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1. 85 CR71 TOP E E z z z Tes lo Ue le le la le D le lel bal C2 K 16 86 d iR si z l im d 8 d m 85 BK 87 87 CR69 C2 J 3 BOOM EXTEND BK WH TB8 LIJITITIILDLL D BKWH PD 87 Aa Lee E 30 RD BK Fp 0 3 86 8 CONTROL CR68 C2 E BL 87 PA SECONDARY BOOM BL BK TB6 B OX LAYOUT ly bbe erre e rela lere le T b e Ts b 8 gl 8 gl gl XT caro coc MH 87 5 PLATFORM ROTATE WHIBK WHBK 5 85 CR72 cap 87 87 gi can 9 L TERMINAL 85 WH
2. 1 CR78B TERMINAL 86 2 05 4 ALARM 1 AS R20 BK WH ONLY BNG ir EN BN65 O O BN67 Oj p2 BOOM PLATFORM EMERGENCY EXTEND RETRACT LeveL STOP no 1 OR U35 5 141 1 1 SNBK OR IPIS BDBK U35 NO RD WH RESISTOR BN62 BN63 1K OHM FUNCTION ENABLE PRIMARY BOOM R14 BOOM UF EXTEND R22C 6 PLATFORM ROTATE BK FUNCTION RESISTOR RIGHT SPEED 5 6K OHM 10K OHM x CR74 TERMINAL 86 NEN R20 __ RESISTOR ZENER Cip u BUBK 10K OHM DIODE Y 5 1V DC BN66 BN61 BN64 TURNTABLE 0 ROOM DOWN E SECONDARY BOOM ROTATE BOOM RETRACT UP DOWN G Q TURNTABLE AND H PLATFORM ROTATE LEFT CR78B TERMINAL 87A CR74 TERMINAL 86 CR74 TERMINAL 87 AND CR78B TERMINAL 30 CR78B TERMINAL 86 V ATE 2 H2 BN5 AUTO STYLE HORN HORN OPTION er Ml BK WH C1P G BK WH CR55 BN66 LOAD SENSE D 86 BN67 8 5
3. M L K J G F E D PLATFORM CONTROL BOX 1 PLATFORM E STOP POWER BN66 ROTATE Edi 2 ENABLE LEVEL CR78B CR78B 2 BN64 BN63 BN65 SEC A4 EXT A ENABLE ENABLE 7 ENABLE R14 GARR 10 POT o R22C o 2 Q 9 9 3 39K P 2 2 2 2 4 I A 2 e wW wW 2 3 8118 i 8 5 8 Zo 9 E 2 A A GROUND CONTROL BOX m Q 9 9 9 TB3 p m p p 0 I A 59 BN60 DOWN Renee ENABLE ENABLE 4 1818 16 BN57 t H E 8 17 8 cy I 2 4 PLATFORM e s 19 4 H TB9 LEVEL CR65A i ENABLE 12 TK OHM BN54 BN56 BN55 CR78A 1021 iTB20 SECONDARY PRIMARY EXT ENABLE ENABLE ENABLE 7 T 2 5 y OUTRIGGER LIMIT SWITCHES 11 7 ORES LS13 LS15 gt 7 C3 H RF O R RROR C3 F 6 TB10 187 TB8 CR28 5 bui TB22 Tm 2 mum 59 89 0 5 CR65B ko EGRO dS CR71 G6 cRei LS12 LS14 U16A d 12 15 C4 13 CR72 5 cres 9 1 HM 8 7 7 7 7 7 51 6 P 4 2 LOAD CR70 CR68 CR67 CR69 CR70 5 4 3 2 1 6 e TN E 9 gg gg 9 g g lt 9 NS P BATTERY 24V gt i eus oot D w
4. M L K J H G F E D PLATFORM CONTROL BOX 1 PLATFORM E STOP POWER LOAD SENSE POWER LS19A R202 f f DOWN RG 1519 pENABLE j AS ONLY A BN66 ROTATE p dd ENABLE LEVEL Y ENABLE Se 29228 78 2 BN64 BN63 BN65 R22B SEC PRI EXT CR55 CR55 1K ENABLE 7 ENABLE 7 ENABLE 14 CR d 9 e Q Q 3 3 6K 5 2 P P P a z O A AN g gf Z 3 5 I Y ok jee eee be gt GROUND CONTROL BOX ES 9 9 9 9 TB3 O jel c A BN59 BN6O DOWN _ UP CR65A ENABLE ENABLE 18184 18169 57 4 PLATFORM LEVELING l i l ROTATE ENABLE 8 171 kd 1 h PLATFORM 6 e 19 TB4 9 4 4 LEVEL CR65A i ENABLE 12 TK OHM BN54 BN56 BN55 CR78A MT e TB20 SECONDARY PRIMARY _ EXT 57078 TT BE 14 ENABLE ENABLE ENABLE 5 7 OUTRIGGER LIMIT SWITCHES 11 1513 1815 5 7 Y C3 H RF O R TB6 TB10 187 8 5 lt lt TB22 CR28 E e e LF O R LR O R tM cs CR65B oko chcrv7 ca CR70 CR71 G6 CRe1 1512 1814 M 03 d 15 4 13 CR72 5 CR68 3 1 HM 8 7 7 7 7 7 51 6 CP 4 2 LOAD CR70 CR68 CR67 CR69 CR70 5 4 3 2 1 m Q o o o o o o o o L 50 6
5. 3 20 Genie Part No 825934 Genie TZ 34 20 ix 2013 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued 4 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 20 C 5 Grease the Axle Wheel Bearings 3 21 6 Adjust the Brakes 3 22 Checklist D Procedures D 1 Perform Axle Maintenance 3 23 D 2 Check the Boom Wear Pads 3 23 D 3 Replace the Hydraulic Tank Return 3 24 D 4 Check the Turntable Rotation Bearing Bolts 3 25 0 5 Inspect for Turntable Bearing 3 26 Checklist E Procedure E 1 Testor Replace the Hydraulic 04 24 01 000 3 28 Section 4 Repair Introduction iei oi HE detiene bees 4 1 Platform Components 11 icit tet nk tee tot esto Dd c P Ett i eu 4 2 12 Platform Rotator if equipped ssssssseseeeeeneeennneennnennnns 4 2 Primary Boom Components 2 1 Cable Track C nerd ed 4 7 2 2 Primary eee em aea ee Petites 4 9 2 3 Primary Boom Lift Cylinder sssseseseeeeeeeeeeennen nnns 4 13 2 4 Platform Leveling 4 14
6. BK 1 RD BK RD BK BL FoG 2 BL 3 WH WH BK stop 4 GN 5 OR 6 RD WH 7 BK 8 WH BK YL TURN BK RUN BACKUP LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT 7 L34 LEFT REAR TAIL LIGHT SIDE MARKER TURN SIGNAL FOG LIGHT RED REFLECTOR REVERSE LIGHT BRAKE LIGHT LICENSE PLATE LIGHT WM Genie 5 10 GenieTZ 34 20 Part No 825934 July 2013 Section 5 Schematics Trailer Lighting Wiring Diagram Hydraulic Axle AS Trailer Chassis Wiring Harness GR GR OR OR WH RD Baa BL BK BK 1 RD BK 1 RD BK RD BK 2 BL foe WH BK WH BK Hs 8 WH 5 4 GN 8 6 RD 5 OR 97 7 7 BK 6 RD 10 8 WH BK 7 BK e e 6 8 WH BK 20 04 9 13 Not Used ne e 127 L33 RIGHT REAR TAIL LIGHT BK 1 RD BK RD BK BL FoG 2 BL 3 WH WH BK stop 4 GN 5 OR 6 RD WH 7 BK 8 WH BK YL TURN BK RUN BACKUP LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT 7 L34 LEFT REAR TAIL LIGHT SIDE MARKER TURN SIGNAL FOG LIGHT RED REFLECTOR REVERSE LIGHT BRAKE LIGHT LICENSE PLATE LIGHT WM Genie Part No 825934 Genie TZ 34 20 5 11 Section 5 Schematics
7. Section 1 Safety Rules General Safety Rules indc iv Section 2 Specifications Machine Specifications 0 0 4 100 2 1 Performance Specifications 2 2 Hydraulic nennen nnns 2 2 Manifold Component Specifications sssessssssssseeeeeeeeeeen nennen 2 3 Hydraulic Hose and Fitting Torque Specifications 2 4 SAE and Metric Fastener Torque Chart 2 6 Section 3 Scheduled Maintenance Procedures ai foie Bele EL 3 1 Pre delivery Preparation 3 3 Maintenance Inspection eene 3 5 Checklist A Procedures A 1 Inspect the Manuals and Decals 3 6 2 PerformPre operation Inspection 3 7 A 3 Perform Function 22212 0 0000 3 7 4 Torque the Lug Bolts ANSI CSA AS sse 3 7 5 Torque the Lug Bolts 442 4024 1 01 nennen nnns 3 8 Genie viii Genie TZ 34 20 Part No 825934 July 2013 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued 6 Perform Hitch Maintenance 3 8 7
8. Genie 5 28 TZ 34 20 PartNo 825934 Genie Scandinavia Phone 46 31 57 51 00 Fax 46 31 57 51 04 Genie France Phone 33 2 37 26 09 99 Fax 33 2 37 26 09 98 Genie Iberica Phone 34 93 572 5090 Fax 34 93 572 5091 Genie Germany Phone 0800 180 9017 Phone 49 4221 491 810 Fax 49 4221 491 820 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 53853768 Fax 86 21 53852569 Genie Sinapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 44 1476 584333 Fax 44 1476 584334 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual TZ 34 20 Part No 825934 RevA
9. Secondary boom circuit 11 13 ft Ibs 15 17 Nm 11 Relief valve 1800 psi 124 1 bar AK Boom extend circuit M 11 13 ft lbs 15 17 Nm 12 Flow regulator 0 4 1 5 L min Blu Platform level turntable rotate circuit 7 8 ft lbs 9 5 10 5 Nm 11 13 ft lbs 15 17 Nm 13 Relief valve 1200 psi 82 7 bar AM Turntable rotate circuit Genie 4 28 Genie TZ 34 20 Part No 825934 July 2013 Section 4 Repair Procedures MANIFOLDS Ar 6 8 7 8 OR Al 2245 4 lt E f x Y x EON AJ AD es TS 10 27 d A AE QUE Genie Part No 825934 Genie TZ 34 20 4 29 Section 4 Repair Procedures July 2013 ee MANIFOLDS 6 2 Outrigger Counterbalance Valve Manifold Components The outrigger manifold is located under the hydraulic power unit cover Index Schematic No Description Item Function Torque 1 Counterbalance valve AN Outrigger 19 22 ft Ibs 25 30 Nm 2 Counterbalance valve AO Outrigger Extend 19 22 ft Ibs 25 30 Nm AO AN Genie 4 30 Geni
10. e 7 i amp Beco Q Nee 0 037 Q o gt Q 0 94 0 94 8 i IS i LAW L 1 L M d P xi s c2 al TE _ l 4 5 1 4 5 1 2000 psi 3000 psi T i i T 138 207 bar LEFT REAR NY Nr RIGHT REAR ie 7 e L 2 TURNTABLE 037 i Vf 0 028 i 2 ROTATE a 4 5 4 MASTER PES bool Se cci NS tow L L CYLINDER Ww eI 99 4 4 5 1 22 LT 5 v2 v1 SBU __ SBD ___ __ PBU PBD __ PBE __ PBR __ __ __ __ li PLU PLD __ __ TRR_ TRL i O T wE pio esl S as 44 t Q qk 4 Q 4 r il gt 1200 psi E o LT psi pre 5 RT Ed zu 9 acl eS ca ee 5 bar t EF RF RR 1 NS AF 7222 702 7277 77757 LE a 4000 psi 4 275 8 bar ao X gt n E D NE e FETA 4 40 T X Y39 1 Y22 Y21 Y26 Ww AL 7 0 34 lon P 5 m FUNCTION 7 MANIFOLD o Dix HYDRAULIC 4 9 Limi T ss sims POWER UNIT 8 Q f Se a a ll
11. 30 Day Service tetuer aee eL E Ee EE EL e 3 9 A 8 Grease the Turntable Rotation Bearing and Rotate 3 9 Checklist B Procedures B 1 Inspect the Batteries nnn nnn 3 10 B 2 Inspect the Electrical 3 11 B 3 Inspect the Electrical 3 11 B 4 Test the Manual Override 3 12 B 5 Platform Rotation if equipped 2 3 13 B 6 Perform Hydraulic Oil Analysis 1 3 14 B 7 Perform Axle Maintenance 5 3 14 B 8 Check the Wheel 0 2 20 2044240 000 11 000000 3 15 B 9 Service the Hitch nennen nennen 3 15 B 10 Perform Axle Maintenance CE 0 0 2 1 1 0 3 16 B 11 Inspect the Parking Brake eene 3 17 B 12 Service the Tongue nennen 3 17 Checklist C Procedures C 1 Grease the Platform Overload Mechanism if equipped 3 18 C 2 Test the Platform Overload System if equipped 3 18 C 3 Perform Axle Maintenance
12. Primary boom extend retract Primary boom up down Secondary boom up down Ground controls side 2 Toclose the valve push the thumbscrew in and turn fully in a counterclockwise direction and release 3 Pullthe thumbscrew out and turn fully in a clockwise direction to open the valve O Result The thumbscrew should move easily Genie GenieTZ 34 20 4 Toclose the valve pull the thumbscrew out and turn fully in a clockwise direction and release Note The machine functions will not operate unless the valves are closed 5 Locate the secondary boom up down valve at the manifold Push the thumbscrew in and turn fully in a clockwise direction to open the valve Result The thumbscrew should move easily 6 Toclose the valve push the thumbscrew in and turn fully in a counterclockwise direction and release 7 Pull the thumbscrew out and turn fully in a clockwise direction to open the valve Result The thumbscrew should move easily 8 Toclose the valve pull the thumbscrew out and turn fully in a counterclockwise direction and release Note The machine functions will not operate unless the valves are closed 9 Locate the primary boom extend retract valve at the manifold Push the thumbscrew in and turn fully in a clockwise direction to open the valve Result The thumbscrew should move easily 10 To close the valve push the thumbscrew in and turn fully i
13. c1B R TB24 x e ps EL EM WH 3 TB20 H HQ HH TB24 86 7 D CO 4 5 2 1 Wt CR73 2 C C42 RD 5 FUNCTION ENABLE RD BN49 3 poa ES WH ss 5 tj 87 87A CR75 BN49 6 WH 30 LEVEL SENSOR 7 C2 M I 86 8 sn 85 7 CR64 2 po 8 2 d E 3 FAULT GROUND WH 19 pa 86 til lt a 85 65 1 12 76 87 LIMIT SWITCH FAULT C 14 30 2 15 oOo 6A 16 2 85 17 Y a ER CR65A 6A M U6 CUTOUT si 19 Quy 30 86 14 22 85 1000 WH 21 TB18 Teze WH RDMH cipg 2211 6 CR77 2 Q C x v tps WH T DOWN ENABLE 5 24 4 9 t 2411 2 85 WH 87 87 CR78A sv Do ie LIFT CUT OUT 2 Bb 30 L_ZENER DIOPE _ R28 TERMINAL 87 BN55 4A E ES0441G T ZENER DIODE as 85 5 a L0 28 TERMINAL 87A 87 LLL 30 TU 1 24 BK a CR65B CR77 TERMINAL 30 Genie Part No 825934 Genie TZ 34 20 5 17 Section 5 Schematics July 2013 Platform Control Box Wiring Diagram AS CE
14. d CR28 TERMINAL 87 CR28 TERMINAL 87A 1 C1B F CR77 TERMINAL 30 GenieTZ 34 20 Section 5 Schematics 2013 Platform Control Box Wiring Diagram ANSI CSA CR74 TERMINAL 30 CR74 TERMINAL 86 C1P E CR74 TERMINAL 86 C1P B CR78B TERMINAL 85 CR78B TERMINAL 86 ALARM OR BK BN65 BN67 p2 BOOM PLATFORM EMERGENCY EXTEND RETRACT Q LEVEL Q STOP RD GNBK RD R23 BN62 RESISTOR d E cime PRIMARY BOOM R14 4 UP DOWN Nt soom R22C p TURNTABLE AND PLATFORM ROTATE BK FUNCTION RESISTOR RIGHT SPEED 5 6K OHM j 10K OHM BL J R20 2 ZENER T prin e siVDO r BN66 BN61 BN64 TURNTABLE FUNCTION ENABLE BOOM DOWN SECONDARY BOOM
15. 1 disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING cate 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 Part No 825934 Genie Genie TZ 34 20 PRIMARY BOOM COMPONENTS 2 Attach a lifting strap of suitable capacity from an overhead crane to the lift cylinder 3 Remove the pin retaining fastener from the lift cylinder rod end pivot pin 4 Placearod through the hole in the outrigger pivot pin and twist to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 5 Lowerthe cylinder to a horizontal position 6 Remove the pin retaining fastener from the lift cylinder barrel end pivot pin 7 Place a rod through the hole in the outrigger pivot pin and twist to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 8 Carefully remove the cylinder from the machine Crushing hazard The lift cylinder AWARNING could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard The solenoid valve can be damaged Use caution when removing the cylinder from the machine Section 4 Repair Procedures July 2013 P
16. BN59 MEN C BOOM DOWN L4 H ROTATE LEFT AND lt a LED 5 G OUTRIGGER EXTEND wH Red TEE RD BK Oo G WH BN56 BOOM BN49 G AUTO LEVEL RD RD OR RDMWH Buwn O Q BL WH 5 54 BN58 34 5515 PRIMARY PLATFORM E BOOM LEVEL GT OUTRIGGER lo UP DOWN UP DOWN 52 RD Ne WH BK G BN51 OUTRIGGER eS 9 olo 7 gt Py 55 57 BN53 OUTRIGGER SECONDARY TURNTABLE OR WH BOOM ROTATE ORMWH UP DOWN j WH BL te We Re IDE ES0441G TB1 TB16 TB3 TB18 CR78A TERMINAL 87A TB8 C4 4 CR73 TERMINAL 87A CR73 TERMINAL 85 AND 30 CR76 TERMINAL 30 C1B D TB7 TBO TB12 TB14 TB12 CR73 TERMINAL 87 CR75 TERMINAL 85 TB24 TB15 TB13 TB4 TB6 TB3 CR64 TERMINAL 30 TB5 TB24 Genie Genie TZ 34 20 Part No 825934 July 2013 Section 5 Schematics Ground Control Wiring Diagram AS CE
17. July 2013 Ground Control Box Wiring Diagram ANSI CSA Se E ee Se RD TB1 RD df Pi 5 79 KS1 EMERGENCY BN60 KEY STOR FUNCTION ENABLE switcH PLATFORM UP BOOM UP a E CH ROTATE RIGHT AND F OUTRIGGER RETRACT Lo G gt INT Sol T BD BN59 FUNCTION ENABLE 2 154 PLATFORM DOWN BOOM DOWN H ROTATE LEFT AND OUTRIGGER EXTEND WH TB18 BD CR78A TERMINAL 87A BK TB8 WH BN56 C4 4 CR73 TERMINAL 87A BN49 BOOM EXTEND AUTO LEVEL RETRACT T D O CR73 TERMINAL 30 AND 85 RD TB7 OR TB9 ps f RDMWH ay BL WH 50 BN54 BN58 ger terrm PRIMARY PLATFORM OUTRIGGER BOOM LEVEL E UP DOWN UP DOWN BN52 LEFT FRONT OUTRIGGER BUB RD CR73 TERMINAL 87 Wil CR75 TERMINAL 85 ls TB24 TB13 O O GH 51 RIGHT REAR 6 G OUTRIGGER Qu TEL Gm Q 99 BN57 BN53 RIGHT FRON
18. A Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures July 2013 Platform Components 1 1 Platform How to Remove the Platform 1 Tagand disconnect the taillight control cable at the front of the platform 2 Removethe platform rotate handle if equipped 3 Support and secure the platform to an appropriate lifting device Do not apply any lifting pressure 4 Remove the fasteners securing the platform to the platform mount bracket 5 Remove the pin securing the platform to the platform rotator assembly Crushing hazard The platform AWARNING could become unbalanced and fall if not properly supported when the pin is removed 6 Remove the platform from
19. ENABLE ENABLE 1512 1513 1514 1615 ie 10 44 E H 4d aA 5 CRe5AT BNA9 7 TBi2 TB13 TB14 Teis 12 ENABLE Q Q Q Q CR61 z 4 8 A 5 e je TB11 TB11 m m o CR76 CR76 e 3 2 11 11 CR75 CR p 75 cRz2 7 9 9 6 P Lio H us ui ff us e 9 e e 5 e e d 6 z z F6 n BATTERY 24V 275AMP 8 2 298968 9 E 9 U6 B D a s 1 1 1 1 1 Bot Is L7 Shy35 0 6 CA CEA 2 2 2 7 1x A Y39 117 2 2 pE BT e e 4 BATTERY GROUND E d r E 26 hg e8 b b een 3 5 3 a 5 5 2 ES0441G o I3 eg log P 283 505808 8 8 8 g gt io 1421805 8 8 2 2 3 z 2 2 E gt 2 5 5 D 5 B 2 25 B8 B 8 B 8 8 2 22 2 z Emo m 5 2 2 2 5 o D e m E 189 m m m m m m EL 5 e M D lt Genie 5 20 TZ 34 20 Part No 825934 July 2013 Section 5 Schematics k amp _ SSS Electrical Schematic ANSI CSA
20. m D gt U6 B 5 9g E 9 2 5 9 A ES m 906 0 034 7 d 200 1 3 10W 4 DB 1 1 1 T 7 Y24 i 4 Y53 Y22 i 4 26 i ve 1 1 1 1 1 23 4 Y52 D 21 Y25 2 je 12 2 2 2 2 Jj 2 2 D BATTERY GROUND e o e o e e e e e e ES0441G od Bo 8 e 8 m 3 e 5 edge 2 29 2 E 8 ah A 2 2 2 m zs 2 lt lt lt i Q gt d 3 3 9 EI amp 3 NN 2 B 3 S gt z gt z gt gt 2 5 m m 2 2 D Do Az zz D m E En m m omm m m m m 3 m On am D gt o lt ots gt gt lt lt 0 ES as DD DD m m 2 gt orm 33 5 D 9 Q m m gt o2 2 lt m lt lt lt m Led S 2S m gt gt 2 2 2 2 4 jm m m m m m lt 2 2 m gt lt m m lt r zo m x gt 2 d E d m m DO E gt gt gt E gt 4 38 6353 m m E m lt lt lt lt 2 mon gt 2 gt 2 gt gt x 5 6 8 5 lt lt lt 4 Genie Part No 825934 TZ 34 20 5 21 July 2013 Section 5 Schematics 1 Electrical Schematic ANSI CSA 22 Section 5 Schematics July 2013 1 Electrical Schematic AS CE Section 5 Schematics July 2013 Electri
21. C Note Use Shell Tellus S2 V 46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Service Department before use Continuous improvement of our products isa Genie policy Product specifications are subject to change without notice Part No 825934 July 2013 Section 2 Specifications Function pump 0 101 cu in 1 66 cc Displacement per revolution Flow rate 3500 rpm 1 3 gallons per minute 4 9 liters per minute Relief Valve Pressures System 3500 psi relief valve pressure 241 3 bar Outrigger 4000 psi relief valve pressure 275 8 bar Turntable rotate 1200 psi relief valve pressure 82 7 bar Boom extend 1800 psi relief valve pressure 124 1 bar Primary boom lift cylinder 1600 psi relief valve pressure 110 3 bar Secondary boom lift cylinder 1100 psi relief valve pressure 75 8 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 825934 Genie GenieTZ 34 20 SPECIFICATIONS Manifold Component Specifications Plug torque SAE No 2 50 in lbs 6 Nm SAE No 4 18 ft Ibs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm Valve Coil Resist
22. Secondary boom up down Relief valve turntable rotate circuit Boom extend retract Part No 825934 Section 5 Schematics Description Outrigger retract left rear Outrigger retract right rear Outrigger retract left front Outrigger retract right front Turntable rotate left right Platform level up down Boom extend retract Primary boom up down Secondary boom up down Relief valve turntable rotate circuit Platform level counterbalance Platform level counterbalance Relief valve primary boom Relief valve secondary boom Relief valve boom extend retract Priority flow regulator adjustable Relief valve turntable rotate circuit Genie Genie TZ 34 20 Section 5 Schematics 2013 Hydraulic Symbols Legend 40 Variable speed motor Fixed displacement pump OA Fixed displacement hand pump C3 Bi directional motor Counterbalance valve 0 037 in 0 94 mm Orifice with size 9 Check valve amp Check valve pilot to open e Filter penne 8 Pressure compensated prioity flow regulator 082 H Double acting cylinder with cushion H Solenoid operated 3 position 4 way directional valve with manual over ride LAW Solenoid operated 2 position 3 way directional valve with manual ov
23. 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 to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests 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 to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 825934 Genie Genie TZ 34 20 CHECKLIST A PROCEDURES A 4 Torque the Lug Bolts ANSI CSA AS Axle specifications require that this procedure be performed initially after 10 25 and 50 miles Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can lead to poor axle performance and component damage 1 Check each lug bolt for proper torque Refer to Section 2 Specifications Required maintenance procedures and additional axle information is available in the De
24. overload if equipped C 2 Test platform overload if equipped C 3 Axle maintenance ANSI CSA AS C 4 Breather Cap C 5 Wheel Bearings CE C 6 Brakes CE Checklist D Y N R D 1 Axle maintenance ANSI CSA AS D 2 Boom wear pads D 3 Hydraulic filter D 4 Turntable bearing bolts D 5 Turntable bearing wear Checklist E Y N R E 1 Hydraulic oil Genie TZ 34 20 Section 3 Scheduled Maintenance Procedures July 2013 Checklist A Procedures 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 safety 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 Check to make sure that the operator
25. 5 m om x BATTERY 24V Sp D t BE 42 ggo 1 47 I I a 2 5 AMP S A E w 200 OHM 063 9 09 OPM 10W 1 1 Ti 1 1 7 Y24 Y53 Y22 Y26 Y20 MOTOR CONTROLLER A UR 5 quA E 1 1 1 1 1 52 23 4 Y52 21 Y25 5 5 2 12 2 2 2 1212 12 2 2 MOTOR A AA BATTERY GROUND e eoe o e e e e e e e e e e e 2 25 920 2208 8 8 8 3 5 E egg 8 8 8 83 328 8 32 FR 5 ES0441G H 28 z lt lt j 3 8 E d e d amd 3s 3 9 92 fg gd 4 d 8 2 F 58 BH 2 2 5 5 amd 5 a g BEI REY y 3 pg i2 22 o Q 2 2mm m m 6 2 26 6 m 6 m a z 2 2 c O I gt lt lt lt lt S g lt lt 9 a 25 m 2 D 9 m a m oom D 5 D m Q mi m gt 25 2 E 2 m z 2 9 2 2 2 mz z m BS m c E gt 2 2 2 2 m m m m m 4 m lt m z m m m m m X m m m 4 m x m m r 2 gt m m DO gt 2 gt gt gt gt 4 258 63 E m EB m m lt lt lt lt zm m 4 gt z gt z gt gt gt 5 o o lt lt lt 24 d Genie Part No 825934 TZ 34 20 5 25 July 2013 Section 5 Schematics m Electrical Schematic AS CE 26 Sectio
26. Do not allow oil to squirt or spray Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 12 Attach a lifting strap of suitable capacity from an overhead crane to the platform level master cylinder 13 Remove the pin retaining fasteners securing the platform level master cylinder pivot pin to the primary boom Lower the cylinder 14 Using a soft metal drift remove the platform level master cylinder pivot pin at the primary boom Crushing hazard The cylinder AWARNING could fall if not properly supported when the pivot pin is removed 15 Tag disconnect and plug the hydraulic hoses at the top of the primary boom near the mid pivot Cap the fittings 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 Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Part No 825934 July 2013 Section 4 Repair Procedures 16 Tag disconnect and plug the hydraulic hoses to the primary boom extension cylinder at the mid pivot end of the primary boom Cap the fittings 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 Component damage
27. G7 H1 H5 KS1 Description Control Relay Platform level Outrigger Function enable ground controls Function enable platform controls Level sensor Limit switch fault Down enable Lift cut out Fuse Function 275A Flashing Beacons option Ground Gauge Hour meter Battery charge indicator option Horn or Alarm Hom Multifunction alarm Keyswitch Section 5 Schematics Electrical Abbreviations Legend Item 14 4 L12 L13 L14 L15 L33 L34 L35 L36 LS LS12 LS13 LS14 LS15 LS18 LS18A LS19 M5 N C NCHO N O NOHC P1 P2 Genie Part No 825934 Description Light or LED Load sense at ground load sense option Load sense at platform load sense option Left front outrigger Rightfrontoutrigger Left rear outrigger Right rear outrigger Right rear tail light Left rear tail light Right side marker Left side marker Limit Switch Left front outrigger Right front outrigger Leftrear outrigger Right rear outrigger Boom down Boom down Load sense Motor Hydraulic power unit Normally closed Normally closed held open Normally Open Normally open held closed Power switch Emergency Stop button at ground controls Emergency Stop button at plat controls Genie TZ 34 20 Section 5 Schematics Am map Ui Electrical Abbreviations and Wire Color Legends July 2013 Item Description Wire Color Legend H Resistor Description R14 Function sp
28. Genie Genie TZ 34 20 3 29 CHECKLIST E PROCEDURE 18 Install the hydraulic hoses onto the power unit Torque to specification 19 Install the brake line to the brake fitting under the motor controller and tighten the fitting Do not overtighten 20 Install the wire harness onto the motor controller and 275A fuse 21 Route the trailer wiring harness through the module bulkhead and to the front of the trailer Secure the wiring 22 Install the wiring harness onto the valve coils at the power unit 23 Fill the tank with hydraulic oil until the oil is visible in the sight gauge Do not overfill Refer to Section 2 Specifications 24 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system 25 Repeat steps 23 through 24 until the hydraulic system and tank are both full 26 Retract the outriggers and return the boom to the stowed position 27 Clean up any oil that may have spilled Properly discard the used oil and filter Section Scheduled Maintenance Procedures July 2013 n This page intentionally left blank Genie 3 30 GenieTZ 34 20 Part No 825934 July 2013 Section 4 Repair Procedures Observe and Obey Repair procedures sha
29. LIMIT SWITCH HARNESS 87A suec 87 87 2 CR GN WH GN 78B 035 3 gt 1 BNe4 D 85 LIFT CUT OUT 85 BK 035 3 R14 BN61 gt BK 2 56 BN62 To GROUND 87 E is CR74 FUNCTION ENABLE BK CIP C amd ES0441G Genie 5 18 Genie TZ 34 20 Part No 825934 19 Section 5 Schematics July 2013 EY Electrical Schematic ANSI CSA Section 5 Schematics July 2013 ELLE Electrical Schematic ANSI CSA A B C D E F G H J K L M PLATFORM CONTROL BOX PLATFORM CONTROL BOX 1 le PLATFORM E STOP POWER P2 Hi FAULT ALARM 2 N ewe Na AUTOLEVEL MODULE v v U 7 2 2 z HALL EFFECT WITH ELECTRONIC DAMPING moo z T S 5 D IT e 4 9 9 3 Q IE E 9 P p p p p 999 gs 9 9 gt lt cl Al o gt z alt T XT T T TT T i T GROUND CONTROL BOX GROUND CONTROL BOX TB3 a TBI ler e 1 KS1 TB2 Q 18AME RD PLAT H5 5 e GRD FAULT CR65A 4 4 ALARM e e BN52 BN53 BN50 BN51 OUTRIGGER LIMIT SWITCHES UP LF O R RF O R LR O R RR O R Eo chei ENABLE ENABLE ENABLE
30. Manual Genie part number 84376 Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures B 8 Check the Wheel Bearings CE Axle specifications require that this procedure be performed quarterly or every 5000 km whichever comes first Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can lead to poor axle performance and component damage 1 Atthe ground controls extend the outriggers until the axle is off the ground and the machine is level 2 Checkfor wheel bearing wear by attempting 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 Result There is side to side or up and down movement See C 5 Grease the Axle Wheel Bearings CE Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number 84443 Part No 825934 Genie Genie TZ 34 20 CHECKLIST B PROCEDURES B 9 Service the Hitch CE Axle specifications require that this procedure be performed quarterly or every 5000 km whichever comes first Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform
31. Push and hold the auto level button O Result The outriggers will lower and adjust to level the machine and raise the wheels off the ground Use the bubble level located below the ground controls to confirm that the machine is level 16 Using a digital level lower the ground control side of the machine until the turntable is 2 4 out of level Result The tilt sensor alarm should not sound W Result The tilt alarm will sound at 180 beeps per minute The level sensor is faulty and must be replaced Repeatthis procedure beginning with step 6 17 Continue to lower the ground control side of the machine until the turntable is 2 7 out of level O Result The tilt alarm will sound at 180 beeps per minute W Result The tilt alarm does not sound The level sensor is faulty and must be replaced Repeat this procedure beginning with step 6 18 Push and hold the yellow function enable button Push and hold the auto level button O Result The outriggers will lower and adjust to level the machine and raise the wheels off the ground Use the bubble level located below the ground controls to confirm that the machine is level Section 4 Repair Procedures July 2013 GROUND CONTROLS 19 Using a digital level lower the platform end of the machine until the turntable is 2 4 out of level Result The tilt sensor alarm should not sound Result The tilt alarm will sound at 180 beeps per minute The level sensor
32. Test all machine functions from the ground controls Result All ground control functions should not operate 1 Lift the test weight off the platform floor using suitable lifting device Result The platform overload indicator light should turn off at both the ground and platform controls Part No 825934 Genie Genie TZ 34 20 CHECKLIST C PROCEDURES 12 Test all machine functions from the ground controls Result All ground control functions should operate normally 13 Turn the key switch to platform control 14 Test all machine functions from the platform controls Result All platform control functions should operate Note If the platform overload system is not operating properly refer to Repair Procedure 11 1 Calibrate the Platform Overload System if equipped Section 3 Scheduled Maintenance Procedures July 2013 CHECKLIST C PROCEDURES C 3 Perform Axle Maintenance ANSI CSA AS Axle specifications require that this procedure be performed every 6 months or 6000 miles whichever comes first Brake Magnets Brake Controller e Suspension Components Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 Genie GenieTZ 34 20 C 4 Replace the Hydraulic Tank Breat
33. Tongue Battery Charger Genie 3 10 GenieTZ 34 20 Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures B 2 Inspect the Electrical Wiring 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 could result in death or serious injury Remove all rings watches and other jewelry 1 Inspectthe following areas for burnt chafed corroded and loose wires Turntable area Ground controls Power unit wiring 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Raise the secondary boom until the platform is approximately 10 feet 3 m off the ground 4 Inspect the boom storage area for burnt chafed and pinched cables 5 Lowerthe boom to the stowed position and turn the machine off 6 Inspectthe following areas for burnt chafed corroded pinched and loose wires Boom to platform cable harness Primary and secondary booms Part No 825934 CHECKLIST B PROCEDURES B 3 Inspect the Electrical Contactor Genie requires that this procedure be performed every 250 hours or quarterly
34. When the axle is installed the brakes should be bled Refer to the appropriate brake manufacturer s manual that was shipped with your Genie TZ Genie 4 34 Genie TZ 34 20 Part No 825934 July 2013 Section 4 Repair Procedures 9 1 Hydraulic and Mechanical Brakes Hydraulic Brake System ANSI CSA AS Models Repair procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 Mechanical Brake System CE Models Repair procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number 84443 Part No 825934 Genie Genie TZ 34 20 Trailer Components 9 2 Parking Brake How to Adjust the Parking Brake ANSI models 1 Adjust the brakes Refer to the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 2 Chockthe wheels 3 Releasethe parking brake 4 Loosen the set screw at the side of the parking brake handle 5 Adjust the handle just to the point where it is difficult to apply the parking brake then rotate the top of the parking brake handle counterclockwise one full turn 6 Tighten the set screw Do not over tighten 7 En
35. and disconnect the wire harness from the motor controller and 275A fuse 6 Pull the trailer wiring harness through the power unit module bulkhead Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures 7 Tag disconnect and plug the hydraulic hoses from the power unit Cap the fittings Note Do not disconnect the hydraulic filter lines from the power unit 8 Tagand disconnect the brake line at the fitting under the motor controller 9 Remove the hydraulic filter from the filter head 10 Remove the power unit module retaining fasteners and remove the power unit module from the machine 11 Remove the mounting fasteners that attach the hydraulic tank to the power unit Remove the tank from the power unit 12 Remove the pick up filter Clean the filter and tank using a mild solvent 13 Install the pick up filter onto the oil pick up 14 Apply thread sealant to the threads of the drain plug Install the drain plug into the pump and tighten Do not overtighten 15 Install the hydraulic tank onto the power unit Component damage hazard The O ring can be damaged if the hydraulic tank is not installed correctly Use caution when installing the hydraulic tank onto the power unit 16 Install the power unit onto the machine and install and tighten the power unit retaining fasteners Do not overtighten 17 Apply a thin layer of fresh oil to the gasket of the new oil filter Part No 825934
36. hazard Cables and hoses can be damaged if they are kinked or pinched 17 Attach a lifting strap of suitable capacity from an overhead crane to the primary boom Raise the boom to a horizontal position 18 Remove the pin retaining fasteners securing the primary boom pivot pin to the mid pivot 19 Using a soft metal drift remove the primary boom pivot pin at the mid pivot AWARNING Crushing hazard The primary boom could become unbalanced and fall if not properly supported when the pin is removed 20 Remove the primary boom from the machine Crushing hazard The primary AWARNING boom could become unbalanced and fall if not properly supported when removed from the machine Part No 825934 Genie Genie TZ 34 20 PRIMARY BOOM COMPONENTS How to Remove the Boom Extension AWARNING This procedure in this section 7 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 required Note Perform this procedure on a firm level surface boom in the stowed position Note 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the primary boom See 2 2 How to Remove the B
37. is faulty and must be replaced Repeat this procedure beginning with step 6 20 Continue to lower the platform end of the machine until the turntable is 2 7 out of level Result The tilt alarm will sound at 180 beeps per minute W Result The tilt alarm does not sound The level sensor is faulty and must be replaced Repeat this procedure beginning with step 6 2 k Push and hold the auto level button Result The outriggers will lower and adjust to level the machine and raise the wheels off the ground Use the bubble level located below the ground controls to confirm that the machine is level 22 Using a digital level lower the tongue end of the machine until the turntable is 2 4 out of level Result The tilt sensor alarm should not sound Result The tilt alarm will sound at 180 beeps per minute The level sensor is faulty and must be replaced Repeat this procedure beginning with step 6 23 Continue to lower the tongue end of the machine until the turntable is 2 7 out of level Result The tilt alarm will sound at 180 beeps per minute W Result The tilt alarm does not sound The level sensor is faulty and must be replaced Repeat this procedure beginning with step 6 24 Return the outriggers to the stowed position Push and hold the yellow function enable button How to Install and Calibrate the Outrigger Level Sensor Tip over hazard Failure to install or calibrate the leve
38. s and safety manuals are present and complete in the storage container on the platform 2 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 W 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 Genie 3 6 GenieTZ 34 20 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility anddamage Result The machine is equipped with all required decals and all decals are legible and in good condition W 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 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures A 2 Perform Pre operation Inspection 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
39. that each turntable rotation bearing mounting bolt is torqued in sequence to specification See below Note The rotate bearing bolt access is located next to the turntable rotate motor Tongue 9 mq e 0 T3 16 30 4 2 O15 12 2 10 Bearing to chassis bolt torque sequence Turntable rotation bearing bolt torque specifications D 5 Inspect for Turntable Bearing Wear Periodic inspection of turntable 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 Note Perform this procedure with the machine ona firm level surface and the boom in the stowed position 1 Grease the turntable bearing See 8 Grease the Turntable Rotation Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 4 Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and raise the primary and secondary booms to full height Do not extend the primary boom 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place Bearing to chassis lubricated 95 ft lbs 129 Nm the dial i
40. the hydraulic pump valve body and completely drain the tank into a suitable container Refer to Section 2 Specifications for capacity information 3 Tag disconnect and plug the hydraulic hoses Cap the fittings on the power unit AWARNING 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 4 Tag and disconnect the electrical wiring from the valve coils Part No 825934 Genie Genie TZ 34 20 HYDRAULIC POWER UNIT 5 Tag and disconnect the power cables from the hydraulic power unit motor AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 6 Remove the power unit mounting fasteners and remove the power unit from the machine Note If a new power unit is installed the pressure relief valve must be properly adjusted See 5 2 How to Adjust the System Relief Valve How to Remove the Hydraulic Pump 1 Remove the power unit 2 Remove the hydraulic tank from the power unit valve body 3 Remove the pump mounting fasteners and remove the pump from the valve body Component damage hazard Improper alignment during assembly can damage the pump to motor seal Use caution when installing the pump Section 4 Repair Procedures July 2013 Manifolds 6
41. the pivot pin is removed 8 Carefully remove the cylinder from the machine Crushing hazard The lift cylinder AWARNING could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard The solenoid valve can be damaged Use caution when removing the cylinder from the machine Section 4 Repair Procedures July 2013 Ground Controls 4 1 Level Sensor Each machine is equipped with two types of level sensors Tilt level sensor One level sensor monitors the incline of the turntable after the outriggers are deployed and the machine is level When this level sensor activates an alarm will sound making the operator aware of a potentially hazardous situation The tilt alarm sounds when the incline of the chassis exceeds 2 5 in any direction The tilt level sensor is located on the side of the machine opposite the ground controls Outrigger auto level system When deploying the outriggers using the autolevel function outrigger level sensors are used to monitor the incline of the turntable and assist in leveling the machine In early production two level sensors are components of the outrigger auto level circuit Later in production a single autolevel module was used The outrigger level sensor s are located on the ground controls side of the machine How to Install and Calibrate the Tilt Level Sensor Tip over hazard Failure to install or calibrate the
42. the platform rotator assembly 1 2 Platform Rotator if equipped The platform rotator is a manually operated gear assembly used to rotate the platform How to Remove the Platform Rotator 1 Genie Genie TZ 34 20 Remove the platform See 1 1 How to Remove the Platform Tag and disconnect the platform control cable s from the platform controls Tag and disconnect the wiring at the power to platform junction box on the platform rotator assembly Completely loosen the shaft retaining fasteners at the bottom of the platform pivot shaft Remove the platform rotate assembly from the machine Part No 825934 July 2013 Section 4 Repair Procedures f PLATFORM COMPONENTS How to Adju st the 2 Remove the platform rotate mount platform mount and platform rotate gear assembly from Platform Rotator the machine The platform rotator is designed to allow the 3 Remove the four bolts securing the cover over platform to slip in the event of striking an object to the rotate handle shaft Remove the cover help prevent damage to the platform If the platform rotator is too tight or seized damage to the 4 Remove the rotate handle shaft and pinion from platform may occur If the platform rotator is too the rotate gear case loose the platform may rotate side to side 5 Remove the fasteners securing the rotate gear unexpectedly resulting in a unsafe operating case to the gear shaft seal plate Remove th
43. up and down and adjust the load spring adjustment nut clockwise or counterclockwise just until the limit switch is alternately opening and closing Note When the limit switch is adjusted correctly there will be continuity slightly longer than no continuity 10 Remove the continuity tester from the limit switch wires Securely install the wires onto the limit switch Part No 825934 July 2013 Section 4 Repair Procedures er PLATFORM OVERLOAD COMPONENTS Confirm the setting 11 Turn the key switch to platform control 12 Lift the test weight off the platform floor using a suitable lifting device 13 Place the test weight back onto the platform floor using a suitable lifting device Result The platform overload indicator light should be off at both the ground and platform controls 14 Add an additional 44 Ibs 20 kg of weight to overload the platform Result The platform overload indicator light should be flashing at both the ground and platform controls 15 Test all machine functions from the platform controls Result All platform control functions should not operate 16 Turn the key switch to ground control 17 Test all machine functions from the ground controls Result All ground control functions should not operate Genie Part No 825934 Genie TZ 34 20 4 39 Section 4 Repair Procedures July 2013 This page intentionally left blank Genie 4 40 Genie TZ 34 20 Par
44. update Genie iv Genie TZ 34 20 Part No 825934 July 2013 Genie A TEREX BRAND Model TZ 34 Serial number 723411 299 Model year 2011 Manufacture date 03 14 11 Electrical schematic number Position 3 Machine unladen weight 99 999 Ibs 99 999 kg Rated work load including occupants Position 4 Maximum number of platform occupants Pos 5 Maximum allowable side force Position 6 Maximum allowable inclination of the chassis Position 7 Maximum wind speed Position 8 Maximum platform height Position 9 Maximum platform reach Position 10 Power supply voltage Position 12 Gradeability Position 11 Control system voltage Position 13 Nominal battery design voltage power Position 14 Nominal Power Position 40 Maximum hydraulic pressure Position 27 Country of manufacture Manufacturer Terex USA LLC 590 Huey Road Rock Hill SC 29732 USA Genie UK LTD The Maltings This machine complies with Compliance STD 1 Compliance STD 2 Compliance STD 3 PN 77055 e European Representative Wharf Road Grantham Lin 31 6BH United Kingdom stamped on chassis Genie Part No 825934 Introduction Serial Number Legend 14 34 11 299 Fat Sequence number Genie A TEREX BRAND 4 DATE GVWR PNBV 99 999 Ibs 99 99 kg GAWR PNBE 99 999 Ibs 9
45. used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm 2 Make areference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 Part No 825934 Genie GenieTZ 34 20 SPECIFICATIONS Figure 1 a hex nut b reference mark hex fitting 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Figure 2 Note Use the 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position Note The
46. whichever comes first Maintaining the electrical contactor in good condition is essential to safe machine operation Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage 1 At the ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position Disconnect the batteries Remove the hydraulic power unit cover Locate the electrical contactor mounted by the hydraulic power unit Visually inspect the contact points of the contactor for the following items Excessive burns Excessive arcs Excessive pitting AWARNING Electrocution burn hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactor if any damage is found Genie Genie TZ 34 20 Section 3 Scheduled Maintenance Procedures July 2013 CHECKLIST B PROCEDURES B 4 Test the Manual Override Testing the manual override for malfunctions is essential for safe machine operation An unsafe working condition exists if the manual override function does not operate in the event of a main power loss 1 Locate the primary boom up down valve at the manifold on the ground controls side of the machine Push the thumbscrew in and turn fully in a clockwise direction to open the valve Result The thumbscrew should move easily Ole rotate
47. 0 4 9 PRIMARY BOOM COMPONENTS How to Remove the Primary Boom AWARNING This procedure in this section u 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 required Note Perform this procedure on a firm level surface with the boom in the stowed position Note 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 1 1 How to Remove the Platform 2 Removethe cover under the ground controls Tag and disconnect the platform to ground control cable from the underside of the ground controls Note Looking at the ground control box the cable is at the far right and directly under the secondary boom up down button 4 Tagand disconnect the 8 pin wire harness connector behind the ground control box Section 4 Repair Procedures July 2013 PRIMARY BOOM COMPONENTS 5 Remove the battery charger cover at the rear of the machine and remove the cable clamp securing the power to platform plug to the chassis near the battery charger 6 Pullthe cables from steps 3 4 and 5 fully through the secondary boom and mid pivot until they are clear of the mid p
48. 1 Function Manifold Components The function manifold is located under the turntable cover Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way with manual override ARN is Turntable rotate left right 7 8 ft lbs 9 5 10 5 Nm Solenoid valve 3 position 4 way AB Platform 7 8 ft lbs 9 5 10 5 Nm Solenoid valve 2 position 3 way with manual override AC Boom extend retract 19 22 ft Ibs 25 30 Nm 4 Solenoid valve 3 position 4 way with manual override AD Primary boom up down 7 8 ft lbs 9 5 10 5 Nm 5 Solenoid valve 3 position 4 way with manual override AE Secondary boom up down 7 8 ft lbs 9 5 10 5 Nm 6 Relief valve 1200 psi 82 7 bar AE iu Turntable rotate circuit 7 8 ft Ibs 9 5 10 5 Nm 7 Counterbalance valve AG Platform level up circuit 19 22 ft Ibs 25 30 Nm 8 Counterbalance valve Platform level down circuit 19 22 ft Ibs 25 30 Nm 9 Relief valve 1600 psi 110 3 bar Al zo Primary boom circuit 11 13 ft Ibs 15 17 Nm 10 Relief valve 1100 psi 75 8 bar
49. 16A WH 85 5 87 87 WH 514 CR75 30 LEVEL SENSOR com WH 86 9 85 87 CR64 FAULT GROUND H5 30 86 9 85 C5 1 87 87A CR76 LIMIT SWITCH FAULT 30 86 gt 85 RD TB2 87 87 CR65A U6 CUTOUT WH cibo BL 30 12 56 4 WH WH 85 TB18 RD WH 87 87 C1B B 30 CR77 DOWN ENABLE 86 WH 13 85 BK TB4A 87 87 CR78A LIFT CUT OUT 30 BNs5 56 TB24 ES0441G Part No 825934 Genie TOP 3 w ls Le T3 le Le CONTROL BOX LAYOUT RODD 4 446 HHAH 1 dE B 3 7 4 5 51 6 9 m I I I o gt D gt I 22505212 CT BASE 169 aAA 9x 1000 OHM
50. 34 20 5 5 Section 5 Schematics July 2013 Electrical Symbols Legend TB1 Terminal gt Diode WHOdIV ld KS1 KEY SWITCH Key switch 1 EMERGENCY STOP Emergency stop button normally closed 2 15 Circuit breaker i t mO 7 2 NOHC Limit switch M Toggle switch P 4 86 Control relay We Resistor N 2 N LED T os Hour meter f Alarm EX Solenoid valve with diode e e Quick disconnect Genie 6V Battery e Fuse Motor controller Battery charger Level sensor Genie TZ 34 20 Part No 825934 July 2013 SE i Hydraulic Abbreviations Legend Item caomJouozzrac Description Test port Outrigger extend retract Check valve outrigger circuit Relief valve outrigger circuit System relief Check valve auxiliary pump Sight gauge Priority flow regulator adjustable Flow control turntable rotate circuit Relief valve turntable rotate circuit Turntable rotate left right Platform level counterbalance Platform level up down Platform level counterbalance Fluid regeneration boom extend retract Relief valve boom extend retract Primary boom up down Relief valve primary boom Relief valve secondary boom
51. 34 20 xi July 2013 TABLE OF CONTENTS Section 5 Schematics elle cm 5 1 Electrical Abbreviations 5 2 Wire 5 4 Limit Switch Legend ied Re tte E e e E E ERR 5 5 Electrical Symbols nennen nennen nnns 5 6 Hydraulic Abbreviations 5 7 Hydraulic Symbols Legend ssssssessseseeeeeeee eene nnns 5 8 Trailer Lighting Wiring Diagram ANSI CSA sse 5 9 Trailer Lighting Wiring Diagram Mechanical Axle 5 10 Trailer Lighting Wiring Diagram Hydraulic Axle AS 5 11 Control Box Wiring Diagrams ANSI CSA Ground Control Box Wiring Diagram ANSI CSA 5 12 Platform Control Box Wiring Diagram 5 14 Control Box Wiring Diagrams AS CE Ground Control Box Wiring Diagram 5 5 16 Platform Control Box Wiring Diagrams AS CE sse 5 18 Electrical Schematics ANSI CSA Electrical Schematic ANSI CSA 4224 0 00 5 20 Electrical Schematics AS CE Electrical Schematic AS CE nennen nne 5 24 Hydraulic Schematics
52. 365 48 64 5 875 882 117 171 233 229 311 238 323 317 430 278 377 371 503 20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713 22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970 24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233 Genie GenieTZ 34 20 Part No 825934 July 2013 Section 3 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 Scheduled maintenance inspections shall be completed daily quarterly and semi annually as specified on the Maintenance Inspection Report The frequency and extent of periodical examinations and tests may also depend on national regulations AWARNING Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance pro
53. 4 16 Nm 20 Hose fitting To function manifold 10 12 ft lbs 14 16 Nm 21 Relief valve ES System 28 33 ft lbs 38 44 Nm 22 Check Eas Auxiliary pump circuit 28 33 ft Ibs 38 44 Nm 23 Hose fitting iiec tette To function manifold P 10 12 ft Ibs 14 16 Nm 24 Sight gauge uds Hydraulic fluid level 106 in Ibs 12 Nm Genie 4 24 Genie TZ 34 20 PartNo 825934 July 2013 Section 4 Repair Procedures HYDRAULIC POWER UNIT Genie Part No 825934 Genie TZ 34 20 4 25 Section 4 Repair Procedures er HYDRAULIC POWER UNIT 5 2 Valve Adjustments Hydraulic Power Unit How to Adjust the System Relief Valve 1 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the hydraulic power unit schematic item A Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Fully raise the primary boom Press and hold the platform up function enable button and press and hold the primary boom up down button and observe the pressure reading on the pressure gauge Turn the machine off Hold the
54. 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than mA and are different by a minimum of 20 The coil is good W Result If one or both of the current readings mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Part No 825934 July 2013 Section 4 Repair Procedures Turntable Rotation Components 7 1 Turntable Rotation Motor How to Remove the Turntable Rotation Motor Note 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Secure the primary boom to the turntable with the hold down latch Note The hold down latch is located at the platform end of the primary boom 2 Remove the cover support if equipped 3 Tag disconnect and plug the hydraulic hoses Cap the fittings on the turntable rotation motor AWARNING ee 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
55. 9 99 kg TIRES PNEU Position 25 RIMS JANTE Position 24 COLD TIRE INFLATION Position 26 PRESS DE GONFL A FROID SINGLE THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN ON THE DATE OF MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLAMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUER A LA DATE DE SA FABRICATION V I N N I V TYPE OF VEHICLE TYPE DE VEHICULE TRAILER REMORQUE MODEL TZ 34 SERIAL NUMBER 723411 299 MODEL YEAR 2011 ELECTRICAL SCHEMATIC ES0441 PN 77172 NOMINAL Position 40 POWER NL Serial label Serial number Q GenieTZ 34 20 Section 1 Safety Rules July 2013 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine M You read understand a
56. 952 120 1654 ere 3158 412 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 320 142 1640 2223 2190 2969 2670 3620 3560 4826 300 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 Class 12 9 _ LUBED LUBED LUBED LUBED fin tbs Nm inibs Mm inibs Nm intbs Nm intbs Nm intbs Nm in tbs Nm Nm 5 16 18 21 24 4 463 54 615 58 663 78 884 68 775 91 103 6 19 3 05 36 4 07 69 787 105 100 11 3 132 15 132 155 176 s 542 e 683 116 1321 155 176 167 189 223 252 195 221 260 294 ft lbs Nm ft lbs Nm ft Ibs Nm_ ft lbs Nm ft Ibs ft lbs Nm_ ft lbs Nm ft Ibs Nm 8 54 741 72 9 88 14 19 1 18 8 25 5 20 1 273 269 365 23 6 32 314 426 10 10 8 147 144 196 279 378 372 505 399 541 53 2 722 467 63 3 623 84 4 42 189 256 251 341 486 66 649 88 697 945 922 125 81 110 108 147 14 301 408 40 543 774 105 103 140 110 150 147 200 129 175 172 234 16 46 9 63 6 62 5 848 125 170 166 226 173 235 230 313 202 274 269
57. ES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be required to perform this procedure AEA 4 Genie 3 2 GenieTZ 34 20 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours or every 3000 miles 5000 km A B Semi annually or every 500 hours or every 6000 miles 10 000 km A B C Ann
58. Genie A TEREX BRAND Serial Number Range TZ 34 VA 20 from TZ3413 596 Part No 825934 RevA July 2013 Introduction July 2013 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings
59. Hydraulic Schetnatic eet 5 28 Genie Xii GenieTZ 34 20 Part No 825934 July 2013 Section 2 Specifications Machine Specifications Specifications Tires and wheels ANSI CSA AS Batteries Axle Type 6V DC Tire size ST205 75 R14 Group T 105 Load range C Lug nut torque dry 100 ft Ibs tit 4 135 Nm Battery capacit 225AH Tire pressure maximum cold 50 psi Reserve capacity 25A rate 447 minutes 3 4 bar Fluid capacities Tongue jack Hydraulic tank 2 8 gallons Tire size 4 10 3 50 4 10 6 liters 5 Hydraulic system 4 5 gallons Tire pressure maximum cold i including tank 17 liters Tires and wheels CE Axle Tire size 185 R14C 104 102N Lug bolt torque dry 66 ft lbs 90 Nm Tire pressure maximum cold 65 psi 4 5 bar Tongue jack Tire size 8x2 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 Part No 825934 GenieTZ 34 20 2 1 Section 2 Specifications July 2013 SPECIFICATIONS Performance Specifications Boom function speeds maximum from platform controls no weight in platform Primary boom up 14 to 22 seconds Primary boom down 24 to 32 seconds Primary boom extend 18 to 28 seconds Primary boom retract 18 to 28 seconds Second
60. RIMARY BOOM COMPONENTS 2 4 a b Platform Leveling Cylinders 0 How to Remove the Master Cylinder The master cylinder located inside the mid pivot acts as a pump for the slave cylinder which is located at the platform end of the extension boom The master cylinder operates in a closed circuit hydraulic loop with the slave cylinder keeping the platform level through the entire range of boom motion Note 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 master 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 Genie 4 14 Genie TZ 34 20 a platform level slave cylinder b platform level master cylinder 2 Remove the pin retaining fastener from the master cylinder barrel end pivot pin 3 Using a soft metal drift remove the master cylinder barrel end pivot pin 4 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder 5 Removethe pin retaining fastener from the rod end pivot
61. ROTATE BOOM RETRACT UP DOWN 5 Q Q TURNTABLE AND l PLATFORM ROTATE 1 LEFT CR78B TERMINAL 87A M RD WH CR74 TERMINAL 87 AND CR78B TERMINAL 30 CR78B TERMINAL 86 pepe l D 5 gt Ei E a ee ee ee E BK WH H2 CiP G AUTO STYLE a BKWH HORN OPTION 1 86 BN67 OR BK 5 BN66 RD 30 CR78B BN64 85 LIFT CUT OUT BK BN61 D 87 87 P2 as 74 FUNCTION ENABLE BK ii ES0441G Genie 5 14 GenieTZ 34 20 Part No 825934 July 2013 Section 5 Schematics _ This page intentionally left blank Genie Part No 825934 Genie TZ 34 20 5 15 Section 5 Schematics July 2013 Ground Control Box Wiring Diagram AS CE B ee ee TS R RD EJ gt KS1 7 EMERGENCY BN60 STOR FUNCTION ENABLE switcH PLATFORM UP BOOM UP I CH ROTATE RIGHT AND Hs OUTRIGGER RETRACT wy _ VIS 5 j x d NUM RD
62. Result The platform should rotate to the right and operate smoothly without any hesitation or binding 2 the hand crank at the platform in the counterclockwise direction Result The platform should rotate to the left and operate smoothly without any hesitation or binding Section 3 Scheduled Maintenance Procedures July 2013 CHECKLIST B PROCEDURES B 6 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil 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 Note 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 Genie GenieTZ 34 20 B 7 Perform Axle Maintenance ANSI CSA AS Axle specifications require that this procedure be performed quarterly or every 3000 miles whichever comes first Brake Adjustment Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service
63. Secondary Boom Components 3 1 Secondary BOOM eerie tert e een eei d e e RE E etr et P 4 17 3 2 Secondary Boom Lift Cylinder 4 19 Ground Controls 4 1 oir ite t eeu 4 20 Genie x Genie TZ 34 20 Part No 825934 July 2013 TABLE OF CONTENTS Section 4 Repair continued Hydraulic Power Unit 5 1 Hydraulic Power Unit 0 4 24 5 2 Valve Adjustments Hydraulic Power 4 26 5 3 ice hen ae RR GRE E hv 4 27 Manifolds 6 1 Function Manifold Components 4 28 6 2 Outrigger Counterbalance Valve Manifold Components 4 30 6 3 Valve ire Rete Pede i acte ERAS 4 31 Turntable Rotation Components 7 1 Turntable Rotation 4 33 Axle Components 8 10 4 34 Trailer Components 9 1 Hydraulic and Mechanical ne 4 35 9 2 Parking Brake aue cca ep etta ene E ET ERR RR 4 35 Outriggers 10 1 Outrigger Components 04044 0000 4 36 10 2 Outrigger Cylinder etae iei e rp Reip e tede Re 4 37 Platform Overload Components 11 1 Platform Overload System ssssssssssseeseeeeeeeneeeennenen nnne 4 38 Genie Part No 825934 Genie TZ
64. T 55 TURNTABLE QUTPIGOER GNWH seconpary ROTATE CST BOOM GN WH TB15 UP DOWN OR WH C3 U A WH BL TB6 ES0441G sis WH CR64A TERMINAL 30 H5 alarm 06 HOURMETER TB24 P Genie Genie TZ 34 20 Part No 825934 July 2013 85 Section 5 Schematics 74 7 Ground Control Box Wiring Diagram ANSI CSA OR 87 87 CR71 c2 PLATFORM LEVEL OR BK 5 C2 K 86 85 BK 87 CR69 C2 J BOOM EXTEND BKWH gs 30 co BKWH I 86 85 RD 87 87A CR67 C2 G PRIMARY BOOM RD BK RD BK xs C2 F 5 86 85 BL 87 87 CR68 C2 E SECONDARY BOOM BL BK Tee 30 cap BUBK lo 86 85 WH 87 87 CR70 2 PLATFORM ROTATE 30 86 85 RD 2 GN BK 87 87A CR72 C3 P OUTRIGGERS GN BK 30 ca 8N WH Tgn C4 Ja CR28 TB24 gt POWER SUPPLY WH 30 TB24 0 9 86 gt C4A 85 TBS 87 87A m PP BN49 be CR73 BN49 WH 86 FUNCTION ENABLE U
65. ance Description Specification Solenoid valve 3 position 4 way 29 to 310 24V DC with diode schematic item B AA AB AC AD and AE Solenoid valve 3 position 4 way 20 to 220 24V DC with diode schematic items M Q and T Solenoid valve 2 position 3 way 29 to 310 24V DC with diode schematic items and V Solenoid valve 2 position 2 way N C 29 to 310 24V DC with diode schematic items W X Y and 2 Section 2 Specifications 1 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok ORFS or 37 JIC fittings and hose ends July 2013 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash size Torque Genie specifications require that fittings and hose 4 ends be torqued to specification when they are 14 ft lbs 19 Nm removed and installed or when new hoses or fittings are installed 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm Seal Lok Fittings hose end ORFS 12 84 ft lbs 114 Nm SAE Dash size Torque 16 125 ft lbs 169 5 Nm 4 10 ft lbs 13 6 Nm 20 151 ft lbs 204 7 Nm 6 30 ft lbs 40 7 Nm 24 184 ft lbs 249 5 Nm 8 40 ft lbs 54 2 N
66. ary boom lift cylinder barrel end AND secondary boom pivot pin platform level master cylinder lt mid pivot latch ground controls secondary boom lift cylinder barrel end pivot pin turntable secondary boom pivot pin secondary boom link pivot pin secondary boom link secondary boom secondary boom lift cylinder secondary lift cylinder rod end pivot pin secondary boom link pivot pin Genie TZ 34 20 Part No 825934 July 2013 Section 4 Repair Procedures 2 1 Cable Track The boom cable track guides 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 boom cable track may be necessary when performing major repairs that involve removing the boom How to Remove the Cable Track Note 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 Working at the turntable locate the three wire cables which are routed to the platform through the inside of the secondary boom mid pivot cable tray cable track cable bridge secondary boom tur
67. ary boom up 14 to 24 seconds Secondary boom down 14 to 24 seconds 80 to 115 seconds Airborne noise emissions 80 dB Maximum sound level at normal operation workstations A weighted Turntable rotate 359 Hydraulic Specifications Hydraulic Oil Specifications Hydraulic oil type Viscosity grade Chevron Rando HD equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG Dexron III oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Genie GenieTZ 34 20 Optional fluids Petro Canada Environ MV 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron Aviation A Arnica 32 Mineral based Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below 0 F 17
68. at may have spilled during the replacement procedure Properly discard the used filter breather cap hydraulic tank filler cap hand pump sight gauge hidden from view hydraulic pump motor drain plug hydraulic filter Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures 6 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 7 Pressand hold the yellow function enable button and activate the outrigger autolevel function Result The motor should activate and the outriggers should lower 8 Inspectthe filter and related components to be sure that there are no leaks Part No 825934 Genie Genie TZ 34 20 CHECKLIST D PROCEDURES 0 4 Check the Turntable Rotation Bearing Bolts Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque or torque sequence could result in an unsafe operating condition and component damage 1 sure that each turntable rotation bearing mounting bolt above the turntable is torqued in sequence to specification See below Tongue 13 4 3 1 i 9 of 6 129 Og u 2 4 10 7 14 Bearing to turntable bolt torque sequence Section 3 Scheduled Maintenance Procedures July 2013 CHECKLIST D PROCEDURES 2 Working through the bearing bolt access be sure
69. bricant to the internal gears Note The lubrication opening is located on the side of the jack above the support plate 2 Lightly grease the inner tube of the jack with the same type of grease 3 Lubricate the handle at both sides of the tube with a lightweight oil 4 Lubricate the axle bolt and nut assembly with a lightweight oil ANSI models 5 Check each tire with an air pressure gauge and add air as needed Refer to Section 2 Specifications AWARNING Bodily injury hazard An over inflated tire can explode and could result in death or serious injury Section 3 Scheduled Maintenance Procedures July 2013 Checklist C Procedures C 1 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed every 500 hours or 6 months whichever comes first Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a multi purpose grease Genie GenieTZ 34 20 C 2 Test the Platform Overload System if equipped Genie specifications requ
70. c Hose and Fitting Torque Specifications 1 Remove the primary boom See 2 2 How to Remove the Primary Boom Part No 825934 Genie Genie TZ 34 20 SECONDARY BOOM COMPONENTS Remove the mid pivot 2 Attach a lifting strap of suitable capacity from an overhead crane to the primary lift cylinder Raise the cylinder to a horizontal position 3 Remove the pin retaining fasteners securing the primary lift cylinder pivot pin to the mid pivot 4 Using a soft metal drift remove the primary lift cylinder pivot pin at the mid pivot AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed 5 Attach a lifting strap of suitable capacity from an overhead crane to the mid pivot Do not apply any lifting pressure 6 Remove the pin retaining fasteners securing the secondary boom pivot pin to the mid pivot 7 Remove the pin retaining fasteners securing the secondary link pivot pin to the mid pivot 8 Remove the hose clamps securing the hydraulic hoses to the mid pivot 9 Tag disconnect and plug the hydraulic hoses to the hydraulic hard lines at the mid pivot end of the secondary boom Cap the fittings 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 Component damage hazard Cables and hoses can be damaged if
71. cal Schematic AS CE A B D E F G H J K L M PLATFORM CONTROL BOX PLATFORM CONTROL BOX 1 le PLATFORM E STOP POWER P2 LOAD SENSE POWER SENSE POWER LS19A P EC LS19 T a 1319 SENSE FAULT LS19A LIMIT SWITCH ALARM 4 2 A AUTOLEVEL MODULE 9999299 9 9 9 9 v v U 7 7 Uu 79 EE pe p z E g HALL EFFECT WITH ELECTRONIC DAMPING moo 29 5 o 2 2 2 2 UC 4 e 4 9 9 3 9 5S 2 E 9 p p p p v p p Qoo 9 9 lt l A ol gt D o9 ot T 5 T T T T T T GROUND CONTROL BOX GROUND CONTROL BOX e TB3 am TB1 ler e bd 1 KS1 TB2 g 1SAMP __ RD T RD PLAT H5 y 5 E GRD FAULT CR65A 4 ele ALARM 4 e e 5 PLATFORM LEVELING e BN52 BN53 50 BN51 OUTRIGGER LIMIT SWITCHES CE ONLY G e OB 4 ENABLE ENABLE ENABLE ENABLE 1512 1513 LS14 1615 M 10 SENS H H 4d G7 LED t BN49 4 7 we SS CR65A AUTOLEVEL 12 TB13 TB14 TB15 12 ENABLE g g g Q CR61 lt c E 8 5
72. cedure with the machine in the following configuration Machine disconnected from tow vehicle Machine parked on a firm level surface Boomin the stowed position with both latches secured Key switch in the off position with the key removed Wheels chocked Parking brake applied Part No 825934 Genie Genie TZ 34 20 3 1 About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous ADANGER situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures July 2013 SCHEDULED MAINTENANCE PROCEDUR
73. cedures B 1 Inspect the Batteries Proper battery condition is essential to good machine performance and operational safety A faulty battery cell can result in poor machine performance and improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING 00 injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 2 Puton protective clothing and eye wear 3 that the battery cable connections are free of corrosion 4 Be sure that the battery retaining fasteners and cable connections are tight Remove the battery vent caps from all batteries and check the specific gravity of each battery cell with a hydrometer Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced Check the battery acid level of each battery If needed replenish with distilled water to the bottom of each battery fill tube Do not overfill Install the battery vent caps Check each battery pack and verify that the batteries are wired correctly f
74. ding or scraping of the boom Genie part number 84376 Note Always maintain squareness between the outer and inner boom tubes Boom wear pad specifications Wear pad thickness minimum 7he inch 11 Genie Part No 825934 Genie TZ 34 20 Section 3 Scheduled Maintenance Procedures July 2013 CHECKLIST D PROCEDURES D 3 Replace the Hydraulic Tank Return Filter Replacement of the hydraulic tank return filter element is essential for good machine performance and service life A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter element be replaced more often Burn hazard Beware of hot oil ACAUTION Contact with hot oil may cause severe burns 1 Clean the area around the hydraulic oil filter Remove the filter with an oil filter wrench AWARNING aii 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 2 Use a permanent ink marker to write the date and number of hours from the hour meter on the new filter 3 Apply a thin layer of fresh oil onto the gasket of the new oil filter Genie GenieTZ 34 20 4 Install the filter and tighten it securely by hand Power unit components a b f g h i 5 Clean up any oil th
75. e NG31 6BH England 44 1476 584333 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 July 2013 T This page intentionally left blank Genie 3 4 GenieTZ 34 20 Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Dail
76. e condition case from the rotate gear assembly 1 Remove the platform See 1 1 6 Remove the gear assembly retaining nut from How to Remove the Platform the top of the shaft KS 6 rotate gear assembly rotate gear shaft oil seal gear shaft seal plate rotate handle shaft cover pinion rotate shaft handle T ri T sae ro Q0 07M Genie Part No 825934 Genie TZ 34 20 4 3 Section 4 Repair Procedures July 2013 PLATFORM COMPONENTS 7 Disassemble the gear assembly Note For ease of assembly note the order of disassembly of the gear assembly 8 Visually inspect the inside of the platform rotator for the following items Excessive wear Broken or damaged parts Rustor corrosion Binding Note If any parts are lightly rusted or corroded remove them and clean rust or corrosion off with a wire brush If parts are worn heavily rusted or corroded replace them 9 Remove the gear shaft from the shaft retainer bracket 10 Thoroughly degrease and dry the case covers and gear components 11 Install the gear shaft fully into the shaft retainer bracket Torque to specification 12 Assemble the gear assembly in the reverse order of disassembly in step 7 13 Install the gear assembly retaining nut onto the top of the shaft Torque to specification 14 Install the case over the gear assembly and onto the shaft seal plate Install and securely tig
77. e failure How to Remove the Secondary Boom Lift Cylinder Note 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 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure on a firm level surface with the boom in the stowed position 1 Tag disconnect and plug the hydraulic hoses on the lift cylinder Cap the fittings on the cylinder AWARNING cate 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 Part No 825934 Genie Genie TZ 34 20 SECONDARY BOOM COMPONENTS 2 Attach a lifting strap of suitable capacity from an overhead crane to the lift cylinder 3 Remove the pin retaining fastener from the lift cylinder rod end pivot pin 4 Place a rod through the hole in the outrigger pivot pin and twist to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pivot pin is removed 5 Lower the cylinder to a horizontal position 6 Remove the pin retaining fastener from the lift cylinder barrel end pivot pin 7 Place a rod through the hole in the outrigger pivot pin and twist to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when
78. e machine is level 2 Release the boom hold down latch and raise the platform approximately 2 feet 70 cm Level the platform 3 Tagand disconnect the wire harness from the load sense limit switch Note The load sense limit switch is located near the platform support 4 Setamulti meter to measure continuity Connect the leads from the multi meter to the black and red wires disconnected from the limit switch in step 3 5 Determine the maximum platform capacity Refer to the machine serial plate 6 Using a suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor Genie Genie TZ 34 20 Determine the limit switch trigger point 7 Gently move the platform up and down by hand so it bounces 1 to 2 inches 2 5 to 5 cm 8 Check the continuity between the black and red wires originating from the limit switch of the platform overload assembly Result There is no continuity Slowly tighten the load spring adjustment nut by turning it clockwise just until the limit switch closes and shows continuity Result There is continuity Slowly loosen the load spring adjustment nut by turning it counterclockwise just until the limit switch opens and shows no continuity Note The platform will need to be continuously moved up and down while making adjustments Fine adjustment of the switch trigger point 9 Continue moving the platform
79. e TZ 34 20 Part No 825934 July 2013 Section 4 Repair Procedures ee MANIFOLDS 6 3 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 that provides this force field AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wire harness from the coil to be tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 W Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Description Specification Solenoid valve 3 position 4 way 2910310 24V DC with diode schematic item B AA AB AC AD and AE Solenoid valve 3 position 4 way 20 to 220 24V DC with diode schematic items K M Q and T Solenoid valve 2 position 3 way 29 to 310 24V DC with diode schematic items O and V Solenoid valve 2 position 2 way N C 29 to 310 24V DC with diode schematic items W X Y and Z Part No 825934 Genie Genie TZ 34 20 How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes nat
80. eed 0 10K ohms Blz Blue R16 2000 ohm BK Eni Black R20 10000 ohm em Green R22 4300 ohm OR zo tesi ete entered Orange R22A 5600 ot oe o bud i tits Red S Sensor White S7 Loveleensor Ste SHE Blue Black S9 Level sensor front rear axis auto level 5 09 eve suo love BAW ener ean en Black White U Electronic Component asocio E n Green Black U6 Motor controller 8 Green White U9 Battery charger ORIBK sine ans etes Orange Black 016 Time delay Orange Red 035 delay relay Orange White Y Valve Coil ROBK teens Red Black Y19 Platform down RDANH inte ed Red White Y20 Platform up WEUBK uiii ctt ere des White Black Y21 Primary down White Red Y22 Primary up Y23 Turntable rotate left Y24 Turntable rotate right Y25 26 Left rear outrigger Y34 Right rear outrigger Y35 Left front outrigger Y36 Right front outrigger Y39 Outriggerretract Y40 Outrigger extend Y52 Secondary down Y53 Secondary up Genie 5 4 Genie TZ 34 20 PartNo 825934 July 2013 Section 5 Schematics Limit Switch Legend Item Description Schematic a Boom limit switches LS18 LS18A b Outrigger limit switches LS12 LS13 LS14 LS15 Genie Part No 825934 Genie TZ
81. enie TZ 34 20 12 Pull the boom extension out of the primary boom approximately 18 inches 50 cm 13 Remove the pin retaining fasteners securing the barrel end of the extension cylinder to the extension boom at the platform end 14 Remove the retainer securing the hydraulic hoses at the platform end of the boom 15 Remove the pin retaining fasteners securing the platform level slave cylinder pivot pin to the boom extension 16 Using a soft metal drift remove the platform level slave cylinder pivot pin 17 Remove the pin retaining fasteners securing the boom extension cylinder pivot pin to the primary boom 18 Using a soft metal drift remove the boom extension cylinder pivot pin 19 Remove the boom extension and cylinder from the boom Part No 825934 July 2013 Section 4 Repair Procedures 2 3 Primary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a bi directional solenoid valve to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Lift Cylinder Note 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 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure on a firm level surface with the boom in the stowed position and latched
82. er ride iL Az L re Solenoid operated 3 position 4 way directional valve zl Solenoid operated 2 position 3 way directional valve Double acting wd e cylinder z J i d Relief valve Genie GenieTZ 34 20 Part No 825934 July 2013 Section 5 Schematics Trailer Lighting Wiring Diagram ANSI CSA L35 WH RIGHT SIDE MARKER QD12 RD TRAILER PLUG N BN BN 1 GN L33 BN YL BN 2 0 LIGHT YL 3 BN BK WH 4 C YL RD BK BN 2 YL 8 BN YL L36 WH SBN SIDE MARKER L34 LEFT REAR AOWA J TAIL LIGHT Genie Part No 825934 Genie TZ 34 20 5 9 Section 5 Schematics July 2013 Trailer Lighting Wiring Diagram Mechanical Axle Trailer Chassis Wiring Harness GR GR OR OR WH RD 2 BK BK 1 RD BK fa RD BK RD BK 2 BL foe WH BK WH BK Hs 8 WH 5 4 GN 8 6 RD 5 OR 97 9 7 UB 6 RD 10 8 WH BK 7 BK e 8 WH BK 20 04 9 13 Not Used ne e 127 L33 RIGHT REAR TAIL LIGHT
83. fe TB11 TB11 m m o CR76 CR76 2 2 11 11 CR75 CR757 I cRz2 7 9 9 6 Yf o Sus a Ys e e e e e o e e 6 z z F6 d BATTERY 24V 275AMP 8 2 229g 3 2 2 ne z s s 8 U6 B 2 pts 1 1 1 1 RENE BS IW 1 IFB1 Y40cu amp 5 5 6 WA 4 57 18 Je 2 2 2 7 T an vag 7 T L t sd 117 A E 2 2 EF oz es 5 5 J t 5 BATTERY GROUND 5 m 2 ene 2 m m m 2 2 ES0441G m 20 m Ru do gt 99 IOI c 2248 S S a 1221 8 8 2 2 E 2 3 dd d E aS lal 228 B Bg B 8 8 8 o m 8 3 25 E 3 gt Eg x 5 5 D 5 5 o D e m 9 m mns m m m m meri 5 e M 9 D lt 4 Genie 5 24 TZ 34 20 PartNo 825934 July 2013 Section 5 Schematics e a Electrical Schematic AS CE
84. gage the parking brake Attempt to move the machine Result The parking brake should prevent the machine from moving If the parking brake does not prevent the machine from moving repeat this procedure beginning with step 1 CE models Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number 84443 Section 4 Repair Procedures July 2013 Outriggers 10 1 Outrigger Components How to Remove an Outrigger Outriggers are essential to safe machine operation and machine stability Operating a machine with a damaged or improperly operating outrigger will result in death or serious injury Note Perform this procedure with the machine disconnected from the tow vehicle and the parking brake applied Note Perform this procedure with the outriggers in the stowed position 1 Attach a lifting strap of suitable capacity from an overhead crane to the pad end of the outrigger Do not apply any lifting pressure 2 Tagand disconnect the wire harness from the outrigger valve coil 3 Tag disconnect and plug the hydraulic hoses at the outrigger cylinder Cap the fittings 4 Remove the pin retaining fasteners from the outrigger pivot pin Do not remove the pin Genie Genie TZ 34 20 5 Remove the pin retaining fasteners from the outrigger cylinder barrel end pivot pin 6 Place a rod t
85. her Cap Models with Optional Hydraulic Oil The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install a new cap onto the tank Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures C 5 Grease the Axle Wheel Bearings CE Axle specifications require that this procedure be performed every 6 months or 10 000 km whichever comes first Maintaining the axle wheel bearings is essential to safe operation and good machine performance Towing the machine with loose or worn wheel bearings may cause an unsafe towing condition and continued use may result in component or property damage Regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug bolts Do not remove them 2 Atthe ground controls extend the outriggers until the axle is off the ground and the machine is level 3 Remove the lug bolts and remove the tire and wheel assembly from the machine 4 Remove wash and inspect the axle wheel bearings and spacer ring 5 Packboth bearings with clean fresh grease 6 I
86. hrough the hole in the outrigger cylinder barrel end pivot pin and twist to remove the pin Remove the pivot pin from the machine Crushing hazard The outrigger AWARNING could fall if not properly supported when the pivot pin is removed from the machine 7 Place a rod through the hole in the outrigger pivot pin and twist to remove the pin Remove the outrigger pivot pin from the machine Crushing hazard The outrigger will AWARNING fall if not properly supported when the pivot pin is removed from the machine 8 Remove the outrigger and cylinder from the machine Part No 825934 July 2013 Section 4 Repair Procedures 10 2 5 Outrigger Cylinder 6 How to Remove an Outrigger Cylinder 7 Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be 8 replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and 9 Fitting Torque Specifications OUTRIGGERS Attach a lifting strap from an overhead crane to the lug on the rod end of the cylinder Remove the pin retaining fasteners from the outrigger cylinder rod end pivot pin Place a rod through the hole in the outrigger cylinder rod end pivot pin and twist to remove the pin Remove the outrigger cylinder rod end pivot pin from the machine Raise the cylinder to a vertical position Remove the pin retaining fasteners from the outrigger cylinder barrel end pivot pin 1 Extend the o
87. hten the retaining fasteners Do not over tighten Genie 4 4 Genie TZ 34 20 15 Thoroughly and heavily lubricate each tooth of the gear using multipurpose grease Rotate the gear case as required Note When lubricating the gear do not apply any grease to the remainder of the gear assembly components Grease on the balance of the gear components may result in slippage and poor rotator performance 16 Install the rotate handle shaft and pinion into the rotate gear case 17 Thoroughly and heavily lubricate each tooth of the pinion using multipurpose grease 18 Install the rotate handle shaft cover Install and securely tighten the cover fasteners Do not over tighten Torque specification Rotate gear shaft retainer bracket dry 50 Ibs ft 68 Nm Rotate gear nut dry 200 Ibs ft 271 Nm Part No 825934 July 2013 Section 4 Repair Procedures m This page intentionally left blank Genie PartNo 825934 Genie TZ 34 20 4 5 Section 4 Repair Procedures July 2013 Primary Boom Components OOOO D 9 primary boom pivot primary boom primary boom lift cylinder cable tray cable track primary boom lift cylinder rod end pivot pin cable bridge platform level slave cylinder platform mount battery charger prim
88. hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 825934 Genie Genie TZ 34 20 PRIMARY BOOM COMPONENTS a platform level slave cylinder b platform level master cylinder 3 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 4 Remove the external retaining rings from the barrel end pivot pin 5 Using a soft metal drift remove the rod end pivot pin 6 Carefully pull the cylinder out of the boom Component damage hazard Hoses CAUTION can be damaged if they are kinked or pinched How to Bleed the Slave Cylinder 1 Raise the boom to a horizontal position 2 Activate the platform level function in both up and down directions through two complete platform leveling cycles to remove any air that might be in the system The master cylinder acts as a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion The master cylinder is located inside the mid pivot Section 4 Repair Procedures July 2013 Secondary Boom Components secondary boom link secondary boom secondary boom lift cyl
89. ieTZ 34 20 Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures B 11 Inspect the Parking Brake A properly functioning parking brake is essential to safe machine operation The parking brake is manually activated An improperly functioning parking brake will prevent the operator from properly securing the machine when not in use 1 Visually inspect the parking brake cables and components for damage 2 Visually inspect the parking brake cables to ensure both are properly secured and installed into the brake backing plate 3 Setthe parking brake Note If the brake cables are too tight the parking brake will be difficult to set If the brake cables are too loose the brakes will not activate when the lever is set 4 Attempt to manually push the machine Result The machine should not move Result The machine moves Refer to Repair procedure 9 2 How To Adjust the Parking Brake Part No 825934 Genie Genie TZ 34 20 CHECKLIST B PROCEDURES B 12 Service the Tongue Jack Maintaining the tongue jack in good condition is essential to safe operation and good machine performance Failure to lubricate the internal gears and bearings of the jack and axle bolt could result in unsafe operating conditions and may cause component damage 1 Using a needle nose applicator pump a small amount of automotive grease through the lubrication opening Rotate the handle to evenly distribute the lu
90. il the axle is off the ground and the machine is level 2 Releasethe parking brake 3 Working from the exposed inside face of the brake plate opposite the cable entry tighten the adjusting screw until the wheel can only be turned with difficulty or not at all Note When tightening the adjusting screw turn the wheel only in the direction of travel 4 Ease off the adjusting screw approximately one half turn in a counterclockwise direction until the wheel turns freely 5 Repeat steps 3 through 4 for the other brake Genie GenieTZ 34 20 6 Inspect the balance plate at the control cables Result The balance plate is at a right angle to the direction of towing W Result The balance plate is not at a right angle to the direction of towing Tighten or loosen the brake cable ends coming from the axle until the balance plate is at a right angle to the direction of towing Return the outriggers to the stowed position Apply the parking brake Attempt to manually push the machine Result The machine does not move Result The machine moves Repeat this procedure beginning with step 1 Result One wheel rolls and the other one doesn t Repeat step 6 and adjust the balance plate to tighten the brake cable from the wheel which is rolling Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part n
91. inder secondary lift cylinder rod end pivot pin secondary boom link pivot pin platform level slave cylinder platform mount battery charger primary boom lift cylinder barrel end AND secondary boom pivot pin platform level master cylinder i a primary boom pivot pin mid pivot b primary boom latch primary boom lift cylinder ground controls d cable tray secondary boom lift cylinder barrel end pivot pin e cable track turntable f primary boom lift cylinder rod end pivot pin secondary boom pivot pin 9 bridge secondary boom link pivot pin h i j k lt lt Genie 4 16 Genie TZ 34 20 Part No 825934 July 2013 Section 4 Repair Procedures 3 1 Secondary Boom How to Remove the Secondary Boom AWARNING This procedure in this section u 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 required Note Perform this procedure on a firm level surface with the boom in the stowed position Note 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 2 Hydrauli
92. ir solved Section 5 Schematics Electrical Abbreviations Legend Item Description Item B Battery 5 Battery C4 BN Button BN49 Outrigger auto level BN50 Leftrearoutrigger BN51 Rightrearoutrigger CS BN52 Leftfrontoutrigger CB Right front outrigger CB2 BN54 Primary boom up down CR BN55 Secondary boom up down CR28 BN56 Boomextend retract CR55 BN57 Turntable rotate CR61 BN58 Platform level up down CR64 BN59 Function enable boom down CR65 boom retract rotate left outrigger extend CR66 BN60 Function enable boom up boom extend CR67 rotate right outrigger retract CR68 BN61 Function enable boom down boom retract CR69 turntable platform rotate left CR70 BN62 Function enable boom up boom extend turntable platform rotate right BN63 Primary boom up down BN64 Secondary boom up down BN65 Boomextend retract BN66 Turntable rotate BN67 Platformlevel up down Genie GenieTZ 34 20 July 2013 Description Capacitor Zener diode 5 1V DC Zener diode 3 3V DC Zener diode 4 3V DC Zener diode 5 1V DC 4700uF Circuit Breaker Controls 15A Control Relay Power supply Load Sense Auto level system Fault ground Motor controller cutout Level sensor auto level Primary boom Secondary boom Boom extend retract Turntable rotate Part No 825934 July 2013 ING ee Item CR CR71 CR72 CR73 CR74 CR75 CR76 CR77 CR78 F6 FB1 GND G6
93. ire that this procedure be performed every 500 hours or 6 months whichever comes first Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over Note Perform this procedure with the machine ona firm level surface 1 Atthe ground controls extend the outriggers until the tires are off the ground and the machine is level Release the boom hold down latch Turn the key switch to platform control Level the platform a amp Determine the maximum platform capacity Refer to the machine serial plate 6 Using a suitable lifting device place an appropriate test weight equal to the maximum platform capacity in the center of the platform floor Result The platform overload indicator light should be off at both the ground and platform controls Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures 7 Add an additional 44 Ibs 20 kg of weight to overload the platform Result The platform overload indicator light should be flashing at both the ground and platform controls 8 Test all machine functions from the platform controls Result All platform control functions should not operate 9 Turn the key switch to ground control 10
94. ivot Carefully lay the cables over the primary boom Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Note For ease of assembly pay close attention to how the cables are routed when pulling the cables through the boom and mid pivot 7 Tag disconnect and plug the hydraulic hoses to the primary boom lift cylinder Cap the fittings 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 Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 8 Attach a lifting strap of suitable capacity from an overhead crane to the primary boom lift cylinder 9 Remove the pin retaining fasteners securing the primary boom lift cylinder pivot pin to the primary boom 10 Using a soft metal drift remove the primary boom lift cylinder pivot pin at the primary boom Lower the cylinder onto the chassis AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed Genie Genie TZ 34 20 11 Tag disconnect and plug the hydraulic hoses to the platform level master cylinder Cap the fittings 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
95. l sensor as instructed could result in the machine tipping over causing death or serious injury Do not install or calibrate the level sensor other than specified in this procedure Perform this procedure with the machine ona firm level surface that is free of obstructions Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Lower all four outriggers and raise the machine off the ground Level the machine Use the bubble level located below the ground controls to confirm that the machine is level Turn the key switch to the off position Genie 4 22 Genie 2 34 20 Part No 825934 July 2013 Section 4 Repair Procedures 5 Locate the outrigger level sensor s behind the inspection door on the ground control side of the machine 9 b 9 FUNCTION MANIFOLD CR66 AUTOLEVEL RELAY gt X Ai PLATFORM TONGUE outrigger level sensor autolevel relay early production function manifold X indicator adjusting fastener 0 FUNCTION MANIFOLD J e ee Y QU lt PLATFORM TONGUE gt Part No 825934 Genie Genie TZ 34 20 GROUND CONTROLS If you are not installing a new level sensor proceed to step 10 6 Tagand disconnect the wire ha
96. level sensor as instructed could result in the machine tipping over causing death or serious injury Do not install or calibrate the level sensor other than specified in this procedure 1 Perform this procedure with the machine on a firm level surface that is free of obstructions Genie Genie TZ 34 20 2 Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 3 Push and hold the yellow function enable button Push and hold the auto level button Result The outriggers will lower and adjust to level the machine and raise the wheels off the ground Use the bubble levels located on the chassis to confirm that the machine is level 4 Turn the key switch to the off position 5 Locate the tilt level sensor behind the inspection door on the side of the machine opposite the ground controls 0 9 FUNCTION MANIFOLD TURNTABLE ROTATE 9 gt MOTOR 5 lt 2 lt TONGUE PLATFORM a function manifold b turntable rotate motor tilt level sensor d adjusting fastener e X indicator Part No 825934 July 2013 Section 4 Repair Procedures If you are not installing a new level sensor proceed to step 10 Install the level sensor 6 Tag and disconnect the wire harness from the tilt level sensor 7 Remove the three level sensor retaining fasteners Remove the level
97. ll 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 Operator s Manualon your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Readeach 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 disconnected from tow vehicle Machine parked on a firm level surface Boomin the stowed position with both latches secured Key switch in the off position with the key removed Wheels chocked Parking brake applied Part No 825934 Genie Genie TZ 34 20 4 1 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 Then to re assemble perform the disassembly steps in reverse order Symbols Legend
98. llow oil to squirt or spray Section 4 Repair Procedures July 2013 PRIMARY BOOM COMPONENTS 10 Tag disconnect and plug the hydraulic hoses at the mid pivot end of the cable tray Cap the fittings on the hydraulic hard lines Refer to YY in the illustration 11 Place blocks between the cable bridge cable track and cable tray Secure them together AWARNING Crushing hazard If the cable bridge cable track and cable tray 2 are not properly secured together the combination could become unbalanced and fall when removed 3 from the machine 12 Remove the fasteners securing the cable tray to the primary boom Crushing hazard The cable track AWARNING assembly could fall if not properly 4 supported when the fasteners are removed 5 13 Remove the fasteners securing the cable bridge to the extension boom 14 Remove the cable track from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The cable track 6 assembly could fall if not properly supported when removed from the 7 machine 8 9 Genie How to Repair the Cable Track Component damage hazard The cable track can be damaged if it is twisted Visually inspect the cable track and determine which 7 link section needs to be replaced Using a flat blade screwdriver pry open the hinge bar on each link of the 7 link section plus one more on each end making a total of 9 Using a flat blade screwdriver at one side of the li
99. m 10 60 ft lbs 81 3 Nm Jambnut Non adjustable 12 85 ft lbs 115 Nm b fitting Non adj Adjustable 16 110 ft lbs 150 Nm fitting Adj 20 140 ft lbs 190 Nm SAE O ring Boss Port 24 180 ft lbs 245 Nm tube fitting installed into Steel swivel nut or hose connection JIC 37 Fittings SAE Dash size Torque 4 ORFS 37 Adj ORFS Non adj 37 Non adj 15 ft lbs 20 3 Nm 26 ft lbs 35 3 Nm 22 ft lbs 30 Nm SAE Dash size Thread Size Flats 6 ORFS Adj Non adj 35 ft lbs 47 5 Nm 4 7 16 20 2 37 Adj Non adj 29 ft lbs 39 3 Nm 6 9 16 18 11 4 8 ORFS Adj Non adj 60 ft lbs 81 3 Nm 8 3 4 16 1 37 Adj Non adj 52 ft lbs 70 5 Nm 10 7 8 14 1 10 ORFS Adj Non adi 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 1 S us 1 116 12 1 12 All types 135 ft lbs 183 Nm 5 46 ii 1 516 12 1 16 All types 200 ft lbs 271 2 Nm 20 1 5 8 12 1 20 All types 250 ft lbs 339 Nm 7 24 24 All types 305 ft lbs 413 5 Nm Genie GenieTZ 34 20 Part No 825934 July 2013 Section 2 Specifications Torque Procedure Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O rings
100. marks indicate that the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Figure 2 a body hex fitting b reference mark second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Section 2 Specifications July 2013 SPECIFICATIONS SIZE 1 4 5 16 3 8 7 16 1 2 9 16 SAE FASTENER TORQUE CHART THREAD 0 SIE 20 80 9 100 113 10 124 140 158 10 147 28 90 101 120 135 120 135 160 18 14 158 18 13 176 24 14 19 27 366 16 23 312 44 596 24 26 352 35 are 3 50 1 49 664 37 501 49 664 so 678 70 97 29 a sss 55 145 60 813 ao 10848 or 43 57 773 75 1016 90 1084 110 149 20 64 867 8 115 90 122 12 80 1084 12 41 110 149 210 284 18 130 176 10 200 271 270 36 280 379 380 515 220 298 300 f so f sio 420 f 420 59 560 759 E EREHE 640 s67 680 922 990 1342 9 zx 2 z EE 142 670 __ 890 1206 1080 1464 140 1
101. n 5 Schematics July 2013 C O Hydraulic Schematic Section 5 Schematics July 2013 O EEE SESS Hydraulic Schematic A B D E F G H J K L M 1 LEFT FRONT RIGHT FRONT l OUTRIGGER OUTRIGGER SECONDARY BOOM PRIMARY BOOM EXTENSION PLATFORM CYLINDER CYLINDER LIFT CYLINDER LIFT CYLINDER CYLINDER LEVELING gt cee a 5 2 1 a 2 Save 2 amp 5 L CYLINDER E R e R a
102. n a counterclockwise direction and release Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures 11 Pull the thumbscrew out and turn fully in a clockwise direction to open the valve O Result The thumbscrew should move easily 12 To close the valve pull the thumbscrew out and turn fully in a counterclockwise direction and release Note The machine functions will not operate unless the valves are closed 13 Locate the turntable rotate valve at the manifold Push the thumbscrew in and turn fully in a clockwise direction to open the valve O Result The thumbscrew should move easily 14 To close the valve push the thumbscrew in and turn fully in a counterclockwise direction and release 15 Pull the thumbscrew out and turn fully in a clockwise direction to open the valve O Result The thumbscrew should move easily 16 To close the valve pull the thumbscrew out and turn fully in a counterclockwise direction and release Note The machine functions will not operate unless the valves are closed Part No 825934 Genie Genie TZ 34 20 CHECKLIST B PROCEDURES B 5 Test the Platform Rotation if equipped Testing the platform rotation for malfunctions is essential for safe machine operation The platform rotator is operated by manually turning the hand crank in either a clockwise or counterclockwise direction 1 Turn the hand crank at the platform in the clockwise direction
103. nce procedure is a onetime procedure 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 8 Grease the Turntable Rotation Bearing and Rotate Gear B 11 Inspect the Parking Brake D 3 Replace the Hydraulic Tank ReturnFilter D 4 Checkthe Turnable Rotation Bearing Bolts Part No 825934 Genie Genie TZ 34 20 3 9 CHECKLIST A PROCEDURES A 8 Grease the Turntable Rotation Bearing and Rotate Gear Genie specifications require that this procedure be performed every 100 hours of operation Regular application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an insufficiently greased bearing and gear will result in component damage 1 Raise the boom enough to access the turntable bearing 2 Locate the grease fitting on the platform end of the turntable next to the boom hold down latch 3 Pump multipurpose grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm ata time and repeat this step until the entire bearing has been greased 4 Apply grease to each tooth of the drive gear located under the turntable Grease type Multipurpose grease Section 3 Scheduled Maintenance Procedures July 2013 Checklist B Pro
104. nd obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Genie vi Genie TZ 34 20 Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3il such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel
105. ndary boom 19 Using a soft metal drift remove the lift cylinder pivot pin from the secondary boom Lower the cylinder Crushing hazard The cylinder AWARNING could fall if not properly supported when the pivot pin is removed 20 Tag disconnect and plug the hydraulic hoses to the hydraulic hard lines at the turntable end of the secondary boom Cap the fittings 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 Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 21 Attach a lifting strap of suitable capacity from an overhead crane to the secondary boom Raise the boom to a horizontal position 22 Remove the pin retaining fasteners securing the secondary boom pivot pin to the turntable 23 Using a soft metal drift remove the secondary boom pivot pin AWARNING Crushing hazard The secondary boom could become unbalanced and fall if not properly supported when the pin is removed 24 Remove the secondary boom from the machine Part No 825934 July 2013 Section 4 Repair Procedures 3 2 Secondary Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a bi directional solenoid valve to prevent movement in the event of a hydraulic lin
106. ndicator no more than 1 inch 2 5 cm from the turntable rotation bearing Bearing to turntable lubricated 200 ft Ibs 271 Nm Genie GenieTZ 34 20 Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 5 At the dial indicator adjust it to zero the 8 Fully retract the primary boom Raise the indicator primary and secondary booms to full height Visually inspect the dial indicator to be sure the needle returns to the zero 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 turntable dial indicator drive chassis turntable rotation bearing 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 0 025 inch 0 635 mm The bearing is good Result The measurement is more than 0 025 inch 0 635 mm The bearing is worn and needs to be replaced Genio Part No 825934 Genie TZ 34 20 3 27 Section 3 Scheduled Maintenance Procedures July 2013 Checklis
107. nk to be replaced separate the connection and open the joint slightly by sliding the link over the link pivot Repeat for the other side of the link to separate the link sections Repeat step 3 for the other end of the section to be replaced Lift up the hoses and cables and carefully remove the damaged section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched Lift up the hoses and cables and carefully insert the new section of cable track Install the new section of cable track onto the existing track Be sure the link pivot on both sides of the link are in place and that the track hinges correctly Securely lock the hinge bar for each link Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track 4 8 Genie TZ 34 20 Part No 825934 July 2013 Section 4 Repair Procedures 2 2 Primary Boom How to Shim the Primary Boom 1 Extend the boom until the wear pads are accessible 2 Loosenthe wear pad mounting fasteners 3 Install the new shims under the wear pad to obtain zero clearance and zero drag 4 Securely tighten the mounting fasteners Do not overtighten 5 Extendand retract the boom through an entire cycle Check for tight spots that could cause binding or scraping Note Always maintain squareness between the outer and inner boom tubes Part No 825934 Genie Genie TZ 34 2
108. nstall the bearings and spacer ring onto the axle and reassemble the axle 7 Tighten the castle nut until the wheel runs with a little bite Part No 825934 Genie Genie TZ 34 20 CHECKLIST C PROCEDURES 8 Loosen the castle nut just until the cotter pin fits into the next hole Install a new cotter pin and lock into position Install the dust cap Note Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 9 Install the tire and wheel onto the axle Install and torque the lug bolts to specification Refer to Section 2 Specifications 10 Perform steps 3 through 9 for the other side of the machine 11 Return the outriggers to the stowed position Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number 84443 Section 3 Scheduled Maintenance Procedures July 2013 CHECKLIST C PROCEDURES C 6 Adjust the Brakes CE Axle specifications require that this procedure be performed every 6 months or 10 000 km whichever comes first Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can lead to poor axle performance and component damage 1 Atthe ground controls extend the outriggers unt
109. ntable platform mount Q7 oocoontco Part No 825934 Genie Genie TZ 34 20 4 7 PRIMARY BOOM COMPONENTS 2 Tag and disconnect two of these wire cables from their source at the ground control box 3 Atthe rear of the chassis open the AC plug Tag and disconnect the wiring from the plug Remove the wiring from the clamp behind the battery charger cover 4 Working from the mid pivot pull the three wire cables through the turntable secondary boom and mid pivot Set the cables off to the side of the primary boom Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 5 Tag and disconnect the wire harness from the platform control box 6 Tagand disconnect the trailer lighting wire harness at the platform Remove the wiring from the clamp 7 Remove the cover from the AC outlet Tag and disconnect the wiring from the outlet 8 Pullthe three harness cables through the platform mount and lay them off to the side of the primary boom Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 9 Tag disconnect and plug the hydraulic hoses at the platform end of the cable bridge Cap the fittings on the hydraulic hard lines Refer to XX in the illustration 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 a
110. of this and all other manuals Contact Us http www genielift com e mail awp techpub terex com Genie li Genie TZ 34 20 Serial Number Information Genie offers the following Service Manual for these models Title Part No TZ 34 20 Service 84382 From SN TZ3403 001 to TZ3413 595 Copyright 2011 Terex Corporation 825934 Rev A July 2013 Second Edition First Printing Genie and TZ are registered trademarks of Terex South Dakota Inc in the USA and many other countries amp Printed on recycled paper Printed in U S A Part No 825934 July 2013 Revision History Revision Date Section Procedure Schematic Page Description pa meo o Honda Engine Section2 Specifications Electronic Version A 6 B 3 C 7 Section3 Maintenance Procedure 3 2 6 4 9 1 Section4 Repair Procedure Click on any procedure or page number 5 35 5 56 5 104 Section 5 Schematic Page highlighted in blue to view the update Genie Part No 825934 GenieTZ 34 20 ii July 2013 REVISION HISTORY CONTINUED uu ME LED Procedure Schematic Page Description Honda Engine Section2 Specifications Electronic Version A 6 B 3 C 7 Section3 Maintenance Procedure 3 2 6 4 9 1_Section 4_Repair Procedure Click on any procedure or page number 5 35 5 56 5 104_Section 5_Schematic Page st highlighted in blue to view the
111. oom 2 Tag and disconnect the wiring at the power to platform junction box Tag and disconnect the cables from the platform control box 4 Remove the platform controls and controls mounting bracket from the boom extension Section 4 Repair Procedures July 2013 PRIMARY BOOM COMPONENTS 5 Attach a lifting strap of suitable capacity from an overhead crane to the platform mount Do not apply any lifting pressure 6 Remove the pin retaining fasteners securing the platform mount pivot pin to the boom extension cylinder 7 Usinga soft metal drift remove the platform mount pivot pin at the boom extension cylinder Crushing hazard The platform AWARNING mount could become unbalanced and fall if not properly supported when the pin is removed 8 Remove the pin retaining fasteners securing the platform mount pivot pin to the platform level slave cylinder 9 Using a soft metal drift remove the platform mount pivot pin at the platform level slave cylinder AWARNING Crushing hazard The platform mount could become unbalanced and fall if not properly supported when the pin is removed 10 Remove the wear pad retaining fasteners from the primary boom Remove the wear pads from the boom Note For ease of assembly note the quantity and location of shims during disassembly 11 Tag disconnect and plug the hydraulic hoses from the platform level slave cylinder at the cable track Cap the fittings Genie G
112. pin 6 Using a soft metal drift remove the master cylinder rod end pivot pin Remove the master cylinder from the machine AWARNING Crushing hazard The master cylinder could become unbalanced and fall if not properly supported when removed from the machine Part No 825934 July 2013 Section 4 Repair Procedures How to Remove the Slave Cylinder The slave cylinder via a closed circuit hydraulic loop works in tandem with the master cylinder to maintain the platform in a level condition through the entire range of boom motion The slave cylinder located at the platform end of the extension boom is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure Note Before cylinder removal is considered to correct a malfunction bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit Note 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 Extend the boom approximately 12 inches 30 cm 2 disconnect and plug the slave cylinder hydraulic hoses from the tee fittings on the jib manifold and connect them together using a connector Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen
113. relief valve adjusting screw and loosen the lock nut schematic item E Adjust the relief valve screw Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Refer to Section 2 Specifications Tip over hazard Do not adjust the relief valve higher than specified Hold the relief valve screw and securely tighten the lock nut Be sure the relief valve screw does not turn Genie July 2013 Repeat step 4 to confirm the relief valve pressure setting Bleed the hydraulic system by raising the platform to full height If the pump cavitates or platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic tank Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating Genie TZ 34 20 Part No 825934 July 2013 Section 4 Repair Procedures 5 3 Hydraulic Pump How to Remove the Hydraulic Power Unit Note 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 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 2 Remove the drain plug from
114. rness from the outrigger level sensor 7 Remove the three level sensor retaining fasteners Remove the level sensor from the machine 8 Install the new level sensor onto the machine with the X on the level sensor housing located as shown in the illustrations Install and tighten the level sensor retaining fasteners 9 Connectthe wire harness to the level sensor 10 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Note e sure there are threads showing through the top of the adjusting fasteners 11 Turn the key switch to ground control 12 Raise the outriggers until all of the outriggers are off the ground 13 Push and hold the yellow function enable button Push and hold the auto level button O Result The outriggers will lower and adjust to level the machine and raise the wheels off the ground Use the bubble level located below the ground controls to confirm that the machine is level Section 4 Repair Procedures July 2013 Hydraulic Power Unit 5 1 Hydraulic Power Unit Components The power unit is located under the side cover on the side of the machine opposite of the ground controls Index Schematic No Description Item Function Torque 1 Hand pump 5 eiu cederet dde Auxiliary functions 2 Breather Cap W Check Valve Fluid fill Vents to atmosphere 3 Hose fitting entree pee En To outrigger extend fron
115. sensor from the machine 8 Install the new level sensor onto the machine with the X on the level sensor housing located as shown in the illustration Install and tighten the level sensor retaining fasteners 9 Connectthe wire harness to the level sensor 10 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Note Be sure there are threads showing through the top of the adjusting fasteners 11 Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 12 Raise the secondary boom approximately 12 inches 30 cm Result The tilt sensor alarm should not sound 13 Using a digital level lower the tank side of the machine until the turntable is 2 4 out of level Result The tilt sensor alarm should not sound W Result The tilt alarm will sound at 180 beeps per minute The level sensor is faulty and must be replaced Repeatthis procedure beginning with step 6 Part No 825934 Genie Genie TZ 34 20 GROUND CONTROLS 14 Continue to lower the tank side of the machine until the turntable is 2 7 out of level Result The tilt alarm will sound at 180 beeps per minute W Result The tilt alarm does not sound The level sensor is faulty and must be replaced Repeat this procedure beginning with step 6 15 Push and hold the yellow function enable button
116. squirt or spray 4 Remove the turntable rotation motor mounting fasteners and remove the turntable rotation motor from the machine Genie Part No 825934 Genie TZ 34 20 Section 4 Repair Procedures July 2013 Axle Components 8 1 CE models Axle 1 Lower the outriggers and adjust to level the Es machine and raise the wheels off the ground How to Remove the Axle 2 Disconnectthe parking brake cable at the ANSI CSA AS models tenstonequa teer 3 Support and secure the axle assembly to an 1 Lowerthe outriggers and adjust to level the appropriate lifting device machine and raise the wheels off the ground 4 Remove the axle mounting fasteners and 2 Disconnect the parking brake cable at the 1 parking brake handle AWARNING Crushing hazard The axle could become unbalanced and fall if not 4 Tag disconnect and plug the brake line from the properly supported and secured back of the hub Cap the fitting when removed from the machine 3 Pull the cables free of the trailer 5 Clean up any brake fluid that may have spilled 6 Repeat steps 4 through 5 for the other side 7 Support and secure the axle assembly to an appropriate lifting device 8 Remove the axle mounting fasteners and remove the axle from the machine Crushing hazard The axle could AWARNING become unbalanced and fall if not properly supported and secured when removed from the machine Note
117. t E Procedure E 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and 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 Note 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 Note Perform this procedure with the boom in the stowed position 1 Open the power unit module tray 2 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Genie GenieTZ 34 20 3 Remove the drain plug from the power unit valve body and completely drain the tank into a suitable container Refer to Section 2 Specifications for capacity information Power unit components breather cap hydraulic tank filler cap hand pump sight gauge hidden from view hydraulic pump motor drain plug hydraulic filter 4 Tag and disconnect the wire harness from the valve coils on the power unit 5 Tag
118. t No 825934 July 2013 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 damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual your machine before attempting any maintenance or repair procedure Be sure that all necessary tools and test equipment are available and ready for use Part No 825934 Genie Genie TZ 34 20 5 1 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 Schematics 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 repa
119. t circuit 10 12 ft Ibs 14 16 Nm 4 Manifold n eSI ROC aged 10 12 ft Ibs 14 16 Nm 5 Diagnostic nipple Asi ico re to 10 12 ft Ibs 14 16 Nm 6 24V DC electric motor Operates hydraulic pump 50 in Ibs 5 5 Nm 7 Solenoid valve 3 position 4 way open center Outrigger extend retract 28 33 ft lbs 38 44 Nm Goll TUE Uv ein de 60 in Ibs 6 7 Nm 8 Valve coll eut geste ies Outrigger extend function 9 MalV8 Coll eei tefte deett Outrigger retract function 10 Check Outrigger circuit 11 Hydraulic filter Filters hydraulic fluid leaving system 12 Power unit valve body 13 a a 1 3 gallons per minute 3500 psi 4 9 liters per minute 241 3 bar 14 Pick up filter Filters hydraulic fluid entering the pump 15 Du mc 2 1 gallons 8 50 in Ibs 5 5 Nm 16 Breather Cap W Check Valve Vents tank to atmosphere 17 Relief valve 2 2 Den Outrigger system relief 28 33 ft lbs 38 44 Nm 18 Hose fitting edet To outrigger retract front circuit 10 12 ft Ibs 14 16 Nm 19 Manifold Plug ed ERR een 10 12 ft Ibs 1
120. the maintenance procedures can lead to poor axle performance and component damage 1 Clean all visible surfaces of the ball coupler 2 Lubricate the hitch at both grease fittings at the top of the over run hitch 3 Lubricate all bolts and articulated points on the hand brake lever using commonly available machine oil or motor oil 4 Lubricate all bolts and movable parts of the coupler using commonly available machine oil or motor oil 5 Lightly grease the ball mount Section 3 Scheduled Maintenance Procedures July 2013 CHECKLIST B PROCEDURES 6 Confirm that the brake cable is securely installed into the brake handle linkage Apply the hand brake Attempt to manually push the machine Result The machine does not move O Qo N Result The machine moves Adjust the brakes See Maintenance procedure C 6 Adjust the Brakes CE Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual B 10 Perform Axle Maintenance CE Axle specifications require that this procedure be performed annually or every 5000 km whichever comes first Brake Inspection Axle Inspection Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 Genie part number 84443 KNOTT Axle Service Manual Genie part number 84443 Genie Gen
121. they are kinked or pinched Section 4 Repair Procedures July 2013 SECONDARY BOOM COMPONENTS 10 Attach a lifting strap of suitable capacity from an overhead crane to the secondary link Do not apply any lifting pressure 11 Using a soft metal drift remove the secondary boom pivot pin at the mid pivot Crushing hazard The mid pivot AWARNING could become unbalanced and fall if not properly supported when the pin is removed 12 Using a soft metal drift remove the secondary link pivot pin at the mid pivot Crushing hazard The secondary AWARNING link could become unbalanced and fall if not properly supported when the pin is removed 13 Remove the mid pivot from the machine Crushing hazard The mid pivot AWARNING could become unbalanced and fall if not properly supported when removed from the machine Remove the secondary boom 14 Remove the pin retaining fasteners securing the secondary link pivot pin to the turntable 15 Using a soft metal drift remove the secondary link pivot pin Crushing hazard The secondary AWARNING link could become unbalanced and fall if not properly supported when the pin is removed 16 Remove the secondary link from the machine 17 Attach a lifting strap of suitable capacity from an overhead crane to the lift cylinder Do not apply any lifting pressure Genie Genie TZ 34 20 18 Remove the pin retaining fasteners securing the lift cylinder pivot pin to the seco
122. toed shoes Part No 825934 July 2013 Section 1 Safety Rules Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that all tools and working areas Be sure any forklift overhead crane or d other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure that fasteners intended for one i Be sure to properly dispose of old oil or Ge other fluids Use an approved container Please be environmentally safe sure that your workshop or work area is ty 3 properly ventilated and well lit Part No 825934 Genie TZ 34 20 Genie SAFETY RULES vii 2013 Table of Contents Introduction Important Information accede einen eroi ede aed trece HELLE A ii Serial osae ii Hevislor HISTO aoier rT i te AE P iii Serial
123. ually or every 1000 hours or every 12 000 miles A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with employer jobsite and governmental regulations and requirements Part No 825934 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 A TEREX BRAND Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Genie UK The Maltings Wharf Road Grantham Lincolnshir
124. umber 84443 Part No 825934 July 2013 Section Scheduled Maintenance Procedures Checklist D Procedures D 1 Perform Axle Maintenance ANSI CSA AS Axle specifications require that this procedure be performed every 12 months or 12 000 miles whichever comes first Brake lining Brake cylinders Brake lines Trailer brake wiring Hub Drum Wheel bearings Seals Springs Hangers Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual D 2 Check the Boom Wear Pads Maintaining the 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 extremely worn wear pads may result in component damage and unsafe operating conditions Note If the wear pads are within specification refer to Repair Procedure 3 2 How to Shim the Boom 1 Extend the boom until the wear pads are accessible 2 Measure the thickness of the top side and bottom wear pads If the wear pad is within specification shim as necessary to obtain zero clearance and zero drag 3 Extend and retract the boom through the entire range of motion to check for tight spots that may cause bin
125. urally 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 6 3 How to Test a Coil Section 4 Repair Procedures July 2013 MANIFOLDS 2 Connecta 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 Note The battery should read 9V DC or more when measured across the terminals Resistor 10Q Genie part number 27287 COIL AMMETER os s 100 9V RESISTOR Coa mum i Eq T 1 Lon Le 4 multimeter 9V DC battery 10Q resistor coil Note Dotted lines in illustration indicate reversed connection as specified in step 6 Genie Genie TZ 34 20 3 Seta multimeter to read DC amperage Note The multimeter when set to read DC amperage should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil
126. utrigger until the pad just touches 10 Place a rod through the hole in the outrigger the ground Do not rest the weight of the machine on the outrigger 2 Remove the hose guard mounting fasteners cylinder barrel end pivot pin and twist to remove the pin Remove the outrigger cylinder barrel end pivot pin from the machine from the rod end of the outrigger cylinder and AWARNING Crushing hazard The outrigger remove the hose guard from the machine Tag disconnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder AWARNING 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 4 Tag and disconnect the wire harness from the outrigger cylinder valve coil Genie cylinder could fall if not properly supported when the pivot pin is removed from the machine Component damage hazard The solenoid valve can be damaged Use caution when removing the cylinder from the machine Part No 825934 Genie TZ 34 20 4 37 Section 4 Repair Procedures July 2013 Platform Overload Components 11 1 Platform Overload System Calibrate the Platform Overload System if equipped Note Perform this procedure with the machine on a firm level surface 1 Atthe ground controls extend the outriggers until the tires are off the ground and th
127. xter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number 84376 Section 3 Scheduled Maintenance Procedures July 2013 CHECKLIST A PROCEDURES A 5 A 6 Torque the Lug Bolts CE Perform Hitch Maintenance ANSI CSA AS Axle specifications require that this procedure be performed initially after 50 km or 50 km after a wheel change Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can lead to poor axle performance and component damage 1 Check each lug bolt for proper torque Refer to Section 2 Specifications Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Hitch specifications require that this procedure be performed weekly Brake fluid level Inspect actuator Required maintenance procedures and additional hitch information is available in the Demco Model 91 Brake Actuators Owner Operator Manual Demco part number BH20023 Demco Model 91 Owner Operator Manual Genie part number 84592 Genie part number 84443 Genie 3 8 GenieTZ 34 20 Part No 825934 July 2013 Section 3 Scheduled Maintenance Procedures A 7 Perform 30 Day Service The 30 day maintena
128. y or 8 hours Inspection A Quarterly or 250 hours or 3000 mile 5000 km Inspection Semi annually or 500 hours or 6000 mile 10 000 km Inspection A B C Annually or 1000 hours or 12 000 mile Inspection A B C D Two year or 2000 hours 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 in this section to learn how to perform these inspections If any inspection receives an N 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 repaired Checklist A 1 Manuals and Decals Checklist C Y N A 2 Pre operation inspect A 3 Function tests A 4 Lug Bolts ANSI CSA AS 5 Lug Bolts CE A 6 Hitch maintenance ANSI CSA AS Perform after 40 hours A 7 Perform 30 day service Perform every 100 hours A 8 Grease rotate bearing Checklist Y NR B 1 Batteries B 2 Electrical wiring B 3 Electrical Contactor B 4 Manual override B 5 Platform rotation B 6 Hydraulic Oil Analysis B 7 Axle maintenance ANSI CSA AS B 8 Wheel bearings CE B 9 Hitch CE B 10 Axle maintenance CE B 11 Parking brake B 12 Tongue jack Comments Genie Part No 825934 C 1 Grease platform

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