Terex Genie TMZ-34/19 User manual

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Section 4 • Repair Procedures June 2005
4 - 20 TMZ-34/19 PartNo.52075
Ground Controls
TMZ-34 models manufactured in the 1998 and
1999 model years (from serial number T3498-001
to T3499-769) were originally equipped with
ground controls boxes containing three printed
circuit boards. Machine functions are activated
using push buttons on the exterior of the box.
Beginning with the 2000 model year (from serial
number T3400-001 to date), the ground control box
was changed to a two-board configuration. The
push buttons used to activate machine functions
on earlier models were replaced with a membrane
overlay decal, mounted on the exterior of the box.
N.C.
N.O.
N.O.
KS1
KEY
SWITCH
P1
EMERGENCY
STOP
D7
VOLTAGE
REGULATOR
d
e
f
abc
From serial number T3498-001 to T3499-769
a voltage regulator D7
b CPU circuit board U17
c connector circuit board U21
d key switch KS1
e Emergency Stop button P2
f key pad circuit board U15
From serial number T3400-001 to date
a DIP switch SW25A
b DIP switch SW25
c connector circuit board U21
d key switch KS1
e CPU/display circuit board U22
f voltage regulator D7
g Emergency Stop button P2
N.C.
N.O. N.O.
SW25
DIP SWITCH
SW25A
DIP SWITCH
D7
VOLTAGE
REGULATOR
123
48 57 6123 48 57 6
abc
P1
EMERGENCY
STOP
KS1
KEY
SWITCH
gfed

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Section 4 • Repair ProceduresJune 2005
PartNo. 52075 TMZ-34/19 4 - 21
5-1
Ground Control Keypad
Circuit Board
The ground control keypad circuit board controls
the machine functions from the ground. The
ground control circuit board is connected to the
CPU circuit board via a ribbon cable.
TMZ-34 models manufactured in the 1998 and
1999 model years (from serial number T3498-001
to T3499-769) were originally equipped with
ground controls boxes containing three printed
circuit boards. Machine functions are activated
using push buttons on the exterior of the box.
Beginning with the 2000 model year (from serial
number T3400-001 to date), the ground control box
was changed to a two-board configuration. The
push buttons used to activate machine functions
on earlier models were replaced with a membrane
overlay decal, mounted on the exterior of the box.
The following procedure will not
apply for models manufactured in
the 2000 and later model years.
How to Remove the Ground
Control Keypad Circuit Board
1 Disconnect the battery pack from the machine.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
GROUND CONTROLS
2 Remove the four lid retaining fasteners from the
ground control box. Open the lid.
3 Tag and disconnect the ribbon cables from the
ground control circuit board.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
4 Remove the circuit board mounting fasteners
and remove the circuit board from the ground
control box lid.
Component damage hazard. Be
sure not to pinch the wires or
ribbon cable when installing the lid
onto the ground control box.

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Section 4 • Repair Procedures June 2005
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5-3
Connector Circuit Board
The connector circuit board connects the wire
harness to the CPU circuit board using several
cables. From serial number T3498-001 to
T3499-769, the connector circuit board is equipped
with a replaceable 5 amp fuse.
How to Remove
the Connector Circuit Board
1 Disconnect the battery pack from the machine.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
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.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
5 Remove the connector circuit board mounting
fasteners and remove the connector circuit
board.
5-2
CPU Circuit Board
The CPU circuit board controls all machine
functions.
How to Remove
the CPU Circuit Board
1 Disconnect the battery pack from the machine.
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.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
4 Remove the CPU circuit board mounting
fasteners and remove the CPU circuit board.
GROUND CONTROLS

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Section 4 • Repair ProceduresJune 2005
PartNo. 52075 TMZ-34/19 4 - 23
GROUND CONTROLS
5-4
Software Configuration
TMZ-34 models manufactured in the 1998 and
1999 model years (from serial number T3498-001
to T3499-769) were originally equipped with
ground controls boxes containing three printed
circuit boards. Machine functions are activated
using push buttons on the exterior of the box.
Beginning with the 2000 model year (from serial
number T3400-001 to date), the ground control box
was changed to a two-board configuration. The
push buttons used to activate machine functions
on earlier models were replaced with a membrane
overlay decal, mounted on the exterior of the box.
Programming for all configurations of the the 1998
and 1999 model years (from serial number
T3498-001 to T3499-769) is contained in the
EPROM, which is installed into the CPU circuit
board.
Beginning with the 2000 model year, the machine
can be configured by changing the combination of
toggles of the DIP switch mounted on the CPU
circuit board.
The following procedures will not
apply for machines manufactured
in the 1998 and 1999 model years.
How to Determine
the DIP Switch Configuration
A diagnostic display was
incorporated into the ground
controls after serial number
T3402-115. The following
procedure will not apply to
machines before serial number
T3402-116.
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
controls.
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.
b
a
a secondary down
b turntable rotate counterclockwise

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Section 4 • Repair Procedures June 2005
4 - 24 TMZ-34/19 PartNo.52075
N.C.
N.O.
N.O.
SW25
DIP SWITCH
SW25A
DIP SWITCH
D7
VOLTAGE
REGULATOR
P1
EMERGENCY
STOP
KS1
KEY
SWITCH
d
c
b
a
123 4567 8
ON
K
J
123 4567 8
ON
K
J
e
e
How to
Set the DIP Switch
1 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at both the ground and platform
controls.
2 Remove the fasteners securing the top to the
ground controls box and open the ground
control box.
3 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.
4 Locate the DIP switch on the circuit board.
Move the DIP switch settings to correspond
with the configuration of the machine options as
illustratedbelow.
5 Close the lid and install the fasteners.
DIP Switch Legend
Toggle Description Position
1 All models On
2 Hour meter/flashing beacon On
3 Not used Off
4 Outriggers
hydraulic Off
manual On
5 - 16 Not used
GROUND CONTROLS
12 34567 8
ON K
J
12 34567 8
ON K
J
12 34567 8
ON K
J
12 34567 8
ON K
J
a key switch KS1
b ground control lid
c CPU/display circuit board U22
d Emergency Stop P1
e DIP switch SW25A
f DIP switch SW25
models with manual outriggers
models with hydraulic outriggers

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Section 4 • Repair ProceduresJune 2005
PartNo. 52075 TMZ-34/19 4 - 25
GROUND CONTROLS
5-5
Membrane Overlay
The following procedures will not
apply for machines manufactured
in the 1998 and 1999 model years.
How to
Replace the Overlay
1 Disconnect the battery pack from the machine.
Electrocution hazard. Contact with
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.
2 Loosen the control box lid retaining fasteners
and open the lid.
3 Disconnect the large blue connector from the
circuit board at the connection marked KEYPAD
by sliding the connector parallel to the circuit
board.
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 OR 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
16 PIN RIBBON CABLE
16
15
14
13
12
8
7
6
5
11
2
10
1
9
BN44
BN39
FUNCTION ENABLE HIGH
PRIMARY DOWN
BN45FUNCTION ENABLE MEDIUM
BN46
BN35
BN38
BN53
BN52
BN41
FUNCTION ENABLE LOW
HORN
PRIMARY UP
RIGHT FRONT OUTRIGGER
LEFT FRONT OUTRIGGER
SECONDARY DOWN
BN37
BN36
BN43
BN50
BN47
BN48
BN42
BN49
JIB BOOM DOWN
JIB BOOM UP
ROTATE RIGHT
LEFT REAR OUTRIGGER
OUTRIGGER EXTEND
OUTRIGGER RETRACT
ROTATE LEFT
OUTRIGGER AUTO LEVEL
BN51 RIGHT REAR OUTRIGGER
BN40 SECONDARY UP
MODELS WITH
HYDRAULIC OUTRIGGERS
GROUND CONTROLS
MEMBRANE DECAL PANEL
BN44
BN39
FUNCTION ENABLE HIGH
PRIMARY DOWN
BN45FUNCTION ENABLE MEDIUM
BN46
BN35
BN38
FUNCTION ENABLE LOW
HORN
PRIMARY UP
BN37
BN36
BN43
BN42
JIB BOOM DOWN
JIB BOOM UP
ROTATE RIGHT
ROTATE LEFT
BN40
BN41
SECONDARY UP
SECONDARY DOWN
16
15
14
13
12
8
7
6
5
10
9
16 PIN RIBBON CABLE
MODELS WITH
MANUAL OUTRIGGERS
NOTE
THE RANDOM ORDER OF THE 16-PIN
RIBBON CONNECTOR IS DONE ONLY TO
SHOW THE WIRE CIRCUITS. ON THE
MACHINE, THE WIRES OF THE RIBBON
CABLE, WHERE THEY CONNECT WITH
THE CIRCUIT BOARD ARE IN NUMERIC
ORDER FROM 1 TO 16.
THE CIRCUIT BOARD IS MARKED AT ONE
END OF THE BOARD-TO-CABLE
CONNECTION WITH THE NUMBER “1.”
CAREFULLY INSPECT THE CIRCUIT
BOARD TO LOCATE THE NUMBER 1
WIRE OF THE RIBBON CABLE.

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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 Pull the 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 solvent, clean the surface of the
control box lid. Allow the surface to dry.
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.
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.
GROUND CONTROLS