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Service Manual - Genie Industries

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1. N M L K J D C B A PLATFORM LEVEL SLAVE CYLINDER 1 pue SECONDARY BOOM PRIMARY BOOM EXTENSION JIB BOOM 2 pas TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI 4 lt 4 A 5 9 CU IN REV TEENS SEED 58 COEM zo ED MASTER n L MIE M IE i He o MIE a L LS L Los 3000 PSI 3000 PSI 2500 PSI 3000 PSI 2500 PSI B 1 51 31 3 1 3 1 3 1 T3 4 cda PEERS e al HEX 8 GPM 5 P1 Eccl E _ 3200 PSI EE DL 4 r t D rom sonal mter LH DE p E 1 0 022 inch M D E M EU MEL from serial number OX 4 1600 PSI 1400 PSI 1800 PSI 6 3000 PSI 1500 PSI Ue HE E ER 3 1 3 1 TZ Li e o
2. BRN 2 GROUND BLU WHT 3 u TE CFE 2 WHT gt BLU RED 3 Fr PPS 8 DRIVE ENABLE ORG RED 3 RED 5 BLK 5 LIMIT SWITCH 1 m DRIVE ENABLE 5 x 5 p 8 WHT 1 5 WHT 30 EH n Yo 4 DRIVE FORWARD zie 2 8 8 WHT BLK 31 EH a 4 g IHT BLKA gt DRIVE REVERSE gt 92 m SE WHT RED 1 WHT RED 32 CH a 5 4 BRAKE RELEASE 5 2 eee eee nmm a BT EE c a1 gt 5 9 TRAVELALARM dents 1 OPTION 1 5 vd 1 2 3 B BLU 1 BLU 36 MH _ 2 STEER LEFT BLU BLK 1 BLU BLK 37 MH E j2 STEER RIGHT oO aies 4 I os D RED WHT 1 4 MOTOR STROKE MOTOR STROKE E B 9 E 2 axe WHT P WHT 3 BLK BLK 8 WHT 4 9RG1 4 T fe 8 806 7 LIMIT SWITCHES d 5 2 2 5 20 5 gt 9 8 c o 8 WHT RED 3 am WHT RED
3. SPARE WIRES GRN WHT 45 1 9 RED JIB gt 9 999 ORG RED 3 gt Ce ORG RED 42 1 EN 25 2 4 BEBBUCI LABEL DESCRIPTION 0 2 EMERGENCY STOP BUTTON HORN BUTTON C DP1 DRIVE CONTROLLER O BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY SWITCH TS2 START SWITCH 2j CHOKE SWITCH 5 lt gt TS4 FUEL SELECT SWITCH 9 90959 TS5 RPM SWITCH 3 N gt e E 5 TS6 TURNTABLE ROTATE SWITCH TS7 SECONDARY BOOM UP DOWN SWITCH 2 TS8 PRIMARY BOOM UP DOWN SWITCH TS9 EXTEND RETRACT SWITCH 5 TS10 PLATFORM LEVEL SWITCH D n g a PLATFORM ROTATE SWITCH a d 7812 UP DOWN SWITCH S13 DRIVE HIGH LOW OUTPUT SWITCH TS14 DRIVE ENABLE SWITCH 4 R2 250 OHM RESISTER x Rly L1 DRIVE ENABLE LIGHT 1 2 20 o O 49 E 5 0 9 112 13 1415 16 7 d f N 217 On o9 LA DP1 5 J E m 4 a HORSE POWER LIMITER a 2
4. a 2 d o 2 Q OF 49 5 SPARE WIRES WHT GRN WHT 1 ORG RED 1 a H OC ORG BLK 1 gt GRN WHT 3 i p RED WHT 3 z TS 5 Nat e 8 O Occ O gt Q lt C zd 3 gt 5 z 4 5 pO gt 8 I 8 a D i e 8 0018 4 LABEL DESCRIPTION 100 Ja amp P2 EMERGENCY STOP BUTTON d HORN BUTTON DP1 DRIVE CONTROLLER 1 FUNCTION SPEED CONTROLLER o TS1 AUXILIARY TOGGLE SWITCH v RED A x A 2 TS2 START TOGGLE SWITCH 153 CHOKE TOGGLE SWITCH 5 154 FUEL SELECT TOGGLE SWITCH m o 2 3 8 TS5 RPM TOGGLE SWITCH 5 2 TS6 TURNTABLE ROTATE TOGGLE SWITCH TS7 SECONDARY BOOM UP DOWN TOGGLE SWITCH i 4 TS8 PRIMARY BOOM UP DOWN TOGGLE SWITCH e N TS9 EXTEND RETRACT TOGGLE SWITCH BRN TS10 PLATFORM LEVEL TOGGLE SWITCH 6 TS11 PLATFORM R
5. NH8 SPARE WIRES GRNWHT 1 ORG RED 1 ORG BLK 1 BLU RED 1 BLUMWHT 1 GRNMHT 3 RED WHT 3 LABEL DESCRIPTION 2 EMERGENCY STOP BUTTON HORN BUTTON DP1 DRIVE CONTROLLER 1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH TS2 START ENGINE TOGGLE SWITCH TS4 HIGH LOW RPM TOGGLE SWITCH TS6 GLOW PLUG TOGGLE SWITCH TS7 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB UP DOWN TOGGLE SWITCH 59 PLATFORM LEVEL TOGGLE SWITCH TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH Ai TILT ALARM L1 DRIVE ENABLE LIGHT WHT WHT 2 8 pr v 1 n i 4 D E 2 g gt rO 8 Q 5 5 E m m o z Lo 8 gt S z PO d 5 n L e B O
6. LABEL Section 5 Schematics B A SPARE WIRES GRN WHT 1 ORG RED 1 ORG BLK 1 GRN WHT 3 RED WHT 3 DESCRIPTION EMERGENCY STOP BUTTON HORN BUTTON DRIVE CONTROLLER BOOM FUNCTION SPEED CONTROLLER AUXILIARY TOGGLE SWITCH START TOGGLE SWITCH FUEL SELECT TOGGLE SWITCH HIGH LOW RPM TOGGLE SWITCH CHOKE TOGGLE SWITCH PLATFORM ROTATE TOGGLE SWITCH JIB BOOM UP DOWN TOGGLE SWITCH PLATFORM LEVEL UP DOWN TOGGLE SWITCH TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS12 TURNTABLE ROTATE TOGGLE SWITCH TS13 EXTEND RETRACT TOGGLE SWITCH TS14 DRIVE RANGE TOGGLE SWITCH TS15 DRIVE ENABLE TOGGLE SWITCH TILT ALARM DRIVE ENABLE LIGHT Genie V 2 E e S 2 Q 2 d AC 280 d 3 EXC LI 2 OQO 110 FO Ge 5 RI age d z PO 6 pi a 8 9 D 5 22 4 RED 9
7. BRN 2 GROUND BLU WHT 3 H TE 505 2 VW wens BRN 5 WHT BLU RED 3 2 e 8 DRIVE ENABLE LIMIT SWITCH ORG RED 3 RED 5 2 BLK 5 ry a DRIVE ENABLE 5 e 9 WHT 1 WHT 30 EH 4 DRIVE FORWARD 2 a 4 B WHT BLK 31 d g WHT BLK e 4 DRIVE REVERSE o 8 58 o 5 WHT RED 32 CH 5 EE BRAKE RELEASE 4 F i 8 BD i E 1 5 g TRAVEL ALARM amp i 1 5 x 1 Bt 7 71 E 8 BLU 1 BLU 36 MH _ o STEERLEFT UE BLU BLK 1 z BLU BLK 37 MH enk gt STEER RIGHT l BA 5 p I xS RED WHT 1 i REDMETES CH Ibi 4 4 MOTOR STROKE MOTOR STROKE 9 i 8 R 8 F Buca a ro ware 2 BLK 6 no Bk 3 WHT 7 4 ORG 1 PIS ge 7 t LIMIT SWITCHES gt o 8 2 lt gt 5 i ge i c o WHT RED 3 E WHT RED MH Ye FLOW CONTROL 3 a z gt 3 tel JIB UP B c m JIB BOOM E 2 0806 2 1
8. B C D E F CHARGE PRESSURE B 5 i 1 12741 D 95 x 1 GENERATOR OPTION pe r NU 4 mp 2 TER E 3500 PSI 1 PT 4 FM Meus LIFT STEER e OOO 220 PSI 3 p es 12 1 Pal Y gt HYDRAULIC TANK e CHARGE PRESSURE 212 APORT __ __ __ 4 M4 CRE I ot E d 4 m Tor FRONT 0E qp mm 0 i inen 2 us E BRAKE B 25 0 7 ey e L J BRAKE 2 SPEED MANIFOLD REAR Co FRONT RIGHT LEFT F 8 L i TRACTION Dee MANIFOLD Genie 5 44 Z 34 22 IC Part No 119987 STEERING CYLINDER REVA June 2007 Section 5 Schematics H Hydraulic Schematic 4WD
9. BRN2 GROUND BLU WHT 3 uj TL S 2 WHT gt BLU RED 3 WHTS zi BANS 8 DRIVE ENABLE ORG RED 3 RED 5 J LIMIT SWITCH a DRIVE ENABLE 5 5 He p 8 WHT 1 WHT 30 EH 4 DRIVE FORWARD a H 2 WHT BLK 31 EH g WHT BLK 1 Fre 4 DRIVE REVERSE gt 92 m 58 4 WHT RED 32 CH 5 EE BRAKE RELEASE a 2 8 u p m EIS le PASS AR AN E CE D il 8 BT Pd _1 ai g TRAVEL ALARM TE 1 1 4 56 m 8 uj 1 E ilL BLU BLU 36 MH _ b I STEERLEFT de BLU BLK 1 BLU BLK 37 MH gt STEER RIGHT 1 1 5 1 oO hese Ta see ect ay ad 2 m REDAWHT 1 Ibi 4 4 MOTOR STROKE MOTOR STROKE 9 8 si 8 2 Buca wars ware 2 BLK 6 o Bk 4 WHT 7 ORG 4 ORG 1 e PUE T t LIMIT SWITCHES o gt v o tr 8 2 2 lt gt 5 8 0 c o 8 WHT RED 3 Eo WHT RED MH gt Ye FLOW CONTROL 2 E a 8 tel JIB UP Ez EE a JIB BOOM 3 r 4 2 5 9496
10. LABEL DESCRIPTION P2 EMERGENCY STOP BUTTON HORN BUTTON 1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY SWITCH TS2 START SWITCH GLOW PLUG SWITCH TS4 TS5 RPM SWITCH TS6 TURNTABLE ROTATE SWITCH TS7 SECONDARY BOOM UP DOWN SWITCH TS8 PRIMARY BOOM UP DOWN SWITCH TS9 EXTEND RETRACT SWITCH TS10 PLATFORM LEVEL SWITCH TS PLATFORM ROTATE SWITCH TS12 JIB UP DOWN SWITCH TS13 DRIVE HIGH LOW OUTPUT SWITCH TS14 DRIVE ENABLE SWITCH Li DRIVE ENABLE LIGHT 12 OVERLOAD LIGHT OPTION LOAD SENSE OPTION cce SSS RSS a E 1 2 3 4 a i B NA LOAD SENSE P2 FSt_ pep REDIBLK BLK I 172 5 7 12 CH WHT 1 2 BRN i RED BLK x po e SC T 2 O00 0001 000 28 2 000 Qro YOO S 000 ol OOO 3 i X A 5 ol ZR 9 Ol 1 0 WE June 2007 Section 5 Schematics Load Sense Option Wiring Diagram from serial number 1547 to 19
11. BLK 7 BRN 6 BRMEH GROUND BRN 5 BRN 2 46 BRN8 GROUND GRNWHT 1 45 GRN BLK 1 44 GRBK S P JIB DOWN GRN 1 43 GRN S P JIB UP ORG RED 1 42 OG BK 2ISM ORG BLK 1 41 OG BK EH PULSE PICKUP WHT 7 ORG 1 40 WHT 8 WHT 6 LIMIT SWITCH BLU RED CR7 BLU RED 1 39 BU RD S P LP BU WT CR6 BLUMWHT 1 38 BUMWT S P GAS BLU BLK 1 37 BU BK M H STEER LEFT BLU 1 36 BLU MH STEER RIGHT BK RD CR3 BLK RED 1 35 BK RD S P RPM BLK WHT CR8 BLK WHT 1 34 GLOW PLUG BLK 1 BLK S P ENGINE START WHT RED 1 32 wr RD EH BRAKE WHT BLK 1 31 WT BK E H E D C RED 5 WHT 1 30 E D C RANA 29 RD WT EH 2WD AWD RED BLK 1 28 RD BK MH TILT ALARM M RD ISM RED 1 27 RED EH RED S P AUILIARY POWER 26 WT RD EH WT RD S P WATER TEMP SENDER 25 WT BK E H WT BK S P OIL PRESSURE SENDER WT 10 ISM 24 WHT EH WARNING SENDER RD WT MH WHT 2 23 WHT S P KEYSWITCH POWER BLK CRS BLK 2 22 BLK S P POWER TO PLATFORM WHT CR2 21 WHT EH WHT SP DB IGNITION POWER RED CR17 20 RED E H RED S P 12V BATTERY SUPPLY GRN WHT 3 19 GRN BLK 3 18 GR BK S P PLATFORM ROTATE RIGHT GRN 3 17 GRN S P PLATFORM ROTATE LEFT ORG RED 3 16 OPT BLK6 ORGBLK 3 15 ORG BLK M H OG BK S P PLATFORM LEVEL DOWN oRG3 14 ORG MH ORG S P PLATFORM LEVEL UP WHT S BLU RED 3 13 DRIVE ENABLE LIGHT BLK 5
12. VOLTAGE OIL PRESSURE COOLANT TEMPERATURE e BRN 5 BRN OPTION 1 52 GROUND 1 BRN 2 BRN OPT 2 3 52 BRN GND STUD GROUND WHT 6 WHT 8 50 LS2 LS4 JUNCTION SPARE WIRE LIST OPTION NUMBERS WHEZIA BLK 7 BLK 6 49 LS1 LS2 JUNCTION GRNWHT 1 1 PLATFORM LEVEL CUTOUT 1 1 1 WHT RED EH 45 GENERATOR OPTION ORG RED 1 2 FLASHING BEACON OPTION 3 GRN BLK 1 44 GRN BLK SP JIB DOWN ORG BLK 1 3 DESCENT ALARM GRN 1 43 GRN SP JIB UP GRN WHT 3 4 AC GENERATOR BLK 8 ORG 1 40 lt OFF LIMIT SPEED RED WHT 3 WHUB KEH E BLU RED CR7 BLU RED 1 39 BLU RED SP LP BLK 22A CABLE BLU WHT CR6 BLU WHT 1 38 BLU WHT SP GAS 8 BLU BLK 1 37 BLU BLK MH STEER RIGHT WHT RED 32A LS4 BLU 1 36 BLU MH STEER LEFT 2 Pt BLK RED CR3 BLK RED 1 35 BLK RED SP HIGH RPM 2 BLK WHT CR8 BLK WHT 1 34 BLK WHT SP GLOW PLUG 916 BLK ISM 3 BLK 1 33 BLK SP START Ne si WHT RED CH WHT RED 1 32 C WHT RED SP BRAKE RELEASE KS DESDE WHT BLK 1 31 fen WHT BLK EH DRIVE REVERSE GRNWHT 1 45 GRN WHT EH GRN WHT TB35 GENERATOR PO OF Q uu WHT 1 30 WHT EH DRIVE FORWARD BLK RED CR3 BLK RED 1 35 GRN WHT TB45 BLK RED SP HIGH RPM gt RED WHT 1 29 RED WHT CH HIGH LOW DRIVE RED RED BLK 1 28 RED BLK MH TILT ALARM SS een SS ee ee ns
13. 4 33 Hydraulic Pumps 9 1 Auxiliary entr 4 34 82 F nction Pump eid HERES E e ES 4 35 8 3 Drive PUMP raes Lc a E ee ii me 4 36 A Manifolds 9 1 Function Manifold Components 4 38 92 Valve Adjustments Function Manifold 4 42 9 3 Jib Boom Platform Rotate Manifold Components 4 44 9 4 Brake 2 speed Manifold Components 4 45 9 5 2WDTraction Manifold Components 4 46 9 6 4 0 Traction Manifold Components 4 48 9 7 Valve Adjustments Traction 9 4 50 96 ree eter ed at ef etui d 4 50 Genie Part No 119987 Z 34 22 IC June 2007 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued A Fueland Hydraulic Tanks 10 1 Fuel Tank e t Meet peat rens orte e Ed vote eo 4 53 10 2 Hydraulic Tanken nid ep deter ened 4 54 A Turntable Rotation Components 11 1 Rotation Hydraulic Motor 4 55 A Axle Components 12 1 Hub and Bearings 2WD 4 56 Section5 Rev Schematics IntrOduCtiOn D E 5 1 Electrical Symbols Legend nirera iaaea t ere tetti e sieurs 5 2 A Hydraulic Symbols Legend 5 3 A Electrical Schematic Diesel Models from serial number 1187 to 1546
14. tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 25 Nm 6 35 ft lbs 47 5 Nm 6 30 ft lbs 40 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs 55 Nm 10 105 ft lbs 142 4 Nm 10 60 ft lbs 80 Nm 12 140 ft lbs 190 Nm 12 85 ft lbs 115 Nm 16 210 ft lbs 284 7 Nm 16 110 ft lbs 150 Nm 20 260 ft lbs 352 5 Nm 20 140 ft lbs 190 Nm 24 315 ft lbs 427 1 Nm 24 180 ft lbs 245 Nm Genie 2 8 Z 34 22 IC Part No 119987 June 2007 Section 2 Specifications REVA SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Black Oxide Bolts DRY LUBED DRY LUBED Nm Nm Nm 1 14 7 15 8 LUBED ns 10 140 30 720 60 140 LUBED Nm 3 lt 24 27 1 44 7 50 1 67 8 81 3 108 4 122 162 176 217 244 25 27 44 49 70 33 9 28 4 36 6 32 5 59 6 51 5 T8 20 66 4 58 3 765 14 23 53 28 37 94 7 82 7 108 4 92 1 149 126 162 142 203 176 230 189 254 244 325 271 515 433 569 174 827 591 57 5 di 20 867 one 12 80 1084 110 149 120 o 122 10 3162 130 T60 180 280 379 310 220 va 19 320 483 430 583 450 60 60 550 474 40 637 50 68 670 908 755 480 650 640 867 680 92 90 1233 1044
15. SECONDARY PRIMARY PRIMARY EXTENSION JIB BOOM P 0 032 inch do TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI 2 n 5 9 CU IN REV e a E c PT iae psu PETEN MASTER E E E E Al PER EN 3 51 _ EN WEM L du x slk LL 52 3000 PSI 3000 PSI 2500 PSI 3000 PSI 2500 PSI 1 51 3 1 3 1 31 31 TS Ses RE a ee cR ERRORES LE RES LS HEX 8 GPM P1 10025 en 727771 pee 3200 PSI aes pee m o gt T 5 c Pia 1 1 10 022 Q M Hi Q M Ik D 221 SN NEL l Fas 1600 PSI 1400 5 1800PSl 1 4 5 ee an 6 3000 PSI 1500 PSI mi DUM C PEE E L 31 3 1 Slo ao w le o e NZ AU AU ALS 2 AUI 1 D D 9 ON vnd 0 3 GPM bo 0 052 inch 0 052 inch 4 P2 cw X GPM m T2 0 025 inch m J T4 Genie TEREX COMPANY Part No 119987 Z 34 22 IC 5 41 June 2007 Section 5 Schem
16. Waviv LIL P2 EMERGENCY STOP BUTTON ON t HORN BUTTON DPi DRIVE CONTROLLER O 1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY TOGGLE SWITCH TS2 START TOGGLE SWITCH GLOW PLUG TOGGLE SWITCH RPM TOGGLE SWITCH 651 Co ON 1 es es anavo 8 TURNTABLE ROTATE TOGGLE SWITCH Ot oF 2 0 461 88 SECONDARY BOOM UP DOWN TOGGLE SWITCH _ 758 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS9 EXTEND RETRACT TOGGLE SWITCH C TS10 PLATFORM LEVEL TOGGLE SWITCH 0151 2151 1511 PLATFORM ROTATE TOGGLE SWITCH 5 zd TS12 JIB UP DOWN TOGGLE SWITCH a 1513 DRIVE HIGH LOW OUTPUT TOGGLE SWITCH 1514 DRIVE ENABLE TOGGLE SWITCH 4 R2 250 OHM RESISTER L1 DRIVE ENABLE LIGHT gt 1 Lit 5 8 9 112 14 5 6 7 9 2 SIT om a al
17. 119987 June 2007 REVA Kubota D 905 Engine Displacement Number of cylinders Bore and stroke Horsepower gross intermittent Firing order Compression ratio Compression pressure Low idle High idle Governor Valve clearance cold Engine coolant 54 86 cu in 0 90 liters 3 2 83 x 2 90 inches 72 x 73 6 mm 26 3600 rpm 19 3kW 125 23 1 412 to 469 psi 28 4 to 32 3 bar 1300 rpm 260 hz 3000 rpm 600 hz centrifugal mechanical 0 0057 to 0 0072 in 0 145 to 0 183 mm Capacity 3 3 quarts 3 1 liters Lubrication system Oil pressure 36 to 64 psi 2 48 to 4 41 bar Oil capacity 5 4 quarts including filter 5 1 liters Oil viscosity 10W 30 requirements Engine oil should have properties of API classification CD SE or CD SF grades Section 2 Specifications eee ees ESS ee Injection system SPECIFICATIONS Injection pump make Bocsh MD Injection timing 13 to 25 BTDC Injection pump pressure Fuel requirement 1991 psi 137 bar diesel number 2 D Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Starter motor Brush length new 0 5188 in 13 mm Brush length minimum 0 3346 in 8 5 Alternator Output 30A 14V DC Fan belt deflection 1 4 to 3 8 inch 7 to 9 mm Continuous improvement of our produc
18. Part No 119987 Counterbalance valve Pressure switch Brake i Variable orifice or shut off valve Flow divider combiner Sequencing valve Shuttle valve Z 34 22 IC Section 5 Schematics June 2007 Genie A TEREX COMPANY 5 4 Z 34 22 IC Part No 119987 ORG BLK REVA June 2007 Electrical Schematic Diesel Models from serial number 1187 to 1546 Section 5 Schematics a i 0 2 2 c o 5 5 3 o 8 TURNTABLE ROTATE RIGHT j SWING i E WHT 4 E H e TURNTABLE ROTATE LEFT WHT BLK 3 RIGHT TURNTABLE ROTATE LEFT WHT 3 28 E 188 19 Ed v BLK RED 1 mia ee 1 HIGH RPM E RPM CUTOUT COIL 7 2 Je ENGINE SPEED FUNCTION RELAY T ENABLE T 1 BLKRED d THIGH RPM gt ry RPM LI 3
19. BLK WHT 1 34 BKWT S P GLOW PLUG BLK CR3 BK 3 ISM BLK S P START WHT RED 1 32 BRAKE WHT BLK 1 31 wr BK E H E D C RED 5 WHT 1 30 E D C RW 1 29 2WD AWD RED BLK 1 28 RD B M H TILT ALARM RD iSM 1 27 RED EH RED S P AUX PWR 26 WT RD EH WT RD S P WATER TEMP SENDER 25 WT B E H WT BK S P OIL PRESSURE SENDER WT 10 ISM 24 WHT E H WARNING SENDER RDWT M H WHT2 23 WHT S F KEYSWITCH PWR BLK CR5 BLK 2 22 BLK S P PWR TO PLAT WHT CR2 21 WHT EH WHT SP DB IGNITION PWR RED CR17 20 RED EH RED S P 12V BATT SUPPLY GRNWHT 3 19 GRN BLK 3 18 GR BK S P PLAT ROT R GRN 3 17 GRN S P PLAT ROT L ORG RED 3 16 OPT Buce 15 ORG BLK MH OG BK S P PLAT LEVEL DN gt Bike ones 14 ORG MH ORG S P PLAT LEVEL UP WHT 5 BLU RED 3 13 DRV ENA LT BLK 5 BLUWHT 3 12 WHT EH DRV ENA BLU BLK 3 11 BLU BLK MH BLU BK S P SEC BOOM DN BLU 3 10 BLU M H BLU S P SEC BOOM UP BK RD CR5 BLK RED 3 9 HORN BLK WHT 3 BLKWHT MH BK WT S P BOOM RETRACT BLK 3 7 BLK M H BLK S P BOOM EXTEND WHT RED 3 6 WR MH WT RD S P BOOM FUNCTION WHT BLK 3 5 WHT BLK M H 5 TURN ROT L WHT 3 WHT MH WHT S P TURN ROT R RED WHT 3 3 RD WT S P RED BLK 3 2 RED BLKMH RD BK S P PRI BOOM DOWN RED 3 RED M H RED S P PRI BOOM UP D LC 1 START RELAY ORGIBUKATD
20. 8 bd 3 i ORG 6 56 il 4 ys T1 1 5 2 1 6 E 2 WE E 5 1 Te ORG 14 MH E PLATFORM PLATFORM i 2 K LEVEL 5 TDOWN PLATFORM 1 1 1 i LEVEL DOWN Fd 1 1 1 B Fg ELI 41 1 ORG 3 1 1 PLATFORM 1 LEVEL ORG BLK 8 1 1 i 1 1 BLK 7 MH i Ibi PRIMARY Boom EXTEND i 1 1 BOOM BLKWHT 8 MH PRIMARY 7 1 1 1 1 1 BLK 3 EXTEND PRIMARY BLK WHT 3 i i i 1 d i RED 1 MH 1 PRIMARY BOOM RED BLK 2 MH PRIMARY td 1 BOOM DOWN i RED 3 PRIMARY BOOM RED BLK 3 1 1 1 1 1 1 1 i i i 1 z BLU 10 MH Ibi SECONDARY BOOM UP BOOM DOWN BLU BLK 11 MH 1 SECONDARY BOOM DOWN 1 L 1o H 1 1 DECENT ALARM 9 BUS OPTION i lt i SECONDARY RP PRU a BOOM BLU BLK 3 a a E 5 5 10 Genie Z 34 22 IC Part No 119987 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED SWITCH SHOWN WITH BOOM ROTATED P
21. SWITCH RED 1 WHT HOUR METER cre i 1 TB21 ORG BLK AUXILIARY PUMP TB27 RED BLK R1 EH STARTER MOTOR RED 27 EH FUEL SOLENOID RED RED BLK 1 28 AUXILIARY PUMP RELAY AUXILIARY PUMP RED BLK 28 MH WHT 2 RED WHT 23 MH LEVEL SENSOR P2 a Electrical Schematic Diesel Models from serial number 1547 to 1996 Section 5 Schematics TB23 P3 HORN BLK RED 3 BLK RED HORN 22 BLK 2 In TB9 BLK R5 MH RELAY KS1 LAT 1 GRND RED CB2 10 of E BLK RED R4 EH HORN TRUE 5 BLK WHT R8 EH H RPM SOLENOID GLOW PLUG Ss ORG BLK EH CB1 A RED RED 10A RED CB1 EH RED EH WHT 21 EH 12V ALTERNATOR Part No 119987 2 34 22 1 Section 5 Schematics from serial number 1547 to 1996 Electrical Schematic Diesel Models June 2007 WHT FS REVA
22. GLOW PLUG TS56 Added after serial number 2266 TB34 TS2 RED WHT FS1 BLK Je June 2007 START TS1 oo o 2 AUXILIARY PUMP TS52 5 START BLK B33 IGNITION START MODULE E g BLK WHT WHT BRN lt GLOW PLUG RELAY WHT WNT RED EH VOLT METER GAUGE WHT WHT BLK EH WATER TEMPERATURE GAUGE OIL PRESSURE GAUGE START RELAY 1 10 ENG FAULT 2 TACHOMETER 3 START INPUT 4 AUX ON 5 GROUND 6 BATTERY 8 KEY BYPASS 9 IGN FUELON 7 KEY PWR 65 WHT EH WTS1 WHT EH WATER TEMPERATURE SWITCH RED AUXILIARY TS51 PUMP 51 BRN OILPRESSURE SWITCH TB27 RED WHT HOUR METER cR2 n TBR ORG BLK d CR1 BLK R1 EH pu RED 27 EH STARTER MOTOR FUEL SOLENOID RED 1 lt RED BLK 1 28 AUXILIARY PUMP RELAY AUXILIARY PUMP RED BLK 28 MH WHT 2 RED WHT 23 MH P3 HORN TB23 LEVEL SENSOR FLASHING BEACON BLK RED 3 OPTION HORN
23. Scheduled Maintenance Procedures REVA Release the foot switch and stop the engine Move the fuel select switch to LPG Restart the engine and allow it to run at low idle 7 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running Part No 119987 Genie Z 34 22 IC 3 25 CHECKLIST B PROCEDURES B 14 Test the Drive Brakes Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when not fully operational AWARNING Bodily injury hazard Be sure that the machine is not in free wheel or partial free wheel configuration See B 6 Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls 3 Select high range drive machine on level surface symbol 4 Move the engine idle control switch to foot switch activated high idle r
24. TB22 BLK 2 TB9 BLK RED BLK R5 MH RELAY Electrical Schematic Diesel Models from serial number 1997 to 3241 Section 5 Schematics KS1 7 GRND RED CB2 Vy 10A af HORN BLK RED R4 EH om 5 BLK WHT R8 EH RPM SOLENOID GLOW PLUG us WU ORG BLK EH RED CB1 ANA RED 10A RED EH WHT 21 EH 12V ALTERNATOR Part No 119987 Z 34 22 IC G Section 5 Schematics from serial number 1997 to 3241 Electrical Schematic Diesel Models June 2007 REVA WHT FS BRN 2 GROUND BLUWHT 3 FE e E B BRN 5 WHT BLU RED 3 1 8 DRIVE ENABLE LIMIT SWITCH ORG RED 3 RED 5 2 Bs I a DRIVE ENABLE 53 5 L p WH
25. je e F A AA NIZ 2 AL MAP ml V 0 028 0 3 GPM 0 052 inch 0 052 inch n 2 65 E W X M 1969 CT 0055 inch 1 5 TIN _ T4 8 Genie A TEREX COMPANY Part No 119987 Z 34 22 IC 5 35 June 2007 Section 5 Schematics Hydraulic Schematic 2WD Models from serial number 1187 to 1546 Section 5 Schematics June 2007 Hydraulic Schematic 2WD Models from serial number 1547 to 2900 REV A A B D E F G H J K L M N 1 PAT 3 5 T GENERATOR OPTION i Sa 2 pd pe O L 3500 PSI 4l 1 2000 T o LIFTISTEER lt L J Li NEZ Di LES T 1 AM M DRIVE PUMP Es ox PSI HYDRAULIC TANK
26. re A al 1 c7 3200 PSI Pes a om sa li linis L W y em d rom serial number P 1600 PSI 1400 PSI 1800 PSI M uni m J1 J2 1 one 3000 PSI 1500 PSI Hie D N o D V 9 ze AN 7 TZ A Nb D 09 ON 0 028 0 052 inch 0 052 inch inch P2 e W x after serial number 1969 1 _ zl T4 Genie A TEREX COMPANY Part No 119987 Z 34 22 IC 5 43 June 2007 Section 5 Schematics Euu Z Hydraulic Schematic 4WD Models from serial number 1547 to 2900 Section 5 Schematics June 2007 Hydraulic Schematic 4WD Models from serial number 2901 to 3241 AUXILIARY PUMP 0 5 GPM 11241
27. 000 000 5 obl N Zo MEZ E D fa 2 3 4 E 3 A x R I N A BN O O_O ofo 1 2 31 4 8 Ol m BRN 3 0 3 O O 10 9 8 7 5 OgO 4 Od 8 YALINIT H3MOd 3SHOH TEREX COMPANY Z 34 22 IC Part No 119987 3A LABEL DESCRIPTION pz EMERGENCY STOP BUTTON HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY SWITCH TS2 START SWITCH TS3 CHOKE SWITCH TS4 FUEL SELECT SWITCH TS5 RPM SWITCH TS6 TURNTABLE ROTATE SWITCH TS7 SECONDARY BOOM UP DOWN SWITCH TS8 PRIMARY BOOM UP DOWN SWITCH TS9 EXTEND RETRACT SWITCH TS10 PLATFORM LEVEL SWITCH TS11 PLATFORM ROTATE SWITCH TS12 JIB UP DOWN SWITCH TS13 DRIVE HIGH LOW OUTPUT SWITCH TS14 DRIVE ENABLE SWITCH R2 250 OHM REGISTER L1 DRIVE ENABLE LIGHT L2 OVERLOAD LIGHT OPTION LOAD SENSE OPTION porem e 1 2 8 4 1 8 i LOAD SENSE P2 T gt RED BLK BLK 123141516 7 8 9 1011112 i i RED BLK REV ES34GP4E REVA
28. 4 5 14 2 34 221 119987 SWITCH SHOWN WITH ROTATED PAST EITHER NON STEER WHEEL 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED SWITCH SHOWN WITH BOOM EXTENDED NOTES June 2007 Section 5 Schematics M srl Electrical Schematic Gasoline LPG Models from serial number 1547 to 1996 REVA June 2007 Electrical Schematic Gasoline LPG Models from serial number 1997 to 3241 Section 5 Schematics a a a a 2 2 HE 5 65 8 WHT BLKH5 CH TURNTABLE ROTATE RIGHT TURNTABLE T Bil RONTE WHT 4 CH TURNTABLE ROTATE LEFT B WHT BLK 3 RIGHT RIGHT maie ROTATE WHT 3 BLK RED 1 2 LOWRPM L ENGINE FUNCTION ENABLE 8 g 2 SPE
29. 4 4 n HN Mz M CH TEE a al sem 5 3200 PSI m pot ooo te from serial number D T Ds Ier D Gk x mem X 1600 PSI 1400 PSI 1800 PSI _ _ i 6 Dos E mM ME J J2 Tere m _ 2000 PSI 1500 Psi 7 amp less 1 HE e e je e f rab zv n fm Ern M m MN 2 O E w 0 052 inch 0 052 inch ee a l W X 2 0 025 inch il BEES EEEE EE E E ee ee 4 8 Genie Part No 119987 Z 34 22 5 37 June 2007 Section 5 Schematics Hydraulic Schematic 2WD Models from serial number 1547 to 2900 Section 5 Schematics June 2007 Hydraulic Schematic 2WD Models from serial number 2901 to 3241 REV A B D E F G H J K L M N CHARGE PRESSURE 1 50 PSI B E D 71 3500 PSI
30. 1 JIB DOWN 1 i i 1 1 1 1 i i GRN 1 uP 4 7 JIB BOOM DOWN GRN BLK 1 1 1 1 1 1 1 1 1 1 i i 2 o 2 PE S 3 2 1 x E 2 PLATFORM ROTATE RIGHT RIGHT PLATFORM 5 1 ROTATE E D 1 5 PLATFORM ROTATE LEFT gt gt 1 1 T ze i 1 9g 1 E Hi 1 GRN BLK 3 8 RAH 71 17 PLATFORM a ud 1 ROTATE LEFT GRN 3 o 1 1 1 1 1 pee mm a 1 5 F 1 ORG 6 6 it 4 8 amp Ds m 5 L 8 1 A s L4 i B E 5 1 7 ORG 14 MH 121 1 4 PLATFORM t 2 rt LEVELUP PLATFORM 1 2 a LEVEL 5 Fol V ORG BLK 15 MH 1 PLATFORM r1 LEVEL DOWN Lg 1 1 I EE S E 1 1 1 ORG 3 1 EVEL ORG BLK 3 1 1 1 1 1 i i 1 1 1 1 Al BLK 7 MH 4 PRIMARY BOOM EXTEND EXTEND PRIMARY i i BOOM BLKWHT 8 MH Al 4 PRIMARY BOOM 1 1 1 1 1 1 1 i i BLK 3 EXTEND PRIMARY BLK WHT 3 1 1 1 1 1 1 1 1 RED 1 MH PRIMARY T BOOM UP PRIMARY g 1 1 1 EN RED BLK 2 MH 1 n 1 Al PRIMARY BOOM DOWN i i i RED 3 1 1 1 PRIMARY i T BOOM RED BLK 3 1 1 1 1 1 1 1 1 1 1 i i i BLU
31. 119987 June 2007 Section 4 Repair Procedures REVA MANIFOLDS 9 4 Brake 2 speed Manifold Components The brake 2 speed manifold is located under the drive chassis cover at the non steer end Index Schematic No Description Item Function Torque 1 Check Valve AC Pressure circuit 8 10 ft lbs 10 15 Nm 2 Solenoid valve 2 position 3 way 2 speed motor shift 25 30 ft lbs 34 41 Nm 3 Solenoid valve 2 position 3 way 25 30 ft lbs 34 41 Nm 4 Orifice Plug 0 025 inch 0 64 mm AD Tank return circuit os Genie TEREX COMPANY Part No 119987 Z 34 22 IC 4 45 Section 4 Repair Procedures June 2007 MANIFOLDS REVA 9 5 2WD Traction Manifold Components The 2WD traction is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Relief valve 210 psi 14 5 bar Charge pressure circuit 35 40 ft lbs 47 54 Nm 2 Diagnostic 00 Testing 3 Flow divider combiner valve Gage Controls flow to drive motors in forward and reverse 130 140 ft lbs 176 190 Nm 4 Orifice 0 070 inch 1 78 mm Diu Equalizes pressure on both sides divider combiner valve C 5 Shuttle va
32. BLU WHT 38A BLU RED 39A BLK WHT 34A BLK 33A BLK RED 35A DESCRIPTION P1 EMERGENCY STOP BUTTON KS1 KEY SWITCH TS15 AUXILIARY SWITCH TS16 ENGINE START SWITCH TS17 ENGINE CHOKE SWITCH TS18 ENGINE FUEL SELECT SWITCH TS19 ENGINE RPM SWITCH TS20 TURNTABLE ROTATE SWITCH TS21 SECONDARY BOOM UP DOWN SWITCH TS22 PRIMARY BOOM UP DOWN SWITCH TS23 BOOM EXTEND RETRACT SWITCH TS24 PLATFORM LEVEL SWITCH TS25 PLATFORM ROTATE SWITCH TS26 JIB UP DOWN SWITCH CB1 CIRCUIT BREAKER CONTROLS 10A CB2 CIRCUIT BREAKER ENGINE 10A HOUR METER R1 RESISTOR 5 OHM BOOM FUNCTIONS EH ENGINE HARNESS MH MANIFOLD HARNESS June 2007 E D C B Section 5 Schematics X11 Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 1187 to 1546 A gt gt s m o 5 1 CABLE CABLE 8 MANIFOLD HARNESS
33. i i i i RED 3 up PRIMARY DOWN FROM RED BLK 3 1 1 1 1 1 1 1 1 1 1 i E B i i lt BLU 10 MH 1 Il SECONDARY SECONDARY E SOME B te BOOM BLU BLK 11 MH SECONDARY 1 BOOM DOWN 1 bI SSS EE 1 I DECENT ALARM BLU 3 Lk OPTION E 1 id 2 SECONDARY nu BOOM BLU BLK 3 p a a c Mene 2 34 221 119987 1 ALL LIMIT SWITCHES SHOWN WITH IN STOWED POSITION EXCEPT AS NOTED SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL SWITCH SHOWN WITH BOOM EXTENDED NOTES June 2007 Section 5 Schematics Electrical Schematic Diesel Models from serial number 1547 to 1996 WHT FS REVA RED RED RED WHT BLK 3 RED TB5 GND WHT BLK 5 CH TURNTABLE ROTATE WHT 4 CH RIGHT TURNTABLE ROTATE WHT 3 BLK RED 1 FS HI Le ENGINE RPM TS4 HI TS54 FUNCTION ENABLE t HIGH RPM TB35 qu au TB4 GND ES34D1L TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT RPM COIL BLK RED R3 5 CUTOUT RELAY GRN WHT 1 RPM AC GENERATOR ON m AC GENERATOR 547 BLK WHT 1 GRN WHT
34. 2 Repeat step 1 for each link 3 To remove a single link open the lower clip and then use a screw driver to pry the link to the side Primary Boom Components 4 2 Primary Boom How to Shim the Primary Boom Measure each wear pad Replace the pad if it is less than 0 41 inch 1 cm thick If the pad is more than 0 41 inch 1 cm thick perform the following procedure 1 Extend the boom until the wear pads are accessible 2 Loosen the wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Tighten the mounting fasteners Extend and retract the boom through an entire cycle Check for tight spots that could cause scraping or binding Always maintain squareness between the outer and inner boom tubes Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section 4 Repair Procedures June 2007 PRIMARY BOOM COMPONENTS How to Remove the Primary Boom AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and
35. 5 5 A Electrical Schematic Diesel Models from serial number 1547 to 1996 5 7 A Electrical Schematic Diesel Models from serial number 1997 to 3241 5 9 A Electrical Schematic Gasoline L PG Models from serial number 1187 to 1546 5 11 A Electrical Schematic Gasoline L PG Models from serial number 1547 to 1996 sse 5 13 A Electrical Schematic Gasoline L PG Models from serial number 1997 to 3241 5 15 Genie TEREX COMPANY Xii Z 34 22 IC Part No 119987 June 2007 Section 5 Rev TABLE OF CONTENTS Schematics continued A Ground Control Box Wiring Diagram Diesel Models from serial number 1187 to 1546 5 17 A Ground Control Box Wiring Diagram Diesel Models from serial number 1547 to 1985 sse 5 18 A Ground Control Box Wiring Diagram Diesel Models from serial number 1986 to 3241 5 19 A Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 1187 to 1546 5 20 A Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 1547 to 1985 5 21 A Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 1986 to 3241 5 22 Platform Control Box Wiring Diagram Diesel Models from serial number
36. DRE BRN RED E y 3 d _ 3 2 5 018 8 IESI L RED WHT o j z sls m o o vu 5 jo Ja 4 ig 5 5 5 2622 9 5 5 c je a 5 8 5 aps RD OR Bog RP ME 5 9 5 a o amp ja L e 6 enie A TEREX COMPANY Z 34 22 IC Part No 119987 REV A ES34D3L June 2007 Section 5 Schematics EE Platform Control Box Wiring Diagram REV Gasoline LPG Models from serial number 1187 to 1546 N M L K J H G
37. 2 Remove the platform mounting weldment and the platform rotator See 2 3 How to Remove the Platform Rotator 3 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom lift cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the cable cover from the side of the jib boom REVA 5 Tag disconnect and plug the hydraulic hoses from ports T and P of the jib boom manifold Cap the fittings on the manifold Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Tag disconnect the electrical wiring from the jib boom manifold 7 Attach a lifting strap from an overhead crane to the jib boom 8 Remove the pin retaining fasteners from the jib boom pivot pin at the jib boom bellcrank 9 Use a soft metal drift to remove the jib boom pivot pin Remove the jib boom from the jib boom bellcrank Crushing hazard The jib boom AWARNING could fall when the pin is removed if not properly supported by the overhead crane 10 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 11 Remo
38. AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Start the engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 4 Turn the engine off Hold the relief valve and remove the cap item B 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap 6 Start the engine Drive the machine in either direction and check the relief valve pressure 7 Turnthe engine off and remove the pressure gauge REVA 9 8 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide rang
39. Gasoline LPG Models from serial number 1547 to 1985 Section 5 Schematics June 2007 Ground Control Box Wiring Diagram Gasoline LPG Models REVA from serial number 1547 to 1985 A B C D E F G H J K L M N VOLTAGE OIL PRESSURE COOLANT TEMPERATURE 1 BANS BAN OPTION T 52 GROUND SPARE WIRE LIST OPTION NUMBERS C5 BRN 2 BRN OPT 2 3 52 BRN GND STUD GROUND GRNWHT4 4 PLATFORMLEVELCUTOUT _ WHT 6 WHT 8 50 LS2
40. Part No 119987 TEREX COMPANY Z 34 22 IC 4 51 Section 4 Repair Procedures June 2007 MANIFOLDS REVA 4 Connect the negative lead to the other terminal on the coil If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the amperage reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 2096 the coil and or its internal diode are faulty and the coil should be replaced Genie TEREX COMPANY 4 52 2 34 22 1 Part No 119987 June 2007 Section 4 Repair Procedures Fuel and Hydraulic Tanks REVA 10 1 7 Tag disconnect and plug the fuel hoses from the fuel tank Cap the fittings on the fuel tank Fuel Tank 22 Clean up any fuel that have spilled 8 Metal fuel tank Remove the fuel tank strap retaining fasteners located under the tank 1 Raise the secondary boom so the upper pivot is mounting tray approximately 12 feet 4 m off the ground How to Remove the Fuel Tank Plastic fuel tank Remove the fue
41. Scheduled Maintenance Procedures REVA 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 6 Checkthe ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 F 12 2 C above 80 F 26 7 Subtract 0 004 from the reading of each cell for every 10 F 12 2 C below 80 F 26 7 Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 10 Result One or more battery cells display specific gravity of 1 217 or below Proceed to step 7 7 Perform an equalizing charge OR fully charge the battery and allow the battery to rest at least 6 hours 8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results CHECKLIST B PROCEDURES 9 Checkthe ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 F 12 2 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 F 12 2 C below 80 F 26 7 C O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 10 Result The difference in specific gravity readings between cells is greater
42. Section 2 Specifications Starter motor SPECIFICATIONS Brush length new 0 669 in 17 mm Brush length wear limit 0 453 in 11 5 mm Brush spring tension 50 to 91 ounces 13 9 to 25 3 Newtons Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Ignition System Ignition spark advance 18 BTDC Ignition coil primary 1 8 to 1 60 resistance 75 F 24 C Ignition coil secondary resistance 10 7 to 14 5 75 F 24 1 Spark plug wire resistance 2 81 to 4 79 2 Spark plug wire resistance 3 4 to 5 8 Spark plug wire resistance 3 57 to 6 09 Spark plug type BKRAE 1 1 Spark plug gap 0 039 to 0 043 inches Use oils meeting API classification SF labeled SH CC 1to 1 1 mm or SH CD for improved wear protection Engine coolant Fuel pum me PUMP Capacity 3 1 quarts Fuel pressure static 2 84 psi 2 9 liters 0 19 bar Alternator Fuel flow rate 0 125 0 47 Output 30A 14V DC Continuous improvement of our products is a Fan belt deflection 1 4 D ne Genie policy Product specifications are tomm subject to change without notice Genie Part No 119987 2 34 221 2 7 Section 2 Specifications June 2007 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal L
43. TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA needs to be replaced 8 Fully retract the primary boom Raise the primary and secondary booms to full height Visually inspect the the dial indicator to be sure the needle returns to the position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the primary and secondary booms to the stowed position and turn the machine off 12 Remove the dial indicator from the machine CHECKLIST D PROCEDURES D 7 Perform Engine Maintenance Engine specifications requires that this procedure be performed every 1000 hours or annually whichever comes first Required maintenance procedures and additional engine information is available in the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 OR the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota DF750 Operator s Manual Genie part number 97359 Kubota DF752 Operator s Manual Genie part number 84250 Kubota D905 Operator s Manual Genie part number 31743 Genio Part No 119987 Z 34 22 IC 3 41 Section Scheduled Maintenance Procedures June 2007 Checklist E Procedures REVA E 1
44. 0 0521 C 0 inch Y EI PP p que 1e 0 028 inch X 0 1 GPM 0 3 GPM fof Ti Genie A TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 5 Schematics HEREIN Hydraulic Schematic 4WD Models from serial number 2901 to 3241 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 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 31 183 581 1
45. 1 5 i 5 E BLK WHT MM s 1 5 T t CHOKE F 20 oz 2 35 BLK 1 uum MEME z 21 KOSS me Bee LLL engine WNT RED 26 2 START x A xe tu Rx F ENGINE 8 sels ele WHT BLK425 T SW gk 1 458 WHT x E LAN zi o g i i o WHTH21 EH 15 20 gt e i 100000 18 E 5 19 Br love BLK R1 E H AUXILIARY 8 POWER RED427 EH AUXILIARY ED 1 lt 5 1 Da RED RED BLK 1 F RED BLK 28 E H 1 x e Loe o WHT 2 B RED WHT 23 E H ERE 1 ME d z 121 of 8 amp T BLK RED BLK RED 3 BLK RED ES 3 m BLK2 m BLK RS5 E H 2 8 5 5 BLK RED R4 E H e e c 5 BLK WHT R8 E H 4 je E u Es ORG BLK 1 ORG BLK 41 E H 9 RED E H p 1 1 i 1 WHT 21 E H 1 5 2 32 mI IP LESS 8 RED 20 ha os BATTERY N LO co N TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT RPM COIL FLASHING BEACONS RPM CUTOUT COIL RELAY FUEL RELAY FUEL RELAY LPG SO
46. El 2 558 RED 9 RED 27 EH ee gt AUXILIARY POWER RELAY l RED 1 5 g 4 1 a 1 TEEN 14 AUXILIARY PUMP DONE a 8 RED BLK 1 RED BLK 28 MH 1 C z m WHT 2 RED WHT 23 MH 1 Ye LEVEL SENSOR 8 MG a 4 ES ite ttu eese seed FLASHING BEACON OPTION ae gee cee 1 d BLK RED 2 BSED HORN RELAY 3 a BLK R5 MH BLK 2 HORN 5 2 E a 2 o BLK RED R4 EH E e 4 RPM SOLENOID c BLK WHT R8 EH 4 CHOKE SOLENOID ORG BLK EH a 4 9 RED EH ALTERNATOR WHT 21 EH a te ans 858 568 gt amp RED RED CB1 EH 4 CN e LO N ES34GP1L Part No 119987 2 34 22 1 5 15 Section 5 Schematics from serial number 1997 to 3241 G Electrical Schematic Gasoline LPG Models June 2007 WHT FS REVA
47. Genie Service Manual Part No 119987 RevA Refer to inside cover for additional serial number information June 2007 Z 34 221C from serial number 1187 to 3241 Introduction June 2007 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Genie Z 34 22 IC Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides 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 Serial Number Information Genie Industries offers the following Service Manual for this models Title Part No Z 34 22 IC Service Manual First Edition from serial number 101 to 1186 43037 Z 34 22 Service Manual from serial number 3242 to 4799 128267 Z 34 22 Service Manual from serial number 4800 128300 Technical Publications Genie Industries has endeavored to deliver the highest degree of accu
48. 3 18 B 5 Inspect the Tires Wheels and Lug Nut 3 18 B 6 Confirm the Proper Brake Configuration 2 3 19 B 7 Check the Level in the Drive Hubs 3 19 B 8 Check the Glow Plugs Diesel Models 3 20 B 9 Check and Adjust the Engine 3 21 B 10 Test the Ground Control Override 3 22 B 11 the Platform Self leveling sse 3 23 Genie vill Z 34 22 IC Part No 119987 June 2007 Section 3 TABLE OF CONTENTS Rev Scheduled Maintenance Procedures continued 12 Test the Engine Idle 3 23 B 13 Test the Fuel Select Operation Gasoline LPG Models 3 24 B 14 Test the Drive Brakes 3 25 B 15 Test the Drive Speed Stowed Position 3 26 B 16 Test the Drive Speed Raised or Extended Position 3 27 B 17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 28 B 18 Perform Hydraulic Oil Analysis 3 29 B 19 Testthe Alarm Package if equipped 3 29 B 20 Replace the Diesel Fuel Filter Water Separator Element Diesel Models 7 ee ea 3 30 B 21 Perform Engine
49. 3 Gasoline LPG models Disconnect the ignition coil wire from the center of the ignition coil Diesel models Hold the manual fuel shutoff lever clockwise to the closed position 4 Turn the key switch to ground control and pull the Emergency Stop button to the on position at both the ground and platform controls HYDRAULIC PUMPS 5 Observe the pressure gauge while cranking the engine Immediately stop if the pressure reaches or exceeds 3000 psi 206 bar Result The pressure gauge reads 3000 psi 206 bar immediately stop cranking the engine The pump is good Result The pressure fails to reach 3000 psi 206 bar the pump is faulty and will need to be serviced or replaced Component damage hazard CAUTION Hydraulic pressure in excess of 3000 psi 206 bar may result in severe component damage 6 Remove the pressure gauge and install the hydraulic hose 7 Gasoline LPG models Install the ignition coil wire to the center of the ignition coil Diesel models Release the manual fuel shutoff lever How to Remove the Function Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the pump Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loos
50. A Hydraulic Schematic 4WD Models from serial number 1547 to 2899 5 42 A Hydraulic Schematic 4WD Models from serial number 2900 to 3241 5 44 Genie Part No 119987 2 34 22 IC xiii June 2007 This page intentionally left blank Genie TEREX COMPANY 2 34 221 Part No 119987 June 2007 Section 2 Specifications Specifications REV Machine Specifications Fluid capacities Tires and wheels Rough terrain Industrial Fuel tank capacity 12 gallons 45 4 liters Tire si 10 16 5 NHS 9 14 5 LT SR Hydraulic tank capacity 18 gallons Tire ply rating Tread 6 68 1 liters Sidewall 6 Hydraulic system capacity 22 gallons Overall tire diameter 30 5 in 28in including tank 83 3 liters 77 5 71 1 cm Drive hubs 17 fl oz Wheel diameter 16 5 in 14 5 in 0 5 liter 42 cm 36 8 cm Drive hub oil type EP 80 90W gear oil Wheel width 10 in 7 in service classification GL5 25 4 cm 18 cm Wheel lugs 4WD 9 5 8 18 Wheel lugs 2WD Front 8 5 8 18 8 5 8 18 Rear 9 5 8 18 9 5 8 18 Tire pressure 45 psi 100 psi 3 1 bar 6 89 bar Lug nut torque 125 ft lbs 125 ft lbs 170 Nm 170 Nm 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 Genie TEREX COMPANY Part No 119987 2 34 22 1 2 1 Sect
51. B 18 Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil CHECKLIST B PROCEDURES B 19 Test the Alarm Package if equipped Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes Travel alarm Descent alarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the ground controls side turntable cover The alarms and beacon will operate with the engine running or not running 1 Atthe ground controls pull out the red Emergency Stop button to the on position and turn the key switch to ground control Result The
52. BLU WHT 1 E BLKWHT 8 he GLOW PLUG RELAY Fr GLOW g PLUG P RED WHT423 E H D FLASHING BEACONS elow PTS 1 PLUG 2 64 55 a Bal mm ok m i 65 WNT RED 26 WATER TEMPERATURE START SENDER 1 2 io E li ja o a vy a gt g 1 1 2 WHT BLK 25 START ae LE Qe e OIL PRESSURE SENDER 1 WHT a 5 7 HOUR METER Lf BLK R1 E H e Eg STARTER MOTOR FUEL SOLENOID L y 4 if AUXILIARY 3 p POWER RED 27 E H AUXILIARY AUXILIARY POWER p POWER RED 1 RELAY AUXILIARY PUMP 8 25 E m g zy 8 N m x RED REDIBLK 1 RED BLK 28 E H m e g WHT 2 RED WHT 23 E H T e LEVEL SENSOR gt z 1 5 8 BLK RED 3 E BLK RED te BLK 2 SE BLK R5 E H Lj 214 BLK RED R4 E H 1 Mud RPM SOLENOID 9 00 4 1 BLK WHT 41 E H 0 T 5 GLOW PLUGS x ORG BLK 1 BI ORG BLK 41 E H Q Q x3 sets RED EH mE t ALTERNATOR bj WHT421 EH 1 1 I i 1 EE ei 834 LE au besel Ee een el e 8 RED RED 20 E H le 119987 2 34 22 1 Se
53. Es Hydraulic Schematic 2WD Models from serial number 1187 to 1546 REV A A B D E F G H J K L M N B A 1 CHARGE PRESSURE B A fe cc cL I TUTO xU LUE 3500 pa PSI AUXILIARY PUMP pud 5 0 5 GPM 71 2 PSI LIFT STEER TS T PUMP GC 59 4 3 0 GPM H i Li J yop S E 320 1 PSI 51 52 DRIVE PUMP L1 P1 Ex T3 mg e 4 Q25PSI 4 wyorauuictank CHARGE PRESSURE A PORT 221 250 B Psi rl Pe B PORT 69 69 d RIGHT 7 le RER SAG AB 0 025 7 BRAKE 1 eene inch 7 B 2 spo ej e TRACTION L LEFT L MANIFOLD STEERING BRAKE 2 SPEED REAR LA CYLINDER 8 MANIFOLD BRAKE J Genie TEREX COMPANY 5 34 Z 34 22 IC Part No 119987 June 2007 Section 5 Schematics T_T Hydraulic Schematic 2WD Models REV A from serial number 1187 to 1546
54. GENERATOR OPTION 4 go H p HE HH T LL 1 2 aoan 3500 PSI 72000 PSI l Lu co Poe T 3 220 PSI Y Ti a a DRIVE PUMP 3 98 HYDRAULIC TANK e CHARGE PRESSURE 1 5 6 ih NE me inch ii AA 7 2SPD p TRACTION REAR MANIFOLD BRAKE 2 SPEED RIGHT MANIFOLD 8 STEERING 5 38 Z 34 22 IC Part No 119987 REVA PLATFORM LEVELING SLAVE CYLINDER 3000 PSI 4 51 MASTER CYLINDER um 0 052 4 0 052 inch TURNTABLE ROTATE 5 9 CU IN REV X 1500 PSI 3 1 Ze 17 SECONDARY BOOM CYLINDER June 2007 Section 5 Schematics Hydraulic Schematic 2WD Models from serial number 2901 to 3241 F
55. ORG RED 1 ORG BLK 1 BLU RED 1 BLU WHT 1 d GRN WHT 3 RED WHT 3 t z y Ed 20 20 x e ale c z LO 8 Y Or 3 m m P mT 4 o g 58 O z m m o o o c m Qu DE 2 ago 2 z 2 PO GET d E n n m 2 h 4 255 al RED g _ BRN dd c LABEL DESCRIPTION R P2 EMERGENCY STOP BUTTON 2 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER 5 TS1 AUXILIARY TOGGLE SWITCH TS2 START ENGINE TOGGLE SWITCH 754 HIGH LOW RPM TOGGLE SWITCH 4 2 156 GLOW PLUG TOGGLE SWITCH 9 157 PLATFORM ROTATE TOGGLE SWITCH TS8 JIB UP DOWN TOGGLE SWITCH 759 PLATFORM LEVEL TOGGLE SWITCH d TS10 SECONDARY BOOM UP DOWN TOGGLE SWITCH x loe e Fs i TS11 PRIMARY BOOM UP DOWN TOGGLE SWITCH 7 TS12 TURNTABLE ROTATE TOGGLE SWITCH O TS13 EXTEND RETRACT TOGGLE SWITCH 2 TS14 DRIVE RANGE TOGGLE SWITCH 6 1615 DRIVE ENABLE TOGGLE SWITCH 4 zi Ai ALARM CR g d Li DRIVE ENABLE LIGHT 2 LC RED WHT 2 m w w le els o 2 2 o 2 o 2 m lt gt 2 n E E B Sg 9 8 9 E E B g 9 P m
56. The engine should change to low idle 7 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Result The engine should not change to high idle 8 Press down the foot switch Result The engine should change to high idle REVA B 13 Test the Fuel Select Operation Gasoline LPG Models Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made when the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Startthe engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section
57. WA 98073 9730 425 881 1800 Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Copyright 2002 by Genie Industries is a registered trademark of Genie Industries Rev B Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures June 2007 This page intentionally left blank Genie TEREX COMPANY 3 4 Z 34 22 IC Part No 119987 June 2007 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector compan
58. level surface Boom in the stowed position Turntable rotated with the boom between the non steer wheels Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death D 777 Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Without safety alert symbol used CAUTION to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performin
59. links to the ground Tap the pin the other direction and lower the opposite leveling link Do not remove the pin 5 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 6 Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the barrel end pivot pin Crushing hazard The jib boom AWARNING and or platform could fall when the pin is removed if not properly supported 7 Usea soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the machine AWARNING Crushing hazard The jib boom lift cylinder could fall when the pins are removed if not properly supported by the overhead crane Genie TEREX COMPANY 4 14 Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 4 1 Plastic Cable Track The primary boom cable track guides the cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom How to Repair the Plastic Cable Track Component damage hazard The CAUTION primary boom cable track can be damaged if it is twisted a link separation point b lower clip 1 Use a slotted screwdriver to pry down on the lower clip
60. mt RED oe RED ISM 4 RED 1 27 RED EH RED SP AUXILIARY PUMP r OPTION 2 23 RED WHT MH KEYSWITCH POWER BRN RED EH 12GA WHT 2 23 WHT SP KEYSWITCH POWER BLK CR5 BLK 2 22 BLK SP 12 TO PLATFORM 3 Di RED CR1 12GA LS2 WHT CR2 21 WHT EH WHT SP IGNITION POWER cB2 gt J or 27 GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT GRN 3 17 GRN SP PLAT ROTATE LEFT RED 5 ORG RED 3 16 DRIVE ENABLE HM OROIBECISA ORG BLK 3 15 oRG BLI MH ORG BLK SP PLAT LEVEL DOWN ORG 3 14 ORG MH ORG SP PLAT LEVEL UP 1563 559 CABLE WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT ORG TB14B R E BLK 5 BLU WHT 3 12 WHT FOOTSWITCH 5 OPTION 3 BLu BLI a 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN ORG BLK TB15B 9 LS3 BLU 3 10 BLU MH BLU SP SEC BOOM UP RED 6 ORG T4A BLK RED CR5 BLK RED 3 9 HORN 1856 TS58 1361 1957 ORNETA BLK WHT 3 BLK WHT MH BLK WHT SP BOOM RETRACT 4 10 9 BLK 3 7 BLK MH BLK SP BOOM EXTEND 4 0 0 mM WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION De 1 L R WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE RIGHT O u Ou CABLE WHT 3 WHT MH WHT SP TURN ROTATE LEFT V 1 oPTiON3 RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN RED 3 1 RED MH RED SP PRIM
61. o 5 2 5 Ela 2 o D o 2 z 2 2 5 i c i i o 8 BJ 09 2 a 8 B gos pg 9 uic 5 9 5 5 9 5 5 x 27 a l 6 e E e 8 cem 2 Part No 119987 A TEREX COMPANY Z 34 22 IC June 2007 Section 5 Schematics p V M B Platform Control Box Wiring Diagram Diesel Models from serial number 1547 to 1996 Section 5 Schematics June 2007 Platform Control Box Wiring Diagram Diesel Models from serial number 1997 to 3241 Section 5 Schematics R June 2007 Platform Control Box Wiring Diagram Diesel Models from serial number 1997 to 3241 arya VV NOTES REMOVE JUMPER JP1 FOR CE VERSION REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED
62. 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels and place a lifting jack of ample capacity under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support A CAUTION 4 Remove the lug nuts Remove the tire and wheel assembly Crushing damage The machine may fall if not properly supported 5 Remove the dust cap cotter pin and castle nut 6 Pullthe hub off the spindle The washer and outer bearing should fall loose from the hub 7 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing REVA How to Install the Hub and Bearings oN QC When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced Be sure that both bearings are packed with clean fresh grease Place the large inner bearing into the rear of the hub Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub Slide the hub onto the yoke spindle Component damage Do not CAUTION apply excessive force or damage to the lip of the seal may occur Fill the hub cavity with clean fresh grease Place the outer bearing into the hub Install the washer and castle nut Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Rotate the hub by hand wh
63. 11 Platform self leveling A 9 Engine maintenance 10 Fuel filter water EE ENNE B 13 Fuel select separator Perform every 200 hours A 11 Engine maintenance Comments Genie Part No 119987 Gasoline LPG models B 14 Drive brakes B 15 Drive speed stowed B 16 Drive speed raised or extended B 17 Fuel and hydraulic tank cap venting B 18 Hydraulic oil analysis B 19 Alarm and beacon B 20 Replace fuel filter separator Diesel models Perform every 400 hours B 21 Engine maintenance Diesel models TEREX COMPANY 2 34 22 IC Section Scheduled Maintenance Procedures June 2007 MAINTENANCE INSPECTION REPORT Model Checklist C Rev A C 1 Clean fuel tank Serial number Diesel models C 2 Engine maintenance Diesel models Date Perform every 800 hours Hour meter 3 Engine maintenance Machine owner Diesel models Inspected by print ChecklistD RevA Y NR Inspector signature D 1 Boom wear pads D 2 Free wheel Inspector title configuration D 3 Drive hub oil Inspector compan P PE D 4 Replace hydraulic filters Instructions D 5 Turntable rotation bolts Make copies of this report to use for D 6 each inspection Turntable bearing wear Select the appropriate checklist s for D 7 Engine maintenance th
64. 1187 to 1546 5 23 A Platform Control Box Wiring Diagram Diesel Models from serial number 1547 to 1996 1 5 24 A Platform Control Box Wiring Diagram Diesel Models from serial number 1997 to 3241 5 25 A Platform Control Box Wiring Diagram Gasoline LPG Models from serial number 1187 to 1546 5 26 A Platform Control Box Wiring Diagram Gasoline LPG Models from serial number 1547 to 1996 sss 5 27 A Platform Control Box Wiring Diagram Gasoline LPG Models from serial number 1997 324 5 28 A Generator Option Wiring Diagram from serial number 1547 to 1996 5 29 A Generator Option Wiring Diagram from serial number 1997 to 3241 5 30 A Load Sense Option Wiring Diagram from serial number 1187 to 1546 5 31 A Sense Option Wiring Diagram from serial number 1547 to 1996 5 32 A Load Sense Option Wiring Diagram from serial number 1997 to 3241 5 33 A Hydraulic Schematic 2WD Models from serial number 1187 to 1546 5 34 A Hydraulic Schematic 2WD Models from serial number 1547 to 2899 5 36 A Hydraulic Schematic 2WD Models from serial number 2900 to 3241 5 38 A Hydraulic Schematic 4WD Models from serial number 1187 to 1546 5 40
65. 2 so 718 70 962 750 1016 990 1342 1139 m 1749 1477 8 1952 1654 2074 1 2304 ETS 3620 2 7640 2067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size 6 As Class 8 8 Class 10 9 03 Class 12 9 mm 5 6 110 120 150 170 210 240 380 420 m A o DR DRY 854 775 91 105 132 DRY DRY 458 622 612 830 583 791 778 1055 682 925 909 1233 iv ile ER z 5 i ER c 5 5 1 M P gt O1 ol Alo CO O O1 ala age E Em j ole oO oA j J NI zi c a r c 00 8 E lt r c 172 8 9 lt 172 8 i e z M o olol RO s PORSA kaa EA 9 gt w si EN E a za gt a a 0 A O Oo NI AIN ge uA A co po OW co APY OTN No gt olo ERR oo NI ON BR OI 41
66. 2 Close the two hydraulic tank shut off valves at Test or Replace the Hydraulic Oil CAUTION Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key Replacement or testing of the hydraulic oil is switch and tag the machine to essential for good machine performance and inform personnel of the condition service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Genie requires that this procedure be performed every 2000 hours or two years whichever comes first The machine uses Dexron equivalent hydraulic oil Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination 3 Remove the drain plug from the hydraulic tank open closed to verify that changing the oil is and completely drain the tank into a container necessary If the hydraulic oil of suitable capacity Refer to Section 2 is not replaced at the two year Specifications inspection test the oil quarterly 2052 Bodily injury hazard Beware of he oil wh fails th ao ewer lene ACAUTION hot oil Contact with hot oil may cause severe burns Perform this procedure with the boom
67. 21A P5 WHT BLK 25A BLK 22A WHT 23A P1 Onc O O nc RED 27A _ GRN 17A 3 GRN BLK 18A CABLE BLK WHT 8A s BLK 7A C TS25 TS23 WHT RED 3A RED 1A P HM RED BLK 2A 7624 CABLE 5 4 7522 BLU 10A BLU BLK 11A TS26 Eu CABLE 4 TS21 m TS17 TS16 WHT 4A 5 TS20 TS19 WHT BLK 5A 1 1 i E E CABLE CB2 CB1 RED 20A GRN 43A GRN BLK 44A ORG 14A 6 ORG BLK 15A asi RED R1 30 3 BLK WHT 34A BLK 33A BLK RED 35A ENGINE MANIFOLD HARNESS BLK7 BRN 6 47 BRM EH GROUND BRN 5 BRN 2 46 BRN BRN GROUND GRNIWHT 1 45 GRN BLK 1 44 GR BK S P JIB DOWN 43 GRN S P JIB UP ORG RED 1 42 OG BK 21SM ORG BLK 1 41 OG BK E H PULSE PICKUP WHT 7 ORG 1 40 WHT 8 WHT 6 LIMIT SWITCH BLU RED 1 39 LP BLU WHT 1 38 GAS BLU BLK 1 37 BLU BK M H STEER LEFT BLU 1 36 BLU MH STEER RIGHT BKRD CR3 _ BLK RED i 35 BK RD S P RPM
68. 3 4 WHT MH WHT SP TURN ROTATE RIGHT RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN RED 3 1 BED MH RED SP PRIMARY BOOM UP D WHT 12 gt After serial number 2267 L DENOTES TEST PORT SEE OPTIONAL WIRING BLK CR1 1 START RELAY ORG BLK EH C 2 TACHOMETER HO START INPUT RED 27D LC aux on BRN CR4 IGNITION START HC 5 GROUND MODULE 6 BATTERY WHT TB23B LC kevewn KEY BYPASS SRNBLCGR2 HC IGN FUELON WETEN 10 ENG FAULT GRN BLK ISM 9 BLK RED 35D RED SP 12GA WHT 140A CRT CR CR4 BRN ISM 5 BLK RED EH 14GA BLK EH 14GA WHTZID 24 BLK WHT 34D RED ISM 6 BLK RED 9D BRN SP BRN OPT 4 BRN EH BRN 52B CONTROL BOX GROUND gt TEREX COMPANY 5 19 Z 34 22 IC Part No 119987 PLATFORM LEVEL CUTOUT CE VERS ON ONLY SPARE WIRE LIST OPTION NUMBERS GRN WHTA 1 PLATFORM LEVEL CUTOUT ORG RED 1 2 FLASHING BEACON ORG BLK 1 3 DESCENT ALARM GRN WHT 3 4 AC GENERATOR RED WHT 3 GENERATOR OPTION GRN WHT 1 45 GRN WHT EH GRN WHT TB35 AC GENERATOR BLK RED CR3 BLK RED 1 35 GRN WHT TB45 BLK
69. 4 3500 PSI i mam en ie s en A 0 5 2 gt XC CSN L IETSTEER nn OOO 320 PSI Ti 3 Po 2 __ jJ s2 P1 DRIVE PUMP r d T3 99 X 4 o HYDRAULIC TANK o CHARGE PRESSURE M 5 T2 M4 94 Lua KS FRONT he LA Aa RIGHT BRAKE Al 2880 4 I LEFT BRAKE 2 SPEED ieee MANIFOLD 52 4WD STEERING TRACTION MANIFOLD Genie Z 34 22 IC Part No 119987 REVA June 2007 Section 5 Schematics EIc H H Hydraulic Schematic 4WD Models REVA from serial number 1187 to 1546 N M L K J H G F E D C B A PLATFORM LEVEL SLAVE CYLINDER
70. 49 LS1 LS2 JUNCTION 45 GENERATOR OPTION OPTION 3 GRN BLK 44 GRN BLK SP JIB DOWN GRN 1 43 GRN SP JIB UP BLK 8 ORG 1 40 OFF LIMIT SPEED BLU RED 1 39 LP BLUMWHT 1 38 GAS BLU BLK 1 37 m BLU BLK MH STEER RIGHT BLU 1 36 a BLU MH STEER LEFT BLK RED CR3 BLK RED 1 35 BLK RED SP HIGH RPM BLK WHT CR8 BLK WHT 1 34 gt 6 1 5 BLK ISM 3 BLK 1 33 BLK sP START WHT RED CH WHT RED 1 32 Cl WHT RED SP BRAKE RELEASE WHT BLK 1 31 WHT BLK EH DRIVE REVERSE WHT 4 30 WHT EH DRIVE FORWARD REDAWHT 1 29 RED WHT CH HIGH LOW DRIVE RED BLK 1 28 RED BLK MH TILT ALARM RED ISM 4 RED 1 27 RED EH RED SP AUXILIARY PUMP 21 23 RED WHT MH KEYSWITCH POWER WHT 2 23 WHT ISM 7 WHT SP KEYSWITCH POWER BLK CR5 BLK 2 22 co BLK SP 12 TO PLATFORM WHT CR2 21 WHT EH WHT SP IGNITION POWER GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT GRN 3 17 GRN SP PLAT ROTATE LEFT RED 5 ORG RED 8 16 DRIVE ENABLE RELAY ORG BLK 3 15 ORG BLK MH ORG BLK SP PLAT LEVEL DOWN ORG 3 14 ORG MH ORG SP PLAT LEVEL UP WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT BLK 5 BLU WHT 3 12 WHT FOOTSWITCH BLU BLK 3 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN BLU 3 10 BLU MH BLU SP SEC BOOM UP BLK RED CR5 BLK RED 3 9 HORN BLK WHT 3 8 BLKWHT MH BLK WHT SP BOOM RETRACT BLK 3 7 BLK MH BLK SP BOOM EXTEND WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE LEFT WHT
71. 9 Solenoid valve 3 position 4 way EI Steer left right 10 12 ft lbs 14 16 Nm 10 Flow regulator valve 0 1 0 38 L MIN Ms Differential sensing circuit 35 40 ft lbs 47 54 Nm 11 Differential sensing valve C Loss All f nctlons i cuoco ftn rte 35 40 ft lbs 47 54 Nm 12 Diagnostic fitting Testing 13 Priority flow regulator valve 1 4 5 L MIN Steering 2e ee eene 34 40 ft lbs 47 54 Nm 14 Relief valve 3200 psi 221 bar System 25 30 ft lbs 34 41 Nm 15 Solenoid valve 2 position 3 way Mas Primary boom retract 8 10 ft lbs 11 14 Nm 16 Solenoid valve 2 position 3 way Sed Primary boom 8 10 ft lbs 11 14 Nm This list continues Please turn the page Genie TEREX COMPANY 2 34 22 IC Part No 119987 Section 4 Repair Procedures June 2007 MANIFOLDS REV E 0 LBS Ld Or T g 2 34 22 1 119987 Section 4 Repair Procedures June 2007 MANIFOLDS Function Manifold Components continued The function manifold is mounted to the turntable under the gr
72. BLUMWHT 3 12 WHT EH DRIVE ENABLE BLU BLK 3 11 BLU BLK M H BU BK S P SECONDARY BOOM DOWN BLU 3 10 BLU MH BLU S P SECONDARY BOOM UP BK RD CR5 BLK RED 3 9 HORN BLK WHT 3 8 BLKWHT MH BKWT S P BOOM RETRACT BLK 3 7 BLI S P BOOM EXTEND WHT RED 3 6 WR MH WT RD S P BOOM FUNCTION FLOW CONTROL WHT BLK 3 5 WHT BLK MH WT BK S P TURNTABLE ROTATE LEFT WHT 3 4 WHT MH WHT S P TURNTABLE ROTATE RIGHT RED WHT 3 3 RD WT S P RED BLK 3 2 RED BLK MH RD BK S P PRIMARY BOOM DOWN RED 3 1 RED MH RED S P PRIMARY BOOM UP D B A BERR 1 86 1 START RELAY ORG BEKSHD 2 TACHOMETER BLK 33B START INPUT IGN START 4 AUX ON MODULE BRN GRD R4 85 HS Ts GROUND TEREE 6 BATTERY 7 KEY PWR 8 KEY BYPASS 9 IGN FUELON 10 ENG FAULT BRN 5 ISM BLK RED R4 E H rd BLK RED 35D RED CB2 CR1 CR2 1 BLK 1 ISM ES as TT T TL BLK RI EH WHT 21D BLK R5 MH BLUWHT R6 E H BLU RED R7 EH BPLKWHTREEH 695 1 crel BLK 22D BLU WHT 38D BLU RED 39D BLK WHT 34D enie A TEREX COMPANY Part No 119987 Z 34 22 IC June 2007 Section 5 Schematics et Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 1187 to 1546 Section 5 Schematics June 2007 Ground Control Box Wiring Diagram
73. C 4 aux on IGNITION START PLATFORM LEVEL CUTOUT CE VERSION ONLY RED CR1 12GA CO s GROUND MODULE MM M EMEN WHT RED 32A 6 BATTERY CABLE BLK WHT 34A 3 7 Key pwr BLU WHT 38A 8 KEY BYPASS CONTROL RELAY 1 0 6 BLU RED 39A ewe 1 9 IGN FUELON CR1 ENGINE START BLK 33A WHT EH LS vo ene CR2 ENGINE RUN CR3 RPM CUTOUT ese CR4 HIGH RPM LABEL DESCRIPTION a CRS HORN PI EMERGENCY STOP BUTTON ENGINEMANIFOLD SOLENOID KS1 KEY SWITCH CHASSIS HARNESS BLKRED aSD CR8 CHOKE TS15 AUXILIARY TOGGLE SWITCH GRN BLK ISM 9 WHT 14GA TS16 ENGINE START TOGGLE SWITCH TS17 ENGINE CHOKE TOGGLE SWITCH RED SP 12GA 2 7918 ENGINE FUEL SELECT TOGGLE SWITCH BLK ISM 1 BRN ISM 5 7 TS19 FUNCTION ENABLE ENGINE RPM TOGGLE SWITCH Bae md 7520 TURNTABLE ROTATE TOGGLE SWITCH BLK RED EH 14GA TS21 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS22 PRIMARY BOOM UP DOWN TOGGLE SWITCH BLK EH 14 GA WHT 21D TS23 BOOM EXTEND RETRACT TOGGLE SWITCH Q BLK RED MH 14GA BLU WHT EH BLU RED EH BLKWHT EH 14GA TS24 PLATFORM LEVEL TOGGLE SWITCH TS25 PLATFORM ROTATE TOGGLE SWITCH s az 6 7 1526 JIB UP DOWN TOGGLE SWITCH H BLK WHT 34D CB1_ CIRCUIT BREAKER ENGINE 10A BLK 22D C CB2 CIRCUIT BREAKER CONTROLS 10A h HM HOUR METER EH ENGINE HARNESS BLKAED9D BLU RED 39D 8 MH MANIFOLD HARNESS 4
74. CHARGE PRESSURE Mr RE 5 A PORT mcs x pcd cd Ec o 71 T2 6 SRL PSI M4 T P i Wore 1 Em ome B 2SPD ELI L p Ere REAR p IPRC BRAKE 2 SPEED RIGHT LH MANIFOL 8 MANIFOLD i M1 oo STEERING MP j 5 36 2 34 22 IC Part No 119987 June 2007 Section 5 Schematics am rom aH Hydraulic Schematic 2WD Models REV A from serial number 1547 to 2900 M L K J F E D C B A PLATFORM LEVEL SLAVE CYLINDER 1 SECONDARY BOOM PRIMARY BOOM PRIMARY BOOM EXTENSION JIB BOOM 0 032 inch WIE HD E TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI S m 4 5 9 CU IN IREV PU ges w um 1 MASTER ju E HL WIE ST 3 si BN WEE L A 52 3000 PSI 3000 PSI 2500 PSI 3000 PSI 2500 PSI Bi 1 51 3 1 3 1 3 1 3 1
75. Configuration Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake configuration is essential to safe operation and good machine performance Hydraulically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Check each torque hub disconnect cap to be sure it is in the engaged position brake disengaged position brake engaged position CHECKLIST B PROCEDURES B 7 Check the Oil Level in the Drive Hubs Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees plugs plugs Models with O ring plugs Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Apply pipe thread sealant to the plugs then install the plugs into the hub 5 Repeatthi
76. Fitting Torque Specifications Perform this procedure with the boom in the stowed position 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform rotator See 2 3 How to Remove the Platform Rotator 3 Remove the jib boom See 3 1 How to Remove the Jib Boom 4 Remove the jib boom bell crank See 3 2 How to Remove the Jib Boom Bell Crank 5 Supportthe slave cylinder REVA 6 Tag and disconnect the hydraulic hoses to the slave cylinder and connect them together using a connector Plug the slave cylinder hoses from the cable track AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the external snap ring from the slave cylinder barrel end pivot pin 8 Use a soft metal drift to remove the slave cylinder barrel end pin 9 Remove the slave cylinder from the primary boom 10 Support the cable track with an overhead crane or similar lifting device 11 Remove the cable track mounting fasteners then remove the cable track from the boom and lay it off to the side Component damage hazard CAUTION The boom cable track can be damaged if it is twisted 12 Remove the turntable end cover 13 Remove the pin retaining fasteners from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Pull the cy
77. GENERATOR SWITCH OPTION L1 DRIVE ENABLE LIGHT L2 OVERLOAD LIGHT OPTION que M s fes m TILT ALARM Z 7515 912 TS10 m N O 1 ae 2 TS2 TS6 x O O O O O O TS14 a TS9 TS13 L1 L2 7547 O Q D O O O O O O O P3 NO enie G Z 34 22 IC 5 30 Part No 119987 June 2007 Section 5 Schematics Generator Option Wiring Diagram from serial number 1997 to 3241 Section 5 Schematics June 2007 m M M Load Sense Option Wiring Diagram from serial number 1187 to 1546 Section 5 Schematics TT Load Sense Option Wiring Diagram from serial number 1187 to 1546 June 2007 o LOAD SENSOR BLK F S ooo Fuse o gt 35 Q E 8 o o 8 2 g 2108 7
78. KEY SWITCH TS51 AUXILIARY TOGGLE SWITCH TS52 ENGINE START TOGGLE SWITCH TS54 FUNCTION ENAB ENGINE RPM TOGGLE SWITCH TS56 ENGINE GLOW PLUG TOGGLE SWITCH 7 TS57 PLATFORM ROTATE TOGGLE SWITCH TS58 UP DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH 7560 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS62 TURNTABLE ROTATE TOGGLE SWITCH 7563 BOOM EXTEND RETRACT TOGGLE SWITCH CB1 CIRCUIT BREAKER ENGINE 10A CB2 CIRCUIT BREAKER CONTROLS 10A HM HOUR METER EH ENGINE HARNESS MH MANIFOLD HARNESS 8 CH CHASSIS HARNESS SP SWITCH PANEL CR CONTROL RELAY ISM IGNITION START MODULE A2 BRK REL TRAVEL ALARM enie CABLES LS3 CABLE cp JE dp ENGINE MANIFOLD HASSIS HARNESS WHT 7 BLK RED MH 14GA BLK WHT EH 14GA BRN 5 BRN OPTION 1 52 GROUND BRN 2 BRN 2 3 52 BRN GND STUD GRouND WHT 6 WHT 8 50 LS2 LS4 JUNCTION BLK 7 BLK 6
79. LS4 JUNCTION ORG RED 1 2 FLASHING BEACON WHT RED EH BLK 7 BLK 6 49 LS1 LS2 JUNCTION ORG BLK 1 3 DESCENT ALARM 45 GENERATOR OPTION GRN WHT 3 4 AC GENERATOR BRN GND STUD OPTION3 GRN BLK 1 44 GRN BLK SP JIB DOWN RED WHT 3 aA GRN 1 43 GRN SP JIB UP WHT 21A Q BLK 8 ORG 1 40 OFF LIMIT SPEED WHUBUGEH BLU RED CR7 BLU RED 1 39 BLU RED SP LP BLU WHT CR6 BLU WHT 1 38 BLU WHT SP GAS BLK 22A BLU BLK 1 37 BLU BLK MH STEER RIGHT 2 gt WHT 23A BLU 1 36 BLU MH STEER LEFT P1 BLK RED CR3 BLK RED 1 35 BLK RED SP HIGH RPM BLK WHT CR8 BLKWHT 1 34 BLK WHT SP CHOKE NC lo BLK ISM 3 33 BLK SP START KS1 WHT RED CH WHT RED 1 32 WHT RED SP BRAKE RELEASE Gd 1815 cx WHT BLK 1 81 WHT BLK EH DRIVE REVERSE AC GENERATOR OPTION 9 RED 27A WHET GRN WHT 1 45 GRN WHT EH GRN WHT TB35 AC GENERATOR GRN 17A REDWHT 1 28 BEDANHEGH DRIVE BLK RED CR3 BLK RED 1 35 GRN WHT TB45 BLK RED SP HIGH RPM RED BLK 1 28 RED BLK MH TILT ALARM GRN BLK 18A REDisM4 RED 1 27 RED EH RED SP AUXILIARY PUMP L BLK WHT 8A OPTION 2 23 RED WHT MH KEYSWITCH POWER lt lt lt lt WHT 2 23 WHT SP KEYSWITCH POWER 3 oS BLK CR5 BLK2 22 BLK SP 12V TO PLATFORM O TS25 TS23 WHT CR2 21 WHT EH WHT SP IGNITION POWER GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT RED 1A GRN 3 17 GRN SP PLAT ROTATE LEFT HM R
80. R X A RED 3 g 2 p c R L Q d Oj O 7 X B R gt o_o a d g g B o 5 25 5 eis o z Dio o o m m o wo om 2 E IE Wu qo Ww IE m m m ES m I es WE II a im s 3885 8 2 2 2 S FR BE g Rep 8 b B B amp amp 8 68 Sz 9 5 9 5 mg A3 A o ja A fb oL e amp 5 e Part No 119987 A TEREX COMPANY Z 34 22 IC June 2007 Section 5 Schematics p 5 Platform Control Box Wiring Diagram Gasoline LPG Models from serial number 1997 to 3241 Section 5 Schematics June 2007 HERES Generator Option Wiring Diagram from serial number 1547 to 1996 June 2007 Section 5 Schematics Generator Option Wiring Diagram REV from serial number 1547 to 1996 TILT ALARM LABEL DESCRIPTION P2 EMERGENCY STOP BUTTON P3 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY SWITCH TS2 START SWITCH TS3 GLOW PLUG SWITCH 54 TS5 RPM SWITCH TS6 TURNTABLE ROTATE SWITCH TS7 SECONDARY BOOM UP DOWN SWITCH TS8 PRIMARY BOOM UP DOWN SWITCH TS9 EXTEND RETRACT SWITCH TS10 PLATFORM LEVEL SW
81. RED SP HIGH RPM ORG TB14B ORG BLK TB15B RED 6 10 9 BRN 52C ORG BLK MH ORG MH ORG 6 ORG BLK 3 15 ORG BLK CR10 ORG BLK SP PLATFORM LEVEL ORG 3 14 ORG CR9 ORG SP PLATFORM LEVEL UP CONTROL RELAY 1 0 CR1 ENGINE START CR2 ENGINE RUN CR3 RPM CUTOUT CR4 HIGH RPM CR5 HORN CR8 CHOKE REV A ES34D6L REV ES34GP5F BRN GRD ORG TB14B ORG BLK TB15B RED 6 CR10 CR9 ORG BLK E H PLATFORM LEVEL CUT OUT OPTION VOLTAGE GAUGE OIL PRESSURE GAUGE LA COOLANT TEMPERATURE GAUGE P1 ONc O KS1 NO NO WHT RED 26A BRN GROUND WHT 21A WHT BLK 25A BLK 22A WHT 23A Oni tsis RED 27A GRN 17A 1823 GRN BLK 18A BLK WHT 8A BLK 7A WHT RED 3A b RED 1A R1 TS24 TS26 ro O RED BLK 2A TS22 BLU 10A BLU BLK 11A TS21 WHT 4A TS19 Pa 99 WHT BLK 5A CB2 TS20 RED 20A GRN 43A GRN BLK 44A ORG 14A ORG BLK 15A RED R1 30
82. SWITCH TS61 PRIMARY BOOM UP DOWN TOGGLE SWITCH BLK EH 14 GA TS62 TURNTABLE TOGGLE SWITCH BLK RED MH 14GA BLU WHT EH BLU RED EH BLKIWHT EH 14GA TS63 BOOM EXTEND RETRACT TOGGLE SWITCH 1 CIRCUIT BREAKER ENGINE 10 6 7 8 CB2 CIRCUIT BREAKER CONTROLS 10A BLK WHT 34D HOUR METER BLK 22D ENGINE HARNESS MH MANIFOLD HARNESS T i ARES BLK RED 9D BLU WHT 38D BLUREDIQOD 8 SP SWITCH PANEL CR CONTROL RELAY BHN SP BRN OPT 4 ISM IGNITION START MODULE BHN EH BRN 52B A2 BRAKE RELEASE TRAVEL ALARM OPT CONTROLBOXGROUND 22 ES34GP5L enie A TEREX COMPANY Part No 119987 Z 34 22 IC 5 22 June 2007 Section 5 Schematics ti Ground Control Box Wiring Diagram Gasoline LPG Models from serial number 1986 to 3241 Section 5 Schematics June 2007 EE J Platform Control Box Wiring Diagram Diesel Models from serial number 1187 to 1546 Section 5 Schematics June 2007 EE Platform Control Box Wiring Diagram Diesel Models from serial number 1187 to 1546 REV A SPARE WIRES RED JIB 2 Q 9 9 ORGREDS Q ORG RED 42 1 DI _ LABEL DESCRIPTION em kml GRN WHT 45 1 d
83. Specifications 1 Raise the primary boom to a horizontal position Then extend the boom approximately to 4 feet 1 m until the extension cylinder rod end pivot pins are accessible Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 2 Remove the external snap rings from the 9 extension cylinder rod end pivot pins Use a soft metal drift to remove the pins PRIMARY BOOM COMPONENTS Remove the pin retaining fasteners from the extension cylinder pivot pin Use a soft metal drift to remove the pin Remove the rear turntable cover 10 Carefully pull out and properly support the 4 Raise the secondary boom until the master cylinder rod end pivot pin is accessible 5 Remove the drive speed limit switch from the pivot end of the primary boom Do not disconnect the wiring 6 Remove the pin retaining fasteners from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin 7 Manually retract the master cylinder and push it toward the platform end of the boom to obtain enough clearance for the extension cylinder removal 8 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Geni
84. boom bell crank from the extension boom Crushing hazard The jib boom AWARNING bell crank could become unbalanced and fall when the pins are removed if not properly supported and secured to the lifting device JIB BOOM COMPONENTS 3 3 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Lower the jib boom until the platform is resting on the blocks JT T Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section 4 Repair Procedures June 2007 BOOM COMPONENTS REVA 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the jib boom lift cylinder AWARNING P injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Usea soft metal drift to tap the rod end pivot pin half way out and lower one of the leveling
85. boom toggle switch in the up direction Adjust the voltage to 8 5 to 9V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Boom function speed controller specifications Threshold 5 to 6V DC Max out 8 5 to 9V DC Section 4 Repair Procedures June 2007 Platform Components 2 1 Platform How to Remove the Platform 1 Separate the foot switch wiring quick disconnect plug from the platform toeboard 2 Remove the platform control box mounting fasteners and lower the control box If your machine is equipped with an air line to platform option the air line must be disconnected from the platform before removal 3 Place blocks under the platform for support Carefully lower the platform onto the blocks 4 Remove the platform mounting fasteners and remove the platform REVA 2 2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of primary boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Platform Leveling Slave Cylinder When removing a hose assembly or fitting the O ring if equipped on the fitting and
86. brake release terminal ground terminal positive terminal A drive forward threshold potentiometer high range potentiometer 20070000 Turn the keyswitch to platform controls and pull out the red Emergency Stop button out to the on position at both the ground and platform controls Do not start the engine Part No 119987 June 2007 Section 4 Repair Procedures REVA Setthethreshold The drive joystick adjustments are not final adjustments Final adjustments will need to be made to meet drive speed specifications Refer to Section 2 Specifications 7 Press down the foot switch Move the drive joystick off center in either direction just until a current reading appears on the mulitmeter display 8 Hold the drive joystick in position and adjust the THRESHOLD potentiometer until the multimeter displays approximately 600 mA Set the high range 9 Press down the foot switch Move and hold the drive joystick full stroke in either direction 10 Hold the drive joystick in position and adjust the HI RANGE potentiometer until the multimeter displays slightly higher than 1100 mA Set the low range 11 Start the engine from the platform controls and raise the primary boom approximately 3 feet 1 m Turn the engine off 12 Press down the foot switch Move and hold the drive joystick full stroke in either direction 13 Hold the drive joystick in position and adjust the LO RANGE potentiometer u
87. dry 380 ft lbs 5 515 Nm Noe 36in bs Nm 10 center bolt GR 8 lubricated 280 ft lbs SAE No 4 10 ft lbs 13 Nm 379 Nm SAE No 6 14 ft lbs 19 Nm 3 8 16 bolts GR 8 dry 44 ft Ibs 60 Nm SAE No 8 38 ft lbs 51 Nm 3 8 16 bolts GR 8 lubricated 33 ft Ibs 45 Nm SAE No 10 41 ft Ibs 55 Nm Turntable rotate assembly SAE No 12 56 ft lbs 76 Nm Rotate bearing mounting bolts lubricated 180 ft lbs Valve Coil Resistance 244 Nm Note The following coil resistance specifications are at Rotate bearing motor 93 ft lbs an ambient temperature of 68 F 20 C As valve coil mounting bolts lubricated 126 Nm resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by Drive motor and hubs 4 for each 18 F 20 C that your air temperature increases or decreases from 68 20 Drive hub mounting bolts lubricated 180 ft lbs 244 Nm Valve coil specifications Drive motor mounting bolts lubricated 2 position 3 way solenoid valve 10V DC 60 3 8 16 GR 5 23 ft Ibs schematic items V S Q P M U T 31 Nm R O N AA AB CA CB CC and CD 7 16 14 GR 5 37 ft lbs 50 Nm 3 position 4 way solenoid valve 10V DC 60 schematic item E Proportional solenoid valve 12V DC 50 schematic item D Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie TEREX COMPANY 2 34 22 1
88. flashing beacon should be on and flashing 2 Move the primary boom switch to the down position hold for a moment and then release it Move the secondary boom switch to the down position hold for a moment and then release it Result The descent alarm should sound when each switch is held down 3 Turn the key switch to platform control Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES 4 Atthe platform controls pull out the red Emergency Stop button to the on position Result The flashing beacon should be on and flashing 5 Press down the foot switch Move the primary boom switch to the down position hold for a moment and then release it Move the secondary boom switch to the down position hold for a moment and then release it Result The descent alarm should sound when each control switch is held down 6 Press down the foot switch Move the drive control handle off center hold for a moment and then release it Move the drive control handle off center in the opposite direction hold for a moment and then release it Result The travel alarm should sound when the drive control handle is moved off center in either direction REVA B 20 Replace the Diesel Fuel Filter Water Separator Element Diesel Models Engine specifications require that this procedure be performed every 400 hours Rep
89. or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Before cylinder removal is considered bleed the slave cylinder to be sure there is no air in the closed loop 1 Extend the boom until the slave cylinder barrel end pivot pin is accessible 2 Raise the boom slightly and place blocks under the platform for support Lower the boom until the platform is resting on the blocks Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 3 Remove the pin retainer fastener from the rod end pivot pin 4 Remove the external snap ring from the barrel end pivot pin 5 Use a soft metal drift to remove the rod end pivot pin 6 Use a soft metal drift to remove the barrel end pivot pin 7 Carefully pull the cylinder out of the boom 8 Tag and disconnect the hydraulic hoses from the slave cylinder and connect them together with a connector Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray PLATFORM COMPONENTS How to Bleed the Slave Cylinder 1 Raise the jib boom to a horizontal position 2 Activate the platform level toggle switch up and down through
90. plugs Install the plugs into the drive hub 6 Repeatthis procedure for each torque hub Part No 119987 Genie 7 34 22 IC CHECKLIST D PROCEDURES D 4 Replace the Hydraulic Filters Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic filters are essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Hydraulic Return Filter Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns The return hydraulic filter is mounted on the hydraulic tank 1 Clean the area around the oil filter then remove the filter with an oil filter wrench 2 Apply a thin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled Section Scheduled Maintenance Procedures June 2007 CHECKLIST D PROCEDURES Hydraulic Suction Filter before serial number 1547 Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns The suction hydraulic filter is mounted in the engine compartment 4 Close the shut off valve behind the filter 5 Clean the area around the oil filter then remove the filter with an oil filter wr
91. remove the pin Carefully lower the cylinder down through the secondary boom just enough to access the hydraulic hoses Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched andithen torcued to specification 9 Tag disconnect and plug the hydraulic hoses que p from the secondary boom lift cylinder Cap the during installation Refer to ittinas onthe cylinder Section Two Hydraulic Hose and 9 Fitting Torque Specifications Bodily injury hazard Spraying R AWARNING hydraulic oil can penetrate and otate the turntable to the side until the boom is bim skin Loosen hydraulic centered between the steer and non steer tires connections very 1 to allow 2 Raise the primary boom to full height Do not the oil pressure to dissipate extend it Turn the machine off gradually Do not allow oil to squirt or spray 3 Attach a lifting strap from an overhead crane to PS the lug on the rod end of the secondary boom 10 Carefully remove the cylinder by raising it lift cylinder through the top of the secondary boom using the overhead crane AWARNING Crushing hazard The secondary Genie TEREX COMPANY boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Part No 119987 Z 34 22 IC 4 29 Section 4 Repair Procedures June 2007 Kubota D 905 Engine 6 1 6 4 Timing Adjustment Flex Plate Complete in
92. start line 11 Continue at top speed and note the time when the machine reference point crosses the finish line Select a test area that is firm level and free of obstructions Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Startthe engine from the platform controls Move the engine idle select switch to foot switc activated high idle rabbit and foot switch symbol Press down the foot switch and raise the primary boom above horizontal Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line h Genie Part No 119987 Z TEREX COMPANY 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES B 17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Free breathing fuel and hydraulic tank caps are essential for good machine performance and service life A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the caps be inspect
93. than 0 41 inch 1 cm thick If the wear pad is more than 0 41 inch 1 cm thick shim as necessary to obtain zero clearance and zero drag 4 Extend and retract the primary boom through the entire range of motion to check for tight spots that could cause binding or scraping Always maintain squareness between the primary boom outer and inner tubes Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing machine configured to free wheel without operator knowledge may cause death or serious injury and property damage Collision hazard Select a work AWARNING site that is firm and level 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 15000 Ibs 7000 kg under the drive chassis between the non steering wheels 3 the wheels off the ground and then place jack stands under the drive chassis for support 4 Disengage the torque hubs by turning over the torque hub disconnect caps on each non steering wheel hub pj disengaged position ap brake engaged position Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST D PROCEDURES 5 Manually rotate each non steering wh
94. 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 YTJ Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may result in minor or moderate injury Be sure to wear protective eye wear and other protective clothing if the situation Be aware of potential crushing hazards such as moving parts free swinging or warrants it 3i unsecured components when lifting or placing loads Always wear approved steel toed shoes 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 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 that all tools and working areas Be sure any forklift overhead crane or l other lifting or s
95. v B 22 6 z A E L 1 E i lt T 5 L 4 LL 2 T 5 F mio w 0 o 2 Dio E i E E E EE E IE NIE d 41815219 22173 3555 54522 56845 2a 2 amp 5 5 p 20 O B 5 mg E ae a jo 3 51 RGB Ek l 6 56 6 a E e 16 ES34GP3E REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED Genie A TEREX COMPANY Part No 119987 Z 34 22 IC 5 26 June 2007 Section 5 Schematics p MM M M 5 Platform Control Box Wiring Diagram Gasoline LPG Models from serial number 1187 to 1546 Section 5 Schematics June 2007 p Platform Control Box Wiring Diagram Gasoline LPG Models from serial number 1547 to 1996 Section 5 Schematics June 2007 l r H M E Platform Control Box Wiring Diagram Gasoline LPG Models from serial number 1547 to 1996 A B C D E F J K L NOTES i gt REMOVE JUMPER JP1 FOR CE VERSION 2 gt REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED
96. 02 Fax 31 183 581 566
97. 1 1 1 1 i i 1 J 2 a RED WHT REDMWHT 1 25 b iow RED 250 119 WHT 8 d ORG P WHT 7 HE asie lt 0020 jo gt WHT RED 3 B WHT RED E H ze 3 KL amp a 9 E JIB BOOM i 5895 DOWN m JIB BOOM DOWN GRN BLK 1 alm E 55 RIGHT BRNJJIB PLATFORM ROTATE g t so 55 Po GRN BLK 3 8 8 d e qom PLATFORM ROTATE 1 1 mE 3 BLK6 32 dE DE e g E O _ ORGH4EH Ibi UP 7 PLATFORM LEVEL 2 2 DOWN 6 ORG BLK 15 EH Ibi 1 1 1 ORG 3 UP PLATFORM poww LEVEL ORG BLK 3 BLK 7 E H EXTEND PRIMARY BOOM 1 RETRACT Fe BLKWHTHS E H BLK 3 EXTEND PRIMARY RETRACT BOOM BLK WHT 3 t 5 1 1 B RED amp EH Al PRIMARY BOOM DOWN e RED BLKH2 E H Ibi x RED 3 PRIMARY BOOM RED BLK 3 o BLU 10 E H Al UP SECONDARY 2 pown BOOM BLU BLK 11 E H Ibi ie 2 2 BLU 3 SECONDARY BLU BLK 3 27 a 9 9 9 a c c c 5 5 GROUND DRIVE ENABLE LIMIT SWITCH DRIVE EDC STEER LEFT STEER RIGHT MOTOR STROKE SECONDARY BOOM UP LIMIT SWITCH BOOM UP LIMIT
98. 10 MH SECONDARY BOOM UP SECONDARY 1 1 BOOM re BLU BLK 11 MH i SECONDARY DOWN 1 eem i 1 5 DECENT ALARM 9 BLUS OPTION 1 1 SECONDARY dl SS BLU BLK 3 E g 5 5 5 16 2 34 221 119987 1 ALL LIMIT SWITCHES SHOWN WITH BOOM IN STOWED POSITION EXCEPT AS NOTED SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON STEER WHEEL 2 SWITCH SHOWN WITH BOOM EXTENDED 3 June 2007 Section 5 Schematics rtl Electrical Schematic Gasoline LPG Models from serial number 1997 to 3241 Section 5 Schematics June 2007 E Ground Control Box Wiring Diagram Diesel Models from serial number 1187 to 1546 Section 5 Schematics June 2007 IE RO Ow Hr r Ground Control Box Wiring Diagram Diesel Models from serial number 1187 to 1546 A B C D E VOLTAGE OIL PRESSURE COOLANT TEMP WHT RED 26A GROUND O CABLE 2 4 WHT
99. 119987 STEERING CYLINDER REVA June 2007 Section 5 Schematics EI M Hydraulic Schematic 4WD Models REVA from serial number 1547 to 2900 N M L K J H G F E D C B A PLATFORM LEVEL SLAVE CYLINDER SECONDARY PRIMARY BOOM PRIMARY BOOM EXTENSION JIB BOOM 1 M 0 032 inch do E TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI gt a P 2 5 9 CU IN REV ae RUPEE eed 2 E us sn MASTER 3 Me A E AL si HE s py b oux 52 3000 PSI 3000 PSI 2500 PSI 3000 PSI 2500 PSI Bi 221 1 5 1 3 1 3 1 3 1 3 1 51 52 ci 2 M1 M2 5 C6 7
100. 3 1 TOTO JIB DOWN g 1 i i GRN 1 uP JIB BOOM LDOWN GRN BLK 1 1 1 1 1 2 23 5 i 2 1 PLATFORM ROTATE RIGHT az RIGHT E PLATFORM 5 ROTATE E g ae PLATFORM ROTATE LEFT Z gt T sc ES GRN BLK 3 55 ROHT qp oc 1 oo pg PLATFORM LEFT ROTATE GRN 3 i o i 1 I a 2 8 n 1 ORG 6 6 5 S los 1 E 5 Mr gt ORGHA MH PLATFORM t 5 LEVELUP PLATFORM 1 LEVEL 5 ORG BLK 15 MH 4 PLATFORM LEVELDOWN 1 1 1 1 1 ORG 3 1 EVEL ORG BLK 3 1 1 1 1 1 i BLK 7 MH PRIMARY BOOM EXTEND PRIMARY 1 BOUM BLK WHT 8 MH Al PRIMARY BOOM 1 1 1 i EXTEND PRIMARY BOOM BLKWHT 3 1 i 4 _ B 1 i PRIMARY PRIMARY E 1 BOOM de RED BLK 2 MH Al PRIMARY BOOM DOWN 1 i i RED 3 1 PRIMARY BOOM RED BLK 3 1 1 1 i i BLU 10 MH 1 Al SECONDARY E SECONDARY BOOM re BLU BLK 11 MH i SECONDARY BOOM DOWN i i DECENT ALARM BLU 3 g OPTION SECONDARY d BOOM BLU BLK 3 5
101. 34 22 IC Part No 119987 June 2007 Section 5 Schematics NENNEN Electrical Schematic Diesel Models from serial number 1187 to 1546 REVA WHT FS RED RED RED RED 5 WHT BLK 5 CH GND RIGHT TURNTABLE ROTATE LEFT WHT 4 CH WHT BLK 3 RIGHT TURNTABLE ROTATE WHT 3 BLK RED 1 FS HI TS19 FUNCTION ENABLE a L ENGINE RPM TS5 HI TB35 HIGH RPM qu au GND ES34D1G TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT RPM COIL BLK RED R3 CUTOUT RELAY GRN WHT 1 GRN WHT RPM AC GENERATOR un ON BLK WHT 1 BLK WHT OPTION 1 GLOW PLUG TB34 GLOW PLUG RELAY 4 FLASHING BEACON TS17 GLOW PLUG IGNITION START MODULE 1 Ts2 RED FS1 June 2007 WHT AUXILIARY START TS1 PUMP START 1 START RELAY TS16 10 ENG FAULT 2 TACHOMETER 8 START INPUT 4 AUX ON 5 5 GROUND 6 BATTERY B33 7 KEY PWR 8 KEY BYPASS 9 IGN FUELON WHT EH WHT EH WATER TEMPERATURE SWITCH OIL PRESSURE BLK
102. 96 C B A LOAD SENSOR EJ FUSE RED BLK L 18 034 N N BLK 3 gt gt a WHT lt YEL gt LI m o o 2 9 E 4 5 5 zr or P 5 f i E E 3 fen di O 53 Genie Part No 119987 A TEREX COMPANY Z 34 22 IC June 2007 Section 5 Schematics Load Sense Option Wiring Diagram from serial number 1547 to 1996 June 2007 Section 5 Schematics Load Sense Option Wiring Diagram REVA from serial number 1997 to 3241 N M L K J H G F E D C B A LOAD SENSOR lo LABEL DESCRIPTION P2 EMERGENCY STOP BUTTON P3 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER E TS1 AUXILIARY SWITCH o TS2 START ENGINE SWITCH 2 a BRN ge 3 TS4 RPM SWIT
103. ARY BOOM UP ORG BLK MH ORG MH TS53 TS60 D p A 000 WHT BLK 5A Wd L R Qnae 52122 DENOTES TEST PORT SEE OPTIONAL WIRING 5 ORG BLK 3 15 ORG BLK CR10 ORG BLK SP PLATFORM LEVEL DOWN WHT 4A CABLE a stant RELAY ORG 3 14 ORG CR9 ORG SP PLATFORM LEVEL UP BLU 10A 2 j ORG BLK EH LC 2 BLU BLK 11A BUGSSD PLATFORM LEVEL CUTOUT CE VERSION ONLY 1 men 3 START INPUT RED BLK 2A M GRN 43A IGNITION START GRN BLK 44A re 5 GROUND MODULE BLKWHT 34A m LC 6 BATTERY BLU WHT 38A BLU RED 39A 7 KEY POWER KEY BYPASS 6 ME SANBLK CR2 9 IGN FUELON METEN HE 10 ENGINE FAULT LABEL DESCRIPTION CONTROL RELAY 1 0 P1 EMERGENCY STOP BUTTON om CR1 ENGINE START 1 KEY SWITCH CR2 ENGINE RUN TS51 AUXILIARY TOGGLE SWITCH RED ISM 6 CR3 RPM CUTOUT TS52 ENGINE START TOGGLE SWITCH EEPO CR4 HIGH RPM TS53 FUEL SELECT TOGGLE SWITCH GAN ELK ISM 9 WHT 14GA CRS5 HORN 7554 FUNCTION ENAB ENGINE RPM TOGGLE SWITCH M gt 5 n CR6 FUEL PUMP GAS 7556 ENGINE CHOKE TOGGLE SWITCH CR7 LPG SOLENOID TS57 PLATFORM ROTATE TOGGLE SWITCH BLK ISM 1 BRN ISM 5 7 CR8 CHOKE 1558 JIB UP DOWN TOGGLE SWITCH TS59 PLATFORM LEVEL TOGGLE SWITCH SE BLK RED EH 14GA TS60 SECONDARY BOOM UP DOWN TOGGLE
104. AST EITHER NON STEER WHEEL 2 SWITCH SHOWN WITH BOOM EXTENDED 3 June 2007 Section 5 Schematics CE Electrical Schematic Diesel Models from serial number 1997 to 3241 June 2007 Section 5 Schematics Electrical Schematic Gasoline LPG Models from serial number 1187 to 1546 REVA ORG BLK 8 a o6 B WHT BLK 5 E H m d WHT 4 E H Ibi WHT BLK 3 WHT 3 n pepper em s EF J 86 155 1 BLK RED 1 Esel o HIGH RPM D T TES ENGINE SPEED x ENGINE SPEED THIGH RPM EL BLK RED oz id p P 24 lt npe 2 Bee E REDWHT 23 E H RED BLKHRE EH ze o 2 8 BLU RED 1 BLU RED R7 EH m we oe FUEL BLU WHTA oe BLUWHT R6 E H e MP 4 B 5 2 E BLU WHTAR6 EH te De gt FUEL
105. CH TS6 GLOW PLUG SWITCH RED BLK 5 E ws TS7 PLATFORM ROTATE SWITCH a TS8 JIB UP DOWN SWITCH WHT 5 a bue ci TS9 PLATFORM LEVEL SWITCH at z TS10 SECONDARY BOOM SWITCH TS11 PRIMARY BOOM SWITCH A WHT FS 2 5 TS12 TURNTABLE ROTATE SWITCH O20 e 9 1913 PRIMARY BOOM EXTEND SWITCH I em OOO 7514 DRIVE RANGE SWITCH 2 REDAWHT TS15 DRIVE ENABLE SWITCH 4 TS47 AC GENERATOR SWITCH OPTION L1 DRIVE ENABLE LIGHT L2 OVERLOAD LIGHT OPTION QOO la OOO d n n ou Uu Q 2 SB 8 p m 000 5 g o F gt LOAD SENSE OPTION X ea NT BRN 9 i 2 P2 FS1 oi B w 6 RED FS i T 1 BLK FS O O gt O 1 WHT NO d DICRILE old PEDWHT N WHT FS 7 KCN 4 BRN 1 LOAD SENSE i T z cu O 4 o 2 o Genie A TEREX COMPANY Part No 119987 Z 34 22 IC 5 33 June 2007 Section 5 Schematics Load Sense Option Wiring Diagram from serial number 1997 to 3241 Section 5 Schematics June 2007
106. CH CHASSIS HARNESS BRN SP BRN OPT 4 SP SWITCH PANEL BRN EH BRN 52B CONTROL RELAY ISM IGNITION START MODULE CONTROLBOX GROUND J3 A2 BRAKE RELEASE TRAVEL ALARM EE enie A TEREX COMPANY 5 21 Z 34 22 IC Part No 119987 June 2007 Section 5 Schematics T_T Ground Control Box Wiring Diagram REV A Gasoline LPG Models from serial number 1986 to 3241 N M L K J H G
107. Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged KUBOTA D 905 ENGINE 6 5 Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 225 F 107 C If the coolant temperature rises above the switch point the switch contacts close and the engine will shut off to prevent damage The engine will not start until the temperature drops below the switch point An over temperature indicator light at the ground controls should turn on when the switch closes Component damage hazard CAUTION Do not crank the engine with the over temperature light on The engine oil switch is a normally closed switch The switch contacts open at approximately 7 psi 0 48 bar If the oil pressure drops below the switch point the contacts open and the engine will shut off to prevent damage A low oil pressure indicator light at the ground controls should turn on when the switch opens Component damage hazard CAUTION Do not crank the engine with the low oil pressure light on Genie Part No 119987 TEREX COMPANY Z 34 22 IC 4 31 Section 4 Repair Procedures June 2007 Kubota DF750 DF752 Engine 7 1 Choke Adjustments The choke is solenoid operated and functions only in the gasoline mode This choke will not operate in LPG mode Choke adjustments ar
108. Connectan rpm gauge to the engine and then start the engine from the ground controls Result Low idle should be 1300 rpm Skip to step 3 if the low idle rpm is correct 2 Loosen the lock nut then turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the lock nut and recheck the rpm Diesel idle adjustments a locknut b idle adjustment nut low idle adjustment screw d rpm solenoid 3 Move the engine idle control switch to high idle rabbit symbol from the ground controls Result High idle should be 3000 rpm If high idle rpm is correct disregard adjustment step 4 4 Loosen the lock nut on the solenoid then turn the solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the lock nut and recheck the rpm REVA B 10 Test the Ground Control Override Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the red Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin the platform red Em
109. E D C B A 1 PRIMARY BOOM CYLINDER EXTENSION CYLINDER JIB BOOM 0 032 Inch 2 PLATFORM ROTATE ee ee pv TROU ES 3 Q m H E O w 1E E 3 x li mU NS Ili L1 X eer 3000 PSI 2500 61 V 3000 PSI 2500 PSI 3 1 3 1 1 51 3 1 4 5 _ 9 d L 1 i zs LE P0 1600 PSI 2800 PSI i i 6 removed after serial rare els EL PEDES 6 E j NIA MUR Cri 7 4 4 4 c 2 P 0 3 GPM Lars n a A E 5 8 Genie A TEREX COMPANY Part No 119987 Z 34 22 IC 5 39 June 2007 Section 5 Schematics Hydraulic Schematic 2WD Models from serial number 2901 to 3241 Section 5 Schematics June 2007 Hydraulic Schematic 4WD Models from serial number 1187 to 1546 A B C D E F L B A CHARGE PRESSURE 1 e POE MEER j
110. ED B tz T HIGH RPM E BLK RED R3 gt RPM RELAY Mr EP Re CERE ORC Y ERR en 11 3 GRNMWHT 1 Foe GRNWHT 4 GENERATOR OPTION P ON 1 mn AC GENERATOR 1 e E RPM CUTOUT COIL RELAY o M FUEL RELAY FUEL RELAY o 2 s BLU RED 1 BLURED R7 EH 8 ns LPG SOLENOID FUEL SELECT T cas BLU WHT 1 rel BLUMWHT R6 EH J ANTI DIESEL VALVE 8 o BLUWHT R6 EH p NES Pas FUEL PUMP gt SELECT teas 81 01 Fil E BLK WHT R8 n p 4 CHOKE RELAY E CHOKE BLKAWHT 1 3 5 WHT BRN lt 4 VOLT METER GAUGE 9 X CHOKE WHT WNT RED4 URED EH WATER TEMPERATURE GAUGE gt y BER 853 WHT 4 WHTELK EH 4 OIL PRESSURE GAUGE 15 o D alg E las WHT EH START 4 WATER TEMPERATURE SWITCH N E SE usz 8 58528429862 p ENGINE g foo eleme WHT EH E T START OIL PRESSURE SWITCH 1 1 9 BRN WHT 4 HOUR METER 4 POWER RELAY 3 E if gt 4 e 1 1 5 WHT 21 EH 5 lt 4 IGNITION SYSTEM IE im 8 ia 4 START RELAY a iF BLK R1 EH f 4 gt 1 tr to 1 zz x 1 BRS a STARTER MOTOR lt m lt 6 I
111. ED BLK 2A RED 5 ORG RED 3 16 DRIVE ENABLE RELAY ORG BLK 3 15 ORG BLK MH ORG BLK SP PLAT LEVEL DOWN AU ORG 3 14 ORG MH ORG SP PLAT LEVEL UP WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT O TS24 1822 CABLE BLK 5 BLU WHT 3 12 WHT FOOTSWITCH LO 5 OPTION BLU BLK 3 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN L 153 BLU 3 10 BLU MH BLU SP SEC BOOM UP BLU BLK 11A BLK RED CR5 BLK RED 3 9 HORN 4 7826 BLK WHT 3 8 BLK WHT MH BLK WHT SP BOOM RETRACT BLK 3 7 BLK MH BLK SP BOOM EXTEND QRG BLKTTBISB amp 5 V 7 ar WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION RED 6 192 208 2 4 7 WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE LEFT 1517 1516 WHT 3 4 WHT MH WHT SP TURN ROTATE RIGHT 10 9 OPT I OPTION 3 RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN 4 918 wHT4A RED 3 1 RED MH PRIMARY BOOM UP WHT BLK 5A B i B med 9 99 L G WHT 12 BRN 52C ie y TS20 ORG BLK MH ORG MH TS19 1 CB2 SEE OPTIONAL WIRING 5 4 T RED EH 12GA BLK CR1 51 ORG 6 GRN 43A ORG BLK EH LC 2 ORG BLK 3 15 ORG BLK CR10 ORG BLK SP PLATFORM LEVEL Down GRN BLK 44A BLK 33D ORG 3 14 ORG CR10 ORG SP PLATFORM LEVEL UP LC START INPUT ORG BLK 15A REED
112. EX COMPANY Foot switch PLAT KS1 _4 GRND Key switch HORN Horn button normally open P1 A red Emergency Stop button normally closed CR4 Relay contact normally open Toggle switch REVA v Spark plug Water temperature switch normally open OPS1 Oil pressure switch normally closed VAC Vacuum switch normaly open 250 Resistor h HM Hour meter Z 34 22 IC Part No 119987 June 2007 Section 5 Schematics REVA Pressure gauge Filter T Fixed displacement pump Bi directional motor 2 Bi directional variable displacement pump 2 speed bi directional motor o Pump prime mover engine or motor Double acting cylinder TUN 0 035 Orifice with size us Check valve Di Relief valve Priority flow divider HOT Solenoid operated dump valve LA Differential sensing valve Hydraulic Symbols Legend ESI OA Solenoid operated proportional valve Solenoid operated 2 pos 3 way directional valve S pL AE Solenoid operated 3 pos 4 way directional valve 001 Pilot operated flow control valve
113. EX COMPANY Part No 119987 Z 34 22 IC 4 3 Section 4 Repair Procedures June 2007 PLATFORM CONTROLS 1 2 Drive Joystick after serial number 1546 How to Adjust the Drive Joystick Perform this procedure with the engine off 1 Remove the fasteners from the platform control box lid 2 Open the control box lid and locate the drive joystick AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry o Cow em f le 9 w o boom function speed controller b drive joystick 4 4 Z 34 22 IC REVA Locate and disconnect the wire connected to terminal A on the drive joystick circuit board Set a multimeter to read DC current The multimeter when set to read DC current should be capable of reading up to 1200 mA Connect the black lead from the multimeter to the wire that was just disconnected Connect the red lead of the multimeter to terminal A on the joystick TITI 11 Genie A TEREX COMPANY low range potentiometer terminal R activates low range terminal B drive reverse terminal X
114. Flow divider combiner valve Duis Controls flow to non steer end drive motors in forward and reverse 15 18 ft lbs 20 24 Nm 7 Orifice plug 0 045 inch 1 14 mm K Equalizes pressure across flow divider combiner valve D 8 Check v lve ses esr Direction control circuit 25 30 ft lbs 34 41 Nm 9 Relief valve 210 psi 14 5 bar Bus Charge pressure circuit 35 40 ft lbs 47 54 Nm 10 Orifice plug 0 052 inch 1 32 Equalizes pressure across flow divider combiner valve E 11 Check valve pilot operated Je Smoothes the shift from low to high range 10 12 465 14 16 Nm 12 Shuttle valve 3 position way Bodas Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 10 12 ft lbs 14 16 Nm Genie 4 48 Z 34 22 IC Part No 119987 2007 Section 4 Repair Procedures REVA MANIFOLDS Genie Part No 119987 Z 34 22 IC 4 49 Section 4 Repair Procedures June 2007 MANIFOLDS 9 7 Valve Adjustments Traction Manifold How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 to 600 psi 0 to 41 bar pressure gauge to the test port located on the traction manifold
115. HE 2 TACHOMETER LC START INPUT Omm CO IGNITION BRNGHD R485 5 Ground START RES Res BATTERY He WHT TB23B 7 Kev PWR key Bypass HERES 9 IGN FUELON HE 10 ENG FAULT BRN 5 ISM RED 6 ISM BLKRED 3sp PLERED RA EH WHT 9 ISM aes RED CB2 BLK 38D CRY CRA CR4 BLK 1 ISM THE BLK RI EH BLK R5 M H EM BLKWHT RE EH LORS LORS BLK 22D BLK RED 9D K WHT SSD enie A TEREX COMPANY Z 34 22 IC 5 17 Part No 119987 M LABEL DESCRIPTION Pi EMERGENCY STOP BUTTON KS1 KEY SWITCH TS15 AUXILIARY TOGGLE SWITCH 1516 ENGINE START TOGGLE SWITCH TS17 ENGINE GLOW PLUG TOGGLE SWITCH TS19 ENGINE RPM TOGGLE SWITCH TS20 TURNTABLE ROTATE TOGGLE SWITCH TS21 SECONDARY BOOM UP DOWN TOGGLE SWITCH TS22 PRIMARY BOOM UP DOWN TOGGLE SWITCH TS23 BOOM EXTEND RETRACT TOGGLE SWITCH TS24 PLATFORM LEVEL TOGGLE SWITCH TS25 PLATFORM ROTATE TOGGLE SWITCH TS26 JIB UP DOWN TOGGLE SWITCH 1 CIRCUIT BREAKER CONTROLS 10A CB2 CIRCUIT BREAKER ENGINE 10A HM HOUR METER R1 RESISTOR 5 OHM BOOM FUNCTIONS EH ENGINE HARNESS MH MANIFOLD HARNESS ORG TB14B ORG BLK TB15B RED 6 CR10 CR9 BRN GRD ORG BLK E H ORG E H PLATFORM LEVEL C
116. IARY PUMP I amp o gestores cc ie yi RED RED BLK t RED BLK 28 MH 1 3 e Loe o 1 m lt i i 1 WHT 2 RED WHT 23 MH 1 LEVEL SENSOR e 1 1 E 4H FLASHING BEACON 4 amp 29 BLK RED q EX BLK RED 3 4 HORN RELAY y 1 m BLK 2 BLK R5 MH Le E HORN Q E 3 a 2 em i BLK RED R4 EH 4 RPM SOLENOID 1 BLK WHT R8 EH CHOKE SOLENOID ere 1 t nd peson ORG BLK EH STA 2 1 a RED EH T ALTERNATOR WHT 21 EH Bex LECT a te mex odo 5 2 0777774444 2 858 808 gt amp RED RED CB1 EH 4 4 ES34GP1J Part No 119987 2 34 22 1 5 13 Section 5 Schematics from serial number 1547 to 1996 Electrical Schematic Gasoline LPG Models June 2007 WHT FS REVA
117. ITCH PLATFORM ROTATE SWITCH TS12 JIB UPIDOWN SWITCH TS13 DRIVE HIGH LOW OUTPUT SWITCH TS14 DRIVE ENABLE SWITCH TS15 AC GENERATOR SWITCH OPTION DRIVE ENABLE LIGHT 000 CABLE oe 3 2 d GRN WHT 1 TS14 TS6 TS7 1512 TS5 O OOO O C3 O O 000 S TS2 TS3 TS15 TS8 TS10 C O OF O O RED TS9 TS11 TS13 z z Z 34 22 IC 119987 5 29 Section 5 Schematics June 2007 Generator Option Wiring Diagram from serial number 1997 to 3241 REVA lo N LABEL DESCRIPTION PR EMERGENCY STOP BUTTON P3 HORN BUTTON DP1 DRIVE CONTROLLER BP1 BOOM FUNCTION SPEED CONTROLLER TS1 AUXILIARY SWITCH TS2 START ENGINE SWITCH TS4 RPM SWITCH TS6 GLOW PLUG SWITCH TS7 PLATFORM ROTATE SWITCH TS8 JIB UP DOWN SWITCH TS9 PLATFORM LEVEL SWITCH TS10 SECONDARY BOOM SWITCH 7811 PRIMARY BOOM SWITCH TS12 TURNTABLE ROTATE SWITCH TS13 PRIMARY BOOM EXTEND SWITCH TS14 DRIVE RANGE SWITCH TS15 DRIVE ENABLE SWITCH TS47 AC
118. ITCH m WHT 7 BRN 7 BOOM EXTEND LIMIT SWITCH t 555 858 8 gt WHT RED 3 e WHT RED E H 7 CONTROL r 2 8 3 sf JIB BOOM i 5898 DOWN 5896 1 JIB BOOM a GRN 1 JIB BOOM DOWN GRN BLK 1 1 RIGHT BRN JIB PLATFORM ROTATE us PLATFORM ROTATE so 55 Po GE GRN BLK 3 55 ao lea RE er PLATFORM i p LEFT GRN 3 i i t 1 d 1 2 32 nep 3 1 i A A 1 2 1 a a B ORGH4EH 1 t PLATFORM LEVEL UP PLATFORM LEVEL 2 DOWN Pd T PLATFORM LEVEL DWN 1 1 1 1 EE ER ete c eee 1 ORG 3 yup PLATFORM DOWN LEVEL ORG BLK 3 E BLK 7 E H EXTEND PRIMARY BOOM EXTEND PRIMARY BOOM E BLK WHT 8 E H PRIMARY BOOM RETRACT EXTEND PRIMARY RETRACT BOOM BLKWHT 3 RED amp EH PRIMARY BOOM UP PRIMARY BOOM DOWN RED BLK 2 E H PRIMARY BOOM DWN RED 3 up PRIMARY DOWN BOOM RED BLK 3 8 BLU 10 E H SECONDARY BOOM UP SECONDARY OM E BLU BLK 11 EH SECONDARY DWN 4 DECENT ALARM OPTIONAL 2 x BLU 3 SECONDARY DOWN BOOM BLU BLK 3 1 9 9 2 2 t enie G Z
119. LARM enie A TEREX COMPANY Part No 119987 Z 34 22 IC 5 18 June 2007 Section 5 Schematics Ground Control Wiring Diagram Diesel Models from serial number 1547 to 1985 Section 5 Schematics June 2007 E Ground Control Box Wiring Diagram Diesel Models from serial number 1986 to 3241 Section 5 Schematics June 2007 Ground Control Box Wiring Diagram Diesel Models from serial number 1986 to 3241 A B C D 1 VOLTAGE OIL PRESSURE COOLANT TEMPERATURE WHT 21A WHT RED EH TO C BRN GND WHT BLK EH BLK 22A WHT 23A WHT RED 32A P1 NO NO A2 PO we O4 M 551 RED 27A RED EH 12GA RED CR1 12GA BLK WHT 8A BLK 7A HM TS63 TS59 ORG BLK 15A WHT RED 6A ORG 14A TS58 GRN 17A TS57 GRN BLK 18A TS56 TS52 TS60 TS62 TS54 WHT BLK 5A O o bo WHT 4A BLU 10A BLU BLK 11A RED 1A RED BLK 2A GRN 43A GRN BLK 44A BLK WHT 34A BLK 33A BLK RED 35A LABEL DESCRIPTION P1 EMERGENCY STOP BUTTON KS1
120. LDS REVA 9 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the jib boom Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way CH Jib boom up down 8 10 ft lbs 11 14 Nm 2 Solenoid valve 3 position 4 way CI Platform rotate left right 8 10 ft lbs 11 14 Nm 3 Solenoid valve 2 position way CA uus Jib boom down 8 10 ft lbs 11 14 Nm 4 Solenoid valve 2 position way CB Platform rotate 8 10 ft lbs 11 14 Nm 5 Flow regulator valve 0 3 1 14 L MIN CG Platform rotate circuit 8 10 ft lbs 11 14 Nm 6 Solenoid valve 2 position 3 way CC Platform rotate right 8 10 ft lbs 11 14 Nm 7 Solenoid valve 2 position 3 way CD s Jib boom 8 10 ft lbs 11 14 Nm 8 Orifice 0 025 in 0 64 mm from serial number 1187 to 1891 Orifice 0 022 in 0 56 mm from serial number 1892 to 1969 CE Platform rotate circuit 9 Orifice 0 028 in 0 71 mm located in P port CF Platform rotate and jib boom circuit before serial number 2005 Genie TEREX COMPANY 4 44 2 34 22 1
121. LENOID ANTI DIESEL VALVE FUEL PUMP CHOKE RELAY WATER TEMPERATURE SENDER OIL PRESSURE SENDER HOUR METER IGNITION SYSTEM STARTER MOTOR AUXILIARY POWER RELAY AUXILIARY PUMP LEVEL SENSOR HORN RELAY HORN RPM SOLENOID CHOKE SOLENOID ALTERNATOR ES34GP1E enie G Z 34 22 IC Part No 119987 5 11 Section 5 Schematics from serial number 1187 to 1546 Electrical Schematic Gasoline LPG Models June 2007 REVA ORG BLK CN BRN 2 a 2 BLU RED 3 E WHTS gt BRN 5 WHTA E RED 5 BLK S a 5 BI E ul DRIVE ENABLE 1 BLU WHT 3 8 WHT BLK 1 WHT BLK 31 E H w WHT RED 1 WHT RED 32 E H 8 me BLU 1 E BLU 36 E H se d BLU BLK 1 fg BLU BLK 37 E H MERE
122. Loosen the drain plug located at the bottom of the bowl Allow t to drain into a suitable container until f a head bolt b vent plug separator head d filter bowl e drain plug 3 Tighten the vent plug and clean up any spills or wet surfaces If the fuel bowl is completely drained you must prime or bleed the fuel filter water separator before starting the engine See CHECKLIST A PROCEDURES step 5 4 Start the engine from the ground controls and check the fuel filter water separator for leaks Bleed the fuel system Before bleeding the system fill the fuel tank 5 Loosen the vent plug screw located on the filter head 6 Operate the hand primer until fuel free of air flows from the vent plug screw Tighten the vent plug screw on the filter head 7 Loosen the vent screw located on top of the fuel injection pump 8 Operate the hand primer until fuel free of air flows from the vent plug screw Tighten the vent plug screw on the injection pump 9 Clean up any fuel that may have spilled 10 Attempt to start the engine using the starter motor for a maximum of 15 seconds resting the starter for 30 seconds before trying again 11 Inspect the fuel filter water separator for leaks 1 Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Info
123. MH D Yo FLOW CONTROL _ 4 2 3 a 8 JIB UP mI m JIB BOOM 1 58955 2 i i TOTO E JIB DOWN i 1 1 i GRN 1 up JIB BOOM DOWN GRNBLK 1 1 1 1 1 1 i x 21 PLATFORM ROTATE RIGHT RIGHT 9 PLATFORM 5 1 ROTATE E 8 1 ge PLATFORM ROTATE LEFT g gt 1 a Wu RH ga E n ji 5 GRNBLK 3 8 8 lmeur pp p o 6 bpRM 1 PLATFORM i a 1 T ROTATE c LEFT GRN 3 i o bd iq fM n HR 1 r a bg 1 m 2 MI 1 Ss ORG 6 RED 6 11 p Td 7 PA rn 1 5 los i eL Te __ ORG 14 MH I PLATFORM rt 4r LEVELUP K PLATFORM 1 2 Lj LEVEL 1 ORGBLKHSMH 1 PLATFORM d ry 4 LEVELDOWN b iu L du i 1 ORG 3 uP 1 1 PLATFORM 1 ppown LEVEL ORG BLK 3 1 I 1 1 1 i BLK 7 MH 1 PRIMARY BOOM ExrEND i EXTEND PRIMARY g 1 BOOM BLKAWHT 8 MH PRIMARY t 7 1 1 1 1 1 1 1 i i BLK 3 EXTEND PRIMARY BOOM BLK WHT 3 1 1 1 i H i i RED 1 MH PRIMARY T h 1 BOOM UP PRIMARY g 1 1 BOOM RED BLK42MH i PRIMARY al 4 BOOM DOWN
124. Maintenance Diesel Models 3 32 Checklist C Procedures C 1 Clean Fuel Tank Diesel Models 80 3 33 C 2 Perform Engine Maintenance Diesel Models 3 34 C 3 Perform Engine Maintenance Diesel Models 3 34 Checklist D Procedures D 1 Check the Primary Boom Wear Pads 3 35 D 2 Check the Free wheel Configuration 3 35 D 3 Replace the Drive Hub 3 36 0 4 Replace the Hydraulic 3 37 D 5 Check the Turntable Rotation Bearing Bolts 3 39 D 6 Inspect for Turntable Bearing 3 40 D 7 Perform Engine Maintenance 3 41 Checklist E Procedures Part No 119987 E 1 Testor Replace the Hydraulic Oil 3 42 E 2 Grease the Steer Axle Wheel Bearings 2WD Models 3 43 E 3 Perform Engine Maintenance 3 45 Genio Z 34 22 IC ix June 2007 TABLE OF CONTENTS Section4 Rev Repair Procedures Introduction cT 4 1 PlatformControls 1 1 Horsepower Limiter Board before serial number 1547 4 2 1 2 Drive Joystick after serial number 1546 4 4 A Pl
125. Models REV A from serial number 2901 to 3241 L K J H G F E D C B A PLATFORM LEVELING SLAVE CYLINDER SECONDARY CYLINDER PRIMARY BOOM CYLINDER EXTENSION CYLINDER JIB BOOM 0 032 inch TURNTABLE ROTATE PLATFORM ROTATE 3000 PSI m od 5 9 CU IN RE MASTER 4 CYLINDER ME pee EE ME 21 oO WI 2 Qe Am o a ue X pisses ES PIN 3000 PSI p p asoopsi pu 82 1 5 1 31 3 1 1 5 1 3 1 1 Tu 51 52 ci c2 M1 M2 4 5 C7 C8 ee ieee ED il 1 GPM P1 joe H JU 00 1 1 TO i HELM BM M os Li OE HM MIL e ES x P 1600 PSI 1600 PSI 2800 PSI 3000 PSI 1500 PSI mu 3 1 3 1 _ number 3215 Ros A Bene ge _ __ __ ee __ __ 8 5 D d t M N 8 V ran AM I I 1 LAF Ap I Ap Mir 4m I E X i X ios D X 0 052 inch
126. OMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures ne REVA PRIMARY BOOM COMPONENTS 9 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin 10 Use a soft metal drift to remove the pin from the cylinder Do not remove the pin from the upper mid pivot Push the pin to one side only far enough to remove the cylinder Crushing hazard The upper ACAUTION secondary boom and the upper pivot may fall if the pivot pin is completely removed The pin should remain in one side of the upper secondary boom and upper mid pivot 11 Use the strap around the rod end lug to lower the cylinder out of the machine Genie A TEREX COMPANY Part No 119987 Z 34 22 IC 4 23 Section 4 Repair Procedures June 2007 Secondary Boom Components REVA E 49 Secondary Boom upper pivot upper compression arm mid pivot compression link lower secondary boom lower compression arm turntable pivot upper secondary boom ro Q0 08 Genie 4 24 Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures eer REVA SECONDARY BOOM COMPONENTS 5 1 6 Locate the cables from the primary boom cable track to the platform control box Number each Secondary Boom cable and its entry location at the platform control box How to Disassemble the 7 Open the platform control box Secondary Boom 8 Tag
127. OTATE TOGGLE SWITCH TS12 JIBUP DOWN TOGGLE SWITCH 2 TS13 DRIVE HIGH LOW OUTPUT TOGGLE SWITCH TS14 DRIVE ENABLE TOGGLE SWITCH TILT ALARM WHT DRIVE ENABLE LIGHT RED doc ae lt lt jo x m m m 5 mo gt w 2 2 o o mg 2 m vo o s 5 0 B o x amp 9 E acc 5 338 EX x 8 Be 8 8 8 m ses E pat s s 4 mpi a 8 gis so gps s e AR 8 5 BEAT 5 2 B 8 2 912 amp E amp amp amp 5 a amp amp Genie A TEREX COMPANY 5 27 Z 34 22 IC Part No 119987 REVA ES34GP3J REVA ES34GP3L L a34 June 2007 E NOTES Platform Control Box Wiring Diagram Gasoline LPG Models from serial number 1997 to 3241 lt 1 REMOVE JUMPER JP1 FOR CE VERSION 2 REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED
128. OWRPM ENGINE _ FUNCTION ENABLE 8 g SPEED HIGH RPM E BLK RED R3 e RPM RELAY A ER REEL HE E s 1 2 GRN WHT 1 GRNMWHT GENERATOR OPTION 1 GENERATOR 1 1 eee 2 0 RPM CUTOUT COIL RELAY o EH FUEL RELAY 2 FUEL RELAY 2 BLU RED 1 BLU RED R7 EH o e 4 LPG SOLENOID FUEL SELECT BLUMHT 1 BLU WHT RG EH m GAS i 4 ANTI DIESEL VALVE 8 e BLU WHT R6 EH p LP UE V 7 FUELPUMP D T SELECT teas E 01 Fil BLK WHT R8 v rt CHOKE RELAY CHOKE BLKWHT 1 3 5 0 CHOKE gt y 858 ME 9 825 5 WHT EH START FIERI 4 WATER TEMPERATURE SWITCH 2 582542206 D 8 cem see mo WHT EH E 1 START oelelejeeleio 4 OIL PRESSURE SWITCH STAR 1 BLK 9 WHT 3 4 HOUR METER LN 4 POWER RELAY at s m E 1 5 h c 12 WHT 21 EH IGNITION SYSTEM IE 15 4 START RELAY FU 1 BLK R1 EH t SD 1 1 1 LJ x E La 1 STARTER MOTOR AUXILIARY e 1 5 RED REDREREH 2 04 epe E 5 AUXILIARY 0 AUXILIARY RELAY 7 gt BEDA 8 4 1 1 b i Bi 1 4 AUXIL
129. Operator s Manual Kubota part number 1601 8916 1 OR the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota DF750 Operator s Manual Genie part number 97359 Kubota DF752 Operator s Manual Genie part number 84250 Kubota D905 Operator s Manual Genie part number 31743 Genie A TEREX COMPANY Part No 119987 Z 34 22 IC CHECKLIST E PROCEDURES Section Scheduled Maintenance Procedures June 2007 IO O B This page intentionally left blank Genie TEREX COMPANY 3 46 2 34 22 1 119987 June 2007 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Genie Z 34 22 IC Operator s Manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine p
130. PG models Disconnect the ignition How to Remove the Drive Pump coil wire from the center of the ignition coil CAUTION Component damage hazard The Diesel models Hold the manual fuel shutoff work area and surfaces where this lever clockwise to the closed position procedure will be performed must 3 Crankthe engine with the starter motor for 15 be clean and free of debris that could get into the hydraulic system that could result in severe component damage Dealer service is recommended seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Before serial number 1547 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump After serial number 1546 Disconnect the electrical connectors from the coils of the NFPE controller NFPE located on the drive pump Genie TEREX COMPANY 4 36 Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures I w r This page intentionally left blank Genie TEREX COMPANY Part No 119987 Z 34 22 IC 4 37 Section 4 Repair Procedures June 2007 Manifolds 9 1 Fun
131. R ERU RED CR1 12GA PES 5 GROUND MODULE WHT RED 32A CABLE CO 6 BATTERY WHT TB23B BLKAWHT 34A 3 LC 7 KEY pwr CONTROL RELAY 1 0 BLK 33A y KEY BYPASS CRI ENGINE START SA ___ 9 IGN FUELON 6 CR2 ENGINE RUN WHT EH CR3 RPM CUTOUT 10 ENG FAULT CR4 HIGH RPM _ CR5 HORN CH amp CHOKE LABEL DESCRIPTION N Pi EMERGENCY STOP BUTTON ENGINE MANIFOLD KS1 KEY SWITCH CHASSIS HARNESS TS15 AUXILIARY TOGGLE SWITCH GRN BLK ISM 9 BLK RED 35D TS16 ENGINE START TOGGLE SWITCH E RED SP 12GA WHT 14GA 7517 ENGINE CHOKE TOGGLE SWITCH ee TS18 1 a a n TS19 FUNCTION ENABLE ENGINE RPM TOGGLE SWITCH BRN ISM 5 7 TS20 TURNTABLE ROTATE TOGGLE SWITCH 7521 SECONDARY UP DOWN TOGGLE SWITCH BLK RED EH 14GA TS22 PRIMARY BOOM UP DOWN TOGGLE SWITCH 7523 BOOM EXTEND RETRACT TOGGLE SWITCH Q WHT 21D TS24 PLATFORM LEVEL TOGGLE SWITCH BLK RED MH 14GA BLK WHT EH 14GA TS25 PLATFORM ROTATE TOGGLE SWITCH TS26 JIB UPIDOWN TOGGLE SWITCH b le CIRCUIT BREAKER ENGINE 10A A BLK WHT 34D C CB2 CIRCUIT BREAKER CONTROLS 10A mp HM HOUR METER RED ISM 6 EH ENGINE HARNESS MH MANIFOLD HARNESS 4 BLK RED 9D 8 CH CHASSIS HARNESS SP SWITCH PANEL ERNSP BRN OPT 4 CR CONTROL RELAY BRN EH BRN 52B ISM IGNITION START MODULE CONTROL BOX GROUND A2 BRAKE RELEASE TRAVEL A
132. RG RED 3 16 DRIVE ENABLE RELAY ORG BLK 3 15 ORGBLK MH ORG BLK SP PLAT LEVEL DOWN Llo ORG 3 14 oRG MH ORG SP PLAT LEVEL UP N ABLE WHT 5 BLU RED 3 18 DRIVE ENABLE LIGHT J TS24 TS22 BLK 5 BLU WHT 3 12 WHT FOOTSWITCH 5 OPTION3 BLU BLK 3 11 BLU BLK MH BLU BLK SP SEC BOOM DOWN 45 BLU 10A LS3 BLU 3 10 BLU MH BLU SP SEC BOOM UP ORG TB148 BLU BLK 11A BLK RED CR5 BLK RED 3 9 HORN 7826 BLK WHT 3 8 BLKWHT MH BLK WHT SP BOOM RETRACT 4 JORGIBEKCTBISE BLK 3 7 BLK MH BLK SP BOOM EXTEND RED 6 4 1521 WHT RED 3 6 WHT RED MH WHT RED SP BOOM FUNCTION F C WHT BLK 3 5 WHT BLK MH WHT BLK SP TURN ROTATE LEFT 10 9 1517 1516 O J CABLE WHT 3 4 WHT MH WHT SP TURN ROTATE RIGHT 4 4 OPT 1 1 OPTION 3 RED BLK 3 2 RED BLK MH RED BLK SP PRIMARY BOOM DOWN Es 1 WHT 4A RED 3 1 RED MH RED SP PRIMARY BOOM UP D WHT BLK 5A BRN 52C zb GA 5 WHT 12 ORG MH TS20 SEE OPTIONAL WIRING CB1 CB2 ORGS RED EH 12GA Mu 1 START RELAY 5 15 ORG BLK CR10 ORG BLK SP PLATFORM LEVEL Down ORMSA 2 ORGBIKEH_ TacHOMETER ORG 3 14 ORG CR10 ORG SP PLATFORM LEVEL UP GRN BLK 44A BLK 33D s startineur ORG RED 27D LC 4 AUX ON PLATFORM LEVEL CUTOUT CE VERSION ONLY ORG BLK 15A BRN CR4 IGNITION START ec TC
133. SWITCH BOOM EXTEND LIMIT SWITCH BOOM FLOW CONTROL JIB BOOM PLATFORM ROTATE PLATFORM LEVEL UP PLATFORM LEVEL DWN PRIMARY BOOM EXTEND PRIMARY BOOM RETRACT PRIMARY BOOM UP PRIMARY BOOM DWN SECONDARY BOOM UP SECONDARY BOOM DWN DECENT ALARM OPTIONAL 5 12 2 34 221 119987 June 2007 Section 5 Schematics rl Electrical Schematic Gasoline LPG Models from serial number 1187 to 1546 REVA June 2007 P2 Electrical Schematic Gasoline LPG Models from serial number 1547 to 1996 Section 5 Schematics 2 x c c E 5 5 8 WHT BLK 5 CH e TURNTABLE ROTATE RIGHT RIGHT TURNTABLE ROTATE 9 WHT 4 CH mE TURNTABLE ROTATE LEFT E WHT BLK 3 RIGHT RIGHT TURNTABLE ROTATE WHT 3 4 BLK RED 1 E 9 L
134. T 1 WHT 30 EH _ e 4 DRIVE FORWARD epe 5 5 8 2 5 WHT BLK 31 EH 2 DRIVE REVERSE SE o os WHT RED 32 CH 5 mE BRAKE RELEASE 2 Bo let epg IP rl les 8 ET ener g TRAVEL ALARM i 1 OPTION 1 E e 1 cu BRR I ee esce ee e ce HOE ie eee e pie be eoe eee 26 ge g 1 8 Bi Gi BLU 1 BLU 36 MH qu 4 4 STEER LEFT FE BLU BLK 1 BLU BLK 37 Lia t 1 STEER RIGHT 1 5 1 5 I sQ m A Chen abe P MEME RTE TE Lad RED WHT 1 4 4 MOTOR STROKE MOTOR STROKE 2 9 j 3 V ORG ORG 1 4 wars wure Bk 4 WHT 7 4 T e LIMIT SWITCHES amp i _ 5 2 2 lt 20 5 ge 8 c o 8 WHT RED 3 FE WHT RED MH gt Ye FLOW CONTROL E 2 a E I E JIB UP EE uP aja 2E m JIB BOOM petet ET q 2 DOWN 1 TOTO JIB DOWN i i m i GRN 1 1 1 1 JIB BOOM GRN BLK 1 1 1 1 i i i 85 5 x E 2 PLATFORM ROTATE RIGHT 5 riant PLATFORM Z m 1 T ROTATE B 9 LEFT ge PLATFORM ROTATE LEFT gt i 1 1 1 o 1 27 I i ES GRN BLI 3 55 imer ee PT Sa CSE EE PLATFORM i s if g i ROTATE eave 5 i 7
135. UT OUT OPTION REVA ES34D5E June 2007 Section 5 Schematics Em V O K Ground Control Box Wiring Diagram Diesel Models REV from serial number 1547 to 1985 N M L K J D C B A VOLTAGE OIL PRESSURE COOLANT TEMPERATURE SPARE WIRE LIST OPTION NUMBERS BRN BAN OPTION T 152 GROUND 1 GRNWHTA 1 LEVEL CUTOUT C BRN 2 BRN OPT 2 3 52 BRN GND STUD GROUND ORG RED 1 2 FLASHING BEACON WHT 6
136. WHT 8 50 LS2 LS4 JUNCTION ORG BLK 1 3 DESCENT ALARM WHT RED EH BLK 7 BLK 6 49 LS1 LS2 JUNCTION GRN WHT 3 4 AC GENERATOR i i 45 GENERATOR OPTION RED WHT 3 BRN GND STUD HE OPTION 3 GRN BLK 1 44 GRN BLK SP JIB DOWN TA GRN 1 43 GRN SP JIB UP WHT 21A Q BLK 8 ORG 1 40 OFF LIMIT SPEED WHT BLK EH BLU RED 1 39 LP BLU WHT 1 38 GAS BLK 22A BLU BLK 1 37 BLU BLK MH STEER RIGHT WHT 23A BLU 1 36 BLU MH STEER LEFT 2 1 BLK RED CR3 BLK RED 1 35 BLK RED SP HIGH RPM BLK WHT CR8 BLK WHT 1 34 BLK WHT SP CHOKE UEM 6 BLK ISM 3 BLK 1 33 BLK SP START XAG GENERATOR OPTION 1 WHT RED CH WHT RED 1 32 WHT RED SP BRAKE RELEASE Nc Gd TS15 WHT BLK 1 1 WHT BLK EH DRIVE REVERSE GRN WHT 1 45 GRN WHT EH GRN WHT TB35 AC GENERATOR REDZ27A WHT 1 30 WHT EH DRIVE FORWARD BLK RED CR3 BLK RED 1 35 GRN WHT TB45 BLK RED SP HIGH RPM GRN 17A RED WHT I 29 RED WHT CH FIG EQWDRIVE RED BLK 1 28 RED BLK MH TILT ALARM GRN BLK 18A REDiSM4 RED 27 RED EH RED SP AUXILIARY PUMP lt lt SS lt lt T mkwm OPTION 2 23 RED WHT MH KEYSWITCH POWER beoir NI L WHT 2 23 WHT ISM 7 WHT SP KEYSWITCH POWER BLK CR5 BLK 2 22 BLK SP 12V TO PLATFORM 3 O TS25 TS23 WHT CR2 21 WHT EH WHT SP IGNITION POWER OF gt GRN BLK 3 18 GRN BLK SP PLAT ROTATE RIGHT GRN 3 17 GRN SP PLAT ROTATE LEFT HM RED BLK 2A RED 5 O
137. abbit and foot Switch 5 Lowerthe boom into the stowed position Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES 6 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 7 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 8 Measure the distance between the test line and your machine reference point The brakes must be able to hold the machine on any slope it is able to climb REVA B 15 Test the Drive Speed Stowed Position Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart Start the engine from the platform controls Select high range drive machine on level surface symbol 4 Move the engine idle control switch to foot switch activated high idle rabbit and foot Switch 5 Lowerthe boom into the stowed positio
138. and disconnect each wire from the cables AWARNING Bodily injury hazard The in the platform control box procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant 9 Pullthe cables out of the platform control box component damage Dealer service is required AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 10 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced 11 Remove the hose clamps from the bottom side of the primary boom and then torqued to specification 12 Tag disconnect and plug the hydraulic hoses at during installation Refer to the union located on the bottom side of the Section 2 Hydraulic Hose and primary boom Cap the fittings on the union Fitting Torque Specifications AWARNING Bodily injury hazard Spraying 1 Remove the rear turntable cover hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate Disconnect the battery gradually Do not allow oil to squirt or spray 2 Place a suitable lifting device under the platform for su
139. ar of the hub 15 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 16 Slide the hub onto the yoke spindle Component damage hazard Do CAUTION not apply excessive force or damage to the lip of the seal may 17 Fill the hub cavity with clean fresh grease 18 Place the outer bearing into the hub 19 Install the washer and castle nut 20 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 21 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 22 Install a new cotter pin Bend the cotter pin to lock it in Always use a new cotter pin when installing a castle nut 23 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA E 3 Perform Engine Maintenance Engine specifications requires that this procedure be performed every 2000 hours or every two years whichever comes first Required maintenance procedures and additional engine information is available in the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752
140. arked on a firm level surface Boom in the stowed position Turntable rotated with the boom between the non steer wheels Key switch in the off position with the key removed Wheels chocked All exernal AC power disconnected from the machine Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Used to indicate the presence of animminently hazardous situation which if not avoided will result in death or serious injury AWARNING Used to indicate the presence ofa potentially hazardous situation which if not avoided could result in death or serious injury With safety alert symbol used to ACAUTION indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Used to indicate operat
141. at this procedure be performed every 100 hours Yearly application of lubrication to the turntable bearing and worm drive gear is essential to good machine performance and service life Continued use of an improperly greased gear will result in component damage 1 Raise the secondary boom and place a safety chock on the secondary boom lift cylinder Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from the cylinder and all moving parts when lowering the secondary boom The lift cylinder safety chock is available through Genie Service Parts part number 36555 2 Locate the grease fitting on the inside of the bearing in the middle of the turntable 3 Pump grease into the turntable rotation bearing CHECKLIST A PROCEDURES Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased a grease fitting 6 Pump grease into the gear until you see it coming out of the side of the gear housing 7 Grease each tooth on the outside of the turntable rotation bearing Grease Specification Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST A PROCEDURES REVA A 9 Perform Engine Maintenance Engine specifications require
142. atformComponents 21 Platform iore aee eee RP ent ede i e edes 4 8 22 Platform Leveling Slave Cylinder 4 8 23 Plattorm hotator iege e M ERE CORRER Re 4 10 A JibBoom Components x3 4 12 3 2 Jib Boom Bell Crank ss 4 13 3 2 Jib Boom Lift Cylinder ss 4 13 A Primary Boom Components 41 Plastic Gable racks ua ehe niue tete 4 15 42 Pumary BOON three eee ee eesti 4 15 43 Primary Boom Lift Cylinder sss 4 19 4 4 Extension Cylinder sue 4 20 45 Platform Leveling Master Cylinder 4 22 A Secondary Boom Components 5 1 Secondary Boom 4 25 5 2 Secondary Boom Lift Cylinder 4 29 Genie x Z 34 22 IC Part No 119987 June 2007 naO TABLE OF CONTENTS Section 4 Rev Repair Procedures continued A KubotaD 905 Engine 6 1 lmingAdJustment iicet tme eet he uin ek eie e t EH desert 4 30 6 2 GOW PIUGS DR ote Le Ded quip tend 4 30 63 RPM Adjustment is 4 30 64 Flex Plate eee Tete 4 30 65 Coolant Temperature and Oil Pressure 4 31 Kubota DF 750 DF 752 Engine 7 1 lt Choke Adjustments us 4 32 72 Timing 4 32 7 9 GarburetorAdj stment assistent ne triste 4 32 7 4 4 32 1 0 NOX Plate 4 32 7 6 Coolant Temperature and Oil Pressure
143. atics Hydraulic Schematic 4WD Models from serial number 1187 to 1546 Section 5 Schematics June 2007 Hydraulic Schematic 4WD Models from serial number 1547 to 2900 AUXILIARY PUMP 0 5 GPM 11241 B C D E F CHARGE PRESSURE B 5 i 1 12741 D 95 x 1 GENERATOR OPTION pe r NU 4 mp 2 TER E 3500 PSI 1 PT 4 FM Meus LIFT STEER e OOO 220 PSI 3 p es 12 1 Pal Y gt HYDRAULIC TANK e CHARGE PRESSURE 212 APORT __ __ __ 4 M4 CRE I el jor E d 4 m Tor FRONT 0E qp mm 0 i inen 2 us E BRAKE B 25 0 7 ey e L J BRAKE 2 SPEED MANIFOLD REAR Co FRONT RIGHT LEFT F 8 L i TRACTION Dee MANIFOLD Genie 5 42 Z 34 22 IC Part No
144. cification Genie Part No 119987 TEREX COMPANY Z 34 22 IC 4 5 Section 4 Repair Procedures June 2007 PLATFORM CONTROLS Set the raised drive speed Select a test area that is firm level and free of obstructions 23 Press down the foot switch and raise the primary boom approximately 3 feet 1 m 24 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 25 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 26 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications Result The raised drive speed does not meet specification Adjust the Lo RANGE potentiometer on the drive joystick clockwise to increase the speed or counterclockwise to decrease the raised drive speed Continue to perform steps 24 through 26 until the raised drive speed meets specification 27 Lower the primary boom to the stowed position Turn the engine off 28 Close the platform control box lid and install the fasteners Genie TEREX COMPANY 4 6 Z 34 22 IC REVA Part No 119987 June 2007 Section 4 Repair Procedures REVA 1 3 Boom Function Speed Controller Boom Function Speed Controller Adjustments AWARNING Electrocution hazard Contact
145. condary boom 8 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The primary AWARNING boom could fall when the primary boom lift cylinder rod end pivot pin is removed if not properly supported by the overhead crane 9 Lower the rod end of the cylinder onto the blocks that were placed on the upper secondary boom 10 Remove the pin retaining fasteners from the upper compression arm pivot pin same side of machine as the primary boom lift cylinder barrel end pivot pin retaining fasteners 11 Place a rod through the compression arm pivot pin and twist to remove the pin 12 Swing the compression arm up out of the way and secure it from moving Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section 4 Repair Procedures June 2007 PRIMARY BOOM COMPONENTS 13 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING p injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 14 Support the primary boom lift cylinder with straps or ropes to restrict it from swinging freely when the barrel end pivot pin is removed 15 Remove the pin retaining fasteners from the lift cylinder barrel end pivot pin Do not remove t
146. cs Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service problem B repair solved Genie Part No 119987 TEREX COMPANY Z 34 22 IC 5 1 Section 5 Schematics June 2007 Electrical Symbols Legend 18 900 Wire color with cable number TB20 Terminal Quick disconnect terminal 21 21 BI T circuits connect at terminal T circuits connect Connection no terminal Circuits crossing no connection Diode 15 e Circuit breaker Solenoid or relay coil Horn or alarm Auxiliary pump Battery 9 wie Ground supression circuit NC f 183 Limit switch As NC 1 Limit switch normally closed held open 151 NO Limit switch normally open held closed Rotary OEM flow control PWR Dic GND FWD LIFT REV B x R BRK REL OFF LIMIT Drive control TER
147. ct with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry a horsepower limiter board 3 Connect the black lead from a DC volt meter to the no 2 terminal and the red lead to the no 10 terminal L 12V DC or greater ground engine sensor not used not used low drive speed limit switch not used not used not used output to drive controller 2 o D a g D M e gt 2 E 5 a potentiometer maximum voltage output to the controller in the stowed position b B potentiometer maximum voltage output to the drive controller in the boom raised position C potentiometer reaction rate or how fast the voltage output reacts to the change in engine rpm Genie TEREX COMPANY 4 2 Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA PLATFORM CONTROLS 4 Startthe engine from the platform controls 11 Be sure that the boom is in the stowed position then drive the machine and observe how the engine rpm reacts to drive control handle movement If the engine surges or hunts adjust the C potentiometer counterclockwise until 6 Press down the foot switch and adjust the surging is minimized A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage 5 Move the engine idle control switch to foot switch act
148. ction 5 Schematics June 2007 Electrical Schematic Diesel Models from serial number 1187 to 1546 REVA ORG BLK WHT FS LO co N BRN 2 GROUND 2 a BLU RED 3 E wits gt 2 5 8 DRIVE ENABLE LIMIT SWITCH WHT i B RED 5 BLK 5 E gs B DRIVE ENABLE 1 BLU WHT 3 8 5 B 1 EH WHT BLK 1 T WHT BLK 31 E DANE EDG 8 WHT RED 1 WHT RED 32 E H a 3 BLU 1 E BLU 36 E H se STEER LEFT BLU BLK 1 Bj BLU BLK 37 E H t STEER RIGHT 4 8 REED 3 a RED WHT 1 BL REDWHT 25 E H RED WHT o Ibi MOTOR STROKE HIGH a LOW RED 25011 4 WHT 8 BRN 8 b SECONDARY BOOM UP LIMIT SWITCH N ORG 1 22 BRN 6 v BOOM UP LIMIT SW
149. ction Manifold Components The function manifold is mounted to the turntable under the ground control box REVA Index Schematic No Description Item Function Torque 1 Counterbalance valve 3000 psi 207 E issus Platform level up 25 30 ft lbs 34 41 Nm 2 Counterbalance valve 3000 psi 207 Platform level down 25 30 ft lbs 34 41 Nm 3 Counterbalance valve 1500 psi 103 bar Hou Turntable rotate left 25 30 ft lbs 34 41 Nm 4 Counterbalance valve 1500 psi 103 bar after serial number 673 liis Turntable rotate right 25 30 ft lbs 34 41 Nm 5 Relief valve 1600 psi 110 bar Jiu Secondary boom down 25 30 ft lbs 34 41 Nm 6 Relief valve 1400 psi 97 bar before serial number 2901 Relief valve 1600 psi 110 bar after serial number 2900 Kits Primary boom down 25 30 ft lbs 34 41 Nm 7 Relief valve 1800 psi 124 bar before serial number 2901 Relief valve 2800 psi 193 bar from serial number 2901 to 3215 L Primary boom extend 25 30 ft lbs 34 41 Nm 8 Proportional solenoid valve Daun System flow regulating circuit 35 40 ft lbs 47 54 Nm
150. d crane at the center of the control box side upper compression arm 29 Place a rod through the compression arm pivot pin and twist to remove the pin Remove the compression arm from the machine AWARNING Crushing hazard The upper compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 30 Repeat step 29 for the engine side upper compression arm 31 Remove the plastic plug in the bulkhead to access the secondary boom lift cylinder rod end pivot pin 32 Remove the pin retaining fasteners from the rod end of the secondary boom lift cylinder Use a soft metal drift to remove the pin Secure the cylinder from moving 33 Remove the pin retaining fasteners from the lower pivot pin of the compression link Use a soft metal drift to remove the pin 34 Attach a lifting strap from an overhead crane to the upper secondary boom 35 Remove the pin retaining fasteners from the mid pivot to upper secondary boom pivot pin Use a soft metal drift to remove the pin SECONDARY BOOM COMPONENTS 36 Remove the upper secondary boom with compression link from the machine AWARNING Crushing hazard The upper secondary boom with compression link could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 37 Remove the drive speed limit switch mounted on the inside of the lower mid pivot Do not disconnect the wir
151. dustries if replacement manuals or decals are needed Genie TEREX COMPANY Z 34 22 IC 3 7 Part No 119987 Section Scheduled Maintenance Procedures June 2007 CHECKLIST A PROCEDURES A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information on how to perform this procedure is available in the appropriate Genie Z 34 22 IC Operator s Manual on your machine REVA A 3 Perform Function Tests Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information on how to perform this procedure is available in the appropriate G
152. e extension cylinder from the primary boom using a lifting strap from an overhead crane Crushing hazard The cylinder CAUTION may become unbalanced and fall if not properly supported by the overhead crane when removed from the extension tube During removal the overhead crane strap will need to be carefully adjusted for proper balancing To make installation of the extension cylinder easier be sure that the cylinder rod is extended to 4 feet 1 m A TEREX COMPANY Part No 119987 Z 34 22 IC Section 4 Repair Procedures June 2007 PRIMARY BOOM COMPONENTS 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It is part of the closed circuit hydraulic loop that keeps the platform level through the entire range of primary boom motion The master cylinder is located inside the upper mid pivot at the pivot end of the primary boom How to Remove the Platform Leveling Master Cylinder AWARNING 09 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Before cylinder removal is considered bleed the cylinder to be sure that there is no air in the closed loop See 2 2 How to Bleed the Slave Cylinder When removing a hose assembly or
153. e affected by climate Richer adjustment will be necessary in colder climates leaner adjustment in warmer climates 7 2 Timing Adjustment The ignition timing cannot be adjusted The timing adjustment Screw is factory sealed with a tamper resistant cap installed by the manufacturer If service or repair is needed contact your local Kubota dealer 7 3 Carburetor Adjustment The carburetor cannot be adjusted The carburetor mixture screws are factory sealed with tamper resistant caps installed by the manufacturer If service or repair is needed contact your local Kubota dealer REVA 7 4 RPM Adjustment See the scheduled maintenance procedure B 9 Check and Adjust the Engine RPM 7 5 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 1 Support the drive pump with a suitable lifting device 2 Remove all of the pump mounting plate to engine fasteners 3 Carefully pull the pump assembly away from the engine and secure it from moving 3 Remove the flex plate mounting fasteners Remove the flex plate from the flywheel Genie 4 32 TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline against the flywheel a
154. e cap item L 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 7 Repeat steps 2 through 6 to confirm the relief valve pressure setting Genie TEREX COMPANY 2 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA MANIFOLDS How to Adjust the Secondary Boom Down Relief Valve 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable rpm select toggle switch to the high rpm position and activate and hold the secondary boom toggle switch in the down direction with the secondary boom fully lowered 4 ObDserve the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the machine off Hold the relief valve and remove the cap item J 6 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING Tip over hazard Do not adjust the relief valve higher than specified 7 Repeat steps 2 through 6 to confirm the relief valve pressure setting Genie A TEREX COMPANY Part No 119987 Z 34 22 IC 4 43 Section 4 Repair Procedures June 2007 MANIFO
155. e of operating temperatures AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag disconnect the wiring from the coil to be tested 2 Testthe coil resistance Coils with 2 terminals Connect the leads from the ohmmeter to the valve coil terminals Coils with 1 terminal Connect the positive lead from the ohmmeter to the valve coil terminal then connect the negative lead from the ohmmeter to the internal ring of the valve Coil Result The resistance should be within specification plus or minus 30 Wi Result If the resistance is not within specification plus or minus 3096 replace the Coil Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 20 As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 that your air temperature increases or decreases from 68 F 20 Valve coil specifications 2 position 3 way solenoid valve 10V DC 6Q schematic items V S Q P M U T R O N AA AB CA CB CC and CD 3 position 4 way solenoid valve 10V DC 60 schematic item E CH CI Propor
156. e primary functions of the hydraulic tank are to cool clean and deaereate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply suction lines and has an external return line filter How to Remove the Hydraulic Tank 1 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications 2 Close the two hydraulic tank shut off valves at the hydraulic tank Component damage hazard The CAUTION engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed REVA 3 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Section 2 Specifications Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns 4 Tag disconnect and plug the hoses from the return filter Cap the fittings on the return filter 5 Tag disconnect and plug the suction hoses from the bottom of the tank Cap the fittings 6 Remove the fasteners from the hydraulic tank hold down straps Remove the straps 7 Remove the turntable cover using a suitable lifting device Crushing hazard The turntable AWARNING cover could become unbalanced and fall if not properly supported when removed from t
157. e procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 31743 REVA 3 Perform Engine Maintenance Diesel Models Engine specifications require that this procedure be performed every 800 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 31743 Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures Checklist D Procedures D 1 D 2 Check the Primary Boom Check the Free wheel Wear Pads Configuration Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the primary boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Extend the primary boom approximately 10 inches 25 cm 3 Measure each wear pad Replace the wear pad if itis less
158. e type of inspection to be performed ChecklistE RevA Y NR E RevA Daily or 8 hour E 1 Replace hydraulic oil Inspection A E 2 Grease wheel bearings Quarterly or 250 hour E 3 Engine maintenance Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Comments Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures Checklist A Procedures REVA A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safet
159. ed more often Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach REVA 1 Remove the cap from the fuel tank 2 Checkfor proper venting O Result Air passes through the fuel tank cap Proceed to step 4 Result If air does not pass through the clean or replace the cap Proceed to step 3 When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the fuel tank cap onto the fuel tank Remove the breather cap from the hydraulic tank 6 Checkfor proper venting O Result Air passes through the fuel tank cap Proceed to step 8 Result If air does not pass through the clean or replace the cap Proceed to step 7 Note When checking for positive tank cap venting air should pass freely through the cap 7 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 6 8 Install the breather cap onto the hydraulic tank Genie A TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA
160. eel Result Each non steering wheel should rotate with minimum effort 6 Re engage the torque hubs by turning over the hub disconnect caps Carefully remove the jack stands lower the machine and remove the jack lision hazard AWARNING Collision hazard Failure to re engage the torque hubs may cause death or serious injury and property damage Genie 3 36 7 34 22 IC REVA D 3 Replace the Drive Hub Oil Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacing the torque hub oil is essential for good machine performance and service life Failure to replace the torque hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage 1 Select the drive torque hub to be serviced Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees plugs plugs Models with O ring plugs Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA 2 Remove both plugs and drain the oil 3 Drive the machine until one plug is at the top and the other is at 90 degrees 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Refer to Section 2 Specifications 5 Models with pipe plugs Apply pipe thread sealant to the plugs Install the plugs into the drive hub Models with O ring
161. el connect a grounding wire between the machine and pump or container Be sure to only use a hand operated pump suitable for use with gasoline and or diesel fuel Tag disconnect and plug the fuel supply and return hoses at the tank Clean up any fuel that may have spilled Models with metal fuel tank Remove the tank strap fasteners and remove the straps Remove the tank from the machine Models with plastic fuel tank Remove the tank retainer plate fasteners at the bulkhead Remove the tank from the machine Component damage hazard The CAUTION fuel tank is plastic and may become damaged if allowed to fall Rinse out the inside of the tank using a mild solvent Models with metal fuel tank Install the tank onto the machine Install the tank straps and tighten the tank strap retaining fasteners Models with plastic fuel tank Install the tank onto the machine Install the tank retainer plate fasteners at the bulkhead Install the fuel supply and return hoses to the tank Tighten the clamps Models with fuel shutoff valve Turn the manual fuel shutoff valve located next to the tank to the open position Genie TEREX COMPANY Part No 119987 Z 34 22 IC 3 33 Section Scheduled Maintenance Procedures June 2007 CHECKLIST C PROCEDURES 2 Perform Engine Maintenance Diesel Models Engine specifications require that this procedure be performed every 500 hours Required maintenanc
162. emove the Primary Boom Lift Cylinder AWARNING P dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the primary boom enough to access the primary boom lift cylinder rod end pivot pin 2 Raise the secondary boom enough to access the primary boom lift cylinder barrel end pivot pin 3 Attach a lifting strap from an overhead crane to the primary boom for support Do not apply any lifting pressure PRIMARY BOOM COMPONENTS 4 Place a block of wood across the upper secondary boom to support the cylinder when the rod end pivot pin is removed 5 Attach a lifting strap from a second overhead crane or other similar lifting device to the primary boom lift cylinder Remove the rear turntable cover 7 Place a 4x4 inch 10 x 10 cm block between the lower compression arms and the cross member of the upper secondary boom Carefully lower the secondary boom onto the block AMARNING Crushing hazard Keep hands away from the block and all moving parts when lowering the se
163. emoved from the machine if not properly supported by the overhead crane Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 5 2 4 Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary 5 boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure 6 How to Remove the Secondary Boom Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair 7 skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or 8 serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced SECONDARY BOOM COMPONENTS Open the engine side turntable cover Pull up on the engine tray lock pin and swing the engine tray out and away from the machine Secure the engine tray from moving Remove the pin retaining fasteners from the secondary boom lift cylinder barrel end pivot pins Use a slide hammer to remove the barrel end pivot pins Access the pins using the access holes located in the bulkheads one on each side Remove the pin retaining fasteners from the secondary boom lift cylinder rod end pivot pin Use a soft metal drift to
164. en hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the pump mounting fasteners Carefully remove the pump Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section 4 Repair Procedures June 2007 HYDRAULIC PUMPS REVA 8 3 2 Tag disconnect and plug the hydraulic hoses Drive Pump from the pump AWARNING 221 injury hazard Spraying The drive pump is a bi directional variable hydraulic oil can penetrate and displacement piston pump The pump output is burn skin Loosen hydraulic controlled by an electronic displacement controller connections very slowly to allow located on the pump The only adjustment that can the oil pressure to dissipate be made to the pump is the neutral or null gradually Do not allow oil to squirt adjustment Any internal service to the pump or spray should only be performed at an authorized Sauer 3 Support the pump with a suitable lifting device Danfoss service center 4 Remove the drive pump mounting bolts Models before serial number 1547 Carefully remove the pump were equipped with an EDC electrical displacement control proportional control Models after serial number 1546 were equipped How to Prime the Pump with NFPE non feedback 1 Connect 0 to 6000 psi 0 to 414 bar pressure proportional electrical proportional gauge to the test port on the drive pump control 2 Gasoline L
165. ench 6 Apply a thin layer of oil to the new oil filter gasket 7 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled 8 Startthe engine from the ground contols 9 Activate any boom function and inspect the filters and related components to be sure that there are no leaks 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the filters REVA Medium pressure filter after serial number 1546 Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns The medium pressure filter is mounted in the engine compartment 4 Placea suitable container under the medium pressure filter 5 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing Remove the filter element from the housing 7 Inspect the housing seal and replace it if necessary 8 Install the new filter element into the housing and tighten securely 9 Clean up any oil that may have spilled during the installation procecure 10 Start the engine from the ground contols 11 Activate any boom function and inspect the filters and related components to be sure that there are no leaks 12 Use a permanent ink marker to write the date and number of hours from the hour meter on the filters Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedur
166. enie Z 34 22 IC Operator s Manual on your machine Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA CHECKLIST A PROCEDURES 4 5 Perform Engine Maintenance Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Required maintenance procedures and additional engine information is available in the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number 1601 8916 1 OR the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota DF750 Operator s Manual Perform 30 Day Service The 30 day maintenance procedure is a onetime sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures A 11 Perform Engine Maintenance B 5 Inspect Tires Wheels and Lug Nut Torque 0 4 Replace the Hydraulic Filters 0 5 Checkthe Turnable Rotation Bearing Bolts Genie part number 97359 Kubota DF752 Operator s Manual Genie part number 84250 Kubota D905 Operator s Manual Genie part number 31743 Genie Part No 119987 Z 34 22 IC 3 9 Section Scheduled Maintenance Procedures June 2007 CHECKLIST A PROCEDURES A 6 Perform Eng
167. ergency Stop button to the off position 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 3 Startthe engine from the ground controls and operate each boom function through a partial cycle at the ground controls Result All boom functions should operate Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA B 11 Test the Platform Self leveling Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which is controlled by the master cylinder located at the base of the primary boom A platform self leveling failure creates an unsafe working condition 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Lower the boom to the stowed position 3 Adjust the platform to a level position using the platform leveling switch 4 Raise and lower the primary boom through a full cycle Result The platform should remain level at all times to within 5 degrees CHECKLIST B PROCEDURES B 12 Test the Engine Idle Select Genie requires that this procedure be performed every 250 hours or q
168. es REVA D 5 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the secondary boom and place a safety chock on the secondary boom lift cylinder Carefully lower the boom onto the lift cylinder safety chock Turn the machine off Crushing hazard Keep hands AWARNING away from the cylinder and all moving parts when lowering the secondary boom The lift cylinder safety chock is available through Genie part number 36555 2 Check to ensure that each turntable bearing bolt is torqued in specified order to 180 ft lbs 244 Nm Bolt torque sequence CHECKLIST D PROCEDURES 3 Remove the safety chock Lower the boom to the stowed position 4 Access the turntable bearing bolts through the access hole on the side of the chassis 5 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in specified order to 180 ft lbs 244 Nm d d og o 30 04 Bolt torque sequence Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST D PROCEDURES D 6 Inspect for Turntable Bearing Wear Genie requires thatthis procedure be performed every 1000 hours or annually whichever comes first Periodic inspection of tu
169. fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the rear turntable cover REVA 2 Raisethe secondary boom until the master cylinder barrel end pivot pin is above the turntable counterweights 3 Raise the primary boom until the master cylinder rod end pivot pin is accessible 4 Attach a lifting strap from an overhead crane to the upper pivot for support Do not apply any lifting pressure 5 Secure the upper secondary boom to the pivot end of the primary boom with a strap Securing the upper secondary boom to the pivot will prevent the upper secondary boom from falling when the master cylinder barrel end pivot pin is removed from the cylinder 6 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING ud injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Tieastrap around the lug on the rod end of the master cylinder and secure the strap to the primary boom The strap will be used to lower the cylinder out of the upper pivot 8 Remove the pin retaining fasteners from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Genie TEREX C
170. form a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Six months or every 500 hours A B C Annual or every 1000 hours A B C D Two years or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years Genie TEREX COMPANY 3 2 Z 34 22 IC Part No 119987 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie Industries USA 18340 NE 76th Street PO Box 97030 Redmond
171. formation to perform this procedure is available in the Kubota D 905 Workshop Manual Kubota part number 97897 02432 Kubota D905 Workshop Manual Genie part number 31742 6 2 Glow Plugs Refer to maintenance procedure B 8 Check The Glow Plugs Diesel Models 6 3 RPM Adjustment See the scheduled maintenance procedure B 9 Check and Adjust the Engine RPM The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 1 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 2 Carefully pull the pump away from the engine and secure it from moving 3 Remove the flex plate mounting fasteners then remove the flex plate from the engine How to Install the Flex Plate 1 Install the flex plate onto the flywheel with the raised spline away from the flywheel a pump b pump shaft pump coupler d flex plate e flywheel Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 2 Install the coupler onto the pump shaft with the set screw towards the pump Leave a 1 32 inch 0 8 mm gap between the coupler and pump end plate 3 Apply Loctite removable thread sealant to the coupler set screw Torque the set screw to 65 70 ft lbs 88 95 Nm CAUTION
172. g a series of steps Genie Part No 119987 TEREX COMPANY Z 34 22 IC 3 1 Section Scheduled Maintenance Procedures June 2007 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 appear 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 engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service is required to perform this procedure Bis 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 six months annual and two years 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 per
173. g t 3850 1 9 to 4 4 bar operating temps Spark plug gap 0 039 to 0 043 inches Oil capacity 3 9 quarts 1 0 to 1 1 mm including filter 3 7 liters Engine coolant Oil viscosity requirements Above 9 13 10w 30 Capacity 3 1 quarts Below 10 F 12 C 5W 30 2 9 liters Use oils meeting API classification SF labeled SF CC Alternator or SF CD for improved wear protection Output 30A 14V DC Fuel pump Fan belt deflection 1 4 to 3 s inch Static pressure 2 84 psi 7 to 9 mm 0 19 bar A Continuous improvement of our products is a Fuel flow rate 0 125 gpm Genie policy Product specifications are 0 47 L min subject to change without notice Genio 2 6 Z 34 22 IC Part No 119987 June 2007 REVA Kubota DF 752 Engine Displacement 45 21 cu in 0 74 liters Number of cylinders 3 2 68 x 2 68 inches 68 x 68 mm Bore amp stroke Horsepower gross intermittent 24 8 3600 rpm 18 5 kW 3600 rpm Firing order 1 2 3 Low idle 1600 rpm 320 hz High idle 3000 rpm 600 hz Governor centrifugal ball mechanical Compression ratio 9 2 1 Compression pressure approx 128 to 185 psi 8 8 to 12 7 bar 0 0057 to 0 0072 inches 0 145 to 0 183 mm Valve clearances cold Lubrication system Oil pressure 28 to 64 psi operating temp 3850 rpm 1 9 to 4 4 bar Oil capacity 3 4 quarts including filter 3 25 liters Oil viscosity requirements Above 9 F 13 C 10W 30 Below 10 F 12 C 5W 30
174. he pivot pin 16 Use the overhead crane to raise the primary boom 1 inch 2 5 cm This will relieve pressure on the barrel end pivot pin 17 Place a rod through the barrel end pivot pin and twist to remove the pin Crushing hazard The primary ACAUTION boom lift cylinder may fall when the barrel end pivot pin is removed if not properly supported by the overhead crane 18 Attach a lifting strap from an overhead crane or similar lifting device to the rod end of the primary boom lift cylinder Carefully loosen the straps and allow the barrel end of the primary boom lift cylinder to slowly swing down 19 Carefully remove the cylinder from the machine REVA 4 4 Extension Cylinder The extension cylinder extends and retracts the primary boom extension tube The extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinder AWARNING injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque
175. he machine 8 Support and secure the hydraulic tank to a suitable lifting device Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING tank could become unbalanced and fall if not properly supported when removed from the machine Genie 4 54 TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures Turntable Rotation Components 11 1 Rotation Hydraulic Motor The turntable rotation hydraulic motor is the only serviceable component of the turntable rotation assembly The worm gear may not be removed from the housing In order to remove the housing the entire turntable assembly has to be removed How to Remove the Turntable Rotation Motor Do not allow the turntable to rotate until the hydraulic motor is installed 1 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor Cap the fittings on the motor AWARNING Sud injury hazard Spraying ydraulic can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the turntable rotation motor mounting fasteners Remove the motor from the worm gear housing Genie TEREX COMPANY Part No 119987 Z 34 22 IC Section 4 Repair Procedures June 2007 Axle Components 12 1 Hub and Bearings 2WD Models How to Remove the Hub and Bearings
176. he stowed position and turn the engine off 6 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the primary jib and secondary booms Jib boom to platform cable harness Inside of the platform control box REVA B 5 Inspect the Tires Wheels and Lug Nut Torque Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products The tires on some machines are foam filled and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Check the pressure in each air filled tire Refer to Section 2 Specifications Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA B 6 Confirm the Proper Brake
177. ile torquing the castle nut to make sure the bearings seat properly Loosen the castle nut one full turn and then torque to 35 ft Ibs 47 Nm 10 Install a new cotter pin Bend the cotter pin to lock it in Always use a new cotter pin when installing a castle nut 11 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 5 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 printed in the appropriate Genie Z 34 22 IC Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schemati
178. imately 5 seconds then release it Fully rotate the platform to the left and continue holding the platform rotate toggle switch until air stops coming out of the bleed screw Immediately release the platform rotate toggle switch and close the bleed screw Rotate the platform to the right until it is centered Connect the clear hose to the bottom bleed screw Open the bottom bleed screw but do not remove it Rotate the platform to the right and continue holding the platform rotate switch until air stops coming out of the bleed screw ACAUTION Crushing hazard Keep hands clear of the platform pivot weldment during rotation 10 Close the bleed screw and remove the hose 11 Turn the key switch to the off position and clean up any hydraulic oil that may have spilled 12 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 13 Rotate the platform full left and right and inspect the bleed screws for leaks Section 4 Repair Procedures June 2007 Jib Boom Components 3 1 Jib Boom How to Remove the Jib Boom Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform
179. in the stowed position 4 Tag disconnect and plug the hoses from the return filter Cap the fittings on the return filter 1 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications Tag disconnect and plug the suction hoses from the bottom of the tank Cap the fittings 6 Remove the fasteners from the hydraulic tank hold down straps Remove the straps 7 Remove the turntable cover using a suitable lifting device Crushing hazard The turntable AWARNING cover could become unbalanced and fall if not properly supported when removed from the machine Genie TEREX COMPANY 3 42 Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA 8 Support and secure the hydraulic tank to a suitable lifting device Remove the hydraulic tank from the machine 9 Remove the suction strainers and clean them using a mild solvent 10 Rinse out the inside of the tank using a mild solvent 11 Install the suction strainers using a pipe thread sealant on the threads 12 Install the drain plug into the tank using a pipe thread sealant on the threads 13 Install the hydraulic tank on to the machine Install the hydraulic tank hold down straps and tighten the retaining fasteners 14 Fill the tank with hydraulic oil until the fluid until the fluid is within the top 2 inches 5 1 cm of the sight gauge Do not overfill 15 Open the two hydraulic tank shu
180. ine Maintenance Engine specifications require that this one time procedure be performed after the first 50 hours of operation Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual REVA A 7 Perform Engine Maintenance Engine specifications require that this procedure be performed every 50 hours or weekly whichever comes first Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Genie part number 31743 Genie part number 31743 Kubota DF750 Operator s Manual Kubota DF750 Operator s Manual Genie part number 97359 Genie part number 97359 Kubota DF752 Operator s Manual Kubota DF752 Operator s Manual Genie part number 84250 Genie part number 84250 Genie 3 10 Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA A 8 Grease the Turntable Rotation Bearing and Worm Drive Gear Genie specifications require th
181. ing 38 Remove the cable covers from the top of the lower secondary boom Pull all the cables and hoses towards the counterweight end of the turntable 39 Gasoline LPG models Remove the LPG hose from the tank and then remove the LPG tank 40 Remove the battery hold down and battery 41 Remove the pin retaining fasteners from the secondary boom lift cylinder barrel end pivot pins 42 Attach a lifting strap from an overhead crane to the lug on the rod end of the secondary boom lift cylinder Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section 4 Repair Procedures June 2007 SECONDARY BOOM COMPONENTS 43 Tag disconnect and plug the hydraulic hoses from the secondary boom lift cylinder Cap the fittings on the cylinder AWARNING au injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 44 Use a slide hammer to remove the secondary boom lift cylinder barrel end pivot pins Remove the secondary boom lift cylinder from the machine AWARNING Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Access the pins using the access holes located in the bulkheads one on each side 45 Attach a lifting strap from an overhead crane to the mid pivot for s
182. ion 2 Specifications June 2007 a T SPECIFICATIONS REVA Performance Specifications Drive speeds maximum 2WD 4WD Boom stowed high range 4 5 mph 4 0 mph 7 2 km h 6 4 km h 40 ft 6 1 sec 40 ft 6 8 sec 12 2 m 6 1 sec 12 2 m 6 8 sec Boom raised or extended 0 6 mph 0 6 mph 1km h 1km h 40 ft 40 sec 40 ft 40 sec 12 2 m 40 sec 12 2 m 40 sec Gradeability See Operator s Manual Boom function speeds maximum from platform controls with rated load in platform Jib boom up 24 to 30 seconds Jib boom down 15 to 21 seconds Primary boom up 15 to 21 seconds Primary boom down 13 to 19 seconds Primary boom extend 24 to 30 seconds Primary boom retract 14 to 20 seconds Secondary boom up 15 to 21 seconds Secondary boom down 11 to 17 seconds Turntable rotate 355 62 to 68 seconds Platform rotate 160 4 to 7 seconds Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie TEREX COMPANY 2 2 2 34 22 1 Part No 119987 June 2007 Section 2 Specifications REVA Hydraulic Specifications SPECIFICATIONS Function manifold System relief 3200 psi Hydraulic fluid Dexron equivalent y E valve pressure 220 7 bar Drive pum Primary boom down relief Type bi directional variable valve pressure displacement piston p
183. ion or maintenance information Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Genie Part No 119987 TEREX COMPANY 2 34 22 IC 4 1 Section 4 Repair Procedures June 2007 Platform Controls 1 1 Horsepower Limiter Board before serial number 1547 The horsepower limiter board is responsible for governing drive pump output It senses engine rpm from the alternator The horsepower limiter board senses drops in rpm normally due to increased drive resistance rough terrain or incline and decreases voltage to the drive controller which in turn decreases voltage to the drive pump thereby reducing pump output to maintain optimum engine rpm and horsepower Three adjustments are required for optimum performance How to Adjust the Horsepower Limiter Board The engine rpm must be correct before performing this procedure Refer to Maintenance Procedure B 9 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alternator is operating properly with 12 5 to 14 5V DC output Gasoline LPG models Perform this procedure in gasoline mode 1 Remove the fasteners from the platform control box lid REVA 2 Open the control box lid and locate the horsepower limiter board AWARNING Electrocution hazard Conta
184. ivated high idle rabbit and foot switch symbol Underan extreme load an excessive counterclockwise adjustment to the C potentiometer specifications all models potentiometer will cause the Voltage setting 8 5 V DC engine to stall The C potentiometer adjustment is a compromise between engine 7 Move the engine idle control switch to low idle stability surging and engine turtle symbol rpm droop 8 Press down the foot switch and then adjust 12 Disconnect the volt meter the C potentiometer counterclockwise to increase voltage or clockwise to decrese voltage to obtain a OV DC voltage reading 13 Raise the primary boom above the drive limit switch 9 Move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Move the drive select switch to high range machine on level ground symbol 10 Press down the foot switch and re adjust the A potentiometer to the previous voltage i setting in step 6 a drive limit switch 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction 15 Adjust the B potentiometer clockwise to increase voltage or counterclockwise to decrease voltage until raised drive speed meets specification Refer to Section 2 Specifications 16 Close the platform control box lid and install the fasteners Genie TER
185. l tank 2 Gasoline LPG models Turn the LPG shutoff retaining plate fasteners at the bulkhead valve to the closed position on the LPG tank 9 Remove the fuel tank from the machine using 3 Gasoline LPG models Remove the LPG hose an appropriate lifting device from the tank and then remove the tank from Metal fuel tank Clean the fuel tank and inspect for rust and 4 Gasoline LPG models Remove the mounting corrosion before installing fasteners from the LPG bottle bracket then remove the bracket from the machine the machine Plastic fuel tank Clean the fuel tank and inspect for cracks and 5 Turn the manual fuel shutoff valve if equipped damage before installing to the closed position on the fuel tank 6 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel Genie TEREX COMPANY Part No 119987 Z 34 22 IC 4 53 Section 4 Repair Procedures June 2007 FUEL AND HYDRAULIC TANKS 10 2 Hydraulic Tank Th
186. lacing the diesel fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often TA Explosion and fire hazard Engine fuels are combustible Replace the fuel filter in an open well ventilated area away from heater sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Locate the fuel filter water separator and loosen the vent plug located on the fuel filter water separator head Genie A TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA a head bolt b vent plug Seperator head d filter bowl e drain plug 2 Place a container under the filter bowl Loosen the drain plug located at the bottom of the bowl Completely drain the fuel 3 Loosen the head bolt then rotate the filter bowl counterclockwise and remove it 4 Remove the filter element from the bowl 5 Apply athin layer of oil to the bowl gasket and then install the new filter element onto the bowl 6 Tighten the drain plug and fill the bowl and filter assembly with clean diesel fuel CHECKLIST B PROCEDURES Bleed the fuel system Before bleeding the sy
187. linder back and secure it from moving 14 Remove the drive speed limit switch mounted on the side of the boom at the pivot end Do not disconnect the wiring Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 15 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 16 Attach an overhead 5 ton 5 000 kg crane to the center point of the boom 17 Attach a similar lifting device to the primary boom lift cylinder 18 Using the overhead crane raise the primary boom to a horizontal position 19 Place support blocks across the secondary boom to support the boom lift cylinder 20 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pin Use a soft metal drift to remove the pin Crushing hazard The boom lift ACAUTION cylinder will fall unless it is properly supported 21 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage 22 Remove the hose clamp brackets from the underside of the primary boom PRIMARY BOOM COMPONENTS 23 Remove the hose clamp from the side of the primary boom 24 Remove the limit switch cam moun
188. lve 3 position way B asses Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 10 12 ft lbs 14 16 Nm O 3 Genie TEREX COMPANY 4 46 2 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures I M rt REVA MANIFOLDS This page intentionally left blank Genie TEREX COMPANY Part No 119987 Z 34 22 IC 4 47 Section 4 Repair Procedures June 2007 MANIFOLDS 9 6 REVA 4WD Traction Manifold Components The 4WD traction manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Diagnostic fitting Testing 2 Directional control valve 2 position Linie Diverts all flow to steer end drive motors when in high range 130 140 ft Ibs 176 190 Nm 3 Flow divider combiner valve E 3e hes Controls flow to flow divider combiner valves Dand 130 140 ft lbs 176 190 Nm 4 Orifice plug 0 052 inch 1 32 Equalizes pressure across flow divider combiner valve F 5 Flow divider combiner valve Eas Controls flow to steer end drive motors in forward and reverse 15 18 ft lbs 20 24 Nm 6
189. m the overhead crane approximately 2 feet 60 cm from the platform end of the primary boom Measure from the platform end of the primary boom tube June 2007 REVA 22 Remove the pin retaining fasteners from the upper pivot to upper secondary compression arm pivot pins Place a rod through the compression arm pivot pin and twist to remove the pins 23 Swing the compression arms down and out of the way Secure them from moving 24 Remove the pin retaining fasteners from the upper pivot to the upper secondary boom pivot pin Use a soft metal drift to remove the pin 25 Carefully remove the entire primary boom assembly from the machine primary boom assembly jib boom assembly platform master cylinder primary lift cylinder and upper pivot AWARNING Crushing hazard The primary boom assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Do not remove the assembly from the machine until it is properly balanced During removal the overhead crane strap will need to be carefully adjusted for proper balancing 26 Place the entire assembly onto a structure capable of supporting it 27 Remove the pin retaining fasteners from the upper secondary compression arm pivot pins Do not remove the pins Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 28 Position a lifting strap from an overhea
190. n 6 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 7 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 8 Continue at full speed and note the time when the machine reference point passes over the finish line Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA B 16 Test the Drive Speed Raised or Extended Position Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range CHECKLIST B PROCEDURES Continue at full speed and note the time when the machine reference point crosses the finish line Lower the boom to the stowed position and extend the boom 1 foot 30 cm Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 10 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the
191. ntil the multimeter displays approximately 700 mA 14 Push in the red Emergency Stop button to the off position at the platform controls 15 Disconnect the multimeter 16 Connect the wire that was disconnected in step 3 to terminal A of the drive joystick PLATFORM CONTROLS Setthe stowed drive speed Select a test area that is firm level and free of obstructions 17 Pull out the red Emergency Stop button out to the on position at both the ground and platform controls 18 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 19 Start the engine from the platform controls and move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 20 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 21 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 22 Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications Result The stowed drive speed does not meet specification Adjust the RANGE potentiometer on the drive joystick clockwise to increase the speed or counterclockwise to decrease the stowed drive speed Continue to perform steps 20 through 22 until the stowed drive speed meets spe
192. ntrol red Emergency Stop button to the on position and then operate the choke switch and listen for choke solenoid operation REVA B 1 2 Check the Engine Choke Gasoline LPG Models o Genie requires that this procedure be performed every 250 hours or 4 quarterly whichever comes first 5 A properly functioning choke is essential to good engine performance An improperly functioning choke will result in difficulty with engine starting The manual choke is solenoid operated and is only operational in the gasoline mode This choke will not operate in propane mode 1 Checkthe choke linkage connections a carburetor b linkage linkage lock nuts d choke solenoid Genie Part No 119987 2 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES B 2 Check the Exhaust System Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life Running the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns 1 Pull up on the pull pin on the engine pivot plate l
193. o Adjust the Primary Boom Down Relief Valve 1 Connecta 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable rpm select toggle switch to the high rpm position and activate and hold the primary boom toggle switch in the down direction with the primary boom fully lowered 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the machine off Hold the relief valve and remove the cap item K 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING hazard Do not adjust the relief valve higher than specified 7 Repeat steps 2 through 6 to confirm the relief valve pressure setting REVA How to Adjust the Primary Boom Extend Relief Valve before serial number 3216 1 Connect a 0 to 3000 psi 0 to 206 bar pressure gauge to the test port on the function manifold 2 Startthe engine from the ground controls 3 Hold the function enable rpm select toggle Switch to the high rpm position and activate and hold the primary boom extend toggle switch in the extend direction with the primary boom fully extended 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications 5 Turn the machine off Hold the relief valve and remove th
194. ocated under the pump Swing the engine pivot plate away from the machine to access the exhaust system 2 Be sure that all nuts and bolts are tight Inspect all welds for cracks Inspect for exhaust leaks i e carbon buildup around seams and joints REVA B 3 Inspect the Battery Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are free of corrosion Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery retainer and cable connections are tight 4 Fully charge the battery Allow the battery to rest 24 hours before continuing this procedure to allow the battery cells to equalize Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section
195. ok 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 SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 11 ft lbs 14 9 Nm 6 23 ft lbs 31 2 Nm 8 40 ft lbs 54 2 Nm 10 69 ft Ibs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft lbs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port REVA 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 Seal Lok Fittings
196. op gt OLA O1 00 DEN C Poy RININ f co rol afoj NIO N ATO ONS O1 A En D N AY 4 562 Genie TEREX COMPANY Part No 119987 Z 34 22 IC 2 9 Section 2 Specifications June 2007 REVA This page intentionally left blank Genie TEREX COMPANY 2 10 2 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly six months annually and every two years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial machine damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Use only Genie approved replacement parts Keep records on all inspections for three years Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm
197. ound control box Index Schematic No Description Item Function 17 Solenoid valve 2 position 3 way Qus Secondary boom up 18 Solenoid valve 2 position 3 way Pins Turntable rotate left 19 Solenoid valve 2 position 3 way Platform level up 20 Solenoid valve 2 position 3 way Js Primary boom extend 21 Solenoid valve 2 position 3 way Tia Primary boom down 22 Solenoid valve 2 position 3 way Fuss Secondary boom down 23 Solenoid valve 2 position 3 way Quis Turntable rotate right 24 Orifice 0 052 inch 1 32 mm S EE Turntable rotate circuit 25 Solenoid valve 2 position 3 way IN au nee Platform level down 26 Orifice 0 052 inch 1 32 mm Turntable rotate circuit Genie REVA Torque 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm 8 10 ft lbs 11 14 Nm TEREX COMPANY 4 40 2 34 221 119987 2007 Section 4 Repair Procedures REV MANIFOLDS Gp S Le who OO SUK GL 2 U D m A 3 27 5 22 03 Genie Part No 119987 Z 34 22 IC 4 41 Section 4 Repair Procedures June 2007 MANIFOLDS 9 2 Valve Adjustments Function Manifold How t
198. ow oil pressure indicator light at the ground controls should turn on when the switch opens Component damage hazard CAUTION Do not crank the engine with the low oil pressure light on Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section 4 Repair Procedures June 2007 Hydraulic Pumps 8 1 How to Remove the Auxiliary Auxiliary Pump Pump How to Test the Auxiliary Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Section Two Hydraulic Hose and 1 Tag disconnect and plug the hydraulic hoses Fitting Torque Specifications from the pump 1 Tag disconnect and plug the high pressure ilv ini i 9 AWARNING Bodily injury hazard Spraying hydraulic hose from the auxiliary pump Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt 2 or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the
199. pport 4 Remove the cable cover from the side of the jib boom 13 Remove the hose clamp from the side of the 5 Remove the wire loom from the cables at the primary boom at the pivot end platform control box 14 Remove the primary boom extend drive speed limit switch mounted on the side of the primary boom at the pivot end Do not disconnect the wiring Genie TEREX COMPANY Part No 119987 Z 34 22 IC 4 25 Section 4 Repair Procedures SECONDARY COMPONENTS 15 Attach a lifting strap from an overhead crane to the pivot end of the primary boom 16 Using the overhead crane carefully lift the secondary and primary boom assembly until the master cylinder and primary boom lift cylinder hydraulic hoses are accessible 17 Remove the cable covers from the top of the upper secondary boom 18 Tag disconnect and plug the primary boom lift cylinder and master cylinder hydraulic hoses Cap the fittings on the cylinders AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 19 Using the overhead crane lower the boom assembly to the fully stowed position 20 Pull all the cables and hoses through the upper pivot CAUTION Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 21 Position a lifting strap fro
200. pump b pump shaft pump coupler d flex plate e flywheel 2 Apply removable Loctite thread sealant to the flex plate mounting fasteners Torque the flex plate mounting fasteners to 36 ft Ibs 49 Nm 3 Install the coupler onto the pump shaft with the set screw towards the pump Leave a a2 inch 0 8 mm gap between the coupler and pump end plate 4 Apply removable Loctite thread sealant to the coupler set screw Torque the set screw to 65 70 ft lbs 88 95 Nm CAUTION Component damage hazard Do not force the drive pump during installation or the flex plate teeth may become damaged KUBOTA DF750 DF752 ENGINE 7 6 Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 225 F 107 C If the coolant temperature rises above the switch point the switch contacts close and the engine will shut off to prevent damage The engine will not start until the temperature drops below the switch point An over temperature indicator light at the ground controls should turn on when the switch closes Component damage hazard CAUTION Do not crank the engine with the over temperature light on The engine oil switch is a normally closed switch The switch contacts open at approximately 7 psi 0 48 bar If the oil pressure drops below the switch point the contacts open and the engine will shut off to prevent damage A l
201. racy 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 other manuals Contact Us http www genieindustries com e mail techsup genieind com Z 34 22 IC Copyright 1997 by Genie Industries 119987 RevA June 2007 Second Edition First Printing Genie and Z are registered trademarks of Genie Industries in the USA and many other countries Printed on recycled paper Printed in U S A Genie A TEREX COMPANY Part No 119987 June 2007 Joe 1 INTRODUCTION Serial Number Legend Genie Model Z 34 22 Serial number 2342207 12345 Model year 2007 Manufacture date 02 01 07 Electrical schematic number ESXXXX Machine unladen weight Rated work load including occupants XX kg Maximum number of platfrm occupants XX Maximum allowable side force XXN Maximum allowable inclination of the chassis 0 deg 23422 07 12345 Maximum wind speed XX m s Maximum platform height XX m Maximum platform reach m Sequence 2 number Gradeability N A Country of manufacture USA Model year This machine complies with ANSI A92 5 CAN B 354 4 Serial number Genie Indus
202. red Emergency Stop button to the on position at both the ground and platform controls 4 Activate any function using auxiliary power Result The pressure gauge reads 2800 psi 193 bar immediately stop The pump is good Result The pressure fails to reach 2800 psi 193 bar the pump is faulty and will need to be serviced or replaced 5 Remove the pressure gauge and install the hydraulic hose Genie hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the pump mounting fasteners Carefully remove the pump TEREX COMPANY 4 34 Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 8 2 Function Pump How to Test the Function Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the function pump Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Connect 0 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump
203. rmation to perform this procedure is also available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 31743 Genie TEREX COMPANY Part No 119987 Z 34 22 IC 3 13 Section Scheduled Maintenance Procedures June 2007 CHECKLIST A PROCEDURES A 11 Perform Engine Maintenance Engine specifications require that this procedure be performed every 200 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Genie part number 31743 Kubota DF750 Operator s Manual Genie part number 97359 Kubota DF752 Operator s Manual Genie part number 84250 Genie TEREX COMPANY 3 14 Z 34 22 IC REVA Part No 119987 June 2007 Section Scheduled Maintenance Procedures Checklist B Procedures Turn the key switch to ground control and then pull out the ground control red Emergency Stop button to the on position While operating the choke switch inspect the choke solenoid Result The choke solenoid should be fully retracted when the choke switch is activated Turn the key switch to platform control Pull out the platform co
204. rn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Support the platform mounting weldment with a suitable lifting device Do not apply any lifting pressure 4 Remove the six mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator Genie TEREX COMPANY and jib boom lift cylinder could fall when when the platform rotator is removed if not properly supported by the overhead crane 4 10 Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA How to Bleed the Platform Rotator 1 Connect a clear hose to the top bleed screw Place the other end of the hose in a container to collect any discharge a clear hose b top bleed valve C bottom bleed valve d container 2 Open the top bleed screw but do not remove it 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 4 Hold the platform rotate toggle switch in the right direction for approximately 5 seconds then release it Repeat three times Crushing hazard Keep hands ACAUTION clear of the platform pivot weldment during rotation Genie TEREX COMPANY Z 34 22 IC Part No 119987 PLATFORM COMPONENTS Hold the platform rotate toggle switch in the left direction for approx
205. rntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage 1 Grease the turntable bearing See A 8 Grease the Turntable Rotation Bearing and Worm Drive Gear 2 Torquethe turntable bearing bolts to specification See D 5 Check the Turntable Rotation Bearing Bolts 3 Raise the primary and secondary booms to full height using the ground controls Do not extend REVA the primary boom 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or in line with the boom and no more than 1 inch 2 5 cm from the bearing To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing 52 turntable dial indicator drive chassis turntable rotation bearing 5 Adjust the dial indicator to 6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom 7 Note the reading on the dial indicator Result The measurement is less than 0 055 inch 1 4 mm The bearing is good Result The measurement is more than 0 055 inch 1 4 mm The bearing is worn and Genie
206. rterly whichever comes first Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Gasoline LPG Models Perform this procedure in gasoline mode with the engine at normal operating temperature 1 Connect an rpm gauge to the engine then start the engine from the ground controls Result Low idle should be 1600 rpm Skip to step 3 if the low idle rpm is correct CHECKLIST B PROCEDURES 2 Turn the low idle adjustment screw on the carburetor clockwise to increase rpm or counterclockwise to decrease rpm Gasoline LPG idle adjustments a solenoid boot b high idle adjustment nut c spring lock nut d low idle adjustment e carburetor 3 Move the engine idle control switch to high idle rabbit symbol from the ground controls Result High idle should be 3000 rpm If high idle rpm is correct disregard adjustment steps 4 through 6 4 Loosen the spring lock nut 5 Turn the high idle adjustment nut and spring lock nut clockwise to increase the rpm or counterclockwise to decrease the rpm 6 Tighten the spring lock nut Then recheck the rpm Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES Diesel models 1
207. s 5 525 O 20 ze j 1 O 7 O O4 HORSE POWER LIMITER 4 OR 5 6 NIE ox A dH L LHM i 2 x 2 pa 5 B 5 w B 5 2 w z Ha 35 3 Ala 2 S9 B ls ala 219 Ole le B S 2 s 5 jeja 3 3 lo 5 km RE 27 6 wo 5 e 8 5 8 8 REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED Ess4paE TEREX COMPANY 5 23 Z 34 22 IC Part No 119987 REVA ar a SIf LHM ES34D3J 9 June 2007 Section 5 Schematics 7 7 HNA Platform Control Box Wiring Diagram Diesel Models from serial number 1547 to 1996 F E D C B A NOTES i REMOVE JUMPER JP1 FOR CE VERSION 1 REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED WHT WHT SPARE WIRES 2 GRNWHT 1 2 alo
208. s procedure for each torque hub Genie 3 20 7 34 22 IC REVA B 8 Check the Glow Plugs Diesel Models Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the glow plugs in good condition is essential to good engine performance and service life Improperly functioning glow plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine turned off 1 Connect the leads from an ohmmeter between the far left glow plug and machine ground Result The resistance should be approximately 1 0Q 2 Ifthe ohm reading is different than 1 00 remove the wire and connector plate from the three individual glow plugs Then one glow plug at a time check the resistance between the glow plug and machine ground Result The resistance should be approximately 1 80 for each individual glow plug 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 4 Connect the red lead from a volt meter to the number three glow plug Connect the black lead to ground 5 Hold the glow plug switch in the on position Result The volt meter should read 12V DC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA B 9 Check and Adjust the Engine RPM Genie requires that this procedure be performed every 250 hours or qua
209. se 2 6 Kubota DF 752 Engine Specifications sse 2 7 Hydraulic Hose and Fitting Torque Specifications 2 8 SAE and Metric Fastener Torque Chart 2 9 Genie Part No 119987 Z 34 22 IC Vil June 2007 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures Introduction E De Mined dete 3 1 Pre Delivery Preparation iet eet EEEE n erneute pr e Pat M ees 3 3 Maintenance Inspection Report 3 5 Checklist A Procedures A 1 Inspect the Manuals and Decals 3 7 2 Perform Pre operation Inspection 3 8 3 Perform Function Tests eene nnn 3 8 4 Perform Engine Maintenance 3 9 5 Perform 30 Day Service 3 9 A 6 Perform Engine Maintenance 3 10 A 7 Perform Engine Maintenance 3 10 A 8 Grease the Turntable Rotation Bearing and Worm Drive Gear 3 11 A 9 Perform Engine Maintenance 3 12 A 10 Drain the Fuel Filter Water Separator Diesel Models 3 12 A 11 Perform Engine Maintenance 2 3 14 Checklist Procedures B 1 Check the Engine Choke Gasoline LPG Models 3 15 B 2 Check the Exhaust System 3 16 B 3 Inspect the Battery sun 3 16 4 Inspect the Electrical
210. stem fill the fuel tank 10 Loosen the vent plug screw located on the filter head 11 Operate the hand primer until fuel free of air flows from the vent plug screw Tighten the vent plug screw on the filter head 12 Loosen the vent screw located on top of the fuel injection pump 13 Operate the hand primer until fuel free of air flows from the vent plug screw Tighten the vent plug screw on the injection pump 14 Clean up any fuel that may have spilled 15 Attempt to start the engine using the starter motor for a maximum of 15 seconds resting the starter for 30 seconds before trying again 16 Inspect the fuel filter water separator for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Information to perform this procedure is also available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 31743 7 Install the filter and bowl assembly onto the filter head Torque the head bolt to 65 in Ibs 7 Nm 8 Tighten the vent plug 9 Clean up any diesel fuel that may have spilled during the installation procedure Genie Part No 119987 2 34 22 IC 3 31 Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES B 21 Perform Engine Maintenance Kubota D905 Models Engine specifica
211. t off valves at the hydraulic tank Component damage hazard The CAUTION engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed 16 Clean up any oil that may have spilled Properly discard of oil 17 Start the engine and check for leaks CHECKLIST E PROCEDURES E 2 Grease the Steer Axle Wheel Bearings 2WD Models Genie requires that this procedure be performed every 2000 hours or every two years whichever comes first Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Blockthe non steer wheels and center a lifting jack of ample capacity under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support Crushing damage The machine ACAUTION may fall if not properly supported 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attemp
212. th each wear pad 5 Carefully rotate the barrel end of the extension cylinder until the pin mounting bore is in a vertical position 6 Attach a lifting strap from an overhead crane to the extension tube at the platform end REVA 7 Supportand slide the extension tube out of the outer primary boom tube Place the extension boom tube on blocks for support AWARNING Crushing hazard The boom tubes could become unbalanced and fall if not properly supported by the overhead crane During removal the overhead crane strap will need to be carefully adjusted for proper balancing 8 Remove the external snap rings from the extension cylinder rod end pivot pins at the platform end of the extension tube Use a soft metal drift to remove the pins 9 Support and slide the extension cylinder out of the base end of the extension tube Place the extension cylinder on blocks for support During removal the overhead crane strap will need to be carefully adjusted for proper balancing 10 Remove and label the wear pads from the extension cylinder Pay careful attention to the location of each wear pad Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 4 3 Primary Boom Lift Cylinder The lift cylinder raises and lowers the primary boom The lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to R
213. than 0 1 OR the specific gravity of one or more cells is less than 1 217 Replace the battery 10 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 11 Install the vent caps and neutralize any electrolyte that may have spilled Genie Part No 119987 A TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES B 4 Inspect the Electrical Wiring Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution hazard Contact with hot or live circuits may cause death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires Engine compartment electrical panel Engine wiring harness Inside of the ground control box Turntable manifold wiring 2 Startthe engine from the ground controls 3 Raise the secondary boom until the mid pivot is 10 feet 3 m off the ground 4 Inspect the turntable center area for burnt chafed and pinched cables 5 Lower the boom to t
214. that this procedure be performed every 100 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual A 10 Drain the Fuel Filter Water Separator Diesel Models Engine specifications require that this procedure be performed every 100 hours Poor fuel quality or very wet conditions may necessitate performing this procedure more often Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance and component damage GENERALE 81745 Explosion and fire hazard Engine Kubota DF750 Operator s Manual fuels are combustible Perform this Genie part number 97359 procedure in an open well ventilated area away from heaters Kubota DF752 Operator s Manual sparks flames and lighted Genie part number 84250 tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Genie 3 12 Z 34 22 IC Part No 119987 June 2007 Section Scheduled Maintenance Procedures REVA 1 Locate the fuel filter water separator and loosen the vent plug located on the fuel filter water separator head 2
215. ting fastener if equipped Note the position of the cam before removing it 25 Remove the pin retaining fasteners from the primary boom pivot pin 26 Use a soft metal drift to remove the primary boom pivot pin Carefully remove the boom from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard If the overhead crane is not properly attached the boom could become unbalanced and fall when it is removed from the machine During removal the overhead crane strap will need to be carefully adjusted for proper balancing Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section 4 Repair Procedures June 2007 PRIMARY BOOM COMPONENTS How to Disassemble the Primary Boom Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Hemove the Extension Cylinder 1 Remove the boom See 4 2 How to Remove the Primary Boom 2 Place blocks under the extension cylinder for support 3 Remove the retaining fasteners from the extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 4 Label the location of all wear pads from the outer boom tube at the platform end Remove all wear pads including shims from the platform end of the boom Pay careful attention to the location and amount of shims used wi
216. ting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST E PROCEDURES 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to 158 ft lbs 214 Nm to seat the bearings Rotate the hub by hand while torquing the castle nut to make sure the bearings seat properly 8 Loosen the castle nut one full turn and then torque to 35 ft Ibs 47 Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down O Result If there is no side to side or up and down movement continue with step 10 to grease the wheel bearings Result If there is side to side or up and down movement continue to step 10 and replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 10 Remove the castle nut 11 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 12 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing REVA 13 Pack both bearings with clean fresh grease 14 Place the large inner bearing into the re
217. tional solenoid valve 12V DC 50 schematic item D How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its valve coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Test the coil for resistance See How to Test a Coil MANIFOLDS 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the Coil The battery should read 9V DC or more when measured across the terminals Resistor 100 Genie part number 27287 COIL 4 was No 7 e D ZI 100 9V RESISTOR BATTERY NUT Mig 1 eese pg paces 5 5 multimeter b 9V DC battery 100 resistor Note Dotted lines in illustration indicate reversed connection as specified in step 6 3 Setamultimeter to read DC current The multimeter when set to read DC current should be capable of reading up to 800 mA Genie
218. tions require that this procedure be performed every 400 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 31743 Genie TEREX COMPANY 3 32 Z 34 22 IC REVA Part No 119987 June 2007 Section Scheduled Maintenance Procedures Checklist C Procedures REVA C 1 Clean the Fuel Tank Diesel Models Genie requires that this procedure be performed every 500 hours or six months whichever comes first Removing sediment from the fuel tank is essential to good engine performance and service life A dirty fuel tank may cause the fuel filter to clog prematurely resulting in poor engine performance and possible component damage Explosion and fire hazard Engine fuels are combustible Clean the fuel tank in an open well ventilated area away from heater sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Immediately clean up any fuel that may have spilled during this procedure 1 Models with fuel shutoff valve Turn the manual fuel shutoff valve located next to the tank to the closed position 2 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications for tank capacity Explosion and fire hazard When transferring fu
219. tries stamped on chassis 18340 NE 76th Street Serial label Redmond WA 98052 located under cover USA PN 77055 Genie TEREX COMPANY Part No 119987 Z 34 22 IC lii June 2007 This page intentionally left blank Genie TEREX COMPANY iv Z 34 22 IC Part No 119987 June 2007 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Genie Z 34 22 IC Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Genie TEREX COMPANY Part No 119987 Z 34 22 IC V Section 1 Safety Rules June 2007 SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and
220. ts is a Genie policy Product specifications are subject to change without notice Genie Part No 119987 A TEREX COMPANY 2 34 22 IC Section 2 Specifications June 2007 SPECIFICATIONS Kubota DF 750 Engine Displacement 45 21 cu in 0 74 liters Number of cylinders 3 2 68 x 2 68 inches 68 x 68 mm Bore amp stroke Horsepower gross intermittent 23 8 3600 rpm 17 7 kW 3600 rpm Firing order 1 2 3 Low idle 1600 rpm 320 hz High idle 3000 rpm 600 hz Governor centrifugal ball mechanical Compression ratio 9 1 Compression pressure approx 128 to 185 psi 8 8 to 12 7 bar Pressure psi of lowest cylinder must be at least 9096 of highest cylinder 0 0057 to 0 0072 inches 0 145 to 0 183 mm Valve clearances cold Lubrication system REV Starter motor Brush length new 0 669 in 17 mm Brush length wear limit 0 453 in 11 5 mm Brush spring tension 50 to 91 ounces 13 9 to 25 3 Newtons Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Ignition System Ignition spark advance 18 BTDC Ignition coil primary 1 8 to 1 60 resistance 75 F 24 C Ignition coil secondary resistance 10 7 to 14 5 kQ 75 F 24 C Spark plug wire resistance 10 to 22 kQ Oil pressure 28 to 64 psi Spark plug type NGK BCP4ES 11 tin
221. two platform leveling cycles to remove any air that might be in the system Genie TEREX COMPANY Part No 119987 Z 34 22 IC 4 9 Section 4 Repair Procedures June 2007 PLATFORM COMPONENTS 2 3 5 Platform Rotator 6 The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees 7 How to Remove the Platform Rotator 8 When removing hose assembly 9 or fitting the O ring if equipped on the fitting and or the hose end REVA Support the platform rotator with a suitable lifting device Do not apply any lifting pressure Remove the pin retaining fasteners from the jib boom and leveling links to platform rotator pivot pins Do not remove the pins Use a soft metal drift to remove the leveling link pivot pin Lower the leveling links to the ground Support the jib boom and jib boom lift cylinder with an overhead crane Use a soft metal drift to drive both pins out and remove the platform rotator from the machine must be replaced All connections AWARNING Crushing hazard The jib boom must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the manifold AWARNING ind injury hazard Spraying ydraulic oil can penetrate and bu
222. uarterly whichever comes first A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are three settings Low idle turtle symbol allows the operator to control individual boom functions and to drive the machine at a reduced speed High idle rabbit symbol allows the operator to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Startthe engine from the ground controls Then move the engine idle control switch to high idle rabbit symbol and hold in the ow position Result The engine should change to high idle Release the engine idle control switch Result The engine should return to low idle Turn the key switch to platform controls At the platform controls move the engine idle control switch to high idle rabbit symbol Result The engine should change to high idle Genie Part No 119987 TEREX COMPANY Z 34 22 IC Section Scheduled Maintenance Procedures June 2007 CHECKLIST B PROCEDURES 6 Move the engine idle control switch to low idle turtle symbol Result
223. ump before serial number 2901 1400 psi 96 5 bar Displacement 1 71 cu in per revolution 28 cc after serial number 2900 1600 psi 110 bar Flow rate 3000rpm 22 gpm 84 L min Secondary boom down relief 1600 psi valve pressure 110 bar Function pump Primary boom extend relief Type Fixed displacement gear pump valve pressure Displacement 0 24 cu in before serial number 2901 1800 psi per revolution 4 cc 124 bar Flow rate 3000rpm 3 gpm from serial number 2901 to 3215 2800 psi 11 4 L min 193 bar Drive manifold Auxiliary pump Hot oil shuttle relief pressure 250psi Fixed displacement gear pump 17 2 bar 0 5 Front drive motors 4WD models 1 9 L min Displacement per revolution 0 92 cuin Auxiliary pump 3400 psi 15 cc relief pressure 234 5 bar Rear drive motors all models Hydraulic filters Displacement per revolution 1 83cuin Hydraulic tank Beta 10 2 200 30 cc return line filter with 25 psi 1 7 bar bypass Medium pressure filter Beta 3 gt 200 Medium pressure filter 50 psi bypass pressure 3 45 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 119987 2 34 221 2 3 Section 2 Specifications June 2007 SPECIFICATIONS Manifold Component REVA Machine Torque Specifications Specifications Platform rotator Plugtorque 3 4 10 center bolt GR 8
224. upport Do not lift it 46 Remove the pin retaining fasteners from the mid pivot to lower compression arm pivot pins Place a rod through the compression arm pivot pins and twist to remove the pins 47 Remove the pin retaining fasteners from the mid pivot to lower secondary boom pivot pins Use a soft metal drift to remove the pin REVA 48 Remove the mid pivot from the machine AWARNING Crushing hazard The mid pivot could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 49 Attach a lifting strap from an overhead crane to the control box side lower compression arm 50 Remove the pin retaining fasteners from the lower compression arm to turntable pivot pins Place a rod through the compression arm pivot pin and twist to remove the pin Remove the compression arm from the machine AWARNING Crushing hazard The lower compression arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 51 Repeat step 50 for the engine side lower compression arm 52 Attach a liftiing strap from an overhead crane to the lower secondary boom 53 Remove the pin retaining fasteners from the lower secondary boom to turntable pivot pin Use a soft metal drift to remove the pin 54 Remove the lower secondary boom from the machine AWARNING Crushing hazard The lower secondary boom could become unbalanced and fall when r
225. upporting 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 pins and self locking nuts are not reused These components may fail if they are used a second time CAUTION Without safety alert symbol used to indicate the presence of a oy Be sure to properly dispose of old oil or potentially hazardous situation 2 other fluids Use approved container which if not avoided may result in Please be environmentally safe property damage Sure that your workshop or work area Used to indicate operation or I is properly ventilated and well lit maintenance information Genie vi Z 34 22 IC Part No 119987 June 2007 Table of Contents Introduction Important Information sise li Serial Number Information ii li Serial Number Legend si iii Section 1 Safety Rules General Safety Rules sise Section2 Rev Specifications A Machine Specifications su 2 1 Performance Specifications 2 2 Hydraulic Specifications issus 2 3 Manifold Component Specifications 2 4 Machine Torque Specifications 2 4 Kubota D 905 Engine Specifications 2 5 Kubota DF 750 Engine Specifications s
226. ve both of the jib boom leveling links from the bellcrank 12 Attach a lifting strap from an overhead crane to the rod end of the jib boom lift cylinder 13 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin Remove the jib boom lift cylinder from the jib boom bellcrank Crushing hazard The jib boom AWARNING lift cylinder could fall when the pin is removed if not properly supported by the overhead crane Genie TEREX COMPANY Z 34 22 IC Part No 119987 June 2007 Section 4 Repair Procedures REVA 3 2 Jib Boom Bell Crank How to Remove the Jib Boom Bell Crank Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Hemove the Platform 2 Remove the Jib Boom See 3 1 How to Remove the Jib Boom 3 Support and secure the jib boom bell crank to an appropriate lifting device 4 Remove the pin retaining fasteners from the slave cylinder rod end pivot pin Do not remove the pin 5 Remove the pin retaining fasteners from the jib boom bell crank at the extension boom Use a soft metal drift to remove the pin 6 Use a soft metal drift to remove the slave cylinder rod end pivot pin 7 Remove the jib
227. with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Do not adjust the controllers unless the static battery supply voltage is above 12V DC 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 Open the platform control box lid and locate the boom function speed controller QE 0 T black wire diode white red wire boom function speed controller max out adjustable trimpot threshold adjustable trimpot 0oo0oo0oonmfn Genie TEREX COMPANY Z 34 22 IC 4 7 Part No 119987 PLATFORM CONTROLS Locate the diode between the black wire from the boom function speed controller and the white red wire Connect the red lead from a volt meter to the wire connector of the white red wire next to the diode Connect the black lead to ground Turn the boom function speed controller to the CREEP position Set the threshold Press down the foot switch Move the primary boom toggle switch in the up direction until the voltage reading appears Adjust the voltage to 5 5 to 6V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Turn the boom function speed controller to the 9 position Set the max out Press down the foot switch Move the primary
228. y Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Six Month or 500 hour Inspection A B C Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable no remove from service R repaired Checklist A Rev A YN Checklist Rev Y NR A 1 Manuals and decals 2 Pre operation B 1 Engine choke Gasoline LPG models inspection B 2 Exhaust system A 3 Function tests B 3 Battery 4 Engine maintenance B 4 Electrical wiring Perform after 40 hours B 5 Tires wheels and lug A 5 30 Day Service nut torque Perform after 50 hours B 6 Brake configuration A 6 Engine maintenance B 7 Drive hub oil level Perform every 50 hours B 8 Glow plugs Diesel models A 7 Engine maintenance Enaine RPM Perform every 100 hours ee 10 Ground control override A 8 Grease rotation bearing B
229. y and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Checkto make sure that the operator s and safety manuals are present and complete in the storage container on the platform Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or are illegible Remove the machine from service until the manual is replaced Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie In

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