 BN74 BOOM RETRACT ID7B 5 12V DC 5v DC 211 BL l HORN VOLTAGE age BN73 BOOM EXTEND Teves 31 G G 4 6 e BN76 PLATFORM LEVEL DOWN n 4321 P2 aa all sa C CN oe BN75 PLATFORM LEVEL UP EMERGENCY STOP EMERGENCY a EEE e Us e fj SOP BN77 ENGINE START EN7 Z z qt z x o j S 3 BN5 HORN 9 ze m mr m DRIVE CONTROL BOX a 4 BN12 FUNCTION ENABLE HIGH QD9B ES BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 1113598 BN13 FUNCTION ENABLE LOW ee ees M p d EN2 E PLATFORM CONTROL BOX EGU CONTROL fa ee ee BOX J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE gran RN NE SRh o on o FI EE t S835 L Jaee bet tt et 1137 is n Bu 7 2 X 1 X X I X 1 X X I X I X X I x LS2 i i S N O H C c A x X x x X 2125 CX 41527 i i 1 i 1 i 1 i n S N C 5 ai ay pi 23 s 62 5 BB ux 66 8598 28 dor SOL Edi 90 OZ rr K 8 oo F 2 as 1 gt I EE 9 Ea 2 d E 66 2 ES o 8 88 8 2 a DE M 99 99 8 33 b 5258
155. EVEL B 2 IN THE STOWED 175A FUSE tae de POSITION WITH n e M3 103 107 019 Y U20 THE POWER OFF UI AH E aa HIGH IDLE CHOKE IGNITION SPARK 2 8 SOLENOID COIL PLUG Q ES0231B ES0236B 2 TEREX COMPANY 6 20 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic REVA Gasoline Models after serial number TMZ5003 228 Part 2 of 2 ee 1 al DRIVE lua 1 PLATFORM CONTROLS OPTION PLATFORM 2 MEMBRANE DECAL PANEL contROLs 3 SS s PRINTED 4 DRIVE CONTROLS CIRCUIT z m 5 MEMBRANE DECAL PANEL BOARD LE 5 BN78 OUTRIGGER EXTEND z BN29 PRIMARY UP QZ m 79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 e BN80 OUTRIGGER RETRACT 12 Del 5V DC 11 BN31 SECONDARY UP
156. F XP 25 HE Y26 Genie Part No 65162 TMZ 50 30 4 57 Section 4 Repair Procedures June 2005 MANIFOLDS 9 9 Drive Manifold Components before serial number T5000 91 The drive manifold is located on the axle at the ground controls side of the machine Index Schematic No Description Item Coil nut item JD Coil nut items JB and JC 1 Check valve 70 psi 4 8 bar JA 2 Solenoid valve 3 position 4 way JB aues 3 Solenoid valve 3 position 4 way JC 4 Solenoid valve 2 position 2 way JD 5 valv _ u ul uuu JE in 6 Check valve JE S ius 7 Flow regulator valve 6 22 7 stets How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Function Controls the ground controls side drive motor in forward and reverse Controls the function manifold side drive motor in forward and reverse Drive motor cylinder circuit Drive motor cylinder circuit Drive motor cylinder circuit Controls flow from drive motors back to tank Genie 4 58 TEREX COMPANY
157. Flow Charts REV B FAULT CODE CHART AFTER SERIAL NUMBER T5002 24 Fault Code Fault Condition Possible Cause Solution Coil not connected to 0057 Beacon fault Flashing open wire harness OR open Restore connection OR g P circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR 0058 Flashing beacon short OR faulty circuit board replace circuit board Coil not connected to 0059 Extend out cail fault Extend out coil open Wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board 0060 Extend out coil fault Extend out coil short narness Repair faulty rg OR OR faulty circuit board replace circuit board Coil not connected to 0061 Extend in coil fault Extend in coil b f wire harness OR open Restore connection OR d P circuit OR faulty circuit replace circuit board board 0062 Extend in coil fault Extend in coil short SHOE narness Repair faulty AINO OR OR faulty circuit board replace circuit board Coil not connected to 0063 Drive coil fault wire harness OR open Restore connection OR P circuit OR faulty circuit replace circuit board board 0064 Drive coil fault Drive coil short Short in wire harness Repair faulty wiring OR 7 OR faulty circuit board replace circuit board Coil not connected to Right drive forward coil wire harness OR open Restore connection OR 0065 Dri
158. GERS FRONT FRONT LEFT RIGHT er SIT SIT oO REAR REAR PLATFORM LEFT RIGHT LEVEL SLAVE SII ID KIND 4 FT MS US ri e _ 1 feet Hee 20e Spar 298 bar MASTER ml qr COUNTER BALANCE m VALVE _ _ __ __ MANIFOLD v2 V1 FA E At er HE 2 5 FD I 2y 9 wann H amp 66 F tay 1 i 1 1 1 Iii Yo 1 IL l1 Dose 1 LL 1 P2 3 DC 3 gpm 11 4 L min IC 3 gpm 11 4 L min HYDRAULIC TANK 1 3000 psi 206 8 bar 1__ Y39 muaj Y20 Y19 1 A TEREX COMPANY HS0135C TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Hydraulic Schematic Bi Fuel Models without Drive Option REVA after serial number T5000 90 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EX
159. GH QD9B 58 L3 BN26 FUNCTION ENABLE MEDIUM QD4 T QD9A J i BN13 FUNCTION ENABLE LOW r HE E P MM MEN 1113598 EE IL eie oe eee EN2 PLATFORM CONTROL BOX GROUND CONTROL SS SS SS SS BOX CSS SS SS J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 412356 J6 OUTRIGGER U21 LIFT DRIVE SoLo RENG VES 9SR ae o on of rz t 88 58 r Eton t toto tt H Ls13 ie DE 1511 2 1 4 N C H O N O H C d jt X vA 7 7 7 E O gt s12 0 LS2 X X X X N I i N O H C EX x x 9 9 gt Zz X r x Z r 4y LA LA FALEALEA 2 aa 82 88 55 95 22 E sz g 2l B OS 00 25 82 88 ce cc fo OG 5 9 I 98 5 a d oo GO 9 o o lt EO EE 5 55 ei nz GO 9 c rz 8 998 82 5 a P S5 S9 gr 99 R 32 56 d Za OF zi 99 rr 65 BG 5 ssor 74402085 05 69 50 6 I g 59 88 88 59 252 bo 85 S25 22 52 28 5 S0 ore 2 2 ss EO a 295 gt s 5 OO OO rcr 8 20 O 5505 SIC FF OG 635 F lt lt r Co EE EE ZZ mm O59 552 rc 22 5L OG 5
160. Genie Service Manual June 2005 TMZ 50 30 June 2005 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genieindustries com e mail techsup genieind com Copyright 2000 by Genie Industries 65162 Rev June 2005 First Edition Second Printing Genie is
161. ION not apply excessive force or damage to the lip of the seal may occur 12 Place the outer bearing into the hub 13 Install the washer and castle nut 14 Tighten the spindle nut until resistance is felt when rotating the hub by hand 15 Loosen the castle nut until the first slot on the castle nut lines up with the hole in the spindle Do not loosen the castle nut more than 1 4 turn 16 Install a new cotter pin Bend the cotter pin to lock it in place 17 Install the dust cap 18 Install the tire and wheel assembly Torque the wheel lug nuts or lug bolts to specification Refer to Section 2 Specifications Genie Part No 65162 TEREX COMPANY TMZ 50 30 4 69 Section 4 Repair Procedures June 2005 Trailer Components 12 1 Trailer Brakes Hydraulic Brake System ANSI Models Repair procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 Electrical Brake System ANSI Models Repair procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 Mechanical Brake System CE Models Repair procedures and additional axle information is available in the KNOTT Axle S
162. June 2005 CHECKLIST B PROCEDURES B 13 Perform Axle Maintenance ANSI Models Axle specifications require that this procedure be performed quarterly or every 3000 miles whichever comes first Proper axle maintenance as specified in the axle manufacturer s maintenance schedule is essential to good axle 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 Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual REV B B 14 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 Hyaraulic Oil Genie part number 84376 Genio 3 22 TMZ 50 30 Part No 65162 June 2005 Section S
163. KEYSWITCH 21 J9 J2 J3 Lo Lo Lo Lod Lod 11 PIN 26 PIN 40 PIN mn Ss MU NN A JUMPER CABLE RIBBONCABLE RIBBON CABLE L P1 EMERGENCY STOP Ji J3 J4 1 2 BK P5 JA RD P4 P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER i mes ee 3229 a t III TII T 1 GY T u LS15 mige N C H O w 5 210 oc a u z 2 5 LS14 gt 35 N CH O aac rT 20 IKS3 KEY SWITCH wH U33 QD1 VOLTAGE e9 WH REGULATOR p io ee Se x oo QO 26 oo CO OZ rr ee l INT gt Go OO OO G6 22 oo GG OG BKWH EE Hec 2 ES EE EE 55 55 4 lt lt 22 x o aO 5 6 00 ce F9 EE Er ce se 5 4 6V T E 05 uu cc ce BATTERY 15A oo cr CI LL eiusdem FUSE f pepe 24V 279 EE e ig ao J4 I 0 5V CR1 8 5 SIAR gt gt 21 gt AC INPUT moron QD7 CONTROLLER b d NOTE z Sz MACHINE SHOWN F11 B 22 IN THE STOWED S 175A FUSE POSITION WITH we M3 U19 U20 E THE POWER OFF sc IGNITION SPARK 8 COIL PLUG O2 ES0233B ES0238B TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics
164. LS DIP Switch Legend models with GREEN circuit boards REV B DIP Switch Legend models with BLUE circuit boards Toggle Description Position Toggle Description Position 1 Drive option 1 Drive option enabled Off enabled Off disabled On disabled On 2 Hour meter flashing beacon 2 Hour meter flashing beacon enabled On enabled On disabled Off disabled Off 3 Not used Off 3 Batteries DC or Bi Fuel models Off 4 Valve coils Engine models On DC or Bi Fuel models Off Engine models On 4 Valve coils DC or Bi Fuel models Off 5 Platform level Engine models On ANSI models Off CE models On 5 Platform level ANSI models Off 6 Audible alarm for Drive option CE models On enabled On disabled Off 6 Audible alarm for Drive option enabled On 7 16 Not used Off disabled Off 7 Engine if equipped Gasoline Off li Diesel On ON CK ON CK 8 Machine power rn nnn U 1a 528 G 1718 12345 67 8 Pir uel eh Engine On d n As 9 16 Not used Off a DIP switch SW25 b DIP switch SW25A position 1 d position 8 e position 9 f position 16 Genie TEREX COMPANY 4 32 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 7 4 Membrane Overlay How to Replace the Overlay 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watch
165. MS raNMYTNONDADPELSES gt z c Sg 21 5 rose NE ap SNOOV38 ONIHSV14 TEN I2 9 Sa 93 RIBBON CABLE N SN E Luxor a E 2 3 lt ue 8 SI 109 H3OOIH1nO LNOH 1HOlH ge d e To q ze 709 H395lH100 LNOYS LHOIY Pils Pin lel lz x BK WOO H399IH1n0 LNOH4 LHDIH ps oje 1s Jez 157 E wk 2 ON H399IH1nO 1NOHJ LHDIH Eda Jalgi 77 oo ma i Qruso m 8 NT VIVG NO kii to M o08 ON H3DDIHLNO INOH4 1431 g7 no MEZZO ne VIVG HM Mi 9 WOO H3DDIHLNO 1NOHJ 1431 TN SSEES Osc eL an DrocoA FIFE Nie to 1 S S no e 100 399110 14043 1491 On E 1 the IOO H399IH1n0 LNOYS 1431 TMZ 50 30 G Part No 65162 Section 6 Schematics Dt Electrical Schematic DC Models from serial number T5002 25 to TMZ5003 228 June 2005
166. MZ 50 30 Part No 65162 June 2005 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev B Checklist B Rev B YNR A 1 Pre operation inspect B 1 Batteries Serial number LE A 2 Function tests B 2 Electrical wiring Date A 3 Engine maintenance B 3 Emergency Stop if equipped B 4 Key switch Hour meter A 4 Ae maintenance B 5 Auxiliary lowering ANSI models 3 B 6 Tires and wheels Machine owner 5 Axle maintenance Bo i ab int ANSI models ngue ecte rin nsp y print WO Ale maintenance B 8 Parking brake B 9 Horn Inspector signature CE models A 7 Axle maintenance B 10 Flashing beacon Inspector title CE models if equipped A 8 Engine maintenance B 11 Platform rotation Inspector company Honda models if equipped if equipped B 12 Tank venting system Instructions A 9 Axle maintenance B 13 Axle maintenance Make copies of this report to use for ANSI models ANSI models each inspection A 10 Axle maintenance B 14 Hydraulic oil analysis Select the appropriate checklist s for CE models B 15 Engine rpm the type of inspection to be Perform after 40 hours performed A 11 Perform 30 day service Checklist C Rev YNR Daily or 8 hours Inspection A Quarterly or 250 hours or 3000 mile 4800 km Inspection A B Semi annually or 500 hours or 6000 mile 9600 km Inspect
167. N 6 v2 J3 L3 RIBBON CABLE us JC5 BN34 ROTATE RIGHT JOYSTICK 4321 1 2 J3 U24 ei E ol m 4 oe BN33 ROTATE LEFT DRIVE CONTROLS 22 z B PRINTED CIRCUIT BOARD 33 H2 BN74 BOOM RETRACT ID7B 5 E VOLTAGE o 12V DC 5 DC 211 BL EEEE S HORN BN73 BOOM EXTEND al Yt S S J4 6 HBK e BN76 PLATFORM LEVEL DOWN n 14 321 T a adr A cs P2 oe BN75 PLATFORM LEVEL UP sage EMERGENCY STOP ge EMERGENCY a EEE e Us e fj SOP BN77 ENGINE START EN7 puka dadas ma BN5 HORN DRIVE CONTROL Box a ee BN12 FUNCTION ENABLE HIGH QD9B BN26 FUNCTION ENABLE MEDIUM apal ME QD9A 1113598 J BN13 FUNCTION ENABLE LOW PLATFORM CONTROL BOX EGU CONTROL SS BOX H LEELLE J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE Zee RN VS 28a o or 9 o9 99 HSB tt et Lo 15137 LS11 4 4 N C H O oss 41 2 7 NE X 1 X X X I X 1 X X X X I 1512 0 LS2 AD PON NOR 9 9 Is gt x X x x X Z G CX LS27 i i 1 i 1 i 1 i N C za 1 w _ s 21 Sy ad 58 a 22 35 95 55 82 88 x 88 82 29 0 E gt g 22 8 a2 laa ce ce HH
168. N 26 PIN 40 PIN Ss MU NN A JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE P1 EMERGENCY STOP P5 J2 J1 J3 J4 1 5 ov RD U21 p 5 4 P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER 4 3 18 5 3 89 82 88 LI 1 d z LS15 Q E uj 2 5 a N C H O iu E x 2 5 g E r 1515 3 2 7 b m EE LS14 Le I E N C H O la as U23 EIC H15 ENGINE foe al CIRCUIT D1 KS3 BOARD legsz jj zo 98 88 aa 55 z IT T 315241 88 Sz EE EB 55 55 t 22 oo OG TE 90 O90 aa EE 22 55 88 38 22 05 cr cc 3 oo rr crc lt lt lt lt ve cr mm CE co CR4 CR8 G6 55 Ek EE HIGH FUEL 5 fe LE EE GG IDLE CUTOFF oo 33 3535 CE EE 30 86 730 86 lo e 19 pn B 85 P 87A 85 3 4 gt EDIT Lis Ee 28 NOTE OIL CYLINDER 5 MACHINE SHOWN 11 PRESSURE Zz IN THE STOWED RUSE lt P L ux POSITION WITH Q8 gt THE POWER OFF HIGH IDLE FUEL ao SOLENOID CUTOFF 0232 ec ES0237A enie A TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics
169. Nm 20 260 ft lbs 352 5 Nm 20 172 ft lbs 233 2 Nm 24 315 ft lbs 427 1 Nm 24 208 ft lbs 282 Nm Genie 2 8 TMZ 50 30 Part No 65162 June 2005 Section 2 Specifications REV B SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Grade 5 LUBED DRY in Ibs 100 11 3 80 A574 High Strength Black Oxide Bolts LUBED 9 LUBED DRY in Ibs_ Nm 9 140 158 110 124 130 147 10 1 120 120 m gt LUBED DR ft lbs 17 6 17 LENIN 16 312 35 2 35 55 85 80 1084 110 90 122 120 e o o e 176 270 298 300 430 474 470 640 718 710 7 790 908 890 7 1120 148 24 16 24 14 20 13 20 12 11 18 10 16 14 8 12 12 7 12 6 12 1460 1979 1950 1640 2223 2190 Nm ft Ibs 18 33 50 80 130 11 m m masm m 160 217 LUBED DRY Nm ens Nm mis 20 LUBED 37 eo 813 80 1084 68 921 90 180 366 280 379 310 583 450 610 510 691 500 560 759 867 680 922 770 1044 750 1016 990 1342 840 1139 1071 970 1315 1090 1477 1080 1220 1654 1518 1360 12 1240 1510 1700 2670 2670 1844 1820 2467 1530 2074 3620 3560 4826 3000 7 75 91 10 3 116 155 5 2 1 95 260 DRY LUBED ft lbs Nm
170. ON CABLE RIBBON CABLE E G7 J2 J1 J3 J4 1 2 BK P5 38 M RD 021 P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT BREAKER MEC 4 16 3 18 5 2x Qo 82 8 amp 8 LL 1 TII 1 d z LS15 t S y 2 5 B N C H O u EE u a lt An 5 5 o 8 076 EB H HE 5 LS14 te M N C H O la 8 U23 EIC H15 ENGINE aie CIRCUIT D1 KS3 BOARD T B KEY lo o ng E 2 LUE 2a 55 g 28 88 SO OZ Fe rr Gh 5c 66 30 15 t gt gt OO 00 cc OG TE 90 00 aa zr rr FE EE mn zz 55 55 88 zz co co 3 oo rr rc lt lt lt lt CR4 G6 re m cc CC HIGH ERS 8 kk kk 55 FUEL 5 FE bhh OO IDLE CUTOFF oo 33 JJ EE EE 86 730 86 L iD e 2 sia i p od dqeseeem I 5 e no n e 85 86 87 485 gt gt gt el 4 SS 28 NOTE OIL b CYLINDER 5 MACHINE SHOWN 11 PRESSURE PED Zz IN THE STOWED 175A FUSE 1 MU l lt P i POSITION WITH Q3 gt THE POWER OFF HIGH IDLE FUEL ao SOLENOID CUTOFF ES0217B wc ES0222B 30 2 50 30 Part No 65162 June 2005 Section 6 Schematics
171. OR replace drive circuit board Replace ground key pad or touch pad OR replace circuit boards Joystick activated at power up OR faulty joystick Ground controls has stuck or faulty button Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board 0022 ow r boom up coil fault Secondary lower up Shortin wire harness Repair faulty wiring OR ihi P u valve coil shorted OR faulty circuit board replace circuit board 0023 Lower boom down coil fault Lower boom down coil fault 0024 0025 Upper boom up coil fault Secondary lower down valve coil open Secondary lower down valve coil short Primary upper up valve coil open Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR OR faulty circuit board replace circuit board Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Primary upper up Short in wire harness Repair faulty wiring OR 0026 Upper boom up Goil fault valve coil shorted OR faulty circuit board replace circuit board Upper boom down coil fault 0027 0028 0029 Upper boom down coil fault Outrigger up coil fault Primary upper down valve coil open Primary upper down valve coil shorted Outrigger up valve
172. Procedures REV B 10 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during operation The tank has an internal strainer filter for oil supply to the pump and an external line filter for oil being returned to the tank How to Remove the Hydraulic Tank When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the boom in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Genie TEREX COMPANY 9 9 Hydraulic Tank return tube gasket bulkhead fitting 90 elbow return hose from filter breather cap hydraulic tank supply hose to pump strainer assembly drain plug 725070000 Tag and disconnect the hydraulic hose from the return filter to the tank Cap the fitting on the filter head
173. RACT ID7B 5 E 12V DC 5v DC 211 BL HORN VOLTAGE B age BN73 BOOM EXTEND 565 a J4 BK e BN76 PLATFORM LEVEL DOWN n 14 321 T a adr A cs P2 oe BN75 PLATFORM LEVEL UP sage P3 EMERGENCY STOP EMERGENCY a EEE e Us e fj SOP BN77 ENGINE START EN7 L3 REPAR a cm BN5 HORN 9 aea DRIVE CONTROL BOX a ee BN12 FUNCTION ENABLE HIGH QD9B BN26 FUNCTION ENABLE MEDIUM apal ME QD9A 713598 713598 1713598 1 BN13 FUNCTION ENABLE LOW E a A PLATFORM CONTROL BOX EGU CONTROL SS BOX H LLILLLA J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE Zo 9o RS Qe 28a ao o or 9 of r 99 HSB et 15137 is LS41 EN N C H O N O H C 7 X X I X X X I X 1 X 1 X X i ista 0 LS2 S N O H C jc ix iW Ja PA PAI PAI A gE PA did 2 iB BB 28 88 22 3 9 55 88 EAM 88 82 29 0 E gt g 22 98 laa E 3 me 1 823 88 2 Ez z D 5 99 x 5 2 P e 25 8 8 88 8 LE a rr rr 3 Z 5254 2 Za Od 4 89 62 EE EE 55 55 65 9 ssor 923 85 89 2g a9 88 2
174. Relief Valve Perform this procedure with the platform in the stowed position 1 Connecta 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 2 Press and hold the function enable button and press the primary boom retract button Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 3 Turn the machine off Hold the relief valve item AH BC CB or DB and remove the cap 4 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap ADANGER Tip over hazard Do not adjust the relief valve higher than specified 5 Repeat steps 2 through 4 to confirm the relief valve pressure 6 5 Genie TEREX COMPANY 4 64 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 9 13 Valve Coils MANIFOLDS Valve Coil Resistance Description Specification How to Test a Coil Solenoid valve 2 position 3 way 6 to 80 f 10V DC engine models schematic item BD A properly functioning coil provides an electromotive force which operates the solenoid Solenoid valve 2 position 3 way 26 to 280 valve Critical to normal operation is continuity 20V DC DC models schematic item BD within the coil that provides this force field Solenoid valve 2 position 3 way 6 to 80 AWARNING Electr
175. Return to Perform service problem repair solved Part No 65162 TMZ 50 30 6 1 Section 6 Schematics FC E Electrical Component and Wire Color Legends June 2005 REV A ABBREVIATION LEGEND ABBREVIATION LEGEND Item Description Item Description B B1 One 12V battery I Light or LED B5 Four 6V batteries L12 Left front outrigger BN Button L13 Right front outrigger BN5 Horn L14 Left rear outrigger 12 Function enable high L15 Right rear outrigger BN13 Function enable low L46 Low battery indicator BN26 Function enable medium L48 Machine level BN27 Jib boom up LS Limit switch BN28 Jib boom down LS2 Primary boom up BN29 Primary up LS11 boom down BN30 Primary down WIRE co LOR LEG END LS12 Left front outrigger BN31 Secondary up in LS13 Right front outrigger BN32 Secondary down Color Description LS14 Left rear BN33 Rotate left BK Black LS15 Right rear outrigger BN34 Rotate right BL Blue M Motor BN35 Horn GN Green Engine starter Se a Rm 5 Hydraulic power unit ID boom down N C Normally closed BN38 Primary up RD Red N C H O Normally closed held open Bree WH White N O Normally open BN41 Secondary down YL Yellow N O H C Normally o
176. SN MW 3000 psi 3000 psi p ps y T 3000 ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 31 31 31 3 1 S1 A3 A5 B5 A4 B4 A6 B6 A7 B7 ee o gt Nu Y23 Y22 om Y53 ti om Y26 Y61 om a REI ME AOX 0 6 gpm _ 2 27 L min FUNCTION MANIFOLD HS0136C Part No 65162 TMZ 50 30 6 63 Section 6 Schematics June 2005 Hydraulic Schematic Bi Fuel Models with Drive Option REV B before serial number T5000 91 Part 1 of 2 DRIVE OUTRIGGERS FRONT IFRONT LEFT x RIGHT ros LEFT RIGHT CYLINDER IESU gp f BRAKE RELEASE CK Ll A LE CYLINDER 0 PM LEFT 4 4 21 x li a 0 m ge aMi M2 o cs ol i 9 DRIVE MANIFOLD el PLATF RM REAR REAR n yw WD yi me LEFT RIGHT LEVEL i SLAVE cam mw
177. START EN7 o 3 6 al BN5 HORN E DRIVE CONTROL BOX e a 5 BN12 FUNCTION ENABLE HIGH QD9B BN26 FUNCTION ENABLE MEDIUM QD4 Se QD9A 1113598 J BN13 FUNCTION ENABLE LOW EN2 LEN1 PLATFORM CONTROL BOX __ __ __ __ __ __ __ __ GROUND CONTROL BOX J5 12 364 5 CONNECTOR PC BOARD P2 28 5 616 i OUTRIGGER U21 LIFT DRIVE Ve 8 o on So of X 2 9888 m bet tt et Lo 1137 n Bu 7 O gt 2 all amp X Des Xe ee ee Xp N O H C g x 5 UM UN 5 AX 2 2 2X 41827 i i N C za 1 55 89 28 88 8 g 88 Bux ad a r I OO OZ Fe 8 55 as gt I Ez zz S 3 9 Esa z a 622 I E I gg 99 99 gn 5 2 EE E gt 8 8 68 82 5 2 L SS EE rr 29 22au 37256 2 Za zQ O3 Q i 89 EE 55 66 55g py 8g 222 25 52 298 12 O8 22 22 00 00 09 GIES 2250 go OG 5 BO 15 oo oo 55 j z 305 dec m M oo 603 G5 2 2 lt cg EE EE 5 Oa 55 rc 22 OE PUE BE Z se zz zz 66 66 ma ia uoi Et Eo 4
178. Secondary lower boom up down 18 20 ft lbs 24 27 Nm 9 Solenoid valve 2 position 3 way Es Regenerative circuit for outriggers 18 20 ft lbs 24 27 Nm 10 Counterbalance valve EJ i Platform level up 30 35 ft lbs 41 47 Nm 11 Shuttle valve Turntable rotate brake circuit 4 5 ft los 5 7 Nm 12 Solenoid valve 3 position 4 way ELE Ls Outriggers up down 18 20 ft los 24 27 Nm 13 Solenoid valve 3position 4 way EM Platform level up down 18 20 ft los 24 27 Nm 14 Counterbalance valve EN au Platform level down 30 35 ft lbs 41 47 Nm 15 Solenoid valve 3 position 4 way EO Turntable rotate left right 18 20 ft lbs 24 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie TEREX COMPANY 4 50 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha numeric callouts refer to corresponding notes on the electrical schematic
179. SrNOX mg Sa WOO HOLIMS 25125 29 211 5 14 PIN ey E 5 iu ae ap SNOOV39 NIHSYH gy o RIBBON CABLE EOS NE ite 12 NOLLdO SNOOV38 SNIHSV14 2 lt ue ar 109 H3OOIH1nO LNOH 1HOlH ge d e q ze 7109 H399IH1n0 1NOtid LHDIH ole lo x 8 ale Le Ju WOO H399IH1n0 INOW is E g T 2 ON H399lH1n0 1NOHJ LH9IH Eda gog T GNO 2 oo QS lt lt PTP3 EP lt NT VIVG NO kii to 22 095 O N H395lH100 LNOWS 1 91 S u EERE aK G gt 8 2151 KZ 204 ne HM Te 10 9 WOO H399IH100 LNOYS 1431 aO viva Sagte gt lt le 8H an e 1 oo no e 100 399110 14043 1491 ann ee ge c Lec ee 1 the IOO H399IH1n0 LNOYS 1431 6 11 TMZ 50 30 G Part No 65162 Section 6 Schematics Electrical Schematic DC Models after serial number TMZ5003 228 June 2005
180. T BOARD 555 H2 BN74 BOOM RETRACT ID7B Tt 5 A a HORN 22 ivottace ov De sv oc at EEEE gt BN73 BOOM EXTEND die cds a HYL 455 6 S 44 BK BN76 PLATFORM LEVEL DOWN x 4321 S a cs P2 oe BN75 PLATFORM LEVEL UP zd P3 EMERGENCY STOP EMERGENCY a E e e fj SOP BN77 ENGINE START EN7 525888 E 4 BN5 HORN i mimm DRIVE CONTROL amp ox E a BN12 FUNCTION ENABLE HIGH QD9B p BN26 FUNCTION ENABLE MEDIUM QD4 ME QD9A 1113598 J BN13 FUNCTION ENABLE LOW MEG EN2 LEN1 PLATFORM CONTROLBOX __ __ __ __ __ __ __ e GROUND CONTROL Rire F BOX J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE BES RE NE SSR wo vv on So of 99 t BAB L Jaee bet 1137 is ES n 7 2 X X I X X X I X X I X X I i Sts12 x LS2 i amp N O H C x joc Ja HN A x X x x X 2125 X 11627 i i 1 i 1 i 1 i 9 9 2 e N C 2 uu E 51 o 88 a 8 B8 lt OO 88 oz ZO 5 E Z 22 R8 cd x 56 BB HES 8 5 88 9 Bd da E x oe 5 9 5 9 zi gt SS 8s 22 S9 oo 5 33 US sz 29 Sa Ba a ae al
181. T4 5 A a HORN lt ivoutace ov sv oc at 555 Pers BN73 BOOM EXTEND 5 a J4 e BN76 PLATFORM LEVEL DOWN M 14 321 T a P2 oe BN75 PLATFORM LEVEL UP EMERGENCY STOP EMERGENCY amp el e STOP D BN77 ENGINE START EN7 5 BN5 HORN DRIVE CONTROL BOX E eee 58 BN12 FUNCTION ENABLE HIGH QD9B AO BN26 FUNCTION ENABLE MEDIUM QD4 T QD9A 1113598 J BN13 FUNCTION ENABLE LOW MELOS LIU Ti 2 pe PLATFORM CONTROL BOX ROUND CONTROL BOX J5 12364 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 OUTRIGGER U21 LIFT DRIVE RE VS 8 o on No of X 9 99585 Lo 1513 LS11 4 4 N C H O 4 1 2 jt 7 d 2 J 1 DX z 12 ihe 152 Y Y x AT Xe X8 XS N CH O NOHC x x wit c S 4y p FX A 1 1511 PX PX 15 1 6 6 A 11527 S E N C ig oy 29 22 2 a2 z5 98 66 5 u 8S 2 39 44 x oo 99 zo s San Que r F 4 4 7 OO OZ rr rr K as gt I gg 8 EES 8 988 S a RE 2 2 da 66 E 9 P 8 rr S 8 88 8 ER
182. TENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER T Wi Lene i w 124 M 9 m HSN MW 3000 psi 3000 psi p ps y T 3000 ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 31 31 31 3 1 S1 A3 A5 B5 A4 B4 A6 B6 A7 B7 ee o gt Nu Y23 22 om Y53 ti om Y26 Y61 om fide EDE MF AOX 0 6 gpm _ 2 27 L min FUNCTION MANIFOLD HS0135C Part No 65162 TMZ 50 30 6 71 Section 6 Schematics June 2005 E This page intentionally left blank A TEREX COMPANY 6 72 TMZ 50 30 Part No 65162 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 9
183. UTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 t BN39 PRIMARY DOWN T T OUTRIGGER EXTEND BN47 TE oe BN53 RIGHT FRONT OUTRIGGER T T OUTRIGGER RETRACT BN48 ar BN40 SECONDARY UP T T PLATFORM LEVEL DOWN BN70 n o BN41 SECONDARY DOWN fic m PLATFORM LEVEL UP BN69 D BN52 LEFT FRONT OUTRIGGER T 2 3 BOOM RETRACT BN72 36 JIB BOOM UP T T BOOM EXTEND BN71 e BN37 JIB BOOM DOWN G8 DIAGNOSTIC HORN BN35 o e e 51 RIGHT REAR OUTRIGGER DISPLAY T Eas FUNCTION ENABLE HIGH BN44 e E BN43 ROTATE RIGHT gt FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT T T FUNCTION ENABLE LOW BN46 5 I BN50 LEFT REAR OUTRIGGER 5 ot ON g mon HORN 112 L13 114 115 16 PIN Rex Me Ae RIBBON CABLE Ct 585 4 i 925 u ss iy Iho a pc sv al U22 87554821 DIP SWITCH s 1447 ROX BEI PLATFORM 4 D7 UTU CPU DISPLAYBOARD 111114444 SW25A 8 J8 VOLTAGE REGULATOR 87054321 DIP SWITCH KS1 E 21 J6 J9 J2 J3 e F Ly J 7 PIN 11 PIN 26 PIN 40 PIN JUMPER CABLE JUMPER CABLE RIBBON CABLE RIBBON CABLE Lo P1 EMERGENCY STOP P5 J2 J1 J3 J4 1 5 ov RD U21 P4 P1 CONNECTOR PC BOARD P3 CB2 ENGINE OUTRIGGER CIRCUIT
184. XS 19A n U _ _ O h gt 1 ae I welt ZSA 5 ac z geom Or cH OZ 5 709 dn 1A9 14 ESA amp amp Su 8 die T 709 TAS 1311 H3MO1 LZA 2 E yyy gt lt lt zu i5 aaa 85 L4 709 dN TAD 1J 1H3MO1 ZZA 2 0 gt gt j lt lt lt O i D x Br ZZ z 22 21 zz e 7 a gt ao Q G z Lb Kk gt 2 2 211 7109 103138 SA E amp Sup 6 y 9 9 9 bd ez s s 9 k z z E E2266 6 n No 7109 1437 SLVLOH ECA lt o 9 5 5 9 9 s lt 9 5 2 gt 2 ES lt EEUU S 24 QO OQ os 9 R GG 9 P P wi 9 1100 LHDIH EA m E zu a 889 se S 3 9 E KEK KE s S EES 8 e Naaa WHOA 61 um N gt a a 5 a a amp 5 amp amp amp amp amp 5 v R 109 AM3 dN d3A31WHOdlvld OZA 5 a 2 zr 4 709 N3O3H H399lH1nO LA T TL u z 7109 ON31X3 14A31u399IH1nO OFA T P lt z m n 4 MP ol br e Qovui3u dnuaoomino Eu a x q q of q of e af af of q of of of ed igli dnouo FE 12 Q oe z 1109 IVNOLLHOdOUd oz 12 6 7109 ANTVA i 1 i 1 i E
185. __ __ __ __ GROUND CONTROL Bir ccr dicen occum ee ee urs s BOX J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE BES RE NE SSR wo vv on So of 99 t BAB L r bet 1137 is ES Eu 7 2 X X I X X X I X X I X X I i Sts12 x LS2 i i S N CH O N O H C EN c x X x x X 2 12 gt X 5 ici ME x a B zu gt gt 23 z5 98 55 5 acB 2 88 x QQ zo OO E Sica CO E RAS OO OZ Fe 55 E 2 as 2 i GE 89 88 8 oo 2 Es x ES Q x o Q E IDE OO OO c Q E 90 99 22 22 29 5 2 253 b 2 5Z 29 8 g IGF 88 22 zr EE 22 9 55 SSN 290 5a 59 s 28 95 8 ia 9o EE 55 55 00 EOD SS oe aa 0872 95 50 20 O 119 22 55 99 BIS 3250 g OQ 5 22 15 of 55 PE EE 395 doo 55 55 Se Q 116 gu EE 66 66 29 P28 6555 zz Sh CGE EE ko 9B E 16 6 9g ge EE 22 382 99 55 hu gee 25 I6 28 B 198 8 58 fr LL fe kL FF BBE 9059 99 00 EE GSE ge ck bz S7 u Ek 38 38 33 S225 55 kk BE Eo g8 8 iet 8 uu gg 55 oo amp amp 369 95 55 5 8 l
186. a kus er BOX J5 1 2 3 6 4 5 P3 CONNECTOR PC BOARD P2 41235 6 J6 i OUTRIGGER U21 LIFT DRIVE Ve 8 o on So of X 2 t 9888 m et es bet 1137 is n Bu 7 2 X X I X X X I X 1 X 1 X X I Sus d 52 s ere N O H C ix iW Ja x X x x X 2125 CX B8 s d2 20 22 gt gt lt 98 BB 8 2 99 88 B2 22 88 ss sr TUBES rg uu 8 9 2 dad E 3 88 229 P8 3 8 2 uu g8 8 8 88 8 3 o D sig 98 998 rr rr 3 2 22 5 55 2 Za 20 02 D 95 EE EE 55 55 5500 gg 595 85 6 28 ig 9 88 33 ag 909 95 99 ors 2230 gg BU 59 U ge 118 Qu og EE 9 2292 JC HES oo o2 cz lt ag c o ZZ ZZ mm dud ob PSE t o 4 SE 00 990 Go E zz pu wou Lk ES QE rc 4 mc xu OO crc cc 22 gt gt lt OO EE 35 df ES ou amp gt tt EE EE EE S 38g 00 HH Est EE ge GE 57 Ig fe kk g gg 33 83 658 EE EE EE EOS EU vB B tevesensor 92 EE gH ee ee gg 260 88 22 569 85 58 S8 8 55 44 e o N e oo o Ar
187. air 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 re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of ste
188. and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray a platform level master cylinder b platform level slave cylinder 2 Remove the pin retaining fastener from the master cylinder barrel end pivot pin 3 Using a soft metal drift remove the master cylinder barrel end pivot pin 4 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder 5 Remove the pin retaining fastener from the rod end pivot pin 6 Using a soft metal drift remove the master cylinder rod end pivot pin Remove the master cylinder from the machine AWARNING Crushing hazard The master cylinder could become unbalanced and fall if not properly supported when removed from the machine Genie Part No 65162 TEREX COMPANY TMZ 50 30 4 21 Section 4 Repair Procedures June 2005 PRIMARY BOOM COMPONENTS How to Remove the Slave Cylinder The slave cylinder via a closed circuit hydraulic loop works in tandem with the master cylinder to maintain the platform in a level condition through the entire range of boom motion The slave cylinder located at the platform end of the extension boom is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure Before cylinder removal is considered to correct a malfunction bleed the slave
189. as for burnt chafed corroded pinched and loose wires Boom to platform cable harness Primary secondary and jib booms Part No 65162 June 2005 Section Scheduled Maintenance Procedures REV B B 3 Test the Emergency Stop A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Pull out the red Emergency Stop button to the on position at the drive controls if equipped Result The power light should be on 2 Pushin the red Emergency Stop button to the off position at the ground controls Result The engine if equipped should turn off No machine functions should operate 3 Pull out the red Emergency Stop button to the on position at the ground controls 4 Pushin the red Emergency Stop button to the off position at the platform controls Result The engine if equipped should turn off No machine functions should operate 5 Pull out the red Emergency Stop button to the on position at the platform controls 6 Push in the red Emergency Stop button to the off position at the drive controls if equipped Result The engine if equipped should turn off No machine f
190. capacity 244AH Reserve capacity 25 rate 530 minutes Engine models Type 12V DC Group C31 1000 Quantity 1 Cold cranking ampere O F 18 C 1000 Reserve capacity 25A rate 200 minutes Fluid capacities Hydraulic tank capacity 8 gallons 30 3 liters Hydraulic system capacity 10 gallons including tank 37 9 liters Trailer hitch load maximum ANSI and CSA models 200 Ibs 91 kg CE models 227 kg For operational specifications refer to the Operators Manual Part No 65162 A TEREX COMPANY Specifications Tires and wheels All models before serial number T5099 006 Tire size ST225 75D 15 Load range D Tire pressure cold 65 psi 4 5 bar Wheel lugs 5 1 2 20 Lug nut torque 80 ft lbs 108 Nm ANSI CSA models after serial number T5099 005 Tire size 8 14 5 LT Load range F Tire pressure cold 100 psi 6 9 bar Wheel lugs 5 1 2 20 Lug nut torque 80 ft lbs 108 Nm CE models after serial number T5099 005 Tire size 215 R14C 112 110 Load range Tire pressure cold 4 5 bar Wheel lugs 5 18 1 5 Lug bolt torque 260 Nm Tongue jack jockey wheels Tire size pnuematic tire 4 10 3 50 4 Diameter 12 in 30 5 cm Tire pressure maximum cold 50 psi 3 4 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice TMZ 50 30 2 1 Section 2 Specifications June 2005 SPE
191. cheduled Maintenance Procedures REV B B 15 Check and Adjust the Engine RPM Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Honda GX340K1 Engine 1 Remove the platform controls Open the clamp on the back of the platform controls and slide the controls up and off of the platform 2 Before serial number T5002 25 Connect an rpm gauge to the engine 3 Before serial number T5002 25 Start the engine from the platform controls Check the engine rpm on the gauge Refer to Section 2 Specifications After serial number T5002 24 Start the engine from the platform controls Press and hold the engine start button BN77 at the platform controls and check the engine rpm on the diagnostic display at the side of the ground controls Refer to Section 2 Specifications Skip to step 5 if the low idle rpm is correct CHECKLIST B PROCEDURES 4 Honda models Locate the adjustment screw on the carburetor and turn the adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm and repeat this procedure beginning with step 3 Hatz models Loosen the low idle lock nut Turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and repeat thi
192. ckwise direction 1 Turn the hand crank at the platform in the clockwise direction O Result The platform should rotate to the right and operate smoothly without any hesitation or binding 2 Turn the hand crank at the platform in the counterclockwise direction Result The platform should rotate to the left and operate smoothly without any hesitation or binding CHECKLIST B PROCEDURES B 12 Inspect the Hydraulic Tank Cap Venting System Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machine to perform poorly Extremely dirty conditions may require that the cap be inspected more often 1 Remove the breather cap from the hydraulic tank 2 Check for proper venting Result Air passes through the breather cap W 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 Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section Scheduled Maintenance Procedures
193. coil open Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR OR faulty circuit board replace circuit board Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board 0030 triG e ub coil fault Outrigger up valve coil Short in wire harness Repair faulty wiring OR utrigger up shorted OR faulty circuit board replace circuit board A TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 5 Troubleshooting Flow Charts REVA 003 1 Outrigger down coil fault Outrigger down valve 0032 Outrigger down coil fault coil shorted Outrigger regen coil fault 0033 0034 0035 0036 Outrigger regen coil fault Left front outrigger coil fault Left front outrigger coil fault Right front outrigger coil fault 0037 0038 0039 0040 0041 0042 0043 Right front outrigger coil fault Left rear outrigger coil fault Left rear outrigger coil fault Right rear outrigger coil fault Right rear outrigger coil fault Pump coil fault FAULT CODE CHART AFTER SERIAL NUMBER T5002 24 Fault Code Fault Condition Possible Cause Solution Outrigger down valve coil open Outrigger regen valve coil open Outrigger regen valve coil shorted LF outrigger valve coil open LF
194. ction 2 from entering pump section 1 18 20 ft lbs 24 27 Nm 10 Check vakve BJ Prevent flow from pump section 1 from entering pump section 2 18 20 ft lbs 24 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie TEREX COMPANY 4 44 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Back NU 09 s 8 T BH 8 9 Genie TEREX COMPANY Part No 65162 TMZ 50 30 4 45 Section 4 Repair Procedures June 2005 p a s x r1 MANIFOLDS REV B 9 3 Pump Manifold Components Models without Drive before serial number T5000 91 The pump manifold is located next to the function manifold under the function manifold side cover Index Schematic No Description Item Function Torque Coil N t item ede en ad ec i dae ees 5 7 ft los 7 9 Nm 1 Proportional valve engine models
195. ctrical Schematic Gasoline Models REV A after serial number TMZ5003 228 Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a a OUTRIGGER AUTO LEVEL BN49 E BN38 PRIMARY UP T T ENGINE START BN68 ee BN39 PRIMARY DOWN T OUTRIGGER EXTEND BN47 BN53 RIGHT FRONT OUTRIGGER S OUTRIGGER RETRACT BN48 oe gt BN40 SECONDARY UP T T PLATFORM LEVEL DOWN 70 BN41 SECONDARY DOWN fic PLATFORM LEVEL UP BN69 BN52 LEFT FRONT OUTRIGGER BOOM RETRACT BN72 gt 36 JIB BOOM UP p End G8 BOOM EXTEND BN71 e BN37 JIB BOOM DOWN E E DIAGNOSTIC HORN BN35 o e e 51 RIGHT REAR OUTRIGGER DISPLAY FUNCTION ENABLE HIGH BN44 BN43 ROTATE RIGHT pr T FUNCTION ENABLE MEDIUM BN45 BN42 ROTATE LEFT T FUNCTION ENABLE LOW BN46 I BN50 LEFT REAR OUTRIGGER H5 O 0 HORN
196. cturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information is available in the Hatz 1B30 Engine Instruction Book Hatz part number 433 0802 01 Hatz 1B30 Instruction Book Genie part number 97363 Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures Checklist E Procedures REV B E 1 Test or Replace the Hydraulic Oil 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 2 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications ACAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns Tag and disconnect the hydraulic hose from the return filter to the tank Cap
197. cuit OR faulty circuit replace circuit board board A TEREX COMPANY 5 8 TMZ 50 30 PartNo 65162 June 2005 Section 5 Troubleshooting Flow Charts REV B FAULT CODE CHART AFTER SERIAL NUMBER T5002 24 Fault Code Fault Condition Possible Cause solution m Short in wire harness Repair faulty wiring OR 0086 Spare output fault Spare output D hon OR faulty circuit board replace circuit board Coil not connected to 0087 Engine fault Ende cce edis nen wire harness OR open Restore connection OR g 9 P circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR 0088 Engine coil fault Engine choke eo short OR faulty circuit board replace circuit board Coil not connected to 0089 Spare Spare Sut C open wire harness OR open Restore connection OR P P P p P circuit OR faulty circuit replace circuit board board m Short in wire harness Repair faulty wiring OR 0090 Spare output fault Spare output 2 short OR faulty circuit board replace circuit board Coil not connected to 0091 Proportional valve coil Proportional valve coil wire harness OR open Restore connection OR fault open circuit OR faulty circuit replace circuit board board 0092 Proportional valve coil Proportional valve coil Short in wire harness Repair faulty wiring OR fault shorted OR faulty circuit board replace circuit board A TEREX COMPANY Part No 65162
198. cylinder to be sure there is no air in the closed loop hydraulic circuit When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Extend the boom approximately 1 foot 30 cm 2 Tag disconnect and plug the slave cylinder hydraulic hoses from the tee fittings on the jib manifold and connect them together using a connector Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray REV B a platform level master cylinder b platform level slave cylinder 3 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 4 Remove the external retaining rings from the barrel end pivot pin 5 Using a soft metal drift remove the rod end pivot pin 6 Using a soft metal drift remove the barrel end pivot pin 7 Carefully pull the cylinder out of the boom Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched How to Bleed the Slave Cylinder 1 Raise the boom to a horizontal position 2 Activate the platform level function in both up and down directions through two comple
199. d 4 89 62 EE EE 55 55 55 2355 ssor 923 85 89 2g 112 a9 88 0T 2250 gu 09 USN ge a 5 15 ag 990 00 00 22 22 2202 f Fe DOS oo o2 lt Sel fH EE EE ZZ zz mo 5z9 685r 22 6k c dm es 115 36 ge 00 990 Go E a uu EE ES Q rc 4 mc xu gg rE EE 99 Ek lt 6 oo T3 2035 35 56 fx 55 tt EE EE 288 9559 99 HH Eag Er gk S7 E 66 55 99 22 995 EE FOS se ED D LEVELSENSOR D gt Li tc w ox PUR Q a a uu uu gr ee gg 5535 E amp amp 0 oo ze S68 85 55 2 amp 8 B ec e o o e sx Vr NN S A DH ON A 1D gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS MODELS WITH DRIVE IN THE STOWED POSITION WITH ES0216C THE POWER OFF ES0221C TEREX COMPANY Part No 65162 TMZ 50 30 6 17 Section 6 Schematics June 2005 H M Electrical Schematic Gasoline Models REVA from serial number T5002 25 to TMZ5003 228 Part 1 of 2
200. dyr 14 189 Hl a E e ra O a psi Y40 i Ll X ys Y20 i v n FER m mle O US UEM 1 t rorem BP Y 68 egy Y ER PUMP MANIFOLD FUNCTION MANIFOLD pq oro P1 P2 P4 P3 Ti 2 1 DC 3 gpm 3 gpm 11 4 L min 11 4 L min e HYDRAULIC TANK HS0137D 6 50 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Hydraulic Schematic 0 6 gpm 2 27 L min REV A DC Models with Drive Option after serial number T5000 90 Part 2 of 2 TURNTABLE PRIMARY SECONDARY EXTENSION JIB ROTATE CYLINDER CYLINDER CYLINDER BOOM UPPER LOWER 1 E 1 mT i AE mo ou 3000 psi 3000 psi 2500 ni y T 3000 ps 206 8 bar 206 8 bar 172 4 bar 206 8 bar 3 1 3 1 3 1 3 1 1 B3 A5 B5 A4 B4 A6 B6 AT B7 o gt HL D Y24 im Y23 Y22 Y19 Y53 ti Y52 Y26 Y61 Y60 DR Gat LDA FUNCTION MANIFOLD HS0137D Genie Part No 65162 TMZ 50 30 6 51
201. e Use only 12 AWG heavy duty extension cord Power cable firmly connected to the AC input plug or fitted into the AC input connector Faulty fuse 120V models faulty circuit breakers 230V models Correct wiring at the batteries Red charger wire to battery positive Black charger wire to battery negative Component damage hazard This CAUTION 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 Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 7 7 Lester Battery Charger North America models The Lester 19740 battery charger used on machines after serial number T5003 116 is a 24V 25A charger Designed for use with wet liquid filled batteries this self regulating charger is equipped with built in line voltage compensation which supplies consistent DC output even when the AC supply voltage varies by as much as 10 This 120V AC charger is equipped with and protected by a 30A fuse located on the charger face plate next to the AC input plug Worldwide models The Lester 22310 battery charger used on machines after serial number T5003 116 is a 24V 20A charger Designed for use with wet li
202. e potentiometers on the bottom of the level sensor or calibrate the level sensor other than specified in this procedure Failure to calibrate the tilt level sensor as instructed will cause the machine to tip over resulting in death or serious injury Be sure there are threads showing through the top of each adjusting nut 19 Disconnect the positive and negative leads 20 Apply Sentry Seal to the adjusting nuts Test the machine 21 Raise the primary secondary and jib booms approximately 12 inches 30 cm Result The tilt sensor alarm should not sound 22 Press down one side of the tilt sensor and place the tilt sensor test tool under one of the posts Result The alarm located in the platform should sound at 180 beeps per minute after 1 second The interlock display light should flash 23 Test all machine functions Result The primary boom up secondary boom up jib boom up and boom extend functions should not operate The primary boom down secondary boom down jib boom down boom retract and turntable rotate functions should operate normally 24 Turn the key switch to platform control 25 Test all machine functions Result The primary boom up secondary boom up jib boom up and boom extend functions should not operate The primary boom down secondary boom down jib boom down boom retract and turntable rotate functions should operate normally Genie TEREX COMPANY TMZ 50 30 Par
203. e See Repair procedure 12 2 How to Adjust the Parking Brake 3 Visually inspect the parking brake cables and components for damage CHECKLIST B PROCEDURES 4 Confirm the following All brake cables are properly secured Parking brake equalizer adjustment rod is properly secured There is equal tension on the brake equalizer bracket Brake cylinder is properly secured Drive enable limit switch is properly set and secured 5 Checkthe tension of the brake cables by manually pulling on each cable Result The brake cables should be tight with no movement in the lines If the parking brake lines are too tight the parking brake assembly will be difficult to apply If the brake lines are too loose the brake cylinder will not activate the drive enable limit switch will not engage and the unit will not drive Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 9 Test the Horn A functioning horn is essential to safe machine operation The horn is activated at the ground platform or drive controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the Emergency Stop button to the on position at both the ground and platfo
204. e Eo RR RR 2 7 Hydraulic Hose and Fitting Torque Specifications 2 8 SAE and Metric Fasteners Torque Charts 2 9 Scheduled Maintenance Procedures u l u 3 1 Pre delivery Preparation Report u u 3 3 Maintenance Inspection Report sss 3 5 Checklist A Procedures Part No 65162 A 1 Perform Pre operation Inspection u 3 6 A 2 Perform Funcion Tests denies arid dh 3 6 A 3 Perform Engine Maintenance if equipped 3 7 4 Perform Hitch Maintenance ANSI Models 3 7 5 Perform Axle Maintenance ANSI Models 3 8 TMZ 50 30 June 2005 p TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued 6 Perform Axle Maintenance CE Models 3 8 7 Perform Axle Maintenance CE Models 3 9 A 8 Perform Engine Maintenance Honda Models if equipped 3 9 9 Perform Axle Maintenance ANSI Models 3 10 A 10 Perform Axle Maintenance CE Models 3 10 A 11 Perform
205. e coil nut onto the valve stem and torque to specification Genie A TEREX COMPANY 4 52 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on FA the hydraulic schematic Cre 9 e FK p 6 ON CFD e lt i FF XP 25 er _ Genie Part No 65162 TMZ 50 30 4 53 Section 4 Repair Procedures June 2005 p M mer MANIFOLDS REV B 9 7 Function Manifold Components DC Models before serial number T5000 91 The function manifold is located under the function manifold side cover Index Schematic No Description Item Function Torque Coil nut items GD GE GF GG GH Gl GL GO monti Ha ORTU teens 4 5 ft lbs 5 7 Nm 1 Diagnostic nipple GA Testing 2 Flow regulator valve 0 6 gpm 2 27 L min Turntable rotate Circuit 18 20 ft lbs 24 27 Nm 3 Orifice Plug 0 025 inch 0 64 mm GC Turntable rotate circuit Solenoid valve 2 position 3 way Primary boom extension 18 20 ft lbs
206. e machine 18 Using dielectric grease at the connection securely connect the platform control wire harness to the harness connector at the platform pivot Genie TEREX COMPANY 4 4 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 2 1 Platform How to Remove the Platform Models with Platform Rotate option 1 Support the platform with an appropriate lifting device 2 Remove the fasteners securing the platform to the platform mount on the platform rotator assembly AWARNING Crushing hazard The platform may become unbalanced and fall if not properly supported by a lifting device when the fasteners are removed 3 Lift and remove the platform from the mount Models without Platform Rotate 1 Remove the platform controls from the platform control box mount Release the clamp on the back of the platform control box and slide the controls up and off of the mount 2 Supportthe platform with an appropriate lifting device 3 Remove the toggle pin securing the platform to the platform mount AWARNING 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 Platform Components 2 2 Platform Rotator if equipped The platform rotator is a manually operated gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator 1 R
207. e machine REV B How to Repair the Cable Track Component damage hazard The CAUTION cable track can be damaged if it is twisted 1 Remove the fasteners securing both cable track top covers to the primary boom Remove both covers from the boom 2 Visually inspect the cable track and determine which 7 link section needs to be replaced 3 Using a flat blade screwdriver pry open the hinge bar on each link of the 7 link section plus one more on each end making a total of 9 links 4 Using a flat blade screwdriver at one side of the link to be replaced separate the connection and open the joint slightly by sliding the link over the link pivot Repeat for the other side of the link to separate the link sections 5 Repeat step 4 for the other end of the section to be replaced 6 Liftup the hoses and cables and carefully remove the damaged section of cable track Component damage hazard CAUTION Hoses and cables can be damaged if they are kinked or pinched 7 Liftup the hoses and cables and carefully insert the new section of cable track 8 Install the new section of cable track onto the existing track Be sure the link pivot on both sides of the link are in place and that the track hinges correctly 9 Securely lock the hinge bar for each link 10 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track Genie A TEREX COMPANY TMZ 50 30
208. e pump coupler set screw 4 Loosen the set screw Slide the pump coupler off the pump shaft 5 Remove the bell housing mounting fasteners Remove the bell housing from the engine 6 Loosen the set screw on the engine side pump coupler 7 Slide the pump coupler off of the engine shaft Engines How to Install the Pump Coupler CAUTION Component damage hazard Be sure that the crankshaft key and the rubber spacer are not damaged prior to the installation of the pump coupler assembly 1 Align the engine side of the pump coupler over the crankshaft key and slide it onto the crankshaft 2 Apply Loctite removable thread sealant to the engine side pump coupler set screw and tighten Torque to specification Install the bell housing mounting fasteners 4 Install the hydraulic pump side coupler onto the hydraulic pump shaft 5 Apply Loctite amp removable thread sealant to the hydraulic side pump coupler set screw and tighten Torque to specification 6 Install the pump coupler rubber spacer 7 Install the hydraulic pump bell housing 8 Tighten the hydraulic pump mounting fasteners Torque specification 15 ft lbs 20 3 Nm Pump coupler set screw dry Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005 Ground Controls The ground controls contain 2 printed circuit boards the wire harness connector board and the CPU display board On the e
209. e stowed position Drive Components option 14 1 Drive Motor How to Remove a Drive Motor When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the drive wheel retaining fasteners 2 Remove the drive wheel 3 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings Bodily injury hazard Sprayin AWARNING 19 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the drive motor mounting fasteners Remove the drive motor from the machine Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005 DRIVE COMPONENTS OPTION How to 5 Remove a Drive Motor Cylinder 6 When removing a hose assembly REV B Place a block under the rod end of the cylinder for support Remove the rod end clevis pin or fitting the O ring on the fitting ACAUTION Crushing hazard The drive motor and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and 7 Fitting Torque Specifications 1 disconnect and plug the hose at the cylinder Cap the fitting Bodily in
210. e the Extension Cylinder The boom extension cylinder extends and retracts the primary boom The boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disassemble the boom extension See 4 3 How to Disassemble the Boom Extension Genie TEREX COMPANY 4 20 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B PRIMARY BOOM COMPONENTS 4 6 Platform Leveling Cylinders How to Remove the Master Cylinder The master cylinder located inside the mid pivot acts as a pump for the slave cylinder which is located at the platform end of the extension boom The master cylinder operates in a closed circuit hydraulic loop with the slave cylinder keeping the platform level through the entire range of boom motion When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hyaraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate
211. ection Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the platform controls from the harness connector at the platform mount 2 Tag and disconnect the platform controls wire harness at the platform mount 3 Tag and disconnect the limit switch wire harness at the platform mount 4 Tag and disconnect the wires from the AC outlet box 5 Release the wire harnesses which are secured to the platform mount and the jib boom PRIMARY BOOM COMPONENTS 6 Pullall the harness cables through the jib boom and jib mount Lay them off to the side of the primary boom Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched 7 Tag disconnect and plug the hydraulic hoses at the jib boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 8 Tag disconnect and plug the hydraulic hoses at the platform level slave cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING 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 9 Pull all the hoses through the jib mount Lay them off to the side of the primary boom Comp
212. ectrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when 8 PLATFORM CONTROLS handling printed circuit boards MEMBRANE DECAL PANEL 14PIN 7 RIBBON BN29 PRIMARY UP CABLE T 10 e BN30 PRIMARY DOWN 11 e BN31 SECONDARY UP l 12 T l 13 BN32 SECONDARY DOWN BN27 JIB UP a 1 BN28 JIB DOWN a 1 BN34 ROTATE RIGHT VES BN33 ROTATE LEFT BN74 BOOM RETRACT BN73 BOOM EXTEND ES e BN76 PLATFORM LEVEL DOWN a BN75 PLATFORM LEVEL UP BN77 ENGINE START a BN5 HORN a BN12 FUNCTION ENABLE HIGH a Ls BN26 FUNCTION ENABLE MEDIUM ex e BN13 FUNCTION ENABLE LOW 1 Genie TEREX COMPANY TMZ 50 30 Part No 65162 Section 4 Repair Procedures June 2005 PLATFORM CONTROLS 5 Install the lid onto the control box Finger tighten the retaining fasteners 6 Starting at the upper corners of the touch pad remove all layers of the key pad from the control box lid The wire harness and large blue connector will interfere if removing the touch pad from the bottom 7 Pullthe large blue connector through the slot in the control box lid and discard the old touch pad Remove any remaining sealant from the slot 8 Using a mild solvent clean the surface of the contro
213. efer to Section 2 Hydraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Hemove the Platform Models with Platform Rotate Remove the platform controls from the platform contro box mount Release the clamp on the back of the platform control box and slide the controls up and off of the mount Tag and disconnect the platform control box pigtail from the platform controls wire harness connector at the side of the platform mount Tag and disconnect the platform controls wire harness from the ground control box Install the platform control box pigtail into the ground control box Raise the jib boom approximately 3 feet 1 m Lower the jib boom until the platform mount rests on sawhorses or a work table of sufficient capacity Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 8 Tag and disconnect the wires from the AC outlet box Genio 4 8 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 9 Mark the location of each cable retaining plate in the upper jib boom 10 Tag and remove the cable retaining plates from the upper jib boom 11 Attach a lifting strap of suitable capacity from an overhead crane to the rod end of the jib boom lift cylinder 12 Remove the pin retaining fastener from the jib
214. el Models after serial number TMZ5003 228 6 28 Electrical Schematic Diesel Models before serial number T5000 91 6 30 Electrical Schematic Diesel Models from serial number T5000 91 to T5002 24 6 32 Electrical Schematic Diesel Models from serial number T5002 25 to TMZ5003 228 6 34 Electrical Schematic Diesel Models after serial number TMZ5003 228 6 36 Electrical Schematic Diesel Bi Fuel Models before serial number T5000 91 6 38 Electrical Schematic Diesel Bi Fuel Models from serial number T5000 91 to T5002 24 6 40 Electrical Schematic Diesel Bi Fuel Models from serial number T5002 25 to TMZ5003 228 6 42 Electrical Schematic Part No 65162 Diesel Bi Fuel Models after serial number TMZ5003 228 6 44 Hydraulic Symbols Legend a 6 47 Hydraulic Schematic DC Models with Drive Option before serial number T5000 91 6 48 Hydraulic Schematic DC Models with Drive Option after serial number T5000 90 6 50 Hydraulic Schematic DC Models without Drive before serial number T5000 91 6 52 TMZ 50 30 xi June 2005 SS SSS TABLE OF CONTENTS Section6 Re
215. emove the platform See 2 1 How to Remove the Platform 2 Remove the platform controls from the platform control box mount Release the clamp on the back of the platform control box and slide the controls up and off of the mount Lay the platform controls off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 2 Supportthe platform rotator with an appropriate lifting device 3 Remove the toggle pin securing the platform to the platform mount AWARNING Crushing hazard The platform rotator may become unbalanced and fall if not properly supported when the toggle pin is removed 4 Lift the platform rotator off the platform mount Genie Part No 65162 TEREX COMPANY TMZ 50 30 4 5 Section 4 Repair Procedures June 2005 PLATFORM COMPONENTS How to Adjust the Platform Rotator The platform rotator is designed to allow the platform to slip in the event of striking an object to help prevent damage to the platform If the platform rotator is too tight or seized damage to the platform may occur If the platform rotator is too loose the platform may rotate side to side unexpectedly resulting in a unsafe operating condition 1 Raise the primary boom approximately 3 feet 1 m 2 Pressthe function enable button and the platform level button in the down direction until the platform is horizontal Do not allow the platform to contact the ground 3 Remove t
216. er rod end pivot pin secondary boom pivot pin o secondary boom lift cylinder d mid pivot p primary boom hold down latch e platform level master cylinder q platform level slave cylinder barrel end pivot pin f platform level master cylinder rod end pivot pin hidden from view g primary boom pivot pin r extension boom h extension cylinder barrel end pivot pin S platform level slave cylinder i primary boom t jib mount pivot pin j primary boom lift cylinder u jib mount k primary boom lift cylinder rod end pivot pin v platform level slave cylinder rod end pivot secondary boom w turntable Genie 4 24 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 16 Using a soft metal drift remove the secondary link pivot pin Remove the mid pivot from the machine ADANGER Crushing hazard The mid pivot could become unbalanced and fall if not properly supported when the pin is removed ADANGER Crushing hazard The mid pivot could become unbalanced and fall if not properly supported when removed from the machine 17 Raise the secondary boom to a horizontal position 18 Attach a lifting strap of suitable capacity from an overhead crane to the secondary boom lift cylinder 19 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin 20 Using a soft metal drift remove the lift cylinder rod end pivot pin Lower the cylinder onto the secondary link AWARNING Crushing hazard The c
217. erformance 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 Knott Axle Service Manual Knott part number P005 Knott Axle Service Manual CHECKLIST A PROCEDURES A 8 Perform Engine Maintenance Honda Models if equipped Engine specifications require that this one time procedure be performed after one month or 20 hours whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information is available in the Honda GX340 Engine Owner Manual Genie part number 84443 Honda part number 31ZH9603 Honda GX340 Owner s Manual Genie part number 97361 Genie Part No 65162 TMZ 50 30 3 9 Section Scheduled Maintenance Procedures June 2005 CHECKLIST A PROCEDURES A 9 Perform Axle Maintenance ANSI Models Axle specifications require that this procedure be performed initially at 200 miles 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 a
218. ervice Manual KNOTT part number P005 KNOTT Axle Service Manual REV B 12 2 Parking Brake How to Adjust the Parking Brake ANSI models 1 Adjustthe brakes Refer to the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 2 Chockthe wheels Release the parking brake 4 Loosen the set screw at the side of the parking brake handle 5 Adjust the handle 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 6 Tighten the set screw Do not over tighten 7 Engage the parking brake Attempt to move the machine Result The parking brake should prevent the machine from moving If the parking brake does not prevent the machine from moving repeat this procedure beginning with step 1 CE models Required maintenance procedures and additional axle information is available in the KNOTT Axle Genie Part number 84443 Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number 84443 Genie 4 70 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 13 1 Outrigger Components How to Remove an Outrigger Outriggers are essential to safe machine operation and machine stability Operating a machine with a damaged or improperly operating outrigger will result
219. es and other jewelry 2 Loosen the control box lid retaining fasteners and open the lid GROUND CONTROLS 3 Disconnect the large blue connector from the circuit board at the connection marked KEYPAD by sliding the connector parallel to the circuit board CAUTION CAUTION CAUTION Component damage hazard The circuit board will become damaged if the wire harness and connector are disconnected without proper care Do not pull upwards on the connector Component damage hazard The circuit board may become damaged if the weight from the control box lid pulls on the wire harness Do not put any weight or strain on the wires Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when handling printed circuit boards 4 Install the lid onto the control box Finger tighten the retaining fasteners GROUND CONTROLS MEMBRANE DECAL PANEL o a OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP Ma ps ENGINE START BN68 oe BN39 PRIMARY DOWN SP Ip OUTRIGGER EXTEND BN47 o o BN53 RIGHT FRONT OUTRIGGER IP ES OUTRIGGER RETRACT BN48 o lt BN40 SECONDARY UP Aes eas PLATFORM LEVEL DOWN BN70 t ES BN41 SECONDARY DOWN E T PLATFORM LEVELUP BN69 oe o BN52 LEFT FRONT OUTRIGGER T T BOOM RETRACT BN72 e gt BN3
220. es clean and free of debris that could get into machine components and cause damage Be sure that your workshop or work area is i RI properly ventilated and well lit other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure ae fasteners intended for one N time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time oy Be sure to properly dispose of old oil or ud other fluids Use an approved container Please be environmentally safe PartNo 65162 June 2005 Introduction Section 1 Section 2 Section 3 Rev U U U U U UU g Rev Table of Contents Important Information LL Lu li Safety Rules General Safety Rules a Specifications Machine Specifications a 2 1 Performance Specifications 222 2 2 Hydraulic Specifications sistas sass aaa aR ae 2 2 Manifold Component Specifications sse 2 4 Machine Torque Specifications 2 5 Honda GX340K1 Engine 2 6 Hatz 1B30 ENGINE uu u u Aie ere er HE De sexe e
221. ext to the function manifold under the function manifold side cover Index Schematic No Description Item Function Torque sities ett e ee E uhan ec 4 5 ft lbs 5 7 Nm Coil n t items AB and AG 3 2 o ated ta rr eui bun 5 7 ft los 7 9 Nm 1 Solenoid valve 2 position 3 way AA Boom function select 18 20 ft los 24 27 Nm 2 Proportional valve AB Boom functions 25 27 ft lbs 34 36 Nm 3 Proportional valve AC Drive functions 25 27 ft lbs 34 36 Nm 4 Check vaklve AD Prevents flow from DC power unit from entering port P2 18 20 ft lbs 24 27 Nm 5 Check vaklve Prevents flow from engine pump from entering port P4 18 20 ft lbs 24 27 Nm 6 Check vakve AF Prevents flow from DC power unit from entering port P1 18 20 ft lbs 24 27 Nm 7 Check vakve AG Prevents flow from engine pump from entering port P3 18 20 ft lbs 24 27 Nm 8 Relief valve 3000 psi 206 8 bar AH System Relief 18 20
222. fications REV B SPECIFICATIONS Machine Torque Specifications Turntable rotate motor M12 bolts dry 60 ft lbs 81 Nm Turntable rotate bearing all bolts lubricated refer to Maintenance Procedure D 2 A TEREX COMPANY Part No 65162 TMZ 50 30 2 5 Section 2 Specifications June 2005 SPECIFICATIONS Honda GX340K1 Engine Displacement Number of cylinders Bore amp stroke 20 6 cu in 337 1 3 2 x 2 5 inches REV B Starter motor 12VDC Cooling System Forced air Ignition System Spark plug type BPR6ES Spark plug gap 0 028 to 0 031 inches 82 x 64mm 0 7 to 0 8 mm Horsepower 11 hp 3600 rpm Fuel tank capacity 1 6 gallons Low idle 1500 rpm High idle 2800 rpm Valve Clearance cold Intake 0 006 in 0 15 mm Exhaust 0 008 in 0 20 mm Lubrication system splash Oil capacity 0 32 quarts 0 3 liters Oil viscosity requirements Temperature below 30 F 0 C 5W 30 5 F to 85 F 20 C to 29 C 10W 30 Temperature above 50 F 10 C 30W Use oils meeting API classification SG SF as they offer improved wear protection Units ship with 10W 40 SG A TEREX COMPANY 2 6 TMZ 50 30 Part No 65162 June 2005 Section 2 Specifications REV Hatz 1B30 Engine Fuel Injection system SPECIFICATIONS Injection pump make Hatz Displacement 21 16 c
223. ge intentionally left blank A TEREX COMPANY 6 46 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics REV B Filter sie E Check valve Fy Pilot operated check valve Relief valve Ee km Proportional valve Single acting cylinder 9 1 Dual acting cylinder isle cas hse eee Proportional valve HE Solenoid operated 2 position 2 way directional valve G Part No 65162 A TEREX COMPANY Hydraulic Symbols Legend M gt Ss gt Auxillary pump power unit 2 Engine powered pump s D Battery powered pump s 0 046 inch 1 17 mm Orifice with size AP Solenoid operated 2 position 3 way directional valve AAR Solenoid operated 2 position 3 way directional valve with manual over ride enie ES Bi directional motor 4 Brake lt Shuttle valve X Priority flow regulator si IESUS ale Solenoid operated 3 position 4 way directional valve Solenoid operated 3 position 4 way directional valve with manual over ride TMZ 50 30
224. ger Cylinder 3 When removing a hose assembly or fitting the O ring on the fitting 8 and or hose end must be replaced and then torqued to specification 9 during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Extend the outrigger just until the pad touches the ground Do not rest the entire weight of the REV B Attach a lifting strap of suitable capacity from an overhead crane to the lug on the rod end of the cylinder Remove the pin retaining fasteners from the outrigger cylinder rod end pivot pin Use a soft metal drift to remove the outrigger cylinder rod end pivot pin Raise the cylinder to a vertical position Remove the pin retaining fasteners from the outrigger cylinder barrel end pivot pin 10 Use a soft metal drift to remove the outrigger cylinder barrel end pivot pin 11 Remove the cylinder from the machine outrigger on the ground i i 9g 9 AWARNING Crushing hazard The outrigger 2 Remove the cylinder guard mounting fasteners from the rod end of the outrigger cylinder Remove the cylinder guard from the cylinder 3 Tag disconnect and plug the hydraulic hoses from the cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Tag and disconnect the wiring from t
225. he platform controls from the platform control box mount Release the clamp on the back of the platform control box and slide the controls up and off of the mount Lay the platform controls off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 4 Remove the fasteners securing the platform box mount and gearbox cover to the platform rotate gearbox Remove the mount and cover from the gearbox 5 Locate the gear assembly retaining nut on the end of the platform pivot shaft Loosen the nut just enough to allow the handle to rotate 6 Tighten the locknut Torque to specification Torque specification REV B How to Service the Platform Rotator 1 Remove the platform See 1 1 How to Remove the Platform 2 Remove the platform controls from the platform control box mount Release the clamp on the back of the platform control box and slide the controls up and off of the mount Lay the platform controls off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 3 Remove the fasteners securing the platform control box mount and gearbox cover to the top of the gearbox case Remove the mount and cover 4 Remove the four bolts securing the rotate handle shaft cover to the gearbox 5 Remove the rotate handle shaft and pinion from the gearbox case 6 Remove the gear assembly retaining nut from the top of the shaft 7 Disa
226. he solenoid valve on the cylinder Genie TEREX COMPANY cylinder may become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Use CAUTION caution when removing the cylinder to avoid damage to the solenoid valve 4 72 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B The drive option allows the machine operator to move the TMZ 50 30 into another position without having to use a tow vehicle to do so This option package includes drive controls a brake cylinder and a drive motor and cylinder for each axle wheel When a drive function is activated at the drive control box a signal is sent to one or more of the drive manifold valve coils enabling the machine to move The drive controls will function only when when the machine is in the stowed position Pressing the drive function enable button will activate the drive cylinders which in turn moves both drive motors into contact with the axle tires At the same time the parking brake is released via the parking brake cylinder located under the chassis Moving the joystick in the desired direction will activate the drive motors which moves the machine Returning the joystick to the neutral position will disable the drive and steer function Releasing the drive function enable button reactivates the parking brake to secure the machine from moving and returns the drive cylinders to th
227. ic Tank Return Filter CHECKLIST A PROCEDURES A 12 Perform Engine Maintenance Honda Models if equipped Engine specifications require that this procedure be performed every 50 hours or quarterly whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information is available in the Honda GX340 Engine Owner Manual Honda part number 31ZH9603 Honda GX340 Owner s Manual Genie part number 97361 Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section Scheduled Maintenance Procedures June 2005 CHECKLIST A PROCEDURES A 13 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 function manifold a zerk fitting b rotate bearing 2 Pump grea
228. ifold Components Models without Drive after serial number T5000 90 The pump manifold is located next to the function manifold under the function manifold side cover Index Schematic No Description Item Function Torque Goil nut e de ea eec i dae Su 5 7 ft los 7 9 Nm 1 Proportional valve engine models DA All functions 25 27 ft lbs 34 36 Nm 2 Relief valve 3000 psi 206 8 DB System relief 18 20 ft Ibs 24 27 Nm 3 Check valve DC Prevents flow from DC power unit to engine pump 18 20 ft Ibs 24 27 Nm 4 Check vaklve Prevents flow from engine pump to DC power unit 18 20 ft los 24 27 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie TEREX COMPANY 4 48 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha
229. ion A B C Annually or 1000 hours or 12 000 mile 19 300 km Inspection A B C D Two year or 2000 hours Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures this section to learn how to perform these inspections If any inspection receives N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments Perform every 50 hours A 12 Engine maintenance Honda models if equipped Perform every 100 hours A 13 Grease rotate bearing A 14 Engine maintenance Honda models if equipped 1 Part 65162 A TEREX COMPANY C 1 Breather cap models with optional oil Axle maintenance ANSI models Hitch maintenance CE models ChecklistD RevB Y NR D Rev B D 1 Boom wear pads D 2 Turntable bearing bolts D 3 Turntable bearing wear D 4 Hydraulic filter D 5 Axle maintenance ANSI models D 6 Engine maintenance Hatz models if equipped ChecklistE RevB YNR E 1 Hydraulic oil E 2 Engine maintenance Honda models if equipped TMZ 50 30 Section Scheduled Maintenance Procedures June 2005 Checklist A Procedures A 1 Perfo
230. is essential for safe machine operation An unsafe working condition exists if the auxiliary lowering function does not operate in the event of a main power loss DC Models 1 Raise the primary secondary and jib booms Extend the primary boom 2 Openthe function manifold side turntable cover 3 Locate the extension boom valve on the function manifold Turntable Rotate Pull for Push for 4 Secondary Boom 5 lt Primary Boom q Jib Boom Extension Boom 6 Push and rotate to retract primary boom Push and rotate to reset primary boom retract function REV B 4 Push in and turn fully in a counter clockwise direction the knob at the center of the extension boom valve stem Operate the hand pump with a push pull motion Result The extension boom retract function should operate 5 Pushin and turn fully in a clockwise direction the knob at the center of the extension boom valve stem to reset the valve The valve spool must be reset for the primary boom extend function to operate 6 Locate the primary boom valve on the function manifold 7 Pull out and hold the knob at the center of the primary boom valve stem Operate the hand pump with a push pull motion Result The primary boom down function should operate 8 Release the knob 9 Locate the secondary boom valve on the function manifold
231. jury hazard Spraying AWARNING hydraulic oil can penetrate and 8 burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 2 Remove the return spring from the clevis pin at the rod end of the cylinder 3 Support and secure the drive motor with to a suitable lifting device 4 Remove the cotter pin from the clevis pin at the rod end of the cylinder Always replace the cotter pin with a new one when removing one from the machine Genie TEREX COMPANY assembly may fall if not properly supported when the clevis pin is removed Remove the cotter pin at the clevis pin at the barrel end of the cylinder Always replace the cotter pin with a new one when removing one from the machine Remove the barrel end cotter pin Always replace the cotter pin with a new one when removing one from the machine Remove the barrel end clevis pin Remove the drive motor cylinder from the machine 4 74 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 14 2 Drive Control Box Circuit Board Activating the joystick or a button of the overlay membrane decal first sends a signal to the drive controls circuit board then the ground controls printed circuit boards which ultimately activates a machine function The drive steer and outrigger functions can only be operated when the machine is in the stowed position
232. l box lid Allow the surface to dry CAUTION Component damage hazard The circuit board will become damaged if it comes in contact with solvent Do not allow solvent to contact the circuit board 9 Remove all the brown backing material from the new touch pad 10 Insert the large blue connector from the new touch pad through the slot Carefully align the low battery LED on the control box lid with the window in the new touch pad and lightly lay the touch pad 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 REV B 11 When satisfied with the position of the touch pad firmly press down the entire surface of the touch pad with your fingers 12 Loosen the control box lid retaining fasteners and open the lid 13 Using RTV type sealant completely seal the opening in the slot of the control box lid around the wire harness 14 Apply dielectric grease to the pins on the circuit board at the connection marked KEYPAD 15 Install the large blue connector onto the circuit board pins at the connection marked KEYPAD Slide the connector parallel to the circuit board until the connector is pushed onto the circuit board pins no less than 0 2 inch 5 mm Be sure all pins are in the connector 16 Install the lid onto the control box and tighten the retaining fasteners Do not overtighten 17 Install the control box onto th
233. l number T5000 91 4 58 9 10 Drive Manifold Components after serial number T5000 90 4 60 9 11 Counterbalance Valve Manifold Components 4 62 9 12 Valve Adjustments Pump Manifold 4 64 9 13 Valve Coils enne nnne enne nnne nnns 4 65 B Hydraulic Tank 10 1 Hydraulic TANK arenas 4 67 B Axle Components uD EP VEMM 4 68 11 2 Hub and Bearings uuu u u u y u emere erre e 4 69 B Trailer Components 12 1 Trailer Brakes sacs te P tete nato neva eee a 4 70 12 2 Parking Brake u uu 4 70 B Outriggers 13 1 Outrigger Components 4 71 13 2 Outrigger Cylinder estaba e 4 72 B Drive Components option 14 1 Drive Molor u ma aaa 4 73 14 2 Drive Control Box Circuit Board 4 75 14 3 Membrane Overlay ss nennen nnne nnn 4 75 PartNo 65162 TMZ 50 30 ix June 2005 rz SSeS TABLE OF CONTENTS Section 5 Rev FaultCodes 5 1 Fault Code Chart after serial number T5002 24 5 3 Section 6 Rev Schematics INEFOGUCTION ERE 6 1 Electrical Component and Wire Color Legends 6 2 A Limit Switch Legend uuu ette e 6 3
234. le is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information is available in the Hatz 1B30 Engine Instruction Book Hatz part number 433 0802 01 OR the Honda GX340 Engine Owner Manual Honda part number 31ZH9603 Hatz 1B30 Instruction Book CHECKLIST A PROCEDURES A 4 Perform Hitch Maintenance ANSI Models Hitch specifications require that this procedure be performed daily Proper hitch maintenance following the hitch manufacturer s maintenance schedule is essential to good hitch performance and service life Failure to perform the maintenance procedures can lead to poor hitch performance and component damage Required maintenance procedures and additional hitch information is available in the Demco Model 91 Brake Actuators Owner Operator Manual Demco part number BH20023 Demco Model 91 Owner Operator Manual Genie part number 84592 Genie part number 97363 Honda GX340 Owner s Manual Genie part number 97361 Genie Part No 65162 TMZ 50 30 3 7 Section Scheduled Maintenance Procedures June 2005 CHECKLIST A PROCEDURES A 5 Perform Axle Maintenance ANSI Models Axle specifications require that this procedure be performed initially and following a wheel change after the first 10 25 and 50 miles Proper ax
235. le 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 Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual REV B A 6 Perform Axle Maintenance CE Models Axle specifications require that this procedure be performed initially after the first 50 km or 50 km after a wheel change 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 Knott Axle Service Manual Knott part number P005 Knott Axle Service Manual Genie part number 84443 Genie part number 84376 Genio 3 8 TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures REV B A 7 Perform Axle Maintenance CE Models Axle specifications require that this procedure be performed initially after the first 100 km Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle p
236. lic tank mounting fasteners Torque to specification Torque specifications 60 in Ibs 6 7 Nm Hydraulic tank mounting fasteners dry Hydraulic tank mounting fasteners lubricated 45 in lbs 5 1 Nm 12 Install the hydraulic filter head onto the machine and securely tighten the fasteners Do not over tighten 13 Install the hydraulic lines into the filter head and torque to specification Refer to Section 2 Specifications 14 Connect the battery pack to the machine 15 Fill the hydraulic tank with hydraulic oil until the fluid is at the max mark on the tank Do not overfill Refer to Section 2 Specifications 16 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The CAUTION pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system 17 Repeat steps 15 through 16 until the hydraulic system and tank are both full Inspect for leaks 18 Clean up any oil that may have spilled REV B E 2 Perform Engine Maintenance Honda Models if equipped Engine specifications require that this procedure be performed every two years Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage
237. lty wiring OR replace circuit board Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR 0050 Jib Up Gol Soup valve coil shorted OR faulty circuit board replace circuit board Jib down coil fault 0051 Jib down coil open Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Short wire harness Repair faulty wiring OR 0052 SD On CON taul JI Gown coll SHORE OR faulty circuit board replace circuit board Platform forward coil fault 0053 0054 0055 0056 Platform forward coil fault Platform reverse coil fault Platform reverse coil fault Platform forward coil open Platform forward coil short Platform reverse coil open Platform reverse coil short Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR OR faulty circuit board replace circuit board Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR OR faulty circuit board replace circuit board A TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 5 Troubleshooting
238. m 1 Disconnect the battery pack from the machine T CGU Boat P 7 z Ly 2 AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Disconnect all external AC power supply from the machine 3 Remove the fasteners securing the cover to the top of the battery charger Remove the cover 4 Locate the circuit board Tag and disconnect all circuit board wiring 5 Remove the circuit board 6 Install the new circuit board into the battery charger Securely install all circuit board wiring 7 Setthe DIP switch Determine the type of batteries being used on the machine Then using the following chart set the toggles of the DIP switch accordingly Component damage hazard CAUTION Incorrectly setting the DIP switch may result in decreased battery life Use caution when programming the circuit board Gel setting will increase battery life while decreasing the amount of cycles for the machine Normal setting will decrease the battery life while increasing the amount of cycles for the machine DIP switch location 8 Install the cover onto the battery charger Install and securely tighten the fasteners Do not over tighten DIP settings Normal Liquid Gel Toggle 1 OFF OFF ON Toggle 2 ON OFF OFF If not operating correctly check the following Good power supply at the AC power sourc
239. m controls has stuck or faulty button Open or short in control No drive communication cable OR faulty circuit Drive has stuck key Part No 65162 boards Short in membrane decal OR faulty platform circuit board Repair or replace switches or harness OR replace CPU board Level machine OR charge batteries OR replace outrigger switches OR consult Genie Industries Service Department Replace level sensor Repair power supply circuit to level sensor OR repair ground circuit from level sensor OR replace level sensor Level machine OR repair or replace wire harness or connections OR replace outrigger switches OR consult Genie Industries Service Department Repair or replace control cable OR replace circuit boards Replace platform key pad or touch pad OR replace circuit boards Repair or replace control cable OR replace circuit boards Replace membrane decal OR replace platform circuit board Continued on next page A TEREX COMPANY TMZ 50 30 5 3 Section 5 Troubleshooting Flow Charts June 2005 FAULT CODE CHART AFTER SERIAL NUMBER T5002 24 Fault Code Fault Condition Possible Cause Solution Drive controls fault 0014 0015 0021 Ground keypad fault Lower boom up coil fault Drive has stuck joystick Machine functions inoperative Secondary lower up valve coil open REVA Repair wire circuit from joystick to drive circuit board OR replace drive joystick
240. n and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours or every 3000 miles 4800 km A B Semi annually or every 500 hours or every 6000 miles 9600 km A B C Annually or every 1000 hours or every 12 000 miles 19 300 km 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 Genie A TEREX COMPANY 3 2 TMZ 50 30 Part No 65162 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance in
241. nal axle information is available in the Knott Axle Service Manual Knott part number P005 Knott Axle Service Manual Genie part number 84443 Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section Scheduled Maintenance Procedures June 2005 Checklist D Procedures D 1 Check the Boom Wear Pads Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions If the wear pads are within specification refer to Repair Procedure 4 2 How to Shim the Primary Boom 1 Extend the boom until the wear pads are accessible 2 Measure the thickness of the top side and bottom wear pads If the wear pad is within specification shim as necessary to obtain zero clearance and zero drag REV B 3 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes Boom wear pad specifications 7 16 inch 11mm Wear pad thickness minimum Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 3 Scheduled Maintenance Procedures REV B D 2 Check
242. nto the CPU circuit board How to Determine the DIP Switch Configuration A diagnostic display was incorporated into the ground controls after serial number T5002 24 The following procedure will not apply to machines before serial number T5002 25 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform REV B 2 Press and hold both the secondary down button and the turntable rotate counterclockwise button at the ground controls Result The DIP switch settings will appear in the diagnostic display The display will show each toggle of the DIP switch in numerical order from 1 through 16 and whether the toggle is in the on position 01 or off position 00 For example 0401 shown in the diagnostic display indicates that the fourth toggle is in the on position FN Er 9B J uo 9 ZO 920 6 O O vy QO oy 090 v i E 2 MA controls a secondary down b turntable rotate counterclockwise Genie 4 30 TMZ 50 30 Part No 65162 June 2005 Ei REV How to Set the DIP Switch 1 Section 4 Repair Procedures GROUND CONTROLS 4 Locate the DIP switch on the circuit board Turn the key switch to the off position and push in the red Emergency Stop button to the off position at both
243. o P Lo 7 PIN 11 PIN 26 PIN 40 PIN KS1 _KEY SWITCH d MN ep eae JUMPER CABLE JUMPERCABLE RIBBON CABLE RIBBON CABLE ll 7 BE J2 Ji J3 J4 i M RD 021 P1 CONNECTOR PC BOARD P3 CB2 30a ENGINE OUTRIGGER CIRCUIT BREAKER 1172 48 go 9229 l tee LL 1 TII TN H2V _ 24V 1014 M Bb n 24V 12V 6 5 9 i VOLTAGE iE E g Ez p 1518 3 1 DIVIDER 2 7 E 5 H2 LS14 Le N C H O cet H4 U23 50 gt EIU ENGINE 87 CIRCUIT QD1 I D1 KS3 l BOARD B oz 22 SWITCH 2 EE ii 55 8 28 88 Ir 88 00 OZ Fe cc U9 fao 15 Gh 5c 66 BATTERY 1 88 gg 99 canoes M5 ES s RE EE 55 zz 55 55 35 B5 55 3 ee lt lt lt lt BATTERY 55 ae ga 2g F9 CR4 CR8 e EE 24V 10A HIGH FUEL 5 99 99 FUSE IDLE CUTOFF oo dd Sd fe CE 1 T 30 30 1D o 2 osv cri se E o 8 8 5 5 START fz 185 87A 85 gt gt gt Eee Lt AC INPUT Oo l d 4 cone SW2 Sw2 P QD7 CONTROLLER 8 2 T NOTE ENGINE ENGINE gt b CYLINDER MACHINE SHOWN F11 STARTER I PRESSURE PED 2 E IN THE STOWED PoR 175A FUSE c
244. o the jib boom lift cylinder Support the cylinder Do not apply any lifting pressure 23 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 24 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin 25 Using a soft metal drift remove the jib boom lift cylinder barrel end pivot pin Remove the jib boom lift cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could become unbalanced and fall if not properly supported when the pivot pin is removed Crushing hazard The lower jib AWARNING boom could become unbalanced and fall if not properly supported when the pivot pin is removed Component damage hazard Be the platform mount from the machine CAUTION careful not to damage the solenoid Crushing hazard The platform valve on the cylinder while AWARNING mount could become unbalanced removing the cylinder and fall if not properly supported when the pivot pin is removed Genie Part No 65162 TMZ 50 30 4 9 Section 4 Repair Procedures June 2005 JIB BOOM COMPONENTS 3 2 Jib Boom Lift Cylinder How to REV B 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 counterbalance valve to prevent movement in the event of a hydraulic line failure N
245. oard Repair faulty wiring OR replace circuit board Restore connection OR replace circuit board Repair faulty wiring OR replace circuit board Restore connection OR replace circuit board Repair faulty wiring OR replace circuit board Restore connection OR replace circuit board Continued on next page A TEREX COMPANY TMZ 50 30 5 5 Section 5 Troubleshooting Flow Charts June 2005 FAULT CODE CHART AFTER SERIAL NUMBER T5002 24 REV B Fault Code Fault Condition Possible Cause Solution 0044 Pump coil fault Pump enable coil Short in wire harness Repair faulty wiring OR i shorted OR faulty circuit board replace circuit board 0 0 4 Rotate right clockwise coil fault 00 46 Rotate right clockwise coil fault Rotate left counterclockwise coil fault 0047 Rotate left 0048 counterclockwise coil fault 0049 Jib up coil fault Rotate right valve coil open Rotate right valve coil shorted Rotate left valve coil open Rotate left valve coil shorted Jib up valve coil open Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR OR faulty circuit board replace circuit board Coil not connected to wire harness OR open Restore connection OR circuit OR faulty circuit replace circuit board board Short in wire harness OR faulty circuit board Repair fau
246. ocution hazard Contact with 10V DC schematic items ED EE electrically charged circuits could FE FF El GD and GI result in death or serious injury Remove all rings watches and Solenoid valve 2 position 3 way 4 to 60 other jewelry 10V DC schematic item FJ 1 id rit the wire harness from the Solenoid valve 2 position 3 way 26 to 280 coll to be tested 20V DC schematic item HE 2 Testthe coil resistance Solenoid valve 2 position 3 way 18 to 200 O Result The resistance should be within 20V DC schematic item HJ specification plus or minus 3096 Na Solenoid valve 3 position 4 way 10V DC 6 to 80 W Result If the resistance is not within schematic items EF EG EH EL specification plus or minus 3096 replace the EM EO FG FH Fl FM FN and FP coil Solenoid valve 3 position 4 way 26 to 280 Valve Coil Resistance 20V DC schematic items HM and HN Description Specification Solenoid valve 3 position 4 way 4 to 60 10V DC schematic items JB and JC Proportional valve 12V DC 4 to 60 E schematic items AB AC CA and DA Solenoid valve 3 position 4 way 10V DC engine models 4 to 60 Proportional valve 20V DC DC models aaa 18 to 202 12V DC engine models 4to6Q Schematic items KB and KC 24V DC models eterni 18 to 210 schematic items BA and BB Solenoid valve 2 position 3 way 6 to 8Q 10V DC with manual over ride schematic i
247. of the primary boom Pull the cables through the primary boom and lay them off to the side of the mid pivot Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched For ease of assembly pay close attention to how the cables are routed when pulling the cables to the mid pivot Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005 PRIMARY BOOM COMPONENTS 4 Tag disconnect and plug the hoses from the platform level master cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Tag disconnect and plug the hoses from the primary boom extension cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Attach a lifting strap of suitable capacity from an overhead crane to the rod end of the primary lift cylinder Support the cylinder Do not apply any lifting pressure 7 Remove the pin retaining fasteners from the primary lift cylinder rod end pivot pin 8 Using a soft metal drift remove the primary lift cylinder rod end pivot pin
248. ols the function manifold side drive motor in forward and reverse 25 27 ft lbs 34 36 Nm 4 Solenoid valve 2 position 2 way KD Drive motor cylinder circuit 18 20 ft lbs 24 27 Nm 5 Check vaklve KE waste Drive motor cylinder circuit 12 14 ft Ibs 17 19 Nm 6 Check vaklve Drive motor cylinder circuit 12 14 ft lbs 17 19 Nm 7 Counterbalance valve KG Ground controls left side drive motor 30 35 ft lbs 41 47 Nm How to Install a Valve Cartridge 1 Dip the cartridge in clean oil to lube the O rings 2 Screw the cartridge in by hand until the top O ring is met then torque to specification 3 If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie TEREX COMPANY 4 60 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B 5 A TEREX COMPANY Part No 65162 MANIFOLDS LEFT REV FWD Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on the hydraulic schematic TMZ 50 30 Section 4 Repair Procedures p M p O m t MANIFOLDS 9 11 C
249. omplete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the boom extension from the primary boom See 4 2 How to Remove the Boom Extension 2 Attach a lifting strap of suitable capacity from an overhead crane to the jib mount 3 Tag disconnect and plug the platform level slave cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic 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 REV B 4 Remove the pin retaining fasteners from the platform level slave cylinder rod end pivot pin 5 Place a wood block under the slave cylinder for support 6 Using a soft metal drift remove the platform level slave cylinder rod end pivot pin AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed 7 Remove the pin retaining fasteners from the jib mount pivot pin 8 Using a soft metal drift remove the jib mount pivot pin Remove the jib mount from the machine AWARNING Crushing hazard The jib mount will fall if not properly supported
250. onditions AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this procedure after fully charging the batteries For a more accurate determination of battery condition fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 1 Put on protective clothing and eye wear 2 Besure that the battery cable connections are free of corrosion Genie TEREX COMPANY TMZ 50 30 3 13 Part No 65162 Be sure that the battery retaining fasteners and cable connections are tight Remove the battery vent caps from all batteries and check the specific gravity of each battery cell with a hydrometer Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced Check the battery acid level of each battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill Install the battery vent caps Check each battery pack and verify that the batteries are wired correctly Refer to the Battery Connection Diagram decal on the machine Inspect the battery charger plug and pigtail for
251. onent damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched Genie Part No 65162 TMZ 50 30 4 13 Section 4 Repair Procedures June 2005 PRIMARY BOOM COMPONENTS 10 Remove the retaining fasteners securing both cable track top covers to the primary boom Remove both top covers from the boom 11 Pull the hoses and cables through the cable bridge and cable track Lay them off to the side Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched 12 Remove the cable track hose router clamp from the platform end of the cable bridge 13 Remove the cable bridge front end cover from the platform end of the primary boom 14 Place blocks between the cable bridge and the cable track and secure them together AWARNING Crushing hazard If the cable bridge and the cable track are not properly secured together the combination could become unbalanced and fall when removed from the machine Component damage hazard The cable track can be damaged if it is twisted CAUTION 15 Attach a lifting strap from an overhead crane to the cable track 16 Remove the mounting fasteners that secure the cable track to the boom 17 Remove the cable track from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overhead crane when removed from th
252. ort OR faulty circuit board replace circuit board Coil not connected to 0073 Lift coil fault Lift activate open le harness OR oper RESTore COR SNO circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR 0074 Cinco aul Lt activate coli Shor OR faulty circuit board replace circuit board Coil not connected to 0075 Engine coil fault Endine totic calf ten wire harness OR open Restore connection OR 9 9 P circuit OR faulty circuit replace circuit board board Short in wire harness Repair faulty wiring OR 0076 Engine coll fault SR OR faulty circuit board replace circuit board Coil not connected to 0077 Engine fault Endine starter coilopen wire harness OR open Restore connection OR g g P circuit OR faulty circuit replace circuit board board 0078 Engine fault Engine starter coil short Short in wire harness Repair faulty wiring OR 9 T g OR faulty circuit board replace circuit board Coil not connected to 0079 Enqine coil fault Enqi e stop oall oben wire harness OR open Restore connection OR g g P P circuit OR faulty circuit replace circuit board board 0080 Engine fault Engine stop coil short Short in wire harness Repair faulty wiring OR 9 9 OR faulty circuit board replace circuit board Coil not connected to 0085 Spare output fault Spare output 0 open wire harness OR open Restore connection OR P P P p p cir
253. ounterbalance Valve Manifold Components The counterbalance valve manifold is located on the function manifold side of the machine Index Schematic No Description Item Function 1 Counterbalance valve EA aus Outrigger extend circuit 2 Counterbalance valve EB Outrigger retract circuit 3 Counterbalance valve Outrigger extend circuit before serial number T5000 91 before serial number T5000 91 after serial number T5000 90 How to Install a Valve Cartridge 1 2 Dip the cartridge in clean oil to lube the O rings Screw the cartridge in by hand until the top O ring is met then torque to specification If required install the valve coil s onto the valve stem Install the coil nut onto the valve stem and torque to specification Genie June 2005 REV B Torque 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 30 35 ft lbs 41 47 Nm 4 TEREX COMPANY 62 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B MANIFOLDS Before serial number T5000 91 Note alpha callouts refer to corresponding notes on the hydraulic schematic After serial number T5000 90 Genie TEREX COMPANY Part No 65162 TMZ 50 30 4 63 Section 4 Repair Procedures June 2005 p MC MANIFOLDS REV B 9 12 Valve Adjustments Pump Manifold How to Adjust the System
254. outrigger valve coil shorted RF outrigger valve coil open RF outrigger valve coil shorted LR outrigger valve coil open LR outrigger valve coil shorted RR outrigger valve coil open RR outrigger valve coil shorted Pump enable coil open Part No 65162 Coil not connected to wire harness OR open circuit OR faulty circuit board Short in wire harness OR faulty circuit board Coil not connected to wire harness OR open circuit OR faulty circuit board Short in wire harness OR faulty circuit board Coil not connected to wire harness OR open circuit OR faulty circuit board Short in wire harness OR faulty circuit board Coil not connected to wire harness OR open circuit OR faulty circuit board Short in wire harness OR faulty circuit board Coil not connected to wire harness OR open circuit OR faulty circuit board Short in wire harness OR faulty circuit board Coil not connected to wire harness OR open circuit OR faulty circuit board Short in wire harness OR faulty circuit board Coil not connected to wire harness OR open circuit OR faulty circuit board Restore connection OR replace circuit board Repair faulty wiring OR replace circuit board Restore connection OR replace circuit board Repair faulty wiring OR replace circuit board Restore connection OR replace circuit board Repair faulty wiring OR replace circuit board Restore connection OR replace circuit b
255. ove all rings watches and other jewelry 2 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic 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 PRIMARY BOOM COMPONENTS 3 Attach a lifting strap of suitable capacity from an overhead crane to the lift cylinder 4 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin 5 Using a soft metal drift remove the lift cylinder rod end pivot pin AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed 6 Lower the cylinder onto the secondary boom 7 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin 8 Using a soft metal drift remove the lift cylinder barrel end pivot pin AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed 9 Carefully remove the cylinder from the machine Crushing hazard The lift cylinder AWARNING could become unbalanced and fall if not properly supported when removed from the machine Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005 PRIMARY BOOM COMPONENTS REV B 4 5 Boom Extension Cylinder How to Remov
256. pen held closed BN42 Rotate left Power switch BN43 Rotate right P1 Emergency Stop button at ground controls BN44 Function enable high P2 Emergency Stop button at platform controls BN45 Function enable medium P3 Emergency Stop button at drive controls BN46 Function enable low Q Solenoid BN47 Outrigger extend Q3 High idle BN48 Outrigger retract Q7 Choke BN49 Outrigger auto level Q8 Fuel cutoff BN50 Left rear outrigger QD Quick disconnect BN51 Right rear outrigger QD1 Primary battery disconnect BN52 Left front outrigger QD3 Control cable at platform BN53 Right front outrigger QD4 Control cable at ground BN68 Engine start 907 Auxiliary disconnect BN69 Platform level up QD9 Cable to drive controls BN70 Platform level down S7 Level sensor BN71 Boom extend SW Switch BN72 Boom retract SW2 Engine oil pressure BN73 Boom extend SW28 Engine cylinder head temp BN74 Boom retract U Electronic component BN75 Platform level up U3 Platform controls circuit board BN76 Platform level down U9 Battery charger BN77 Engine start U14 Voltage divider BN78 Outrigger extend U21 Connector circuit board BN79 Outrigger autolevel U22 CPU display circuit board BN80 Outrigger retract U23 Engine circuit board BN81 Horn U24 Drive controls circuit board BN82 Drive enable Y Valve coil CB2 30A Circuit breaker controls Y9 Proportional function CA Control relay Y19 Platform down CR1
257. perty damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Genie Part No 65162 TEREX COMPANY TMZ 50 30 3 1 Section Scheduled Maintenance Procedures June 2005 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be required to perform this procedure Bee amp Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Sectio
258. ps Genie Part No 65162 TEREX COMPANY TMZ 50 30 4 1 Section 4 Repair Procedures June 2005 Platform Controls Activating one or more buttons on the platform controls first sends a signal to the platform controls circuit board then the ground controls printed circuit boards which ultimately activates a machine function Keeping the platform controls clean and defect free is essential to safe machine operation The platform controls consists of a printed circuit board Emergency Stop button alarm and an overlay membrane decal All of the components are replaceable For further information or assistance consult the Genie Industries Service Department 0 J1 GJIPOWER d RD BL O U1 J3l KEYPAD Sa red Emergency Stop button P2 voltage regulator D7 platform controls circuit board U3 mounting fasteners O o oo REV B 1 1 Circuit Board How to Remove the Circuit Board 1 Tag and disconnect the platform controls wire harness from the harness connector at the platform pivot 2 Remove the controls from the machine Open the clamp on the back of the controls and slide the controls up and off of the platform Place the control box on a work bench 3 Remove the fasteners securing the cover to the control box Open the box
259. quid filled batteries this self regulating charger is equipped with built in line voltage compensation which supplies consistent DC output even when the AC supply voltage varies by as much as 10 This charger which automatically adjusts to operate on 110V or 220V AC is equipped with and protected by three circuit breakers located on the face plate next to the AC input connector Two 8A circuit breakers are used on the input side of the charger circuit one 45A circuit breaker is used on the output side GROUND CONTROLS If not operating correctly check the following Good power supply at the AC power source Use only 12 AWG heavy duty extension cord Power cable firmly connected to the AC input plug or fitted into the AC input connector Faulty fuse 19740 models or faulty circuit breakers 22310 models Correct wiring at the batteries Red or White charger wire to battery positive Black charger wire to battery negative Component damage hazard CAUTION These chargers are 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 a North America model c Worldwide model b 30A fuse output d 45 circuit breaker output e ACinput connector f 8A circuit breaker inpu
260. r Battery Charger 4 39 Hydraulic Pumps 83 Function Pump a esas 4 40 8 2 Hydraulic Power Unit DC Models 4 41 Manifolds 91 Pump Manifold Components Models with Drive option before serial number T5000 91 4 42 9 2 Pump Manifold Components Models with Drive option after serial number T5000 90 4 44 TMZ 50 30 PartNo 65162 June 2005 TABLE OF CONTENTS Section 4 Rev Repair continued 9 3 Pump Manifold Components Models without Drive before serial number T5000 91 4 46 9 4 Pump Manifold Components Models without Drive after serial number T5000 90 sse 4 48 9 5 Function Manifold Components Engine and Bi Fuel Models before serial number T5000 91 4 50 9 6 Function Manifold Components Engine and Bi Fuel Models after serial number T5000 90 4 52 9 7 Function Manifold Components DC Models before serial number T5000 91 4 54 9 8 Function Manifold Components DC Models after serial number T5000 90 4 56 9 9 Drive Manifold Components before seria
261. rcuit board pins Be sure all pins are in the connector 16 Install the lid onto the control box and tighten the retaining fasteners Do not overtighten 17 Install the control box onto the machine 18 Using dielectric grease at the connection securely connect the drive controls wire harness to the ground control box Genie A TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 5 Troubleshooting Flow Charts Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine disconnected from tow vehicle Machine parked on a firm level surface with the boom stowed and both latches secured Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked and parking brake applied All external AC power supply disconnected from the machine Part No 65162 A TEREX TMZ 50 30 5 1 MPANY Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator
262. rimary boom side wear pad retaining fasteners Remove the side wear pads and shims from the primary boom For ease of assembly note the quantity and location of shims during disassembly 6 Remove the primary boom lower wear pad retaining fasteners Remove the lower wear pads from the primary boom 7 Remove the pin retaining fasteners from the extension cylinder barrel end pivot pin 8 Using a soft metal drift remove the extension cylinder barrel end pivot pin 9 Pull the extension boom approximately half way out of the primary boom 10 Attach a lifting strap of suitable capacity from an overhead crane to the extension boom Support the boom Do not apply any lifting pressure 11 Remove the boom extension from the primary boom Set it on a suitable structure capable of supporting it IOV ag Crushing hazard The boom extension could become unbalanced and fall if not properly supported when removed from the machine Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005 PRIMARY BOOM COMPONENTS How to Disassemble the Boom Extension AWARNING This procedure in this section requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to c
263. rm Pre operation Inspection Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine REV B A 2 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures REV B A 3 Perform Engine Maintenance if equipped Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Proper engine maintenance following the engine manufacturer s maintenance schedu
264. rm controls 2 Push down the horn button at the platform and drive controls Result The horn should sound 3 Push down the horn button at the ground controls Result The horn should not sound 4 Turn the key switch to ground control Push down the horn button at the ground controls Result The horn should sound 6 Push down the horn button at the platform and drive controls Result The horn should not sound REV B B 10 Test the Flashing Beacon if equipped The flashing beacon is used to alert operators and ground personnel of machine proximity and motion The flashing beacon is located on the upper primary boom 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Pull out the red Emergency Stop button to the on position at the drive controls if equipped O Result The beacons should flash Turn the key switch to platform controls Result The beacons should flash Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures REV B B 11 Test the Platform Rotation if equipped Maintaining the platform rotator if equipped in good condition is essential for safe machine operation and good machine performance The platform rotator is operated by manually turning the hand crank in either a clockwise or counterclo
265. rocedures H r REV GROUND CONTROLS 7 2 Connector Circuit Board The connector circuit board connects the wire harness to the CPU circuit board using several cables How to Remove the Connector Circuit Board 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Tag and disconnect the wire harness connectors from the ground control box 3 Remove the four lid retaining fasteners from the ground control box Open the lid 4 Tag and disconnect all wiring from the connector circuit board Component damage hazard CAUTION Electrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when handling printed circuit boards 5 Remove the connector circuit board mounting fasteners and remove the connector circuit board Genie TEREX COMPANY Part No 65162 TMZ 50 30 4 29 Section 4 Repair Procedures June 2005 GROUND CONTROLS 7 3 Software Configuration The TMZ 50 30 can be adjusted to different configurations by changing the combination of DIP switch settings The DIP switch is located on the CPU circuit board found inside the top of the ground control box Programming for all configurations of the Genie TMZ 50 30 is contained in the EPROM which is installed o
266. roperly supported and secured when removed from the machine When the axle is installed the brakes should be bled Refer to the appropriate brake manufacturer s manual that was shipped with your Genie TMZ Genie TEREX COMPANY TMZ 50 30 become unbalanced and fall if not properly supported and secured when removed from the machine Part No 65162 June 2005 Ei REV 11 2 Hub and Bearings How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them Lower the outriggers and adjust to level the machine and raise the wheels off the ground Remove the lug nuts then remove the tire and wheel assembly Remove the dust cap Remove the cotter pin then the castle nut Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced Pack both bearings with clean fresh grease Place the large inner bearing into the rear of the hub Section 4 Repair Procedures AXLE 10 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 11 Slide the hub onto the spindle Component damage hazard Do CAUT
267. s procedure beginning with step Honda GX340K1 engine a high idle adjustment nut b high rpm solenoid choke solenoid d low idle adjustment screw not shown Hatz 1B30 engine a high rpm solenoid b high idle adjustment nut low idle adjustment screw d low idle lock nut not shown Genio Part No 65162 TMZ 50 30 3 23 Section Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES REV B 5 Before serial number T5002 25 Press the function enable button and any boom function button and check the engine rpm on the gauge Refer to Section 2 Specifications After serial number T5002 24 Press the function enable button and any boom function button and hold the engine start button BN77 at the platform controls and check the engine rpm on the diagnostic display at the side of the ground controls Refer to Section 2 Specifications If high idle rpm is correct disregard adjustment step 6 6 Honda models Loosen the nut on the solenoid Turn the high idle adjustment nut counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the jam nut and repeat this procedure beginning with step 5 Hatz models Loosen the lock nut on the solenoid Turn the high idle adjustment nut counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the lock nut and repeat this procedure beginning with step 5 Genie TEREX COMPANY 3 24 TMZ 50 30 Part No 651
268. se 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 REV B A 14 Perform Engine Maintenance Honda Models if equipped Engine specifications require that this procedure be performed every 100 hours or semi annually whichever comes first Perform this procedure more often if dusty conditions exist Proper engine maintenance following the engine manufacturer s maintenance schedule is essential to good engine performance and service life Failure to perform the maintenance procedures can lead to poor engine performance and component damage Required maintenance procedures and additional engine information is available in the Honda GX340 Engine Owner Manual Honda part number 31ZH9603 Honda GX340 Owner s Manual Genie part number 97361 Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures Checklist B Procedures REV B B 1 Inspect the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous c
269. serial number T5000 91 to T5002 24 Part 2 of 2 ater r as RN 1 PLATFORM CONTROLS Pal PLATFORM 2 MEMBRANE DECAL PANEL controts 3 P 1 PRINTED y 4 E DRIVE CONTROLS BOARD Es I li MEMBRANE DECAL PANEL BN78 OUTRIGGER EXTEND 5 BN29 PRIMARY UP e 4 QZ 8 e BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 BN80 OUTRIGGER RETRACT tunel BN31 SECONDARY UP D7A 12 E A HORN voutace 19 TA SECONDARY DOWN l BN82 DRIVE ENABLE 1l REGULATOR 14 T BN27 JIB UP 54321 EX O e BN28 JIB DOWN 6 PIN v o2 J3 3 RIBBON CABLE 2 148 JC5 4321l 1 2 4a 4 ROTATE RIGHT J3 U24 JOYSTICK A E m 4 BN33 ROTATE LEFT DRIVE CONTROLS 2 2 lg ES s PRINTED CIRCUIT BOARD 555 H2 BN74 BOOM RETRACT ID7B Tt 5 4d HORN 22 1 I vortace o12vec sv oc at EEEE Hr BN73 BOOM EXTEND al Yt amp amp 6 JA 648K
270. spections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX COMPANY Genie UK The Maltings Wharf Road 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 Genie Industries USA 18340 NE 76th Street PO Box 97030 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures June 2005 This page intentionally left blank Genie TEREX COMPANY 3 4 T
271. ssemble the gear assembly For ease of reinstallation note the removal order of each gear component 8 Visually inspect the inside of the platform rotator for the following items Excessive wear Broken or damaged parts Rust or corrosion 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 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 Genie 4 6 TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures REV B N W control box mount gearbox top cover rotate gear assembly gearbox case pinion rotate handle shaft rotate handle shaft cover seal platform pivot shaft platform pivot PLATFORM COMPONENTS 9 Thoroughly degrease and dry the gearbox case covers all gear components and the platform pivot shaft 10 Install the gearbox case onto the platform pivot shaft 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 Torque specification Gear assembly retaining nut dry 180 ft lbs 5 ft lbs 244 Nm 7 Nm
272. t ec nu lt lt lt to b Tf Cv O N N 6D Nr te N ot e o N e oo o Qr QW N OO GN D 2 5 49 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0218B THE POWER OFF ES0223B TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics June 2005 Electrical Schematic Gasoline Bi Fuel Models from serial number T5000 91 to T5002 24 Part 1 of 2 GROUND CONTROLS MEMBRANE DECAL PANEL a a 1 OUTRIGGER AUTO LEVEL BN49 BN38 PRIMARY UP T T ENGINE START BN68 t gt BN39 PRIMARY DOWN s T OUTRIGGER EXTEND BN47 TE BN53 RIGHT FRONT OUTRIGGER iE T OUTRIGGER RETRACT BN48 BN40 SECONDARY UP E PLATFORM LEVEL DOWN BN7O
273. t Genie Part No 65162 TMZ 50 30 4 39 Section 4 Repair Procedures June 2005 Hydraulic Pumps 8 1 Function Pump The TMZ 50 30 is equipped with one two or four hydraulic pumps depending on how the machine is configured Engine models The hydraulic pump s are attached to the engine Engine models with Drive option are equipped with two pumps Engine models without Drive are equipped with one DC models The hydraulic pump s are attached to the DC motor assembly located between the battery packs DC models with Drive option are equipped with two pumps DC models without Drive are equipped with one Bi Fuel models The hydraulic pumps are attached to both the engine and the hydraulic motor assembly located between the battery packs Bi Fuel models with Drive option are equipped with four pumps Bi Fuel models without Drive are equipped with two When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications How to Test the Hydraulic Pump This procedure will require two people 1 Tag disconnect and plug the high pressure hydraulic hose from the hydraulic pump AWARNING uid injury hazard Spraying ydraulic 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 REV B
274. t clean the surface of the control box lid Allow the surface to dry CAUTION Component damage hazard The circuit board will become damaged if it comes in contact with solvent Do not allow solvent to contact the 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 11 Loosen the control box lid retaining fasteners and open the lid 12 Using RTV type sealant completely seal the opening in the slot of the control box lid around the wire harness 13 Apply dielectric grease to the pins on the circuit board at the connection marked KEYPAD REV B 14 Install the large blue connector onto the circuit board pins at the connection marked KEYPAD Slide the connector parallel to the circuit board until the connector is pushed onto the circuit board pins no less than 0 2 inch 5 mm Be sure all pins are in the connector 15 Install the lid onto the control box and tighten the retaining fasteners Do not overtighten
275. t No 65162 June 2005 Section 4 Repair Procedures REV B Callout LED 7 6 Interacter Battery Charger 20 25A Red The Interacter 24 25 battery charger used on machines before serial number T5003 117 is a three stage microprocessor controlled 24V 25A charger with short circuit and reverse battery protection constant current and constant voltage with temperature compensated charging voltage 15 20A Red 10 15A Red 5 10A Red There is no need to switch off the charger once the batteries are charged as the charger senses the condition of the batteries and automatically switches into a float or standby mode The charger is protected with a 10A slow blowing fuse located behind a small panel just below the AC input connector Charge Red There are 7 LEDs on the front panel any combination of which indicates the state of battery charge or charger operating condition Listed in the next column in order from top to bottom as seen on the charger case is an explanation of what these LEDs indicate 8096 Yellow When using the charger be sure the AC supply circuit is grounded Ready Green LEDs on off switch AC input connector fuse panel O o Oo GROUND CONTROLS Description when charge current is 80 of chargers nominal rating when charge current is 60 of chargers nominal rating when charge current is 40 of chargers nominal ra
276. t switch LS27 primary boom up limit switch LS2 jib boom LS11 before serial number T5000 91 jib boom LS11 after serial number T5000 90 o Part No 65162 TMZ 50 30 6 3 Section 6 Schematics June 2005 E This page intentionally left blank A TEREX COMPANY 6 4 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics su Electrical Symbols Legend REV NE t t TTT e me doa E pe er M Solenoid Limit switch gt Level sensor gt LE S x Wu Temperature switch Solenoid valve Voltage regulator Battery charger gt mn Em 1133333 ES E udo E 7654321 85 ey 1 Le KS1 key switcu Motor controller DIP switch Control relay Key switch D1 av MS re Fuse Pressure switch Light or LED Motor Voltage divider Button Horn or Alarm Circuit breaker Part No 65162 TMZ 50 30 6 5 Section 6 Schematics Electrical Schematic DC Models before serial number T5000 91 June 2005
277. te platform leveling cycles to remove any air that might be in the system The master cylinder acts as a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion The master cylinder is located inside the mid pivot Genie A TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair Procedures E Secondary Boom Components 5 1 3 Attach a lifting strap of suitable capacity from an Secondary Boom How to Remove the Secondary Boom AWARNING This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the primary boom See 4 2 How to Remove the Primary Boom 2 Tag disconnect and plug the hydraulic hoses on the primary boom lift cylinder Cap the fittings on the cylinder AWARNING iudi injury hazard Spraying ydraulic oil can pene
278. tem GE Solenoid valve 2 position 2 way 6 to 8Q 10V DC schematic item JD Solenoid valve 2 position 3 way 26 to 282 20V DC with manual over ride schematic item HF Solenoid valve 2 position 2 way 10V DC engine models 6to8Q Solenoid valve 3 position 4 way 6 to 8Q 20V DC DC 26 to 280 10 DC with manual over ride schematic item KD schematic items GF GG GH and GO Solenoid valve 3 position 4 way 26 to 280 20V DC with manual over ride schematic items HG HH HI and HP Genie Part No 65162 TMZ 50 30 4 65 Section 4 Repair Procedures June 2005 MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 9 13 How to Test a Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the
279. tenance procedure with the machine in the following configuration Machine disconnected from tow vehicle Machine parked on a firm level surface with the boom stowed and both latches secured Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked and parking brake applied All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in pro
280. the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 sure that each turntable mounting top bolt is torqued in sequence to specification Turntable to bearing bolt torque specification All bolts lubricated 135 ft lbs 183 Nm Tongue T 12 10 17 5 19 zo 6 7 x o 16 1 11 25 13 Turntable to bearing bolt torque sequence CHECKLIST D PROCEDURES 2 Check to ensure that each bearing mounting bolt and nut under the turntable is torqued in sequence to specification Use the bolt access hole located in the turntable behind the ground control box to hold the bolt while torquing the nut Bearing to chassis bolt torque specification Bolts 1 2 9 10 15 and 16 lubricated 90 ft lbs 122 Nm All remaining bolts lubricated 105 ft lbs 142 Nm Tongue 11 9 _ 7 14 10 2 Bearing to chassis bolt torque sequence Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section Scheduled Maintenance Procedures June 2005 CHECKLIST D PROCEDURES D 3 Inspect for Turntable Bearing Wear Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and
281. the ground and platform controls Remove the fasteners securing the top to the ground controls box and open the ground control box Rotate the top of the ground control box to the position shown in the following illustration to correctly identify the configuration of the DIP switch settings Move the DIP switch settings to correspond with the configuration of the machine options Refer to the DIP Switch Legend on the next page Although both DIP switches have toggles marked from 1 through 8 the CPU recognizes them as a single DIP switch with 16 toggles and reads the toggles switch positions from left position 1 to right position 16 I GQ KS1 KEY SWITCH TA all n jJ fM all J I N O P1 1 EMERGENCY STOP ON D7 VOLTAGE REGULATOR SW25 SW25A DIP SWITCH DIP SWITCH 0 9 el 1 DIP switch SW25 DIP switch SW25A position 1 position 8 position 9 position 16 5 Close the lid and install the fasteners key switch KS1 ground control lid CPU display circuit board U22 Emergency Stop P1 DIP switch SW25A DIP switch SW25 Genie Part No 65162 TEREX COMPANY TMZ 50 30 4 31 Section 4 Repair Procedures June 2005 GROUND CONTRO
282. the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the calibration circles 11 Turn the key switch to ground control Adjust the side to side axis 12 Set a multimeter to read DC voltage 13 Without disconnecting the wire harness from the level sensor connect the negative lead of the multimeter to the black wire at the level sensor 14 Without disconnecting the wire harness from the level sensor connect the positive lead of the multimeter to the yellow wire at the level sensor 15 Adjust the Y axis side to side to 2 5V DC Tap the top of the level sensor lightly with fingers after each turn of an adjusting nut ADANGER Tip over hazard Do not adjust the potentiometers on the bottom of the level sensor or calibrate the level sensor other than specified in this procedure Failure to calibrate the tilt level sensor as instructed will cause the machine to tip over resulting in death or serious injury Be sure there are threads showing through the top of each adjusting nut 16 Disconnect the positive lead Adjust the front to back axis 17 Without disconnecting the wire harness from the level sensor connect the positive lead of the multimeter to the blue wire at the level sensor REV B 18 Adjust the X axis front to back to 2 5V DC Tap the top of the level sensor lightly with fingers after each turn of an adjusting nut ADANGER Tip over hazard Do not adjust th
283. these skills and tools could result in death or serious injury and significant component damage Dealer Service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the jib See 3 1 How to Remove the Jib Boom 2 Tag disconnect and plug the platform level slave cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING ecl injury hazard Spraying ydraulic 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 PRIMARY BOOM COMPONENTS 3 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic 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 The connections to the extension cylinder are at the mid pivot end of the primary boom 4 Remove the primary boom upper wear pad retaining fasteners Remove the upper wear pads from the primary boom 5 Remove the p
284. tic No Description Item Function Torque item BD hc ae T Ra ae 4 5 ft Ibs 5 7 Nm Goil n t items BA and BB 5 rtt e emet e ede ieee ai ee 5 7 ft los 7 9 Nm 1 Proportional valve BA Drive functions 25 27 ft lbs 34 36 Nm 2 Proportional valve BB Boom functions 25 27 ft lbs 34 36 Nm 3 Relief valve 3000 psi 206 8 bar System relief 18 20 ft Ibs 24 27 Nm 4 Solenoid valve 2 position 3 way BD us Boom function select 18 20 ft lbs 24 27 Nm 5 Check vakve BE Prevents flow from DC power unit from entering port P2 18 20 ft lbs 24 27 Nm 6 Check vaklve BE us Prevents flow from DC power unit from entering port P1 18 20 ft lbs 24 27 Nm 7 Check vaklve BG Prevents flow from engine pump from entering port P4 18 20 ft lbs 24 27 Nm 8 Check vakve BH Prevents flow from engine pump from entering port P3 18 20 ft lbs 24 27 Nm 9 Check vakve Bl Prevents flow from pump se
285. ting Illuminates when charge current is 20 of chargers nominal rating NOTE If the batteries are fully discharged all of the above listed LEDs will illuminate at the same time if the batteries are not fully discharged not all will illuminate when battery is connected correctly and AC power is present LED turns off when battery reaches first voltage limit during charging when timer is running battery voltage is held constant at this while this LED is on minimum one hour OR one hour plus half time required to reach first voltage limit Illuminates at end of charging cycle indicating batteries are charged and ready for use and will remain on as long as AC power and batteries remain connected maintaining charger in float or standby mode NOTE If the Green LED flashes constantly at the end of the charge this indicates an override timeout fault condition which happens if the charge cycle is not completed within 18 hours of charge start after which the charger will not output any current This is caused by a charger low output current fault OR a shorted cell in a battery Current settings Normal Liquid Gel First voltage limit 29V 31V 28V Float Standby 27 6V 27 7V 27 5V Genie Part No 65162 TMZ 50 30 4 37 Section 4 Repair Procedures June 2005 GROUND CONTROLS REV B How to I 3 i Install a Circuit Board E ow
286. tion 4 Repair Procedures REV B How to Remove the Hydraulic Pump 1 Tag disconnect and plug the hydraulic hoses from the pump Bodily injury hazard Spraying AWARNING 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 Remove the pump mounting fasteners Carefully remove the pump HYDRAULIC PUMPS 8 2 Hydraulic Power Unit DC Models How to Remove the Hydraulic Power Unit 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Tag disconnect and plug the hydraulic hoses from the pump on the hydraulic power unit Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Tag and disconnect the power cables from the hydraulic motor assembly 4 Remove the power unit mounting fasteners Remove the power unit from the machine Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005 Manifolds 9 1 Pump Manifold Components Models with Drive option before serial number T5000 91 REV B The pump manifold is located n
287. trate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie TEREX COMPANY overhead crane to the primary boom lift cylinder Raise the cylinder to a vertical position Remove the pin retaining fasteners from the primary boom lift cylinder barrel end pivot pin Using a soft metal drift remove the primary boom lift cylinder barrel end pivot pin Remove the primary boom lift cylinder from the machine AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed 6 Tag disconnect and plug the hydraulic hoses on the platform level master cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Attach a lifting strap of suitable capacity from an overhead crane to the platform level master cylinder Remove the pin retaining fasteners from the platform level master cylinder barrel end pivot pin Using a soft metal drift remove the platform level master cylinder barrel end pivot pin Remove the cylinder from the machine AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed Part No 65162 TMZ 50 30 4 23 Section 4
288. tread and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut or lug bolt for proper torque Refer to Section 2 Specifications 4 Check the air pressure of each tire Refer to Section 2 Specifications REV B B 7 Service the Tongue Jack 1 Remove the cap from the tongue jack and apply multipurpose grease to the internal gears and to the inner tube at the jack 2 Lubricate the handle on both sides of the tube with a lightweight oil 3 Check the tongue jack tires with an air pressure gauge and add air as needed Refer to Section 2 Specifications ADANGER Bodily injury hazard An over inflated tire can explode and may cause death or serious injury Genie TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures REV B B 8 Inspect the Parking Brake A properly functioning parking brake is essential to safe machine operation An improperly functioning parking brake will prevent the operator from properly securing the machine when not in use Perform this procedure on a firm level surface For adjustments Refer to Repair Procedure 12 2 How to Adjust the Parking Brake 1 Setthe parking brake 2 Attempt to manually push the machine in both directions Result The machine should not move If there is movement in the brake cables adjust the parking brak
289. tt JU catt i POSITION WITH 1 gt 2 THE POWER OFF M3 Q3 Q8 gt HIGH IDLE FUEL SOLENOID CUTOFF 5 g ES0219B c ES0224A a enie A TEREX COMPANY 6 38 TMZ 50 30 Part No 65162 June 2005 Section 6 Schematics Electrical Schematic Diesel Bi Fuel Models before serial number T5000 91 Part 2 of 2 eter E M us 1 PLATFORM CONTROLS Pal PLATFORM 2 MEMBRANE DECAL PANEL controts 3 PRINTED y 4 B DRIVE CONTROLS BOARD Es I li MEMBRANE DECAL PANEL BN78 OUTRIGGER EXTEND 5 BN29 PRIMARY UP e 4 QZ 8 e BN79 OUTRIGGER AUTO LEVEL e 9 BN30 PRIMARY DOWN XP m 10 BN80 OUTRIGGER RETRACT o2 ved Jsvoe BN31 SECONDARY UP D7A 12 E A HORN voutace 19 TA
290. u in 0 347 liters injection pump pressure 2600 to 2820 psi Number of cylinders 1 179 to 194 bar Bore and stroke 3 15 x 2 72 inches Fuel requirement diesel number 2 D 80 x 69 mm Alternator output 14A 3000 rpm Horsepower 6 25hp 3000 rpm Starter motor 12V DC Compression ratio ze Cooling System Forced air Low idle 1500 Fuel tank capacity 1 3 gallons High idle 2800 rpm 5 liters Governor centrifugal mechanical Valve clearance cold Intake 0 021 in 0 55 mm Exhaust 0 025 in 0 65 mm Lubrication system Oil pressure 3000 rpm 36 psi 2 5 bar Oil capacity including filter 1 16 quarts 1 1 liters Cil viscosity requirements Temperature below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification CD CE CF or CG grades Units ship with 10W 40 SG CC Part No 65162 TMZ 50 30 2 7 Section 2 Specifications June 2005 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Seal Lok Fittings hose end SAE Dash size Torque 4 18 ft lbs 24 4 Nm 6 27 ft lbs 36 6 Nm 8 40 ft Ibs 54 2 Nm 10 63 ft Ibs 85 4 Nm 12 90 ft Ibs 122 Nm 16
291. unctions should operate CHECKLIST B PROCEDURES B 4 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls Pull out the red Emergency Stop button to the on position at the drive controls if equipped 2 Turn the key switch to platform control 3 Check the machine functions from the ground controls Result The machine functions should not operate 4 Check the machine functions from the drive controls Result The drive functions should operate 5 Turn the key switch to ground control 6 Checkthe machine functions from the platform controls Result The machine functions should not operate 7 Check the machine functions from the drive controls Result The drive functions should not operate 8 Turn the key switch to the off position Result No function should operate Genie TEREX COMPANY Part No 65162 TMZ 50 30 3 15 Section Scheduled Maintenance Procedures June 2005 CHECKLIST B PROCEDURES B 5 Test the Auxiliary Lowering Testing the auxiliary lowering for malfunctions
292. v Schematics continued A Hydraulic Schematic DC Models without Drive after serial number 5000 90 6 54 B Hydraulic Schematic Engine only Models with Drive Option before serial number T5000 91 6 56 A Hydraulic Schematic Engine only Models with Drive Option after serial number T5000 90 6 58 B Hydraulic Schematic Engine only Models without Drive before serial number T5000 91 6 60 A Hydraulic Schematic Engine only Models without Drive after serial number T5000 90 6 62 B Hydraulic Schematic Bi Fuel Models with Drive Option before serial number T5000 91 6 64 A Hydraulic Schematic Bi Fuel Models with Drive Option after serial number T5000 90 6 66 B Hydraulic Schematic Bi Fuel Models without Drive before serial number 5000 91 6 68 A Hydraulic Schematic Bi Fuel Models without Drive after serial number T5000 90 6 70 Genie A TEREX COMPANY xii TMZ 50 30 PartNo 65162 June 2005 Section 2 Specifications REV B Machine Specifications Batteries DC models Type 6V DC Group T 145 Quantity models with drive option 8 Quantity models without drive 4 Battery capacity 244AH Reserve capacity 25A rate 530 minutes Bi fuel models Type 6V DC Group T 145 Quantity 4 Battery
293. ve coil fault aa circuit OR faulty circuit replace circuit board board 0066 Drive coil fault Right drive forward coil Short in wire harness Repair faulty wiring OR short OR faulty circuit board replace circuit board Coil not connected to Left drive forward coil wire harness OR open Restore connection OR 0067 Drive coil fault Ne ve eat open circuit OR faulty circuit replace circuit board board 0068 Drive coil fault Left drive forward coil Shortin wire harness Repair faulty wiring OR short OR faulty circuit board replace circuit board Coil not connected to Right drive reverse coil wire harness OR open Restore connection OR 0069 Drive coil fault M NM 2 open circuit OR faulty circuit replace circuit board board Continued on next page A TEREX COMPANY PartNo 65162 TMZ 50 30 5 7 Section 5 Troubleshooting Flow Charts June 2005 FAULT CODE CHART AFTER SERIAL NUMBER T5002 24 REV B Fault Code Fault Condition Possible Cause Solution 0070 Drive coil fault Right drive reverse coil Short in wire harness Repair faulty wiring OR short OR faulty circuit board replace circuit board Coil not connected to Left drive reverse coil wire harness OR open Restore connection OR 0071 Drive coil fault E Ra uan open circuit OR faulty circuit replace circuit board board 0072 Drive coil fault Left drive reverse coil Short in wire harness Repair faulty wiring OR sh
294. xle performance and component damage Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual REV B A 10 Perform Axle Maintenance CE Models Axle specifications require that this procedure be performed 500 km after regreasing the wheel bearings 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 Knott Axle Service Manual Knott part number P005 Knott Axle Service Manual Genie part number 84376 Genie part number 84443 Genie 3 10 TMZ 50 30 Part No 65162 June 2005 Section Scheduled Maintenance Procedures REV B A 11 Perform 30 Day Service The 30 day maintenance procedure is a onetime procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures A 13 Grease the Turntable Rotation Bearing and Rotate Gear B 8 Inspect the Parking Brake D2 Check the Turnable Rotation Bearing Bolts D 4 Replace the Hydraul
295. xterior membrane switches incorporated into an overlay decal are used to activate the various machine functions T1 LT P1 KS1 zz is o EMERGENCY SWITCH REGULATOR Im z STOP Sw25 SW25A DIP SWITCH DIP SWITCH A C97 C97 lo lo o o Con om key switch KS1 CPU display circuit board U22 voltage regulator D7 Emergency Stop button P2 DIP switch SW25A DIP switch SW25 connector circuit board U21 T 1 CPU Circuit Board REV B The CPU circuit board controls all machine functions How to Remove the CPU Circuit Board 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the four lid retaining fasteners from the ground control box Open the lid 3 Tag and disconnect all wiring from the CPU circuit board CAUTION Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when handling printed circuit boards 4 Remove the CPU circuit board mounting fasteners and remove the CPU circuit board Genie A TEREX COMPANY TMZ 50 30 Part No 65162 June 2005 Section 4 Repair P
296. y cr EE ZZ 9 355 5 H 29 5 525 85 Z8 05 8 tf 55 55 00 EOS 222 dd 5 92 gt 09 65 i Low a 55 22 00 99 ozrzzo 2250 gu OG 453 J4 St a 15 TH 98 00 EE EE B zo 5505 3t 62 2 8 gE 52 zz zz 9 PZza4 9905 ust ES Q E loa gU 66 fe 99 5 EE lt 6 oo 2035 55 3G E ES Fe LL LL gE lt 6629 00 060 Hu ce 197 aO wt Qm lt St a5 x 5 RE 38 38 335225 6805 555555 EGS gf EL g8 B Ems 182 8 uu uu 55 260 oo 3569 95 55 5 8 66 e o e Q0 9 o Ar AH HO ON A D 494 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt FOR BOOM FUNCTIONS NOTE MODELS WITHOUT DRIVE AND MACHINE SHOWN FOR BOOM AND DRIVE FUNCTIONS IN THE STOWED MODELS WITH DRIVE POSITION WITH ES0233A THE POWER OFF ES0238A TEREX COMPANY Part No 65162 TMZ 50 30 Section 6 Schematics Sg Electrical Schematic Gasoline Bi Fuel Models after serial number TMZ5003 228 Part 1 of 2 June 2005 GROUND CONTROLS MEMBRANE DECAL PANEL a 1
297. y Do not allow oil to squirt or spray 2 Apply a thin layer of fresh oil onto the gasket of the new oil filter 3 Install the filter and tighten it securely by hand Genie TEREX COMPANY TMZ 50 30 3 29 Part No 65162 CHECKLIST D PROCEDURES Use a permanent ink marker to write the date and number of hours from the hour meter on the new filter Clean up any oil that may have spilled during the replacement procedure Properly discard the used filter Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Raise the platform approximately 3 ft 1 m Inspect the filter and related components to be sure that there are no leaks Section Scheduled Maintenance Procedures June 2005 CHECKLIST D PROCEDURES D 5 Perform Axle Maintenance ANSI Models Axle specifications require that this procedure be performed every 12 months or 12 000 miles whichever comes first Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 REV B D 6 Perform Engine Maintenance Hatz Models if equipped Engine specifications require that this procedure be performed annually Proper engine maintenance following the engine manufa
298. ylinder will fall if not properly supported when the pivot pin is removed 21 Remove the supports securing the cables and hoses to the bottom of the secondary boom 22 Remove the pin retaining fasteners from the secondary boom pivot pin SECONDARY BOOM COMPONENTS 23 Using a soft metal drift remove the secondary boom pivot pin Remove the boom from the machine ADANGER Crushing hazard The secondary boom could become unbalanced and fall if not properly supported when the pin is removed 24 Attach a lifting strap of suitable capacity from an overhead crane to the secondary boom lift cylinder Raise the cylinder approximately 1 foot 30 cm 25 Rotate the rod end of the secondary boom lift cylinder approximately 90 26 Lower the cylinder onto the turntable 27 Release the secondary boom hold down latch 28 Attach a lifting strap of suitable capacity from an overhead crane to the secondary link Raise the secondary link to a horizontal position 29 Open the covers at both sides of the machine 30 Remove the pin retaining fasteners from the secondary link pivot pin 31 Using a soft metal drift remove the secondary link pivot pin Remove the secondary link from the machine ADANGER Crushing hazard The secondary blink could become unbalanced and fall if not properly supported when the pin is removed Genie Part No 65162 TEREX COMPANY TMZ 50 30 Section 4 Repair Procedures June 2005

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