Genie TMZ-34/19 User manual

Service Manual Part No. 52075
Rev C
June 2005
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TMZ-34/19 PartNo.52075
ii
Introduction
Important
Read,understandandobeythesafetyrulesand
operatinginstructionsintheappropriateOperator's
Manualonyour machinebeforeattemptingany
maintenanceorrepairprocedure.
Thismanualprovidesdetailedscheduled
maintenanceinformationforthemachineownerand
user.Italso providestroubleshootingandrepair
proceduresforqualifiedserviceprofessionals.
Basic mechanical, hydraulic and electrical
skillsarerequiredtoperformmostprocedures.
However,severalproceduresrequirespecialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommendthatmaintenanceandrepairbe
performedatanauthorizedGeniedealer
service center.
Technical Publications
GenieIndustrieshasendeavored todeliverthe
highestdegreeofaccuracy possible.However,
continuous improvement of our products is a Genie
policy.Therefore,productspecifications
are subject to change without notice.
ReadersareencouragedtonotifyGenieoferrors
and send in suggestions for improvement. All
communicationswill be carefully considered for
future printings of this and all other manuals.
Contact Us:
PO Box 97030
Redmond,WA98073-9730USA
http://www.genieindustries.com
e-mail:[email protected]
Copyright © 1998 by Genie Industries
52075 Rev C June 2005
First Edition, Third Printing
"Genie" is a registered trademark of Genie
Industries in the USA and many other countries.
"TMZ" is a trademark of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
Introduction
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PartNo.52075 TMZ-34/19 iii
Danger
Failure to obey the instructions and safety rules
inthismanualandtheappropriateOperator's
Manual on your machine will result in death or
seriousinjury.
Many of the hazards identified in the
operator’s manual are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
Safety Rules
Section 1 • Safety Rules
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TMZ-34/19 PartNo.52075
Personal Safety
Anyperson 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.
Readeachprocedurethoroughly.This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personneltopotentialpersonal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—usedtoindicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
seriousinjury.
Orange—usedtoindicatethe
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
seriousinjury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentiallyhazardoussituation
which, if not avoided, may cause
minorormoderateinjury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—usedtoindicateoperation
ormaintenanceinformation.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrantsit.
Beawareofpotential crushinghazards
such as moving parts, free swinging or
unsecuredcomponentswhenliftingor
placingloads.Alwayswearapprovedsteel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lightedtobaccoawayfromflammableand
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisherwithineasyreach.
Be sure that all tools and working areas
areproperlymaintainedandreadyforuse.
Keep work surfaces clean and free of
debris that could get into machine components and
causedamage.
Be sure that your workshop or work area is
properly ventilated and well lit.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capableofsupportingandstabilizingthe
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts)arenotreused.These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
otherfluids.Usean approvedcontainer.
Please be environmentally safe .
iv
SAFETY RULES
Section 1 • Safety Rules
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PartNo.52075 TMZ-34/19
Table of Contents
Introduction
ImportantInformation .........................................................................................ii
Section1 SafetyRules
GeneralSafetyRules ........................................................................................ iii
Section2 Rev Specifications
C MachineSpecifications ................................................................................ 2 - 1
C PerformanceSpecifications ......................................................................... 2 - 1
C HydraulicSpecifications ............................................................................... 2 - 2
C ManifoldComponentSpecifications ............................................................. 2 - 3
C MachineTorqueSpecifications .................................................................... 2 - 3
C HydraulicHoseandFittingTorqueSpecifications......................................... 2 - 4
C SAEand Metric Fasteners Torque Charts .................................................... 2 - 5
Section3 Rev ScheduledMaintenanceProcedures
Introduction .................................................................................................. 3 - 1
Pre-deliveryPreparationReport.................................................................... 3 - 3
MaintenanceInspectionReport .................................................................... 3 - 5
CChecklistAProcedures
A-1 PerformPre-operationInspection ........................................................ 3 - 6
A-2 Perform Function Tests ...................................................................... 3 - 6
A-3 Perform Hitch Maintenance - ANSI Models ......................................... 3 - 7
A-4 Perform Axle Maintenance - ANSI Models .......................................... 3 - 7
A-5 Perform Axle Maintenance - CE Models ............................................. 3 - 8
A-6 Perform Axle Maintenance - CE Models ............................................. 3 - 8
A-7 Perform Axle Maintenance - ANSI Models .......................................... 3 - 9
A-8 Perform Axle Maintenance - ANSI Models .......................................... 3 - 9
A-9 Perform Axle Maintenance - CE Models ........................................... 3 - 10
A-10 Perform 30 Day Service .................................................................... 3 - 10
A-11 GreasetheTurntableRotationBearingandRotateGear ................... 3 - 11
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TMZ-34/19 PartNo.52075
TABLEOFCONTENTS
Section3 Rev ScheduledMaintenanceProcedures,continued
CChecklistBProcedures
B-1 Inspect the Batteries......................................................................... 3 - 12
B-2 Inspect the Electrical Wiring ............................................................. 3 - 13
B-3 Test the Emergency Stop ................................................................. 3 - 14
B-4 Test the Key Switch ......................................................................... 3 - 14
B-5 TesttheManualLoweringOperation ................................................. 3 - 15
B-6 Inspect the Tires and Wheels (including lug nut or lug bolt torque) .... 3 - 16
B-7 Service the Tongue Jack .................................................................. 3 - 16
B-8 Inspect the Parking Brake................................................................. 3 - 17
B-9 Test the Horn .................................................................................... 3 - 18
B-10 TesttheFlashingBeacon(ifequipped) ............................................. 3 - 18
B-11 TestthePlatformRotation(ifequipped) ............................................ 3 - 19
B-12 Inspect the Hydraulic Tank Cap Venting System .............................. 3 - 19
B-13 Perform Hitch Maintenance - ANSI Models ....................................... 3 - 20
B-13 Perform Axle Maintenance - ANSI Models ........................................ 3 - 20
B-14 Perform Hydraulic Oil Analysis ......................................................... 3 - 21
CChecklistCProcedure
C-1 ReplacetheHydraulicTankBreatherCap-
ModelswithOptionalHydraulicOil.................................................... 3 - 22
C-2 Perform Axle Maintenance - ANSI Models ........................................ 3 - 22
C-3 PerformHitchMaintenance-CEModels .......................................... 3 - 23
CChecklistDProcedures
D-1 ChecktheTurntable Rotation BearingBolts...................................... 3 - 24
D-2 InspectforTurntableBearingWear ................................................... 3 - 25
D-3 ReplacetheHydraulicTankReturn Filter .......................................... 3 - 26
D-4 Perform Axle Maintenance - ANSI Models ........................................ 3 - 27
D-5 Perform Hitch Maintenance - ANSI Models ....................................... 3 - 27
CChecklistEProcedure
E-1 Test or Replace the Hydraulic Oil...................................................... 3 - 28
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PartNo.52075 TMZ-34/19
TABLEOFCONTENTS
Section4 Rev RepairProcedures
Introduction .................................................................................................. 4 - 1
CPlatformControls
1-1 CircuitBoard....................................................................................... 4 - 2
1-2 MembraneOverlay ............................................................................. 4 - 3
CPlatformComponents
2-1 Platform.............................................................................................. 4 - 5
2-2 PlatformRotator(ifequipped) ............................................................. 4 - 5
CJibBoomComponents
3-1 Jib Boom ............................................................................................ 4 - 8
3-2 Jib Boom Lift Cylinder ...................................................................... 4 - 10
BBoomComponents
4-1 Boom................................................................................................ 4 - 12
4-2 LiftCylinders .................................................................................... 4 - 18
CGroundControls
5-1 GroundControlKeypadCircuitBoard ............................................... 4 - 20
5-2 CPUCircuitBoard ............................................................................ 4 - 22
5-3 ConnectorCircuitBoard.................................................................... 4 - 22
5-4 SoftwareConfiguration...................................................................... 4 - 23
5-5 MembraneOverlay ........................................................................... 4 - 25
5-6 LevelSensor .................................................................................... 4 - 27
5-7 InteracterBatteryCharger.................................................................. 4 - 30
5-8 LesterBatteryCharger...................................................................... 4 - 32
BHydraulicPowerUnit
6-1 HydraulicPowerUnitComponents.................................................... 4 - 34
6-2 Valve Adjustments - Hydraulic Power Unit........................................ 4 - 36
6-3 HydraulicPump ................................................................................ 4 - 37
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TMZ-34/19 PartNo.52075
Section4 Rev Repair,continued
CManifolds
7-1 TurntableRotationManifoldComponents ......................................... 4 - 40
7-2 ValveAdjustments-TurntableRotationManifold ............................. 4 - 41
7-3 OutriggerManifoldComponents........................................................ 4 - 42
7-4 Valve Coils ....................................................................................... 4 - 43
BTurntableRotationComponents
8-1 TurntableRotationMotor .................................................................. 4 - 45
BAxleComponents
9-1 Axle.................................................................................................. 4 - 46
9-2 HubandBearings ............................................................................. 4 - 46
CTrailerComponents
10-1 TrailerBrakes ................................................................................... 4 - 47
10-2 ParkingBrake................................................................................... 4 - 47
BOutriggers
11-1 OutriggerComponents ...................................................................... 4 - 48
11-2 OutriggerCylinder ............................................................................. 4 - 49
TABLEOFCONTENTS
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PartNo.52075 TMZ-34/19
Section5 Rev TroubleshootingFlowCharts
Introduction .................................................................................................. 5 - 1
A FaultCodeChart(afterserialnumberT3402-115)......................................... 5 - 3
Chart Chart
Number Title
B 1 All Functions Will Not Operate
(beforeserialnumberT3400-001) ................................................. 5 - 6
B 2 PumpMotorWillNot Operate ....................................................... 5 - 8
B 3 All Functions Inoperative, Power Unit Starts and Runs................. 5 - 9
B 4 GroundControlsInoperative ....................................................... 5 - 10
B 5 PlatformControlsInoperative ..................................................... 5 - 11
B 6 JibBoomUpFunctionInoperative.............................................. 5 - 12
B 7 JibBoomDownFunctionInoperative ......................................... 5 - 13
B 8 PrimaryBoomUpFunctionInoperative ...................................... 5 - 15
B 9 PrimaryBoomDownFunctionInoperative .................................. 5 - 16
B 10 SecondaryBoomUpFunctionInoperative.................................. 5 - 18
B 11 SecondaryBoomDownFunctionInoperative ............................. 5 - 19
B 12 TurntableRotateLeftFunctionInoperative ................................. 5 - 21
B 13 TurntableRotateRightFunctionInoperative ............................... 5 - 22
A 14 ParkingBrakeFunctionInoperative............................................ 5 - 23
TABLEOFCONTENTS
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TMZ-34/19 PartNo.52075
TABLEOFCONTENTS
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Section6 Rev Schematics
Introduction .................................................................................................. 6 - 1
B ElectricalComponentandWireColorLegends ............................................. 6 - 2
A LimitSwitchLegend ..................................................................................... 6 - 3
A TrailerLightingWiringDiagram ..................................................................... 6 - 4
A ElectricalSymbolsLegend........................................................................... 6 - 5
B Electrical Schematic - Models with Manual Outriggers
(fromserialnumberT3498-001toT3499-361) .............................................. 6 - 6
A Electrical Schematic - Models with Manual Outriggers
(fromserialnumberT3499-362toT3499-769) .............................................. 6 - 7
B Electrical Schematic - Models with Manual Outriggers
(fromserialnumberT3400-001) .................................................................... 6 - 8
B Electrical Schematic - Models with Hydraulic Outriggers............................ 6 - 10
A HydraulicSymbolsLegendandComponentReference............................... 6 - 13
A HydraulicSchematic-ModelswithManual Outriggers
(fromserialnumberT3498-001toT3499-769) ............................................ 6 - 14
A HydraulicSchematic-ModelswithManual Outriggers
(fromserialnumberT3400-001toT3400-265) ............................................ 6 - 15
A HydraulicSchematic-ModelswithManual Outriggers
(afterserialnumberT3400-265) .................................................................. 6 - 16
A HydraulicSchematic-ModelswithHydraulicOutriggers
(beforeserialnumberT3400-266) ............................................................... 6 - 14
A HydraulicSchematic-ModelswithHydraulicOutriggers
(afterserialnumberT3400-265) .................................................................. 6 - 15
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