Parts and Service Manual Supplement
Contents
1. TOP OF CONTROL BOX WH WH WH BK 16 WH WH 27 1 1 TB GND BK WH mag M lt WH WH BK pog WH J ren WH 60 WH P2 13 PKWH TB 27 13 WH paz 12 WH I 8 E peg WH rer WH WHIBK_ poy OR BK TB 7 PP OR BK pi AT CONN7 8 PRESSURE TIME DELAY TB 7 WH LOAD TB 27 WH MIHI WH 3 J n un tps 8 8 8 mwa ____ A za O TB 27 WH WH TIME DELAY OO Hel O WH_ PRESSURE 18 9 _ BUBK 08 TIME DELAY 9815884 lt BUBK PLAT CONNS paso WH 80 8 8 BUBK SECONDARY q B 3 q 49 BUTTON A oo TB25 VH 5 B 7 78 22 W4 lt RD BK PLAT CONN 11 ET WH ALARM 88 8 J RDK PRIMARY OO fe O Q BUTTON LEVEL CONN 3 WH 8 8 fe 8 8 Bic P3 10 BL 88 HH2. I TB 7 Nur z 2 30 86 TB 5 9 S ___ m 5 X c k b Tes bie 4 co A J eza 87 85 TB 23 78 14 5 ao 86 30 86 30 86 TB 12 TB 12 TB 12 is f E es c 30 2 5 2 8 m Leza le des lez les 18 XL m 30 86 a O O O gt 5 2 ka lsz bs P z4 m 8 z 3 z TB 20 TB 22 TB 24 3 dba es e 0 10 g 5 e e m _ 8 gt 644 644 et M TB 27 15 4 lt 1 TB 13 P3 24 amp co 3 g ie 30 86 30 86 30 86 9 25 8 5 m m 3 3 d EAS 5 19 m Td a m T 5 87 85 7 I 85 Z bza Nu 65 pes P2 6 2 7 P2 18 g R 3 8 5 8 8 g J 5 EX 5 iex iE EX 5 m PX m PX 5 PX m 3 P2 22 P2 28 P2 31 2 9 m 5 Di P2 30 x So TB 0 i i e e e e e GROUND CONTROLS ES7181B Genie TEREX COMPANY Part No 104980 TMZ 34 19 35 Service Information Electrical Schematic Models with H
3. Part 104980 TEREX COMPANY EK R10 87A R13 86 R15 87 R19 86 R21 87A R20 86 R20 87A R21 86 R19 87A P3 25 P2 8 R15 86 P2 14 R16 86 R13 30 R12 30 PLAT CONN 9 R16 87 R17 30 KEY SWITCH PLAT CONN 5 KEY SWITCH RR OUTRIGGER BUTTON LR OUTRIGGER BUTTON RF OUTRIGGER BUTTON LF OUTRIGGER BUTTON AUTO LEVEL BUTTON PLAT CONN 4 R11 86 PLAT CONN 6 R11 87A PLAT CONN 3 R14 30 COIL TIME DELAY LOAD P2 31 P2 23 P2 22 TIME DELAY P2 30 PLAT CONN 12 POWER CONN 3 R20 85 NOTE DIODES ARE 2 AMP UNLESS OTHERWISE MARKED TMZ 34 19 31 Service Information November 2005 Wiring Diagram Ground Controls Models with Hydraulic Outriggers REVA Part3 of 4 PLAT CONN 1 gt TBi4 SNBK R21 30 ON TB 17 PLAT CONN 2 TB 16 WH _ ALARM w HORN AUTO EMERGENCY LEVEL Fer STOP n A RD CIRCUIT BREAKER 2 WH R22 87A RR CE PRIMARY JIB OUTRIGGER RF OUTRIGGER im UP T maogo RBBK m RD GN GNBK
4. DECALS BEFORE SERIAL NUMBER T3400 001 REVA 28161 37145 62066 97777 Ground Controls SI Shading indicates Side that the decal is hidden from view 37145 E 37145 28161 FEES 97847 72899 252 m 27564 3 97778 48734 Serial Label mo ___ 47230 __ B i 28161 52557 s Safety Tape 35579 or 48719 ye 28236 Safety Tape 28176 48726 97846 52475 SS 0 or 72908 44248 52075 NAT s Or 62066 S 40434 Safety Tape 28174 or 28235 lt 40434 27564 gt Safety Tape 28175 37145 28164 28161 28171 28157 e 31060 sa Power afety Tape non Unit Side 62707 72908 52475 Safety 2817407 43658 52475 52495 52496 Tape 28235 44980 TEREX COMPANY 6 TMZ 34 19 Part No 104980 November 2005 Parts Information REVA DECALS BEFORE SERIAL NUMBER T3400 001 ltem Part No Description Quantity This Figure 24 48727 Danger Battery Charger Safety 4 1 25 48733 Danger Tip over batteries nemen nennen nnns 1 26 48734 Notice Battery Connection Diagram 4 1 27 49918 Notice Material Lifting Operation 1 28 52008 Danger General Safety Ground 1 29 52475 Label Transport Tie down 4 30 52495 Notice Manual Lowering Instructions 1 31 52496 Notice Manual Rotation Instructions eenen 1 32 52557 Label Parking Brake mechanical CE 1 33
5. e 914 9 7520 TB 23 Le oes gt TB 27 z 1 3 24 m 23 im ov 9 xz h P3 25 5 TB 29 2 P2 8 P2 10 P2 14 5 o z 5 lt 5 Bex six E 2 REX 5 E 9 lt g E m lt 3 5 2 22 P2 23 pat E gt 39 618 i i af e e GROUND CONTROLS TEREX COMPANY REVA ES7180B 38 TMZ 34 19 Part No 104980 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 465 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 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 431 183 581 102
6. memes 32 73723 Receptacle Connector 4 pin 4 way Flanged models with manual outriggers 1 83130 Terminal P in 16 18 Gauge 60443 Receptacle Lock 4 way 14 18 Gauge emen 33 96452 CIICUIEBTeaker ZA ot tet Eee hoe cti eth ee o Re P e bd 1 This list continues on the next page Genie TEREX COMPANY Part No 104980 TMZ 34 19 21 Parts Information November 2005 GROUND CONTROLS REVA Models With Manual Outriggers 13 696 8 Genie TEREX COMPANY 22 TMZ 34 19 Part No 104980 November 2005 Parts Information REVA GROUND CONTROLS ltem Part No Description Quantity This Figure 34 104999 Receptacle Connector Assembly 35 way Black 1 104873 Receptacle Connector 35 Position 35 104874 Receptacle Connector 3 Position Flanged 1 104875 Terminal Pin 12 14 Gauge 36 23405 Nutsert 10 32 models with hydraulic outriggers 8 models with manual 10 37 49819 Screw PHPM 10 32 x 0 5 inch GR 2 nn 12 38 49378 Screw HHC M8 1 25 x 16 mm GR 8 8 before serial number T3400 001 4 23057 Screw HHC 8 1 25 x 20 mm GR
7. t e ite Re iut 23 96009 R bb r Washer x noce R O en erbe b 1 24 104870 Push Button Momentary models with hydraulic outriggers shown 12 models with manual 5 011 4 7 25 11803 Screw RHSM 6 32 x 1 inch models with hydraulic outriggers shown 2 models with manual 5 3 26 99084 Time Delay Module models with hydraulic outriggers 1 27 104876 Time Delay Mod le murerne 2 28 66812 Push Button Red Mushroom Head 1 66817 Base Push Button includes 1 contact nsn 66818 N C CONC is 29 104714 Relay 24V DC models with hydraulic outriggers shown 22 models with manual outriggers mnes 17 30 104879 Relay Holder Bracket Upper models with hydraulic outriggers 2 models with manual 5 n emnes 1 31 104878 Relay Mount Bracket Upper models with hydraulic 2 models with manual outriggers 4 1 32 73733 Receptacle Connector 12 way Flanged models with hydraulic outriggers 1 83130 Terminal Pin 16 18 Gauge us 54255 Receptacle Lock 12 way 14 18
8. 1 8 28176 Notice Missing tres Dres 1 9 28235 Label Power to Platform 115V AC 2 10 28236 Warning Failure To Read 1 11 31060 Danger Do Not Alter Limit Switch 1 12 35579 Notice Max Cap Hook 500 lbs 227 kg 1 13 37052 Notice Max 500 165 227 kg 1 14 37145 Label Manual Lowering enne nennen nennen nnns 4 15 40434 kabel Eanyard Anchorage c tec tere epe eed eens 2 16 43658 Notice Power to Battery Charger 230V AC l emen 1 17 44248 Notice Max Cap 440 lbs 200 kg 1 18 44980 Notice Power to Battery Charger 115V AC 1 19 44981 Labels AirLine to uc a c ted nC hoe Bb pe n n e tege 2 20 44986 Notice Side Force 90 Ibs 400 1 21 48719 Danger General Safety Platform eee 1 22 48723 Label Parking Brake hydraulic ANSI amp CSA 1 This list continues on the next page TEREX COMPANY Part No 104980 TMZ 34 19 9 Parts Information November 2005 DECALS AFTER SERIAL NUMBER T3499 769 REVA 28161 37145 Note Optional hydr
9. REVA 28161 37145 Note Optional hydraulic 65307 97777 outriggers have two each 62066 37145 of decal 28161 Ground 97047 Shading indicates Controls ek that the decal is hidden from view Side 72971 49918 37145 28161 72899 97778 or 97814 52008 27564 48733 Serial Label u 62719 48723 or penl 62719 52557 OF Oy 4 28161 35579 or 62722 jn S Safety Tape 48727 48719 Safety Tape 28236 48726 28176 97846 52475 i 72897 or 72908 37052 62707 52475 E or 44248 sns Tm 44986 62066 or 65309 40434 72971 Safety Tape 44981 RZ or 65056 28174 2750 9 28235 0 40434 52496 EL a Safety Tape 28175 gt gt 37145 A gt n 28161 jo 25 aa un 44981 or FON 2 65056 Power 31060 Unit Side 28157 62707 72897 Safet Safety 2817407 43658 or 0r82366 Tape 52475 65303 0772908 52475 lape 28235 41980 Genie 12 TEREX COMPANY TMZ 34 19 Part No 104980 November 2005 Parts Information REVA DECALS AFTER SERIAL NUMBER T3499 769 ltem Part No Description Quantity This Figure 46 97778 Ground Control En aes uh 1 47 97814 Ground Control Panel models with hydraulic
10. d BATT m 82 87 85 2 5 z 7 gt lt A O g S 30 86 L m 30 86 1K OHM m 2 Viv 38 5 r __ 6 G BLU 8 2 TB 38 m 2 A z 8 m 87 85 MOTOR 5 ba mr 85 2 1K OHM e 3 1 Io 0 e o 51V 83V GROUND CONTROLS G 36 TEREX COMPANY enie TMZ 34 19 PartNo 104980 November 2005 Service Information Electrical Schematic REVA Models with Hydraulic Outriggers Part2 of 3 BLUE PLATFORM CONTROLS WHITE TB 3 WHITE 8 E E 9 gt 3 5 x B E PLAT 6 PLAT 7 PLAT 9 PA 2 i TB 18 c e 1 TB 26 E g dn El 8 1 8 g LN g E TB 3 e 86 21 8 318vN3 HADOIHLNO 5 SL I 3 g 8 g HOLIMS an E FL _ gol 85 e e hd aiviod HOLIMS AVG BIS b e 1 eu 13 31 31 HH A P2 30 Y Y Y TB 87 TB 9 i i mat tus TB 11 TB 19 gt zt gl er w
11. al WH 100uF 5 TE R 5 p2 13 BKWH 5 TR pp H BRM WH WH 5 5 2 ET 54V 8 B of TB 37 H 4_WH ZEENER o m TES WH TB GND E gt lt 2 BD TB GND 5 R10 30 WH BK GNBK 3 3V ZEENER p1 17 B A p HSHH 2 po CES Tm GN WH LEVEL WH eid TIME DELAY Tesh amp B 8 on SLEEP ou 88 TB 26 gt WH O O lt TB 8 Q 0 WH 95 o Q B 1B 21 WH Q 2 SE Bg B PRESSURE BL BK Q Q TIME DELAY _ WH TB 16 DD 900 fiere C 2 78 15 WH 8 8 1B 37 WH WH Q Q Q Q Q TEE 8 5 d 8 WH WH 5 COIL AE 8 8 HEJ 8 8 TIME DELAY LEVEL CONN 7 BL 0 BE 00 WH_ PRESSURE QO d oo TIME DELAY 8588855 T8 30 WH BUBK 22 _ 88 HH 8 8 J BUBK SECONDARY BUTTON ROTATE BUTTON PP 2 08 HH 8 8 qB g5 WH TB 5 RD 8 9 E 8 3 pao WH BK TB GND 10 upBurroN 8 8 CONN 11 QQ ns Qo RD BK 20 _RD BK PRIMARY TB GND WH BUTTON nd sy 35 RELAY TERMINAL 85 86 LAYOUT 87A 87 104990A G 30 TEREX COMPANY enie TMZ 34 19 PartNo 104980 November 2005 Service Information REVA R10 87 R17 87 P2 10 P3 24 R10 86 R
12. orek w ja M wi Reg LR LF SECONDARY ROTATE OUTRIGGER OUTRIGGER DOWN 1890 RD WHIBK RD BUBK wH WH RD BK w RD gt HE 1 86 P BUBK TB 12 ORBK TB 10 EK PNE T BK s o O s ey o O LOAD toan LOAD PRESSURE COIL uis A AUTO TS RELIEF DELAY LEVEL mas TIME DELAY TIME DELAY TIME DELAY 917 85 R18 30 2 MH Reg 4 R22 86 HBK 104990A Genie 32 TEREX COMPANY TMZ 34 19 Part No 104980 November 2005 Service Information Wiring Diagram Ground Controls REVA Models with Hydraulic Outriggers Part4 of 4 R14 86 WH R13 87 00000000 zO P1 3 POWER CONN 1 1 9 0000000 fis CONNECTOR BN 1 09000000 TB GND 7 LO Ox 23 PIN RD adc CIRCUIT BREAKER 1 RD EMERGENCY 2 1 2 STOP MM TB 38 CIRCUIT POWER BREAKER CONNECTOR 18 BKIWH _ 14 GN 18 25 si sk TB GND 31 TB 0 18 14 _ GNWH 38 22 BK TB 12 OR WH 32 22 BK WH 30 23 BK TB 16 A EK Z N 21 25 Te29 x B 28 BK 180 OF P2 TB 27 2400000099000 357 CONNECTOR 13 00000000 23 P3 p 119990099909
13. 1 48 97846 Notice Operating Instructions Platform nn 1 49 97847 Notice Operating Instructions 222 emm 1 Genie TEREX COMPANY Part No 104980 TMZ 34 19 13 Parts Information November 2005 Platform Controls 8 8 REVA 21 20 5 2 OW 14 Genie TEREX COMPANY 14 TMZ 34 19 Part 104980 November 2005 Parts Information REVA PLATFORM CONTROLS Item Part No Description Quantity This Figure 104858 Platform Control Box Assembly Complete mn 104859 Platform Control Cable Assembly 477 inches 104749 Platform Connector enn nnn 1 6090 Screw HHC 1 4 20 x 0 75 inch GR suited A 3 2 66866 ystick waw tier t Ee e a die 3 3 6889 Low Profile Nylock Nut 4 20 3 4 49820 Screw PHPM 6 32 0 5 inch GR uu tere 4 5 62819 Keeper Over Center Latch sine 1 6 12344 Nylock Nut 6 32 ette ree n bed tec OVE de 4 7 104865 Platform Control Dai err ind 1 8 69773 Weatherstripping Ribbed 1010 000 34 inches 9 104629 Platform Control iscritte rper o EE Ded 1 10 49819 Screw
14. seem 1 73713 Terminal Pin 16 18 Gauge us 54255 Receptacle Lock 12 way 14 18 Gauge rn 15 49820 Screw 6 32 inch GR 6 16 104493 Relay Holder Bracket Lower 1 This list continues on the next page TEREX COMPANY Part No 104980 TMZ 34 19 19 November 2005 Parts Information REVA GROUND CONTROLS Models With Manual Outriggers Part No 104980 TMZ 34 19 20 November 2005 Parts Information REVA GROUND CONTROLS ltem Part No Description Quantity This Figure 17 104706 Relay Mount Bracket Upper 1 1 nennen nnns 1 18 104993 Relay Mount Bracket models with manual outriggers 1 19 104491 Relay Holder Bracket Upper models with manual outriggers 1 20 45383 Warble Tone Alarm 5 30V DC includes retainer nut 1 72326 NUE Re 21 104649 Ground Control Box Lid models with hydraulic outriggers shown 1 104868 Ground Control Box Lid models with manual 22 96008 Key Switch 3 Position includes 1 pair of keys 1 83093 Key single iode teer pepe 37947 Key Package
15. Oy 4 28161 35579 or 62722 il S Safety Tape 48727 48719 Safety Tape 28236 48726 28176 97846 52475 i 72897 or 72908 62707 52475 KI or 44248 ROL 44986 62066 or 65309 40434 72971 Safety Tape 44981 A or 65056 28174 27564 9 28235 6 x 40434 52496 EL a Safety Tape 28175 gt gt 37145 A gt n 28161 jq aa un 44981 or FON 65056 Power 31060 Unit Side 28157 62707 72897 Safet Safety 281740r 43658 or or 82366 Tape 52475 65303 0772908 52475 lape 28235 41980 Genie TEREX COMPANY TMZ 34 19 PartNo 104980 November 2005 Parts Information rsFts ss aa REVA DECALS AFTER SERIAL NUMBER T3499 769 ltem Part No Description Quantity This Figure 72903 Decal Kit Safety Instructional includes items 1 3 5 7 8 10 11 14 15 21 23 27 28 30 33 34 37 38 40 43 44 and 48 49 1 27564 Danger Electrocution Hazard 2 2 28157 kabele DEXON M 1 28161 Warning Crushing Hazard models with manual 5 4 models with hydraulic 12 4 28164 Notice Hazardous Materials cee ete eee cee memes 1 5 28171 Label N0 5 MOKING 1 6 28174 Label Power to Platform 230V AC 2 7 28175 Caution 55
16. 1 27 49918 Notice Material Lifting Operation 1 28 52008 Danger General Safety Ground 1 29 52475 Label Transport Tie down 4 30 52496 Notice Manual Rotation Instructions eem eene 1 31 52557 Label Parking Brake mechanical CE 1 32 62066 Cusmelic TDi cde st lad 2 33 62707 Warning Towing Hazard xit ee M u RE 2 34 62719 kabel 2 35 62722 Notice Cap Hook 440 Ibs 200 kg VV 1 36 65056 Label Water Line to Platform BAR ka ak aa 2 37 65303 Notice Manual Lowering InstructionS 1 38 65307 Caution Forklift Pockets irii ai 2 39 65309 Notice Side Force 90 Ibs f 400a d os eie ain nid GA 1 40 72899 Warning Transport Instructions 120 S E Wa udus 1 41 72897 Notice Tire Specifications ANSI amp CSA nennen 2 42 72908 Notice Tire Specifications CE 2 43 72971 Label Transport to Canada aede ete ete are e reb ice bro 2 44 82366 Label Chevron RYKON site u AA AA RAR Gite a ev aia te 1 45 97777 Platform Control Panel 1 This list continues on the next page TEREX COMPANY Part No 104980 TMZ 34 19 11 Parts Information November 2005 DECALS AFTER SERIAL NUMBER T3499 769
17. 76480 Terminal Block Wieland End Plate eee meme 1 76478 Terminal Block Wieland 4 hole n nrnna 76481 Terminal Block Wieland End Block 24 19251 plice 18 22 Gauge wa ai ses e iren a ha noD aes 3 25 13083 IBID mA ai yy a ae 5 26 99195 Resistor 5 6 Onm 2W eee e 2 27 104335 Diode Zeener 5 1V icr tenete cepe ette Wee eles 1 Genie TEREX COMPANY Part No 104980 TMZ 34 19 17 Parts Information November 2005 Ground Controls REVA lt A m i Models With Manual Outriggers 18 TMZ 34 19 Part No 104980 November 2005 Parts Information REVA GROUND CONTROLS Item Part No Description Quantity This Figure 104857 Ground Control Box Assembly models with manual outriggers before serial number TZ3400 1 Complete seem 104856 Ground Control Box Assembly models with hydraulic and manual outriggers after serial number T3499 796 Complete 104334 gt Zeener 3 3V DC LW 1 104335 Diode Zeener 5 1V DC IWUR 1 104880 Capacitor 100 MF 50V A tp e beta dece e ble o mes 1 1 71874 Carriage Bolt 3 16 24 x 1 25 inches GR 2 2 2 104877 Terminal Rail models with hydraulic outrig
18. 8 8 after serial number T3499 769 39 49408 Lock Washer MS a niewa WA I 4 40 25368 Nylock Nut M8 before serial number 3400 001 0 00022 4 22571 Nut M8 after serial number T3499 769 eene nnns Genie TEREX COMPANY Part No 104980 TMZ 34 19 23 Service Information November 2005 Schematics Observe and Obey Troubleshooting and 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 Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipmentare available and ready for use TEREX CON 24 TMZ 34 19 REVA About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Electrocution hazard Contact with AWARNING 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 slo
19. 88 m 0 QQ 1 24 22 upsurron 5 8 8 8 100uF PLAT CONN 10 Q Q nm O a K GN TB GND BK 8 8 IE 55 Tg 21 WH wej O RELAY TERMINAL 85 86 LAYOUT 87A 87 104991A Genie TEREX COMPANY 26 TMZ 34 19 Part No 104980 November 2005 Service Information swt Wiring Diagram Ground Controls REVA Models with Manual Outriggers Part2 of 4 1K 1K OHM n TB GND Te HH CT gt im R11 87 1 2 pe R11 87A Rios Q 2 gt Q DAC po CX R15 86 5 GN R17 87A bs 3 R16 86 p eu 16 87 C D T 3 R17 86 D 7 4 A C R15 87A P2 10 gt CQ 19 C el EH O gt OU Fee 4 2 F iz D O P2 8 24 16 BE 3 R10 86 C KO 4 R8 30 F C p je ene 3 4 1
20. WHITE RED TB P2 5 BLACK 51 3 S ZENER E m 5 6K a OHM a 8 ci BCI 2 FAULT TB P1 D ALARM gt x m 5 o m c m e PLAT 1 PLAT 2 PLAT 3 PLAT 5 ui amp PLATFORM TB 10 CHASSIS o P3 22 TB 9 Y i 5 e 2 3 5 STRUCTURE RETRACTED LIMIT SWITCHES xg i SHOWN IN STOWED POSITION a 5 P3 10 m P M G P3 18 4 E iT S 2 1 17 5 25 5 o 30 86 20 O m 2 9 FUSE ze 222 SE 7 AMP 5 0 5 VDC 71 5 15 BZ SIGNAL 87 185 1 2 c 85 1 Qe gt 8 O TB 2 7 1 293530 B T2 e 9 2 p B 8 3 2 ch 250 AMP 2 30 86 m 86 m SZ 2 o om MOTOR 5 EE a m So CONTROLLER 5 82 bra Je gs m 85 gt cr 3 2 PE d 4 8 Q LS 3 ET m 24 E 9 V RES m BATT y 82 B 2 86 e I 5 gt 95 Ai gt VS 5 5 FB m 9 bza 87 85 R o MOTOR 9 33V e e oe e e 34 enie TMZ 34 19 Part No 104980 November 2005 Service Information Electrical Schematic REVA Models with Manual Outriggers Part 2 of 2 NMOG DR dn ET PLATFORM CONTROLS TB P5 TB P4 TB P6 31v10H AHVONO93S AHVWIHd air go mania 418 034 N33u5 ova PLAT 6 PLAT 7 PLAT 9 PLAT 8 PLAT 11 PLAT 10 PLAT 12 AHVNWIHd ar TB 11 AHVONOO3S dn
21. 00 2 WHITE 35 PIN 24 600000000000 35 BUBK _ R2 30 EO NNECTOR SAGE lt T 00 jo ol bo 12 29 5 BUBK nage 8 BLEK ror 2 E 4 97 BK 14 m UTU BL BK BM pia TB 10 BDWH __3 5486 GNWH Ree A BK 15 10 BL GN TB GND R1 30 2 96 30 BLWH vw Rg 87 Can R8 87A BK r BL__R2 86 16 WH 18 21 WH BK R3 87 TB GND WH WH J RENE NH R HORN BUTTON p WH BK BkwH 12287 TB 17 BL WHIBK KEY SWITCH TB GND TB GND ALARM R RD __ EMERGENCY STOP O O O O Y d SS LEVEL 290990 PLATFORM CONNECTOR S n 7 8 9 10 11 12 CONNECTOR 12 PIN 7 0000000 12 PIN O BL GN BK e 385 RD BK Buek 1514 R11 87 OREK BK TE GND TB 10 TB 13 _ __ 18 12 R19 30 920 30 TB 22 R21 30 104990A Genie TEREX COMPANY Part No 104980 TMZ 34 19 33 Service Information Electrical Schematic Models with Manual Outriggers Part 10f2 November 2005 REVA e T D PLATFORM CONTROLS 0 10K OHM 5 6K IN OHM
22. 10 32 x 0 5 inch GR 2 eene 4 11 23405 Nuts ft 10 32 wo a 4 12 23134 Battery Charge Indicator on E eren re o e Rae 1 13 104870 Push Button Momentary ins 7 14 104327 Potentiometer Assembly nnne nnns 1 15 66812 Push Button Red Mushroom Head 1 66817 Base Push Button includes 1 contact eene 66818 jMeMonni id as 16 45383 Alarm Warble Tone 5 30V DC includes retainer nut ss 1 72326 NutsRetainer aa tcr eee eec be B e a e e a e e ne epu bn 17 73415 Plug BOot AWAY iere te h aa Eee irae fred aea Ee ga ds tes eaae tes 1 18 6578 Cable T ICS a elt niin booten a h a vitu bea f Doc ER M c pads 18 19 60434 Grey Plug 12 way 14 18 Gauge 1 20 73714 Socket Terminal 16 18 Gauge enne enne nns 12 21 60435 Secondary nasa EE 1 22 96386 Wire Cable 18 12 Gauge ss 120 inches This list continues on the next page TEREX COMPANY Part 104980 TMZ 34 19 15 Parts Information November 2005 PLATFORM CONTROLS REVA 5 5 8 6 6 21 20 5 2 OW 14 Genie TEREX COMPANY 16 TMZ 34 19 Part 104980 November 2005 Parts Information REVA PLATFORM CONTROLS ltem Part No Description Quantity This Figure 23
23. 2 87 FUN 0 vison ROTATE BUTTON gt 1 27 C PEAT CONN 9 Mis 0 CX KEY nus Pas s 0 BE LEVEL CONN 1 9 C 3 4 i KEY SWITCH 7 Cj 3 lt PLAT CONN 6 UP BUTTON 6 ROTATE BUTTON 5 C 24 d coms DOWN BUTTON 7 q hs R6 87A tJ 3 C D SECONDARY BUTTON R9 30 gt C 2 4 PLAT CONN 3 3 3 VZEENER L A 1 27 ma P2 31 0 GT lt P2 22 COIL TIME DELAY LOAD P2 21 28 GND 27 C P2 30 TIME DELAY HORN o TM MEE CK LEVEL TS bnd Powe 2 5 104991A NOTE DIODES ARE 2 AMP UNLESS OTHERWISE MARKED Part No 104980 TMZ 34 19 27 Service Information Wiring Diagram Ground Controls November 2005 Models with Manual Outriggers REVA Part3 of 4 PLAT CONN 1 gt TB 10 PLATCONN2 _ __ me RE KEY WH _ ALARM SWITCH w HORN EMERGENCY 219 STOP 1 E n ROV CIRCUITBREAKER2 R16 30 POK m PRIMARY JIB w UP SECONDARY ROTATE DOWN RD Y WHIBK RD fm P J ua WHBK 5 TB GND S N O Q Loap toan PRESSURE COIL ui RELIEF DELAY 1486
24. 62066 Cosmetic Genie TMZ 34 19 2 34 62707 Warning Towing Hazard xit oett eere 2 35 62722 Notice Cap Hook 440 Ibs 200 kg VV 1 36 72897 Notice Tire Specification ANSI amp CSA 2 37 72899 Notice Transport Instructions 44 0 1 38 72908 Notice Tire specification CE 2 39 97711 Platform Control Panel cda i e e P de ace etae 1 40 97778 Ground Control P anel cien et eee e ee aen 1 41 97846 Notice Operating Instructions Platform nn 1 42 97847 Notice Operating Instructions Ground 1 Genie TEREX COMPANY Part No 104980 TMZ 34 19 7 Parts Information November 2005 Decals after serial number T3499 769 28161 37145 Note Optional hydraulic 65307 97777 outriggers have two each 62066 37145 of decal 28161 Ground 97047 Shading indicates Controls AR that the decal is hidden from view Side 72971 49918 37145 28161 72899 97778 or 97814 52008 27564 48733 Serial Label 4814 62719 48723 or penl 62719 52557 OF
25. 90 PLATFORM 7 8 9 10 11 12 CONNECTOR 0000000 12 PIN Ree OR BK _ TE GND R15 30 BUBK R BK 16 39 TB 11 WHEK R17 30 Genie Part No 104980 TEREX COMPANY TMZ 34 19 29 Service Information Models with Hydraulic Outriggers Part1of4 November 2005 Wiring Diagram Ground Controls REVA WH WH WH WH TOP OF B o gt CONTROL BOX 6 a 28 g 39 129 4 9 Zn w lt 22 6 Z m E WH zx DIT Ll TB 22 WH TB38 Tp PD R14 87 WH WH 8 8 amp PLAT CONN 7 OR EK R21 85 BK OR SE p2 7 WH BK WHIBK 55
26. Fax 31 183 581 566
27. OTATE BUTTON R7 86 R4 86 P3 18 P3 27 LEVEL CONN 5 P3 33 LEVEL CONN 12 LEVEL CONN 11 P3 LEVEL CONN 10 P3 32 R8 30 P3 3 LEVEL CONN 9 R22 85 R5 87A R8 86 UP BUTTON R1 86 DOWN BUTTON SECONDARY BUTTON R7 30 P3 21 P3 14 P3 23 P3 16 LEVEL CONN 6 15 LEVEL CONN 1 R7 87A TB 38 R7 87 R1 85 104990A 1K OHM Wiring Diagram Ground Controls Models with Hydraulic Outriggers 1K OHM L COs ho Part 2 of 4 TB GND b7 35 B p3 32 81 ba ba gt ng C 22 4 pi 2 GA P LO Q cze HH 0 LE EMG UH n GAG ee S CX 037 3 no C ERG GND Ce 5
28. Parts and Service Manual Supplement TMZ 34 19 Part 104980 Rev A November 2005 November 2005 Important Read understand and obey the safety rules and operating instructions in the TMZ 34 19 Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed parts and service information 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 subjectto 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 PO Box 97030 Redmond WA 98073 9730 USA www genieindustries com e mail techsup genieind com TEREX 2 TMZ 34 19 This P arts and Service Manual Supplement provides service parts information and electrical schematics for the recent
29. TIME DELAY TIME DELAY 913 85 914 30 2 MH 104991 Genie 28 TEREX COMPANY TMZ 34 19 Part No 104980 November 2005 Service Information REVA 5 O BN TB GND EE CIRCUIT BREAKER 1 RD Ly 1 2 O O POWER CONNECTOR R30 T amp 9 D 7 19 GN BK 25 17 GN 2 B P3 CONNECTOR 50909095090 23 BLACK 35 PIN 155969 12 2 9 U U 22 TB GND K s 19 TB 16 WH 18 Tg RD TB GND BK O SN LEVEL H 0 A 3 4 PIN O O R285 WH _ 104991A Wiring Diagram Ground Controls Models with Manual Outriggers Part 4 of 4 76 R8 87 BL R986 5 POWER CONN 1 RD 1 0000000 42 CONNECTOR 1 09000000 LO 23 PIN RD EMERGENCY 2 AREK STOP TB 28 CIRCUIT BREAKER 13 BK WH_ Rg 87A 14 GN 1815 sw BK 31 BK A BK 22 BK 23 51 ks 13 000000 CONNECTOR 1 000009990900 2 WHITE 35 PIN 10 _ 18 19 8 BUBK 7p 47 7 WHIBK 6 WH BUBK 30 R787a R1 86 R2 87 WH 1B8 GND WH 8 HORN BUTTON gt TB WH GNBK 18 1 ALARM TB 10 Bars KEY SWITCH R RD EMERGENCY STOP f 3 0000
30. aulic 65307 97777 outriggers have two each 62066 37145 of decal 28161 Ground 97047 7 Shading indicates Controls AR that the decal is hidden from view Side 72971 49918 37145 28161 72899 97778 or 97814 52008 27564 48733 Serial Label 48734 62719 48723 or penl 62719 52557 OF Oy 4 28161 35579 or 62722 jn S Safety Tape 48727 48719 Safety Tape 28236 48726 28176 97846 52475 ing 72897 or 72908 37052 62707 Sr 52475 E or 44248 sns Tm 44986 62066 or 65309 40434 72971 Safety Tape 44981 RZ or 65056 28174 2750 9 28235 0 40434 52496 EL a Safety Tape 28175 gt gt 37145 A gt n 28161 jo 25 aa un 44981 or FON 2 65056 Power 31060 Unit Side 28157 62707 72897 Safet Safety 281740r 43658 or 0r82366 Tape 52475 65303 0772908 52475 lape 28235 41980 Genie 10 TEREX COMPANY TMZ 34 19 Part No 104980 November 2005 Parts Information ss ssh Pr Ss ssuam ssa REV DECALS AFTER SERIAL NUMBER T3499 769 ltem Part No Description Quantity This Figure 23 48726 Notice Battery Charger Operating Instructions 1 24 48727 Danger Battery Charger S 1 25 48733 Danger Tip over batteries 1 26 48734 Battery Connection Diagram mene nennen nennen nnns
31. ber 2005 Decals REV A before serial number T3400 001 28161 37145 62066 97777 Ground Controls E Shading indicates Side that the decal is hidden from view 37145 E 37145 28161 FEES 97847 72899 mcs m 27564 97778 48734 Serial Label mo ___ 487230rT B sl 52557 m Safety Tape 35579 or 48719 ye 28236 Safety Tape 28176 48726 97846 52475 SS 0 or 72908 44248 52475 L Or 62066 X s 40434 Safety Tape 28174 or 28235 lt 40434 27564 gt Safety Tape 28175 37145 28164 28161 28171 28157 e 31060 sa Power afety aoi Tape 570 Unit Side 62707 72908 52475 Safety 2817407 43658 52475 52495 52496 Tape 28235 44980 Genie TEREX COMPANY 4 TMZ 34 19 Part No 104980 November 2005 Parts Information REV DECALS ltem Part No Description Quantity This Figure 48729 Decal Kit Safety Instructional includes items 1 5 7 8 10 11 15 16 21 23 31 37 41 49 _ 1 27564 Danger Electrocution Hazard eee nennen enne nennen 2 2 28157 Labels DEXON i eee ate ei dem i rom bp 1 3 28161 Warning Crushing Hazard 4 4 28164 Notice Hazardous Materials eeen 1 5 28171 Label No Smokin
32. g ee dan 1 6 28174 Label Power to Platform 230V AC 2 7 28175 Caution Compartment Access sien 1 8 28176 Notic Missing Manuals en wh iG ae iia 1 9 28235 Label Power to Platform 115V AC 2 10 28236 Warning Failure To Read 1 11 31060 Danger Do Not Alter Limit Switch 1 12 35579 Notice Max Cap Hook 500 lbs 227 0 1 13 37051 Notice Side Force 150 Ibs 667 ANSI amp CSA 1 14 37052 Notice Max Cap 500 Ibs 227 kg 1 15 37145 Label iManual oWerlng i p sa ceo cereo ret 4 16 40434 Label tob t eben Pe e dr Een 2 17 44248 Notice Max Cap 440 lbs 200 kg 1 18 43658 Notice Power to Battery Charger 230V nene 1 19 44980 Notice Power to Battery Charger 115V AC 1 20 44986 Notice Side Force 90 16 400N CE VU 1 21 48719 Danger General Safety Platform 1 22 48723 Label Parking Brake hydraulic ANSI amp CSA 1 23 48726 Notice Battery Charger Operating Instructions 0200 0010110 11 1 This list continues on the next page TEREX COMPANY Part No 104980 TMZ 34 19 5 Parts Information November 2005
33. gers shown 1 104884 Terminal Rail models with manual lt 5365 Nylock Nut 10224 5 2 ee ree Essere 2 4 19251 Butt Splice 18 22 Gauge models with hydraulic outriggers shown 24 models with manual 5 nennen 15 5 104333 Resistor Lk ONM AW ERE Pe ETE 3 6 13083 Diode 2A models with hydraulic outriggers shown 54 models with manual outriggers nennen 35 7 45782 Dioden GAR E 2 8 6687 Butt S plica 18 22 Gauge esce u 1 9 104650 Ground Control Box models with hydraulic outriggers 5 1 104860 Ground Control Box models with manual outriggers 10 88288 Screw PHP M 4X 3 8 iui deerit et a HERR 12 11 104994 Receptacle Connector Assembly 23 emen 1 104871 Receptacle Connector 23 Position Flanged nn ra 12 104998 Receptacle Connector Assembly 35 way White 1 104872 Receptacle Connector 35 Position mee 13 12344 Nylock Nut 6 32 au ada BA ec reme velba e er kg e E DRE E CEPR ARE de 14 73730 Connector Receptacle 12 way Flanged models with hydraulic outriggers shown
34. ly released TMZ 34 19 Control S ystem which are not included in your parts or service manuals Please add this parts information and electrical schematics to the parts and service manuals for your machine Copyright O 1998 by Genie Industries 104980 Rev A November 2005 First Edition First Printing Genie is a registered trademark of Genie Industries in the USA and many other countries TMZ is a trademark of Genie Industries 6 Printed on recycled paper Printed in U S A Part No 104980 November 2005 Introduction Section 1 Rev Section 2 Rev Table of Contents ImportantinformaliQnus eere ee eoe eae geld ete ed men 2 Service Parts Decals asnata Ao aa c A 4 Platform Control p a deme le eroe P Sa aaa a Aa Pneus 10 GLOURd CONTOS LR Re Ed er ode ve aaa of 14 Schematics Intro DUCTION suu s ui aera 20 Wiring Diagram Platform Controls 21 Wiring Diagrams Ground Controls Models with Manual Outriggers 22 Wiring Diagrams Ground Controls Models with Hydraulic Outriggers 2 mem 26 Electrical S chematic Models with Manual Outriggers sse 30 Electrical S chematic Models with Hydraulic Outriggers 2 32 Genie PartNo 104980 TEREX COMPANY TMZ 34 19 3 Parts Information Novem
35. s ss s 2 30 86 30 86 30 86 30 86 30 86 1 S 5 2 c L 3 L 5 z 5 Z Z 3 EZ CZ 2 9 H 5 P3 3 P3 32 23 4 23 33 J z J 1 2 ka Bib ib __ 87 85 2 87 85 87 85 __ 87 85 87 85 On 49 OQ Og gt 5 2 9 9 y P2 7 z rs e SES Sx SEX YU m R iid z E E 3 Bo g o 8 a 8 5 8 5 8 2 5 P3 14 m P3 21 5 P3 16 m P3 23 m m 5 s 2 5 8 B 9 z gt 3 avoit o GROUND CONTROLS 8 8 g 3 8 3 3 E E B LVL 4 LVL 2 LVL 9 LVL 10 LVL 11 LvL 12 LVL 1 AUTO LEVEL MODULE ES7180B Genie TEREX COMPANY Part No 104980 TMZ 34 19 37 Service Information November 2005 Electrical Schematic Models with Hydraulic Outriggers Part 3 of 3 PLATFORM CONTROLS er 1 TB 6 RED PED e 5 s gt lt 3 2 E m E 5 g g 5 m 2 PLAT 8 PLAT 11 PLAT 10 PLAT 12 AHYWIHd air AHVONO93S TB 36 TB 36 A ML 54 o Q on 9 99 30 86 30 86 LONN 3noor H 4110119 13r1 El J E EL LI q a 87 TB 30 TB 32 lt AV13q INIL
36. wly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Identity Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Part No 104980 November 2005 Service Information Wiring Diagram Platform Controls REVA BL WH ALARM i EMERGENCY BD STOP BATTERY CHARGE INDICATOR CABLE 2 ALARM BK CABLE 11 RD BK TB RD JIB PRIMARY OHM UP CABLE 10 GN RD WH 1B 3 RD RD BK RD WH E BL CABLES SECONDARY ROTATE DOWN SPEED CONTROL WH WH TB 5 CABLE 8 CABLE g WHEK GNIBK CABLE3 WHIBK RD RD SPEED CONTROL CABLE 6 fa CABLE 4 WH BK HORN BUTTON WH 2 BK__ BATTERY INDICATOR ALARM ALARM CABLE 12 UP BUTTON WH ROTATE BUTTON WH BK DOWN BUTTON WH CABLE 7 RD PRIMARY BUTTON 104992A Genie TEREX COMPANY Part No 104980 TMZ 34 19 25 Service Information November 2005 m rc Y sr Wiring Diagram Ground Controls Models with Manual Outriggers REVA Part1 of 4
37. ydraulic Outriggers Part 1 of 3 BL November 2005 REVA e E d D 015 0 10K OHM 5 6K OHM WH HX RD IB BK 5 1 a ZENER e m o gt 5 6K OHM 9 9 d 2 FAULT 678 2 5 ALARM 8 E gt 4 e m e PLATA PLAT 2 PLAT 3 PLAT 4 PLAT 5 JA 2 u A PLATFORM 17 KEY SWITCH e CHASSIS e Y o P3 22 TB 16 TB 16 5 9 e 2 TB 16 STRUCTURE RETRACTED LIMIT SWITCHES a SHOWN IN STOWED POSITION e 5 1 AK E o P3 10 m ej e e P3 18 9 3 58 x 3 P1 17 S 5 R gt ao ae A z8 2 9 FUSE waj 3 d 7 AMP 0 5 VDC 1K OHM 5 a SIGNAL 7A 87 85 A Su P1 2 2 1 3 TB 1 5 9 5 9 4 9 da 2 TB 2 S Ou e TB 15 o o 2 GA Og 5 amp 250 J z 86 5 86 m 30 86 52 MOTOR 5 zi 8 Ed Sa m Fai CONTROLLER 4 6 gt 85 m BzA 87 85 gt 87 85 gt O E E gt 2 e TB 8 4 3 69 e 3 30 86 NR LVL 7 LVL 5 P3 27 a 24
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