Genie TZ-34/20 User manual

Genie TZ-34/20 Part No. 825934
April 2016
ii
Introduction
Copyright © 2011 Terex Corporation
825934 Rev DAugust 2016
Third Edition, Third Printing
"Genie" and "TZ" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
other countries.
Printed on recycled paper
Printed in U.S.A.
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 fault
codes 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.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie 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:
http://www.genielift.com
e-mail: awp[email protected]
Introduction
Serial Number Information
Genie offers the following Service Manual for
these models:
Title Part No.
TZ-34/20 Service Manual ...................................... 84382
From SN TZ3403-001 to TZ3416J-3099
and from SN TZ34J-3100

Part No. 825934 Genie TZ-34/20
April 2016
Revision History
Revision Date Section Procedure / Schematic Page / Description
A 7/2013 New release
B 11/2014 Added rotation brake and EN280 updates
C 11/2015 Update bearing wear tolerance, pg 3-27
C1 1/2016 3 3-26 updated turntable rotation bearing bolt torque spec's
C2 4/2016 5 5-21and 5-25 updated electrical schematics
C3 8/2016 1 Updated front cover, Serial Number Information and
Serial Number Legend and front cover.
REFERENCE EXAMPLES:
Honda Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
5-35, 5-56, 5-104_Section 5_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
iii

Genie TZ-34/20 Part No. 825934
April 2016
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Honda Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
5-35, 5-56, 5-104_Section 5_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
iv

Part No. 825934 Genie TZ-34/20
April 2016
Serial Number Legend
Introduction
v

Genie TZ-34/20 Part No. 825934
April 2016
vi
Safety Rules
Section 1 • Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
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
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates an imminently hazardous situation which,
if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if
not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation which,
if not avoided, may cause minor or
moderate injury.
Indicates a potentially hazardous situation which, if
not avoided, may result in property
damage.
Be sure to wear protective eye wear and other
protective clothing if the situation warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.

Part No. 825934 Genie TZ-34/20
April 2016
SAFETY RULES
vii
Section 1 • Safety Rules
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 surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure any forklift, overhead crane or
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 that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

Genie TZ-34/20 Part No. 825934
April 2016
Table of Contents
viii
Introduction
Important Information ...................................................................................................... ii
Serial Number Information .............................................................................................. ii
Revision History ............................................................................................................. iii
Serial Number Legend .................................................................................................... v
Section 1 Safety Rules
General Safety Rules ..................................................................................................... iv
Section 2 Specifications
Machine Specifications ..............................................................................................2 - 1
Performance Specifications........................................................................................2 - 2
Hydraulic Specifications .............................................................................................2 - 2
Manifold Component Specifications ...........................................................................2 - 3
Hydraulic Hose and Fitting Torque Specifications ......................................................2 - 4
SAE and Metric Fastener Torque Chart......................................................................2 - 6
Section 3 Scheduled Maintenance Procedures
Introduction.................................................................................................................3 - 1
Pre-delivery Preparation Report.................................................................................3 - 3
Maintenance Inspection Report .................................................................................3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals.......................................................................3 - 6
A-2 Perform Pre-operation Inspection.....................................................................3 - 7
A-3 Perform Function Tests .....................................................................................3 - 7
A-4 Torque the Lug Bolts - ANSI/CSA/AS ...............................................................3 - 7
A-5 Torque the Lug Bolts - CE.................................................................................3 - 8

Part No. 825934 Genie TZ-34/20
April 2016
TABLE OF CONTENTS
ix
Section 3 Scheduled Maintenance Procedures, continued
A-6 Perform Hitch Maintenance - ANSI/CSA/AS.....................................................3 - 8
A-7 Perform 30 Day Service....................................................................................3 - 9
A-8 Grease the Turntable Rotation Bearing and Rotate Gear.................................3 - 9
Checklist B Procedures
B-1 Inspect the Batteries.......................................................................................3 - 10
B-2 Inspect the Electrical Wiring ...........................................................................3 - 11
B-3 Inspect the Electrical Contactor......................................................................3 - 11
B-4 Test the Manual Override................................................................................3 - 12
B-5 Test the Platform Rotation (if equipped) .........................................................3 - 13
B-6 Perform Hydraulic Oil Analysis .......................................................................3 - 14
B-7 Perform Axle Maintenance - ANSI/CSA/AS....................................................3 - 14
B-8 Check the Wheel Bearings - CE .....................................................................3 - 15
B-9 Service the Hitch - CE ....................................................................................3 - 15
B-10 Perform Axle Maintenance - CE .....................................................................3 - 16
B-11 Inspect the Parking Brake...............................................................................3 - 17
B-12 Service the Tongue Jack.................................................................................3 - 17
Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped)................................3 - 18
C-2 Test the Platform Overload System (if equipped) ...........................................3 - 18
C-3 Perform Axle Maintenance - ANSI/CSA/AS....................................................3 - 20

Genie TZ-34/20 Part No. 825934
April 2016
TABLE OF CONTENTS
x
Section 3 Scheduled Maintenance Procedures, continued
C-4 Replace the Hydraulic Tank Breather Cap
Models with Optional Hydraulic Oil.................................................................3 - 20
C-5 Grease the Axle Wheel Bearings - CE ...........................................................3 - 21
C-6 Adjust the Brakes - CE ...................................................................................3 - 22
Checklist D Procedures
D-1 Perform Axle Maintenance - ANSI/CSA/AS....................................................3 - 23
D-2 Check the Boom Wear Pads...........................................................................3 - 23
D-3 Replace the Hydraulic Tank Return Filter .......................................................3 - 24
D-4 Check the Turntable Rotation Bearing Bolts ...................................................3 - 25
D-5 Inspect for Turntable Bearing Wear.................................................................3 - 26
Checklist E Procedure
E-1 Test or Replace the Hydraulic Oil ...................................................................3 - 28
Section 4 Repair
Introduction.................................................................................................................4 - 1
Platform Components
1-1 Platform ............................................................................................................4 - 2
1-2 Platform Rotator (if equipped)...........................................................................4 - 2
Primary Boom Components
2-1 Cable Track .......................................................................................................4 - 7
2-2 Primary Boom...................................................................................................4 - 9
2-3 Primary Boom Lift Cylinder.............................................................................4 - 13
2-4 Platform Leveling Cylinders ............................................................................4 - 14
Secondary Boom Components
3-1 Secondary Boom............................................................................................4 - 17
3-2 Secondary Boom Lift Cylinder........................................................................4 - 19
Ground Controls
4-1 Level Sensor...................................................................................................4 - 20

Part No. 825934 Genie TZ-34/20
April 2016
xi
TABLE OF CONTENTS
Section 4 Repair, continued
Hydraulic Power Unit
5-1 Hydraulic Power Unit Components.................................................................4 - 24
5-2 Valve Adjustments - Hydraulic Power Unit......................................................4 - 26
5-3 Hydraulic Pump ..............................................................................................4 - 27
Manifolds
6-1 Function Manifold Components ......................................................................4 - 28
6-2 Outrigger Counterbalance Valve Manifold Components.................................4 - 30
6-3 Valve Coils ......................................................................................................4 - 31
Turntable Rotation Components
7-1 Turntable Rotation Motor ................................................................................4 - 33
Axle Components
8-1 Axle.................................................................................................................4 - 34
Trailer Components
9-1 Hydraulic and Mechanical Brakes ..................................................................4 - 35
9-2 Parking Brake .................................................................................................4 - 35
Outriggers
10-1 Outrigger Components ...................................................................................4 - 36
10-2 Outrigger Cylinder ..........................................................................................4 - 37
Platform Overload Components
11-1 Platform Overload System..............................................................................4 - 38

Genie TZ-34/20 Part No. 825934
April 2016
xii
TABLE OF CONTENTS
Section 5 Schematics
Introduction.................................................................................................................5 - 1
Electrical Abbreviations Legend .................................................................................5 - 2
Wire Color Legend .....................................................................................................5 - 4
Limit Switch Legend ...................................................................................................5 - 5
Electrical Symbols Legend .........................................................................................5 - 6
Hydraulic Abbreviations Legend.................................................................................5 - 7
Hydraulic Symbols Legend.........................................................................................5 - 8
Trailer Lighting Wiring Diagram - ANSI/CSA ..............................................................5 - 9
Trailer Lighting Wiring Diagram - Mechanical Axle, CE ...........................................5 - 10
Trailer Lighting Wiring Diagram - Hydraulic Axle, AS................................................5 - 11
Control Box Wiring Diagrams - ANSI/CSA
Ground Control Box Wiring Diagram - ANSI/CSA ....................................................5 - 12
Platform Control Box Wiring Diagram - ANSI/CSA...................................................5 - 14
Control Box Wiring Diagrams - AS/CE
Ground Control Box Wiring Diagram - AS/CE ..........................................................5 - 16
Platform Control Box Wiring Diagrams - AS/CE.......................................................5 - 18
Electrical Schematics - ANSI/CSA
Electrical Schematic - ANSI/CSA .............................................................................5 - 20
Electrical Schematics - AS/CE
Electrical Schematic - AS/CE ...................................................................................5 - 24
Hydraulic Schematics
Hydraulic Schematic.................................................................................................5 - 28

Part No. 825934 Genie TZ-34/20 2 - 1
Section 2 • SpecificationsJanuary 2016
Specifications
Machine Specifications
Batteries
Type 6V DC
Group T-105
Quantity 4
Battery capacity 225AH
Reserve capacity @ 25A rate 447 minutes
Fluid capacities
Hydraulic tank 2.8gallons
10.6 liters
Hydraulic system 4.5 gallons
(including tank) 17 liters
Tires and wheels - ANSI/CSA/AS
Axle
Tire size ST205/75 R14
Load range C
Lug nut torque, dry 100 ft-lbs
135 Nm
Tire pressure, maximum (cold) 50 psi
3.4 bar
Tongue jack
Tire size 4.10 / 3.50-4
Tire pressure, maximum (cold) 50 psi
3.4 bar
Tires and wheels - CE
Axle
Tire size 185 R14C
104/102N
Lug bolt torque, dry 66 ft-lbs
90 Nm
Tire pressure, maximum (cold) 65 psi
4.5 bar
Tongue jack
Tire size 8 x 2
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.

2 - 2 Genie TZ-34/20 Part No. 825934
Section 2 • Specifications January 2016
Optional fluids
Biodegradable Petro Canada Environ MV 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Chevron Aviation A
Arnica 32
Continued use of Chevron
Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -17°C.
Note: Use Shell Tellus S2 V 46 hydraulic oil when
oil temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Service Department before use.
Performance Specifications
Boom function speeds, maximum
from platform controls
(no weight in platform)
Primary boom up 14 to 22 seconds
Primary boom down 24 to 32 seconds
Primary boom extend 18 to 28 seconds
Primary boom retract 18 to 28 seconds
Secondary boom up 14 to 24 seconds
Secondary boom down 14 to 24 seconds
Turntable rotate - 359° 80 to 115 seconds
Airborne noise emissions 80 dB
Maximum sound level at normal operation workstations
(A-weighted)
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rando HD equivalent
Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rando HD oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
SPECIFICATIONS
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.

Part No. 825934 Genie TZ-34/20 2 - 3
Section 2 • SpecificationsJanuary 2016
SPECIFICATIONS
Function pump
Displacement 0.101 cu in
per revolution 1.66 cc
Flow rate @ 3500 rpm 1.3 gallons per minute
4.9 liters per minute
Relief Valve Pressures
System 3500psi
relief valve pressure 241.3 bar
Outrigger 4000 psi
relief valve pressure 275.8 bar
Turntable rotate 1200 psi
relief valve pressure 82.7 bar
Boom extend 1800 psi
relief valve pressure 124.1 bar
Primary boom lift cylinder 1600 psi
relief valve pressure 110.3 bar
Secondary boom lift cylinder 1100 psi
relief valve pressure 75.8 bar
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Valve Coil Resistance
Description Specification
Solenoid valve, 3 position 4 way 29 to 31
24V DC with diode
(schematic item B, AA, AB, AC, AD and AE)
Solenoid valve, 3 position 4 way 20 to 22
24V DC with diode (schematic items K, M, Q and T)
Solenoid valve, 2 position 3 way 29 to 31
24V DC with diode (schematic items O and V)
Solenoid valve, 2 position 2 way, N.C. 29 to 31
24V DC with diode (schematic items W, X, Y and Z)
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.

2 - 4 Genie TZ-34/20 Part No. 825934
Section 2 • Specifications January 2016
SPECIFICATIONS
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC 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 - ORFS)
SAE Dash size Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1
1/4
-8 3/4-16 1
-10 7/8-14 1
-12 1
1/16-12 1
-16 1
5/16-12 1
-20 1
5/8-12 1
-24 1
7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash size Torque
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
Adjustable
fitting (Adj)
Non-adjustable
fitting (Non-adj)
Jamb nut

Part No. 825934 Genie TZ-34/20 2 - 5
Section 2 • SpecificationsJanuary 2016
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.
Note: The O-rings used in the Parker Seal Lok™
fittings and hose ends are custom-size O-rings.
They are not standard SAE size O-rings. They are
available in the O-ring field service kit (Genie part
number 49612).
2 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.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand-tight,
approximately 30 in-lbs / 3.4 Nm.
2 Make a reference mark on one of the flats of
the hex nut, and continue it on to the body hex
fitting with a permanent ink marker. Refer to
Figure 1.
Figure 1
a hex nut
b reference mark
c body hex fitting
3 Working clockwise on the body hex fitting,
make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Figure 2.
Note: Use the JIC 37° Fittings table on the
previous page to determine the correct number of
flats for the proper tightening position.
Note: The marks indicate that the correct
tightening positions have been determined. Use
the second mark on the body hex fitting to properly
tighten the joint after it has been loosened.
Figure 2
a body hex fitting
b reference mark
c second mark
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
a
b
c
a
b
c
b
SPECIFICATIONS

2 - 6 Genie TZ-34/20 Part No. 825934
Section 2 • Specifications January 2016
10.9 12.98.8
4.6
SPECIFICATIONS

Part No. 825934 Genie TZ-34/20 3 - 1
Section 3 • Scheduled Maintenance ProceduresJanuary 2016
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. The frequency and extent of periodical
examinations and tests may also depend on
national regulations.
Failure to properly complete each
inspection when required may
cause death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Use only Genie approved replacement parts.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
following configuration:
• Machine disconnected from tow vehicle
• Machine parked on a firm, level surface
• Boom in the stowed position with both
latches secured
• Key switch in the off position with the
key removed
• Wheels chocked
• Parking brake applied
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.
Indicates an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

3 - 2 Genie TZ-34/20 Part No. 825934
Section 3 • Scheduled Maintenance Procedures January 2016
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.
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
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B,
C, D, and E. Use the following chart to determine
which group(s) of 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 / 5000 km A + B
Semi-annually or every 500 hours or
every 6000 miles / 10,000 km A + B + C
Annually or every 1000 hours or
every 12,000 miles A + B + C + D
Two year or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental
regulations and requirements.