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Service Manual - Genie Industries

1. 9 TERMINAL BASE p mo TEMA MANIFOLD HARNESS 87 87 87 PIN PL 1 lt a RD CR72 22 DRIVE MANIFOLD HARNESS PIN 8 3 CR78A PIN 85 OUTRIGGERS 85 LIFT CUT OUT TB35 TERMINAL PA 5 87 87 MANIFOLD HARNESS wH 87 87A HEH AHHH BD 7617 MANIFOLD HARNESS 2 gt CR70 Q 85 9 Q 85
2. September 2014 ___ 15 TERMINAL 86 BD CR1 TERMINAL 86 RD TURNTABLE HARNESS MODELS RD POWER CABLE PIN 1 WITH RD TBS ENGINE BD CR6 TERMINAL 30 _ OPTION CR15 TERMINAL 30 1 EMERGENCY STOP RD BCI 5 5 5 49 TURNTABLE HARNESS BN68 N PINB 60 wit FUNCTION ENABLE TB10 START gt 7 E G BOOM UP EXTEND ROTATE RIGHT AND OUTRIGGER RETRACT KST KEY SWITCH 7 BN59 FUNCTION ENABLE BOOM DOWN BN90 O B
3. LEFT RIGHT 1 1 DRIVE MOTOR DRIVE MOTOR LEFTFHONT FRONT EXTENSION SECONDARY BOOM PRIMARY BOOM mm CYLINDER CYLINDER CYLINDER LIFT CYLINDER LIFT CYLINDER P mp4 TURNTABLE JIB PLATFORM PLATFORM iy x Zw ROTATE BOOM LEVEL za co 1 e sl po 8 gt SLAVE 037 i 0 037 ae CYLINDER 2949 0 94 mm Se Aa f el mo del i9 pel 2 B Di D2 D3 D4 ce a ae 2 3 mm 24 9 CU REV 2 SS eee
4. Trailer Chassis Wiring Harness ELECTRIC BATTERY CHARGER 135 5 35 BK WH SIDE MARKER ELECTRIC BREAK AWAY KIT rh vL BR A 1 RD 5 gt 3 e e e IL 2 K 7 R 4 o 1 YL zs 2 7 PIN PLUG INSTALLED BY CUSTOMER 5 3 1 YL LEFT TURN SIGNAL 4 GN 2 BK REVERSE LIGHT 5 BL 2 BK BREAK AWAY BATTERY CHARGER i j 6 RD 3 WH GROUND 7 BN 4 GN RIGHT TURN SIGNAL L36 L36 5 BL ELECTRIC BRAKE LEFT SIDE MARKER Boom Harness 6 RD BRAKE LIGHTS ELECTRIC 7 BN SIDE MARKERS FOG LIGHTS RUN BRAKE L33 RIGHT REAR TAIL LIGHT BY BACKUP L35 J RIGHT SIDE MARKER RUN Platform Wiring Harness GN A TURN BL GND WH e stop WH RD e a L FoG WH BL BR Bi BL FoG 1 YL BK 2 A BK RD 2 BK wH STOP YL YL 3 WH M 4 GN GND 5 BL 6 RD g YL TURN 7 BN L36 K RUN LEFT SIDE MARKER LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT BACKUP L34 LEFT REAR TAIL LIGHT SIDE MARKER TURN SIGNAL FOG LIGHT 5 RED REFL
5. Y zener nione oc 14 BN65 BN67 R22B WV BOOM BOOM PLATFORM 5 6K OHM 822 FUNCTION EXTEND RETRACT LEVEL a 5 6K OHM 10K OHM 52042 2 EMERGENCY STOP O 1 8 RD POWER CABLE PIN 1 BKWH ORBK Eo 1 BN2 BN97 BN63 BN98 MODELS ENGINE JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UPDOWN V ROTATE option a 1 BN62 OPTION FUNCTION ENABLE TURNTABLE AND SSS SSS D PLATFORM ROTATE RIGHT 1 1_ BL TER CR 9 TERMINAL 30 AND P2 6 7 ut 4 BN64 BN66 RD TURNTABLE 22 UP DOWN ROTATE S RD BN61 D FUNCTION ENABLE BOOM DOWN BOOM RETRACT D TURNTABLE AND PLATFORM ROTATE LE an LEFT RDWH WHIBK BK RD _ _ D RD TB7 87 87 f Y cmm
6. A B D E F G H L M PLATFORM CONTROL BOX 1 eTe I e PLATFORM E STOP POWER BN2 PLATFORM J CHOKE START CONTROLS H1 TB9 FAULT ALARM PLATFORM GROUND 2 X 3 2 ENGINE OPTION T 5 5 5 m m 5 e e DRIVE CONTROLS HORN OPTION I ele DRIVE E STOP POWER a 9 55 55 jes A 5 1 2 D m 1618 9 o D 5 2 DRIVE CONTROL BOX 1518 T gt ge 2 3 3 8 2112 5 v E DAJDR GROUND CONTROL BOX 2 9 lt 1 lt 6 TB3 n tod CB2 P KS1 e ED 2 T GRD BN90 BN68 FAUL CR65A START ALARM 1 4 15 TEMA GROUND uot CONTROLS CR65A 6 4 200 10W 112 113 114 115 5 t Le 7 CR76 3 8767 R8 CR15 CR1 U16B 1 fos 3 15 17 75 E GCON GROUND x v y y X x y 240 lt al aT al al a 6 8 4 P gi CR20 5 OUTRIGGER 9 ES i SWITCHES a a 3 w ODR1 ES w 5 m i Fe 8 5 275AMP 9 g 8 D1 pv ALTERNATOR
7. September 2014 gt C4A ZENER DIODE 5 1V DC R14 BN65 BN67 R22B BOOM BOOM PLATFORM 5 6K OHM R22C FUNCTION EXTEND RETRACT LEVEL 5 6 OHM 10K OHM L4A BK RD 6 ee LIMIT SWITCH HARNESS stor TERMINAL 3 08 1 wn RD pOWERCABLEPIN 1 BK WH 2 4 4 AU ORBK BN2 BN97 BN63 8 MODELS JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UP DOWN ROTATE OPTION ENGINE 62 FUNCTION ENABLE BOOM UP EXTEND Es TURNTABLE AND SS TQ E UN Q PLATFORM ROTATE RIGHT 1 1 ps CR 9 TERMINAL 30 AND 2 6 9 BN64 BN66 tpg SECONDARY BOOM TURNTABLE UP DOWN ROTATE S BD TB1 BN61 oO D FUNCTION ENABLE BOOM DOWN BOOM RETRACT D TURNTABLE AND PLATFORM ROTATE B mm E LEFT
8. PLATFORM CONTROL BOX 1 TB3 BN67 BN98 6 PLAT PLAT ROTATE LEVEL ROTATE ENABLE ENABLE ENABLE 0 CR78B 1 2 BN64 BN63 7 BN65 7 2 SEC e PRI e EXT e JIB ENABLE ENABLE ENABLE ENABLE 5 re CR71 CR9 CR87 3 6 6 3 7 7 7 m PLATFORM GROUND 2 NN 8 8 d 8995 B N gt m a 3 d 32680 929 gep s 8 BH 5 5 Yo g 3 E GROUND CONTROL BOX v oy 9 9 o 9 EB g BN57 BN58 BN93 D 2 A 4 BN58 BN93 PLAT 1 1 1 v1 1 1 ROSE LEVEL ROTATE ENABLE ENABLE ENABLE TB11 2 1 Y20 Y61 Y63 4 TB31 1 1 i I m x 7 CR78A ENABLE ENABLE ENABLE ENABLE 1 CR78A 9 5 9 55 54 56 BN36 9 2 25 NI 225 m2 2 2 2 2 a MANIFOLD LL mm 5 gt GCRe1 U16A 10868 creo m 2 8 3 4 T qm Pi m x 4 7 7 7 m m LOAD 5 lt 7 2 J 1 GCON GROUND e m m a 5 6 m d 3 x X 3 383333333 ES0440G 2 2 22020 A l lt 1613 1615 E O R RROR T I w 2 ro 8 B 8 5 1512 1514 lt zi LF O R LR O R A 1 m OUTRIGGER LIMIT SWITCHES Y24 Y53 Y22 Y26
9. PLATFORM CONTROL BOX 1 TB3 BN67 BN98 BN66 PLAT PLAT ROTATE LEVEL ROTATE ENABLE ENABLE ENABLE 78 dL ne 0 CR78B 0 c 2 BN64 BN63 BN65 BN97 J SEC PRI e EXT e JIB e ENABLE ENABLE ENABLE ENABLE 5 1 1 1 0 71 CR9 CR87 gt 3 6 9 10 a 7 7 7 E PLATFORM GROUND ox 3 S S N 5315 3 22 m Je X 3 7 6 98292 ger lt 5 T 5 lt 55 T 3 E 8 GROUND CONTROL BOX 5 i 9 9 9 g g lt lt 2 4 GROUND mm BN93 PLAT 1 1 1 1 1 1 CONTROLS LEVEL ROTATE ENABLE ENABLE ENABLE TB11 Y20 Y61 Y63 e 74 qua TB31 8 i TB34A SEC PRI EXT JIB CR78A ENABLE ENABLE ENABLE ENABLE 1 CR78A Y19 Y60 Y62 9 BN55 54 56 BN36 9 TB32 A 2 2 2 2 2 2 E JIB MANIFOLD lt 5 gt 5 1 U16A 70 8 67 69 8 T Pid Pi b 14 m x 8 a 7 7 7 7 lt lt 2 D LOAD 2 nm 5 5 6 GCON GROUND m m 2 8 d 2 Ty 5 v 5 3 3 2 2 504400 gt A 0 e e m m lt lt 5 0 5 o 1518 1515 e RFO R RROR z Ea ES 2 DES 1512 1514 r I LF O R LR O R 1
10. Genie TZ 50 Genie Part No 824982 September 2014 Section 4 Repair Procedures 3 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 if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tagand disconnect the wire harness from the platform control box 2 Tagand disconnect the wires from the jib manifold 3 Remove the wire harness from the platform mount and the jib boom 4 Pullthe all harness cables through the jib boom 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 Part No 824982 Genie Genie TZ 50 4 9 PRIMARY BOOM COMPONENTS 5 Tag disconnect and plug the hydraulic hoses at the jib boom end of the cable bridge Cap the fittings on the hydraulic hard lines Refer to in the illustration bel
11. September 2014 015 TERMINAL 86 BD CR1 TERMINAL 86 Lus TURNTABLE HARNESS Sse MODELS RD POWER CABLE PIN 1 WITH RD TB3 ENGINE BD CR6 TERMINAL 30 CR15 TERMINAL 30 BD BCI 1 EMERGENCY STOP RD 5 G TURNTABLE HARNESS BN6O PINB ENGINE FUNCTION ENABLE WH TB10 START gt 7 E G BOOM UP EXTEND ROTATE RIGHT OUTRIGGER RETRACT 1 KEY SWITCH D OR 7 59 X OR 4 FUNCTION ENABLE BN90 BOOM RETRACT 6 14 a OUTRIGGER 7 LED EXTEND WH ah AD TB17 WH TB18 8 5 PLATFORM BOOM LEVEL BN49 EXTEND RETRACT UP DOWN 5 G 1 AUTO LEVEL 2 TB35 ff Ko 0 0 CG BL WH TB23 BN52 4 BL WH fe LEFT FRONT OUTRIGGER 5 7 6 BNs4 0 3 L12 0 PRIMARY PLATFORM Ox LF LED LEFT REAR OUTRIGGER BOOM ROTATE UP DOWN 0 OPTION 114 L LRLED BN36 ir fA JIB UP DOWN GNWH pB5 9 5 0 BN51 G RIGHT REAR OUTRIGGER Q Q L15 RR LED GNWH TB24 BN55 57 WH TURNTABLE BN53 RD WH SECONDARY ROTATE 1820 RIGHT FRONT X RD WH PB5 3 UP DOWN OUTRIG
12. valves to prevent movement in the event of a a platform level master cylinder hydraulic line failure b platform level slave cylinder Before cylinder removal is considered to correct a 3 Removethe pin retaining fastener from malfunction bleed the slave cylinder to be sure the slave cylinder rod end pivot pin Do not there is no air in the closed loop hydraulic circuit remove the pin Note When removing a hose assembly or fitting 4 Remove the external retaining rings from the the O ring if equipped on the fitting and or the barrel end pivot pin hose end must be replaced All connections must 5 Using a soft metal drift remove the rod end be torqued to specification during installation Refer pivot pin to Section 2 Hydraulic Hose and Fitting Torque Specifications 6 Carefully pull the cylinder out of the boom 1 Extendthe boom approximately Component damage hazard Hoses 42 inches 30 cm can be damaged if they are kinked or pinched 2 Tag disconnect and plug the slave cylinder hydraulic hoses from the tee fittings on the jib How to Bleed the Slave Cylinder manifold and connect them together using a connector Cap the fittings on the manifold 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 AWARNING Bodily injury hazard
13. 3158 412 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 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 5 16 18 21 24 41 465 54 618 55 663 78 854 68 775 91 103 6 19 3 05 36 407 69 7 87 105 100 11 3 132 15 116 132 155 176 45 542 e 683 116 132 155 176 167 189 223 252 195 221 260 254 ft lbs Nm ft lbs ft lbs Nm ft lbs Nm_ ft lbs Nm ft lbs Nm ft lbs Nm_ ft lbs Nm 8 54 7 41 72 988 14 191 188 25 5 20 1 273 26 9 365 236 32 314 426 10 10 8 147 144 196 279 378 372 505 399 541 53 2 722 467 633 623 844 12 18 9 256 251 341 486 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 84 8 125 170 166 226 173 235 230 313 202 274 269 365 48 6
14. y A NAE E 2263 qam accep 200 4 QO SX pom gt M V 7 red 86 WH 9 mp 7834 87 E ass _____________80_ 30 CR78A 85 LIFT CUT OUT BK TB35 RD AUTO 86 LEVEL 87 87A 5 BD PS 184g U16B D WH ZENER mh 22 5 1V DC L4 3 CR28 POWER SUPPLY ZENER DIODE 3 3V DC 86 87 WH TB32 mg CR77 85 DOWN ENABLE 5 8 BE 15 Su 87 BL TURNTABLE HARNESS 30 65 PINH 85 U6 CUT OUT om 87 87A WH 30 CR65A 85 5 6 CUT OUT WH 7 3 86 WHIBK 87 87 T 30 CR76 85 LIMIT SWITCH FAULT 2 86 WH TB2 87 87A pag 30 CR64 85 FAULT GROUND TB4A 87 87A WH TURNTABLE HARNESS 30 CR75 0 85 LEVEL SENSOR NOTE DIODES ARE 2 AMP UNLESS OTHERWISE MARKED Ped Genie P3 X 200 OHM ES0440G Part No 824982 TZ 50 Platform Control Box Wiring Diagram AS CE Section 5 Schematics
15. Trailer Lighting Wiring Diagram Mechanical Axle RIGHT SIDE MARKER Trailer Chassis Wiring Harness GR Em Em GR OR e OR WH WH BD RD BL 7 BK e 1 RD BK RD BK RD BK 2 BL 1 RD BK 3 WH fom WH BK WH BK ee 3 WH m z m z 5 OR 4 GN 8 1 2 5 OR 9 7 6 RD 6 10 8 7 BK e 5 136 8 WH BK 20 4 LEFT SIDE MARKER L35 RIGHT SIDE MARKER L33 RIGHT REAR TAIL LIGHT Platform Wiring Harness GR ag 2 RD BL 1 RD BK RD BK Eod 2 BL 3 WH WH BK TR 4 GN 5 A I 6 RD Sub 7 BK 8 WH BK 6 LEFT SIDE MARKER TURN RUN LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT LEFT REAR TAIL LIGHT 1 SIDE MARKER 2 TURN SIGNAL 3 FOG LIGHT 4 RED REFLECTOR 5 REVERSE LIGHT 6 BRAKE LIGHT Genie Part No 824982 TZ 50 5 11 Section 5 Schematics September 2014 Trailer Lighting Wiring Diagram Electric Axle AS
16. 85 LIFT CUT OUT 7 4 ap 39 gt 9 8 6 5 3 on ORBK 30 ORBK 7 CR71 PLATFORM LEVEL y ooloologloooooo lgoloooo O 86 4 7 GN 87 87 _ Fee 1 6 GN BN97 80 CR9 m 85 JIB BOOM UP DOWN 67 5 _ BL 87 GNWH BL BK 59 CR87 85 PLATFORM ROTATE TB9 ES0440G BK Genie TZ 50 Part No 824982 September 2014 Section 5 Schematics This page intentionally left blank Genie Part No 824982 TZ 50 5 17 Section 5 Schematics uM Ground Control Box Wiring Diagram 5
17. 3 8 7 Perform Hitch Maintenance Hydraulic Axle 3 9 8 Perform Engine Maintenance if equipped 3 9 9 Perform 30 Day Service nnne 3 10 A 10 Perform Engine Maintenance if equipped 3 10 A 11 Grease the Turntable Rotation Bearing and Rotate Gear 3 11 A 12 Perform Engine Maintenance if equipped 3 11 Checklist B Procedures B 1 Inspect the Batteries 0 4 3 12 B 2 Inspect the Electrical 3 13 B 3 Test the Electrical Contactor 3 14 B 4 Test the Manual 1 3 14 B 5 Perform Hydraulic Analysis 3 16 B 6 Perform Axle Maintenance Electric and Hydraulic Axles 3 17 B 7 Service the Tongue Jack ssssssssssssseeeeeeeeenneeen nnne nnne 3 17 8 Inspect the Parking 3 18 B 9 Check the Wheel Bearings Mechanical 3 20 B 10 Service the Hitch Mechanical Axle 3 20 B 11 Perform Axle Maintenance Mechanical Axle 3 21 B 12 Perform Engine Maintenance i
18. 5 12 Trailer Lighting Wiring Diagram Hydraulic Axle AS 5 13 Control Box Wiring Diagrams ANSI CSA Ground Control Box Wiring Diagram 5 5 5 14 Platform Control Box Wiring Diagram ANSI CSA 5 16 Control Box Wiring Diagrams AS CE Ground Control Box Wiring Diagram 5 2 5 18 Platform Control Box Wiring Diagram 5 5 20 Electrical Schematics ANSI CSA Electrical Schematic ANSI CSA 5 22 Electrical Schematics AS CE Electrical Schematic AS CE nennen enne 5 28 Hydraulic Schematics Hydraulic Schematic 5 34 Genie Part No 824982 Genie TZ 50 September 2014 This page intentionally left blank Genie Genie 7 50 Part 824982 September 2014 Section 2 Specifications Machine Specifications Specifications Tires and wheels Electric and Hydraulic Axles Batteries models without drive option Axle Type 6V DC Tire size ST225 75R15 Group T 105 Load range D Lug torque dry 80 ft lbs tit 4 108 Battery capacit 225AH rio hid Tire pressure maximum cold 65 psi Reserve capacity
19. 3 2 5 55 2 U16B 35 82 C O 5 C4 D ZENER MANIFOLD HARNESS BL 87 87 BUBK O 5 O O penne 87 87 WH MANIFOLD HARNESS _ CREB ro C Q 34 C C 85 CR28 PIN P3 R 33 C t POWER SUPPLY 34A M C D ZENER DIODE 86 C 5 32 ae 3 3 3V DC 86 we TB12 MANIFOLD HARNESS RD 87 87 ag 0 32 E e 0 87 a 67 31 77 MANIFOLD mE RD BK 85 2 30 5 0 85 DOWN ENABLE 29 56 RD 2 O O 28 5 88 BL 15 87 O MANIFOLD HARNESS BKWH 85 CR69 Q Q 27 9 d CR65B PIN H PIN P3 V BOOM EXTEND C SS 9 79 as 5 BD 2 C RET C 2 5 87 7 i BKWH O O 28 DAC 87 87A WH A C G NE 85 U6 CUT OUT WH Q Q 22 O 86 0 e a 3 Q 3 86 WH BK MODELS 6 Bios 20 7 3 P4 10 WITH 8110 5 ey ENGINE X CR1 18 C FAULT OPTION 85 ENGINE START TR 2 O 17 C O 85 1 2 rl He KD 86 BK RD 5 2 4 D ge 3 O WH 87 87 87 87 10 RD E 14 RD P2 10 CRIS P1 Q 2 30 CR64 0 85 STARTING AID lt 85 FAULT GROUND o 48 86 12 DC 6
20. 5 0 G47 mm 2 1 J C0 mm 1 4mm 80psi 1 80 psi 80 psi Ix 207 bars prc i 5 5 bar 5 bar 5 5 Y i arm 34 1 80 psi 1 1 1 5 5 bar 1 i i m i HYDRAULIC MODELS WITH To oom A FUNCTION 5 POWER UNIT pne OPTION pue ioe MANIFOLD MANIFOLD SEC 2 Sa ee ee I1 a HYDRAULIC TANK MODELS WITHOUT HSTZ50 G PLATFORM ROTATE MODELS WITH PLATFORM ROTATE gt MODELS WITHOUT DRIVE OPTION Genie 5 34 TZ 50 Part No 824982 Genie Sweden Phone 0046 3157 5101 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 900 808 110 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 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 Singapore Phone 65 67533544 Fax 465 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1 82 2 558 7267 822 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 408
21. Testing Solenoid valve 2 position 3 way with manual override Primary boom down 18 20 ft Ibs 25 27 Nm 9 Relief valve 1600 psi 110 bar ids Primary boom circuit 18 20 ft lbs 25 27 Nm 10 Solenoid valve 2 position way with manual override Jod Primary boom 18 20 ft lbs 25 27 Nm 11 Solenoid valve 3 position 4 way with manual override Boom extend retract 18 20 ft lbs 25 27 Nm 12 Relief valve 3000 psi 207 Lust System 1 18 20 ft lbs 25 27 Nm 13 Counterbalance valve M Outrigger retract circuit 30 35 ft lbs 41 47 Nm 14 Solenoid valve 3 position 4 way N Outrigger extend retract 18 20 ft Ibs 25 27 Nm 15 Check valve Outrigger retract 25 30 ft lbs 34 41 Nm 16 Solenoid valve 2 position 3 way Pise Secondary boom 18 20 ft Ibs 25 27 Nm 17 Orifice plug 0 080 inch 2 mm Restricts platform down fluid flow E plug iss cies enu t Sieve eee et edit d
22. Platforms sies Ret eis tt dein iui euet 4 2 1 2 eee ct eta et 4 2 Jib Boom Components 2 1 Jib 4 4 2 2 Boom Lift Cylinder 4 6 Primary Boom Components 3 1 Cable Track xiii eet e eee ee 4 9 3 2 Primary eae e dp EO ede E ree te eee nl tef ier 4 11 3 3 Primary Boom Lift Cylinder essen 4 14 3 4 Platform Leveling Cylinders 22002 00 4 15 Secondary Boom Components 4 1 Secondary BOOM sienta eee tea T te R i 4 18 4 2 Secondary Boom Lift Cylinder ssssesseeeeeeneenenennn 4 21 Engine 5 1 4 23 Ground Controls 6 1 4 24 Hydraulic Pump 7 1 Function PUMP is ects iain adenine lage aan tea eene 4 28 Manifolds 8 1 Function Manifold 4 30 8 2 Jib Manifold Components nennen neret 4 32 8 3 Drive Manifold Components if equipped 4 34 8 4 Valve Adjustments Function 4 36 8 5 4 38 Genie Part No 824982 Genie TZ 50 September 2014 TABLE OF CONTENTS Section 4 Repair continued Hydraulic Tank 9 1 Hydraulic Tank e eem eee d tb r
23. gt Model TZ 50 Serial number TZ5011 299 Model year 2011 Manufacture date 03 14 11 Electrical schematic number Position 3 Machine unladen weight 99 999 Rated work load including occu Position 4 Maximum number of platform occupants Pos 5 Genie Maximum allowable side force Position 6 Maximum allowable inclination of the chassis Position 7 Maximum wind speed Position 8 Maximum platform height Positi Maximum platform reach Position 10 Power supply voltage Position 12 Gradeability Position 11 Control system voltage Position Nominal battery design voltage power Position 14 MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE Nominal Power Position 40 Maximum hydraulic pressure Position 27 PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY Country of manufacture Manufacturer Terex USA LLC 590 Huey Road Rock Hill SC 29732 USA This machine complies with Compliance STD 1 Compliance STD 2 Compliance STD 3 Ie 12 50 11 299 rog xl number Model Ibs 99 999 kg odel year pants A TEREX BRAND DATE GVWR PNBV 99 999 Ibs 99 99 kg GAWR PNBE 99 999 Ibs 99 99 kg on 9 TIRES PNEU Position 25 RIMS JANTE Position 24 COLD TIRE INFLATION Position 26 13 PRESS DE GONFL A FROID SINGLE THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL OF MANUFACTURE SHOWN ABOVE THIS VEHICLE ME TO TU
24. B 6 Axle maintenance B 7 Tongue jack B 8 Parking brake B 9 Wheel bearings B 10 Hitch B 11 Axle maintenance Perform every 300 hours B 12 Engine maintenance if equipped Checklist C Y NR C 1 Grease platform overload if equipped C 2 Test platform overload if equipped C 3 Axle maintenance C 4 Breather Cap C 5 Axle wheel bearings C 6 Brakes Checklist D YNR D 1 Axle maintenance D 2 Boom wear pads D 3 Hydraulic return filter D 4 Turntable bearing bolts D 5 Turntable bearing wear Checklist E Rev A YNR E 1 Hydraulic oil E 2 Engine maintenance if equipped GenieTZ 50 Section 3 Scheduled Maintenance Procedures September 2014 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 ha
25. Wheels chocked Parking brake applied Part No 824982 Genio Genie TZ 50 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 aftertroubleshooting 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 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 September 2014 Platform Components 1 1 Platform How to Remove the Platform 1 Tag and disconnect the tail
26. Note Perform this procedure after fully charging the batteries Note For a more accurate determination of battery condition fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 1 Put on protective clothing and eye wear 2 sure that the battery cable connections are free of corrosion 3 12 Genie TZ 50 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 the battery fill tube Do not overfill Install the battery vent caps 7 Check each battery pack and verify that the batteries are wired correctly 8 Inspectthe battery charger plug and pigtail for damage or excessive insulation wear Replace asrequired Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures 9 Connect the battery charger to a properly grounded 115V 60Hz or 230V 60Hz single phase AC power supply O Result The charger should operate and begin charging the batteries 5 Result Simultaneously
27. Orange Red ette Orange White Red Black Red White de White Black WARD ziii White Red Part No 824982 September 2014 Section 5 Schematics Limit Switch Legend Item Description a Boom limit switches b Outrigger limit switch Part No 824982 Schematic LS18 LS18A LS12 LS13 LS14 LS15 Genie TZ 50 5 5 Section 5 Schematics September 2014 ss J Electrical Symbols Legend 1 Terminal gt Diode 1 1 KEY SWITCH Key switch P1 EMERGENCY STOP e Emergency stop button normally closed 15 Circuit breaker 4 i O 7 fae NOHC Limit switch M Toggle switch P 4 86 Control relay We Resistor N LED Hour meter Hm Alarm EX Solenoid valve with diode e e Quick disconnect Genie 6V Battery e 1 5 Power unit or motor Mot
28. vi Specifications Machine Specifications enne nennen 2 1 Performance Specifications 2 2 Hydraulic 06010 0 2 2 Manifold Component Specifications 0 00 2 3 Machine Torque Specifications 2 4 Honda GX160K1 Engine Specifications 2 5 Hydraulic Hose and Fitting Torque Specifications 2 6 SAE and Metric Fastener Torque 2 8 Scheduled Maintenance Procedures X 3 1 Pre delivery Preparation 3 3 Maintenance Inspection 3 5 Checklist A Procedures A 1 Inspect the Manuals and 2 3 6 2 Perform Pre operation 3 7 A 3 Perform Function 4400 3 7 4 Perform Engine Maintenance if equipped 3 7 Genie Genie TZ 50 Part No 824982 September 2014 Section 3 TABLE OF CONTENTS Scheduled Maintenance Procedures continued 5 Torque the Lug Bolts Electric and Hydraulic Axles 3 8 6 Torque the Lug Bolts Mechanical
29. _ 87 87 SAO AS 87 87 WH _ TURNTABLE TURNTABLE HARNESS WH BK WH BK 6 1 CX 11 5 E HARNESS PIN P3 J 30 CR86 1 5532 CV 1o 7 C 30 CR75 PIN C 85 SEQUENCING BK 2 I 85 LEVEL SENSOR 1 XN PO C d Q OQ 5 Q Q OQ Q 6 Oo 6 Q BM 0 O R22 LI 3 1000 Q 3 NOTE DIODES ARE 2 AMP 4 OQ Q UB UNLESS OTHERWISE MARKED Q ITE ms O O LI 1 P3 X 200 OHM HEHE CHEE gt BATTERY CHARGE ES0440G INDICATOR f BK TB35 7 E RD P1 E STOP Genie Part No 824982 TZ 50 5 15 Section 5 Schematics September 2014 Platform Control Box Wiring Diagram ANSI CSA CR 788 TERMINAL 87A BN64 JIB HARNESS PIN P6 3 JIB HARNESS PIN P6 2 JIB HARNESS PIN P6 5 JIB HARNESS PIN P6 4 JIB HARNESS PIN P6 7 JIB HARNESS PIN P6 6
30. 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 7 Tag disconnect and plug the hoses from the primary boom extension cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Attach a lifting strap of suitable capacity from an overhead crane to the rod end of the primary lift cylinder Support the cylinder Do not apply any lifting pressure 9 Remove the pin retaining fastener from the primary lift cylinder rod end pivot pin Genie Genie TZ 50 10 Using a soft metal drift remove the primary lift cylinder rod end pivot pin AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed 11 Lower the cylinder onto the secondary boom 12 Remove the pin retaining fastener from the platform level master cylinder rod end pivot pin 13 Using a soft metal drift remove the platform level master cylinder rod end pivot pin 14 Attach a lifting strap of suitable capacity from an overhead crane to the primary boom Support the boom Do not apply any lifting pressure Componentdamage hazard The cable track can be damaged
31. Item Description Item B Battery BN B5 Battery BN94 BN Button BN2 Engine start BN95 Choke BN36 Jibboomup down BN96 BN49 Outrigger auto level BN97 BN50 Leftrearoutrigger BN98 BN51 Rightrearoutrigger C BN52 Leftfrontoutrigger Rightfrontoutrigger C4A BN54 Primary boom up down BN55 Secondary boom up down C5 BN56 Boomextend retract CB BN57 Turntable rotate 1 58 Platform level up down CB2 BN59 Function enable boom down boom retract rotate left outrigger extend CR BN60 Function enable boom up boom extend CR1 rotate right outrigger retract BN61 Function enable boom down boom retract CR9 turntable platform rotate left CR15 BN62 Function enable boom up boom extend CR28 turntable platform rotate right CR61 BN63 Primary boom up down CR64 BN64 Secondary boom up down CR65 BN65 Boomextend retract CR66 66 Turntable rotate CR67 BN67 Platform level up down CR68 BN68 Engine start CR69 BN90 Choke CR70 Platform rotate Genie 5 2 TZ 50 Part No 824982 September 2014 EE Electrical Abbreviations Legend Item CR CR71 CR72 CR73 CR74 CR75 CR76 CR77 CR78 CR86 CR87 D1 6 FQ FB1 GND G6 G7 H1 H5 JC5 KS1 Description Control Relay Platform level Outrigger Function enable ground controls Function e
32. RD WH TB2 WHIBK TBO GNWH CR 788 TERMINAL 87 22 M 086 _ 2 86 7 gt 87 87 f 5 OOJOO BN64 85 LIFT CUT OUT BL TB4 9 8 7 87 JIB HARNESS 6 3 30 OR BK CR71 JIB HARNESS PIN P6 2 85 PLATFORM LEVEL 4 86 GN 87 87 GN 6 JIB HARNESS 6 5 GN BN97 GN BK a CR9 JIB HARNESS PIN P6 4 85 JIB BOOM UP DOWN 5 86 87 87 JIB HARNESS PIN P6 7 BL GN WH 30 BL BK CR87 JIB HARNESSIRIN Pe 85 PLATFORM ROTATE OPTION TB9 ES0440G Genie TZ 50 Part No 824982 Section 5 Schematics September 2014 4 Electrical Schematic ANSI CSA Section 5 Schematics September 2014 Electrical Schematic ANSI CSA 1 of 3
33. E cok z 5 7 Y23 Y52 2 Y25 Bo NJ 2 2 2 2 2 2 2 2 GCON GROUND HARNESS GROUND PLUG 4 4 4 4 z 2 A 5 3 3 8 8 ad 338 8 Emm 3 4 gt gt gt gt 2 2 m mm 2 2 0 5 Om gt gt m 2 2 z 2 m x 8 gt m m 5 E gm 2 6 6 2 lt og g m gt 2 2 gt 2 9 i E gt Genie Part No 824982 TZ 50 5 25 September 2014 Section 5 Schematics T_T Electrical Schematic ANSI CSA 26 Section 5 Schematics September 2014 2 Electrical Schematic AS CE Section 5 Schematics _______ Electrical Schematic AS CE 1 of 3 September 2014 A B D E F G H L M 1819 1 15194 LOAD SENSE 1 V4 2 LIMIT SWITCH PLATFORM CONTROL BOX ele puce e PLATFORM E STOP POWER LOAD SENSE POWER P2 LOAD SENSE POWER BN2 7 LS19A i BN3 PLATFORM 1519 START CONTROLS H1 i
34. Lt TBS FAULT ALARM 1 PLATFORM GROUND gt gt gt Xi i 2 o 5 ENGINE OPTION DRIVE CONTROLS 5 ele DRIVE E STOP POWER 9 gig g D 5 1518 E 13 9 9 o 2 2 5 DRIVE CONTROL BOX 3 1 gt gt 5 a Gm bm E 3 3 T i y X DA D DEL QD ROUND CONTROL BOX TBS p e e TB3 gt 17 5 P1 jr TB2 4 04 80 H5 1 RD GRD 90 BN68 FAUL CR65A 6 4 m CHOKE START ALARM 15AMP rin 14 GROUND ia d 598 4 CONTROLS CR65A ae 4 200 Ser 1 SOW L12 L13 L14 L15 5 TB7 CR76 R1 U16B 3 7 CR76 CR15 c 65016 3 15 m 75 CR75 1 1 E GCON GROUND x T 20 U up uw ov bd a aT aT a S d Q 7 2 e D m Ki CR20 eo OUTRIGGER Figo v 6 m 0 116 5 m gt E 23 m m z 3 m 2 ODR1 2 2 2 2 p B egf A 5 i 2 8505 3 BATTERY 24V 275AMP a g d D1 7 1 3 U6 B A 8 1 3 kc ud c ed A 3 J 4 1 AMP m m 4 gt Q7 c F9 83 b 5 5 5 B5 L
35. 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 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 824982 Genie GenieTZ 50 CHECKLIST A PROCEDURES A 4 Perform Engine Maintenance if equipped Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Check oil level Check air cleaner Required maintenance procedures and additional engine information i
36. Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate The master cylinder acts as a pump for the slave gradually Do not allow oil to cylinder It is part of the closed loop hydraulic squirt or spray circuit that keeps the platform level through the entire range of boom motion The master cylinder is located inside the mid pivot Genie 4 16 Genie TZ 50 Part No 824982 September 2014 Section 4 Repair Procedures This page intentionally left blank Genie Part No 824982 Genie TZ 50 4 17 Section 4 Repair Procedures September 2014 Secondary Boom Components TD 50 mid pivot primary boom lift cylinder barrel end pivot pin platform level master cylinder primary boom pivot pin platform level master cylinder rod end pivot pin extension cylinder barrel end pivot pin primary boom lift cylinder primary boom lift cylinder rod end pivot pin primary boom primary boom latch extension boom platform level slave cylinder etn 9 O53 3 lt jib boom secondary boom pivot pin secondary boom link pivot pin secondary boom latch secondary boom secondary boom link secondary lift cylinder rod end pivot pin secondary boom lift cylinder secondary lift cylinder barrel end pivot pin located behind ground control box turntable secondary boom p
37. The parking brake should prevent the machine from moving If the parking brake does not prevent the machine from moving repeat steps 5 through 8 until the adjustment is correct OR see B 8 Perform Axle Maintenance Electric and Hydraulic Axles Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures Models with Mechanical Axle 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 assembly will be difficult to apply 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 Proceed to step 5 5 At the ground controls extend the outriggers until the axle is off the ground and the machine is level Release the parking brake Pull out the nose of the hitch as far as it will go Loosen the lock nuts at the tension equalizer or not at all 10 Adjust the wheel brakes until the wheel turns freely Note Slight rubbing noises which do not affect the free turning of the wheel are permitted 11 Repeat steps 9 and 10 for the other wheel Part No 824982 Turn the wheel in a forward motion adjusting the w
38. 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 Part No 824982 Genio Genie TZ 50 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 Checkthe continuity between the black and red wires originating from the limit switch of the platform overload assembly O 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 O 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 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 on
39. 9 Nm Hydraulic tank drain plug lubricated 112 in Ibs 12 6 Nm Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures 10 Install the hydraulic tank and install and tighten the hydraulic tank mounting fasteners Torque to specification Torque specifications 35 in lbs 4Nm Hydraulic tank mounting fasteners dry Hydraulic tank mounting fasteners lubricated 26 in Ibs 2 9 Nm 11 Install the hydraulic line onto the inlet side of the hydraulic pump 12 Install the hydraulic filter head onto the machine and securely tighten the fasteners Do not over tighten 13 Install the hydraulic lines into the filter head 14 Connect the battery pack to the machine 15 Fill the hydraulic tank with hydraulic oil until the fluid is at the FULL mark on the tank Do not overfill Refer to Section 2 Specifications 16 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 17 Repeat steps 15 through 16 until the hydraulic system and tank are both full Inspect for leaks 18 Clean up any oil that may have spilled Part No 824982 Genie GenieTZ 50 CHECKLIST E PROCEDURES E 2 Perform Engine Maintenance if equipped Engine specifications require that this procedure be performed ev
40. 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 binding 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 7 16 inch 11mm Genie 3 28 Genie TZ 50 Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures D 3
41. Crushing hazard The cylinder AWARNING could fall if not properly supported when the pivot pin is removed from the machine 10 Using a soft metal drift remove the outrigger pivot pin Remove the outrigger from the machine AWARNING Crushing hazard The outrigger will fall if not properly supported when the pivot pin is removed from the machine Section 4 Repair Procedures September 2014 OUTRIGGERS 12 2 Outrigger Cylinder How to Remove an Outrigger Cylinder 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 Extend the outrigger until the pad just touches the ground Do not rest the weight of the machine on the outrigger 2 Remove the hose guard mounting fasteners from the rod end of the outrigger cylinder and remove the hose guard from the machine 3 Remove the cover above the barrel end of the outrigger cylinder 4 Tag and disconnect the wire harness from the outrigger cylinder valve coil 5 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 Genie Genie TZ 5
42. Hemove the Jib Boom 3 Remove the primary boom See 3 2 How to the Boom 4 Setthe primary boom assembly on a suitable structure capable of supporting it 5 Place a block between the platform level slave cylinder and the extension boom 6 Remove the fasteners and hose clamp securing the platform level slave cylinder hoses to the extension boom Part No 824982 Genio Genie TZ 50 PRIMARY BOOM COMPONENTS 7 Remove the pin retaining fastener from the platform level slave cylinder barrel end pivot pin 8 Using a soft metal drift remove the platform level slave cylinder barrel end pivot pin 9 Tag disconnect and plug the hoses from the platform level slave cylinder Cap the fittings on the cylinder 10 Remove the platform level slave cylinder from the boom 11 Remove the primary boom upper wear pad retaining fasteners Remove the upper wear pads from the primary boom 12 Remove the primary boom side wear pad retaining fasteners Remove the side wear pads and shims from the primary boom Note For ease of assembly note the quantity and location of shims during disassembly 13 Remove the primary boom lower wear pad retaining fasteners Remove the lower wear pads from the primary boom 14 Remove the pin retaining fastener from the primary boom extension cylinder barrel end pivot pin 15 Using a soft metal drift remove the primary boom extension cylinder barrel end pivot pin 16 Remove the bo
43. Jib boom 18 20 ft lbs 25 27 Nm 2 Solenoid valve 2 position way AB Jib boom down 18 20 ft Ibs 25 27 Nm 3 Relief valve 3000 psi 207 bar AC aes Platform level circuit 18 20 ft Ibs 25 27 Nm 4 Solenoid valve 3 position 4 way AD s Platform rotate left right 18 20 ft Ibs 25 27 Nm 5 Solenoid valve 3 position 4 way AE Platform up down 18 20 ft lbs 25 27 Nm 6 Counterbalance valve BE Platform level circuit 25 30 ft Ibs 34 41 Nm 7 Differential sensing valve AG Maintains fluid flow to jib boom platform level and platform rotate functions 25 27 ft lbs 34 36 Nm 8 Orifice plug 0 055 inch 1 4 mm AM ius Platform rotate circuit eibi iei ide ned 97 117 11 13 Nm 9 Orifice plug 0 055 inch 1 4 mm Bliss Jib boom up circuit uli doi eccrine cede eR kc ee ek 97 117 in lbs 11 13 Nm 10 Orifice plug 0 040 inch 1 mm AJ Jib boom down circuit Port ee eene eo benedi a 97 117 in lbs 11 13 Nm 11 Shuttle valve 2 position 3 way Platform level circuit 4 5 ft lbs 6 Genie 4 32 Genie TZ 50 Par
44. 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 engine will be required to perform this procedure Indicates that a warm engine will be required to perform this procedure Indicates that dealer service is required to perform this procedure Genie 3 2 GenieTZ 50 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 4800 km A B Semi annually or every 500 hou
45. Orifice with size 4 Variable speed motor Pilot operated 2 position 2 way directional valve normally open MES Solenoid operated 2 position 2 way directional valve normally closed 1 Solenoid operated 2 position 2 way proportional valve normally closed Part No 824982 September 2014 Section 5 Schematics er Honda GX160 Engine Wiring Diagram BATTERY STARTER SOLENOID BK WH WH CONTROL BOX WH gt ENGINE CIRCUIT S NM i RECTIFIER BK RD OIL LEVEL TRANSISTORIZED WH SWITCH IGNITION UNIT __ SPARK PLUG CHARGING COIL J i Genie Part No 824982 TZ 50 5 9 Section 5 Schematics September 2014 Trailer Lighting Wiring Diagram ANSI CSA 135 WH RIGHT SIDE MARKER QD12 TRAILER PLUG 6 BN BN T GN L33 BN YL BN RIGHT REAR TAIL LIGHT YL BN BK 4 YL FD 136 LEFT SIDE MARKER L34 LEFT REAR TAILLIGHT Genie 5 10 TZ 50 Part No 824982 September 2014 Section 5 Schematics
46. 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 Raise the secondary boom approximately 12 inches 30 cm Push and hold the blue function enable button Push and hold the turntable rotate button Fully rotate the turntable and continue to hold the buttons while observing the pressure reading on the pressure gauge Refer to Section 2 Specifications Release the buttons Use a wrench to hold the relief valve and remove the cap item B Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified Push and hold the yellow function enable button Push and hold the turntable rotate button and fully rotate the turntable in the opposite direction Begin timing when the turntable begins to rotate Continue rotating the turntable and note the time when the machine stops rotating at 359 Refer to Section 2 Specifications Section 4 Repair Procedures MANIFOLDS Genie Part No 824982 Genie TZ 50 4 37 Section 4 Repair Procedures September 2014 MANIFOLDS 8 5 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal
47. 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 005 KNOTT Axle Service Manual Genie part number 84443 Genie GenieTZ 50 C 6 Adjust the Brakes Mechanical Axle 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 until the axle is off the ground and the machine is level 2 Release the 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 tighten 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 Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures CHECKLIS
48. components to be sure that there are no leaks Genie GenieTZ 50 3 29 Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST D PROCEDURES D 4 2 Working from underneath the turntable be sure that each turntable rotation bearing mounting Check the Turntable Rotation bolt is torqued in sequence to specification Bearing Bolts Refer to Illustration 2 Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Tongue Improper bolt torque or torque sequence could result in an unsafe operating condition and component damage 1 1 that each turntable rotation bearing 9 O 7 mounting bolt above the turntable is torqued in O 0 sequence to specification Refer to Illustration 1 5 O O4 NC Tongue 8 2 9 5 1 Illustration 2 O ___ 11 Bearing to chassis bolt torque sequence 0 2 2 Turntable rotation bearing bolt torque specifications 8O OF Bearing to chassis lubricated 195 ft lbs 264 Nm O O 12 4 Bearing to swing chassis lubricated 195 ft lbs 2 O 6 10 Illustration 1 Bearing to swing chassis bolt torque sequence Genie 3 30 GenieTZ 50 Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures 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 Cont
49. dissipate gradually Do not allow oil to squirt or spray Part No 824982 September 2014 Section 4 Repair Procedures HYDRAULIC PUMP How to Remove the 7 Remove the pump mounting bolts Carefully Hydraulic Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Tagand disconnect the hydraulic power unit cables at the motor controller 3 Removethe hydraulic power unit retaining fasteners 5 Tag disconnect and plug the hydraulic hard line at the pump Cap the fitting on the pump 6 Tag disconnect and plug the high pressure hose at the pump Cap the fitting on the pump 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 remove the pump Tip over hazard After replacing the hydraulic pump it is critical to return the function speed settings to original factory specifications Failure to restore the machine to original fa
50. does not move N Result The machine moves Adjust the brakes See Maintenance procedure C 6 Adjust the Brakes Mechanical Axle Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual CHECKLIST B PROCEDURES B 11 Perform Axle Maintenance Mechanical Axles 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 82 99 KNOTT Axle Service Manual Genie part number 84443 Genie Part No 824982 Genie TZ 50 3 21 Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B 12 Perform Engine Maintenance if equipped Engine specifications require that this procedure be performed every 300 hours or annually whichever comes first Fuel tank and strainer Valve clearance Required maintenance procedures and additional engine information is available in the Honda GX160 Engine Owner Manual Honda part number 317 7630 and the Honda GX160 Engine Shop Manual Honda part number 61ZH700 Honda GX160 Owner s Manual Genie part number 97228 Honda GX160 Shop Manual Genie part number 97229 Genio
51. if not protected when lifting the boom 15 Remove the pin retaining fasteners securing the primary boom pivot pin 16 Using a soft metal drift remove the primary boom pivot pin Crushing hazard The primary boom could become unbalanced and fall if not properly supported when the pin is removed 17 Release the latch at the turntable end of the machine 18 Remove the primary boom from the machine Crushing hazard The primary boom could become unbalanced and fall if not properly supported when removed from the machine Part No 824982 September 2014 Section 4 Repair Procedures How to Remove the Boom Extension 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 Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Removethe platform See 1 1 How to Remove the Platform 2 Removethe jib boom See 2 1 How to
52. 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 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 Genie Genie TZ 50 Valve Coil Resistance Description Specification Solenoid valve 2 position 3 way 25 to 270 20V DC with diode schematic items F G AA and AB Solenoid valve 3 position 4 way 25 to 270 20V DC with diode schematic items J M Q AD and AE Solenoid valve 2 position 4 way 25 to 270 20V DC with diode schematic item BI and BN Solenoid valve 2 position 2 way N C 25 to 270 20V DC with diode schematic item Proportional valve 2 position 2 way N C 25 to 27 20V DC with diode schematic item BK and BO Solenoid valve 2 position 2 way N C 29 to 31W 24V DC with diode schematic items CA CB CC and CD Part No 12 September 2014 Section 4 Repair Procedures 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 spik
53. the machine is in the stowed position the parking brake is set and both wheel motors are in place against the axle tires To begin manually move and lock the drive wheels in place against the axles tires Then by squeezing the joystick to activate the drive function enable button and moving the joystick in the desired direction the parking brake will release via the parking brake cylinder located under the chassis and both drive motors will activate which will in turn move the machine Returning the joystick to the neutral position will disable the drive and steer function and set the parking brake Part No 824982 Genio Genie TZ 50 Drive Components 14 1 Drive Motor How to Remove a Drive Motor 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 Hyaraulic Hose and Fitting Torque Specifications 1 Removethe drive wheel retaining fasteners 2 Remove the drive wheel 3 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings AWARNING Scd 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 Removethe drive motor mounting fasteners and remove the drive motor from the machine Section 4 Repair Procedures Sept
54. the charger alarm sounds and the LED s blink one time Correct the charger connections at the fuse and battery The charger will then operate correctly and begin charging the batteries 5 Result Simultaneously the charger alarm sounds and the LED s blink two times The input voltage is too low or too high Correct the voltage issue The charger will then operate correctly and begin charging the batteries 5 Result Simultaneously the charger alarm sounds and the LED s blink three times The charger is overheated Allow the charger to cool The charger will then operate correctly and begin charging the batteries Note If you have any further questions regarding the battery charger operation please contact Genie Product Support Part No 824982 Genie GenieTZ 50 CHECKLIST B 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 Inspect the following areas for burnt chafed corroded and loose wires Turntable area Groundcontrols Power unit wiring 2 Turn the key switch to ground control and pull out the r
55. 0 6 Attach a lifting strap from an overhead crane to the lug on the rod end of the cylinder 7 Remove the pin retaining fasteners from the outrigger cylinder rod end pivot pin 8 Using soft metal drift remove the outrigger cylinder rod end pivot pin 9 Raise the cylinder to a vertical position 10 Remove the pin retaining fasteners from the outrigger cylinder barrel end pivot pin 11 Using a soft metal drift remove the outrigger cylinder barrel end pivot pin AWARNING Crushing hazard The outrigger cylinder could fall if not properly supported when the pivot pin is removed from the machine Componentdamage hazard The solenoid valve can be damaged Use caution when removing the cylinder from the machine Part No 824982 September 2014 Section 4 Repair Procedures Platform Overload Components 13 1 Platform Overload System Calibrate the Platform Overload System if equipped Note Perform this procedure with the machine ona firm level surface 1 Atthe ground controls extend the outriggers until the axle is off the ground and the machine is level 2 Release the boom hold down latch and raise the platform approximately 2 feet 60 cm Level the platform 3 Tag and 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
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59. 2 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 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
60. 3 22 Genie TZ 50 Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures 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 Grease type Multipurpose grease Part No 824982 Genie GenieTZ 50 C 2 Test the Platform Overload System if equipped Genie specifications require 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 unt
61. 4 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 GenieTZ 50 30 Part No 824982 September 2014 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 damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Useonly Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the mach
62. 5 Liftup 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 6 Lift up the hoses and cables and carefully insert the new section of cable track 7 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 8 Securely lock the hinge bar for each link 9 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track Part No 824982 September 2014 Section 4 Repair Procedures 3 2 Primary Boom How to Shim the Primary Boom 1 Extend the boom until the wear pads are accessible Loosen the 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 Extend and 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 824982 Genio Genie TZ 50 PRIMARY BOOM COMPONENTS How to Remove the Primary Boom AWARNING This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serio
63. 6 25 rate 447 minutes 4 48 bar Batteries models with drive option Tires and wheels Mechanical Axle Type 6 DC Axle Group T 145 Tire size 215 70R14 104 102N Quantity 4 Load range C Battery capacity 244AH Lug bolt torque dry 192 ft lbs Reserve capacity 25A rate 530 minutes 260 Nm Fluid capacities Tire pressure maximum cold 66 psi 4 55 Hydraulic tank 4 75 gallons 18 liters Tongue jack all models Hydraulic system 8 gallons Tire size 10x3x0 75 including tank 30 liters 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 Part No 824982 GenieTZ 50 30 2 1 Section 2 Specifications September 2014 SPECIFICATIONS Performance Specifications Boom function speeds maximum from platform controls no weight in platform Primary boom up 18 to 26 seconds Primary boom down 17 to 26 seconds Primary boom extend 13 to 20 seconds Primary boom retract 16 to 24 seconds Secondary boom up 17 to 25 seconds Secondary boom up 20 to 30 seconds with drive option Secondary boom down 16 to 24 seconds Jib boom up 16 to 22 seconds Jib boom down 16 to 22 seconds Platform rotate if equipped 8 to 12 seconds Turntable rotate 359 110 to 140 seconds Airborne noise emissions 80 dB Maximum sound level at normal operation workstations A weig
64. AN Lares STANDARDS REGULATIONS IN YE ATE OF MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI VONT APPLICABLES EN VERTU DU REGLAMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN European Representative VIGUER ALA DATE DE SA FABRICATION Genie UK LTD Maltings VEHICLE TYPE DE VEHICULE TRAILER REMORQUE Wharf Road Grantham Lin 31 6BH United Kingdom MODEL 0 SERIAL NUMBER 9 MODEL YEAR 2011 ELECTRICAL SCHEMATIC 50440 PN 77172 NOMINAL Position 40 R POWER 0 Serial number Serial label location location 77055 stamped chassis Genie Part No 824982 Genie TZ 50 Section 1 Safety Rules September 2014 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 You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable go
65. B _ a m g 2 2 2 3 21 U26 INO 5 sm A 5 m D 5 5 7 E fee E S7 FB1 9 e o gt 2 5 5 apa 6 B 5 8 EI A 3 AY lt P 2 4 4 4 ES0440G BATTERY GROUND QD1 o e e od m p c oz c i 555 5 amp 5 81 5 480 AAA 2 2 gt lt m a 8 955 9 B mg ge 25 do 8 5 052 OR gt 29 oO 5 mE lt D mco 9 6 9 o m 2 Qc3 m gt gt gt oS m 9 gt gt 4 lt gt 5 gt zo PE 2 xa 9 2 i 2 99 lt 52 9 a s n 9 m Z o 2 Genie TZ 50 Part No 824982 September 2014 Section 5 Schematics Electrical Schematic AS CE 2 of 3 M L K J D C B A PLATFORM CONTROL BOX PLATFORM NTROL BOX 1 PLATFORM E STOP
66. BOOM 30 29 28 MANIFOLD HARNESS 87 04 PIN P33 28 MANIFOLD HARNESS _ 5 CR69 Q Q 52 27 PIN P3 V O O 5 3 Q Bs 24 87A 4 BKWH O QOL 85 IGNITION O O 22 Q 86 7 MODELS E BN68 x 20 WITH O e CR1 5 O ENGINE START O O 17 p12 9 6 M 16 L3 4 BK RD x T 5 87 j RD 3 T 14 P2 10 P1 CR15 ide m 85 STARTING AID x gt L 1 NA 0 6 BL 1815 H C Q 8 87A H 20 1 TURNTABLE HARNESS_WH BK 1 11 FIN Ped CR86 1 5552 85 SEQUENCING BK TB35 H SA i Q 119 Q i OQ O 1 1 IS R22 Q Q 5 1000 C BATTERY CHARGE O INDICATOR BK RD G7 CU P1 E STOP 35 E 9208 OD 2 X CX XO 000000 D 900909099
67. BOOM COMPONENTS 5 Remove the pin retaining fasteners securing the primary lift cylinder barrel end pivot pin 6 Using a soft metal drift remove the primary lift cylinder barrel end pivot pin Remove the cylinder from the machine AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed 7 Attach a lifting strap of suitable capacity from an overhead crane to the mid pivot Support the mid pivot Do not apply any lifting pressure 8 Remove the pin retaining fasteners securing the secondary boom pivot pin at the mid pivot 9 Remove the pin retaining fasteners securing the secondary link pivot pin at the mid pivot 10 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 they are kinked or pinched 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 Section 4 Repair Procedures September 2014 SECONDARY BOOM COMPONENTS 12 Using a soft metal drift remove the sec
68. ECTOR REVERSE LIGHT BRAKE LIGHT Part No 824982 September 2014 Section 5 Schematics Trailer Lighting Wiring Diagram Hydraulic Axle AS RIGHT SIDE MARKER Trailer Chassis Wiring Harness GR Em Em GR OR e OR WH WH BD RD BL 7 BK e 1 RD BK RD BK RD BK 2 BL 1 RD BK 3 WH fom WH BK WH BK ee 3 WH m z m z 5 OR 4 GN 8 1 2 5 OR 9 7 6 RD 6 10 8 7 BK e 5 136 8 WH BK 20 4 LEFT SIDE MARKER L35 RIGHT SIDE MARKER L33 RIGHT REAR TAIL LIGHT Platform Wiring Harness GR ag WH RD BL 1 RD BK RD BK Eod 2 BL 3 WH WH BK TR 4 GN 5 OR A I 6 RD Sub 7 BK 8 WH BK 136 LEFT SIDE MARKER TURN RUN LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT LEFT REAR TAIL LIGHT 1 SIDE MARKER 2 TURN SIGNAL 3 FOG LIGHT 4 RED REFLECTOR 5 REVERSE LIGHT 6 BRAKE LIGHT Genie Part No 824982 TZ 50 5 13 Section 5 Schematics Ground Control Box Wiring Diagram 4
69. EDURES C 5 Grease the Axle Wheel Bearings Mechanical Axle 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 Pack both bearings with clean fresh grease 6 Install the bearings and spacer ring onto the axle and reassemble the axle Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST C PROCEDURES 7 Tighten the castle nut until the wheel runs with a little bite 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
70. FORM CONTROL BOX PLATFORM CONTROL BOX 1 PLATFORM E STOP POWER BET DOWN ENABLE PLATFORM GROUND TB2 DOWN UP ENABLE ENABLE 05 5 2 2 AUTOLEVEL MODULE 2 DRIVE E STOP POWER gt 5 8 325 48555 HALL EFFECT WITH ELECTRONIC DAMPING 552 m R22B 3 8 lt lt 5 6 99 90 me R14 98 5 2 n 4 4 10K POT CB cgo 27 BSF 58 5 Tid 1 eeo 4 5 DRIVE CONTROL BOX 8 2 Pgo 798 8 PLATFORM GROUND D o gx e 2 E lt X E E 9 4 3 177 79 U U U eo 5 g GROUND CONTROL BOX DR DGDJDH DRON DM DLDGDP ANA ay 8 GROUND CONTROL BOX TB3 5 BN59 BN60 A RNN endive CR65A 9 4 i 1 4 4 TB11 BN60 BN52 BN53 BN50 BN51 s 9 11 trom Rrom LROR BRO 77 ENABLE ENABLE ENABLE TB5 6 TB13 BN49 2 7 20 9 21 23 24 Em T o trate h 4 7814 TB15 l 11 CRESB CR61 t TB18 gt 5 8 1 1 i J CR28 5 TB22 5 TB32 ie 404 _ 1812 0 4 a 2 18 GCON GROUND 1838 4 6 s 444 o4 409 1 l GCON GROUND 1 7 da g 6 B d w L1 BATTERY 24V 2 Z m 1158 95 95 5 47 2 5 0 034 gt
71. GER 113 RF LED ORWH _ 21 OR WH PB5 5 um TB GNWH __ TB25 RDIBK__ 1826 TB29 BD CR78A TERMINAL 87A BKWH TB27 pa RD TB32 H5 ALARM 06 HOUR METER BK RC TB35 ES0440G Genie TZ 50 Part No 824982 September 2014 Section 5 Schematics Ground Control Box Wiring Diagram AS CE a 86 TERMINAL DRIVE MANIFOLD HARNESS 8 PLATFORM HARNESS TERMINAL PA MANIFOLD HARNESS 87A PIN oe GNIBK CR72 MANIFOLD 85 OUTRIGGERS 86 MANIFOLD HARNESS wH 87 HHOH 35 MANIFOLD HARNESS _WH BK 85 CR70 12 P3 N 35 G 35 86 MANIFOLD HARNESS BL 87A 2 Q 55 P3 S BUBK 525 3 i 35 CR68 34 MEE ETE BUBK 85 SECONDARY BOOM 33 71 eru 32 MANIFOLD HARNESS np 87A PIN P3 U 506 O Q _ 32 MANIFOLD HARNESS _RD BK 85 CR67 Q Q 31 PIN P3 T PRIMARY
72. Genie A TEREX BRAND Service Manual Serial Number Range TZ 5 0 from TZ5012 254 Part No 824982 Rev 1 September 2014 Introduction September 2014 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 communications will be carefully considered f
73. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Attach a lifting strap of suitable capacity from an overhead crane to the platform mount Support the mount Do not apply any lifting pressure Part No 824982 September 2014 Section 4 Repair Procedures PLATFORM COMPONENTS 7 Remove the pin retaining fasteners securing the How to latform mount pivot pins Bleed the Platform Rotator 8 Using a soft metal drift remove the platform mount pivot pins Remove the platform mount 1 Activate the platform rotate right function and from the machine rotate the platform completely to the right Continue to activate the rotate right function for AWARNING Crushing hazard The platform 3 seconds mount could fall if not properly supported when the pivot pin is 2 Activate the platform rotate left function and removed rotate the platform completely to the left Continue to activate the rotate left function for 3 seconds Genie Part No 824982 Genie TZ 50 4 3 Section 4 Repair Procedures September 2014 Jib Boom Components 2 1 Jib Boom The jib boom lift cylinder raises and lowers the jib boom The jib boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Jib Boom Note When removing a hose assembly or fitting the O ring if equipped on the
74. OOM RETRACT 9 4 Q AND OUTRIGGER l i EXTEND WH 1 puc AD TB17 WH TB18 58 BN56 PLATFORM BN49 EXTEND RETRACT UPIBGUN 5 AUTO LEVEL TB35 ff ff BL WH gt BN52 Am BL WH LEFT FRONT OUTRIGGER X 7 O 5 9 Liz 0 PRIMARY PLATFORM 6 LF LED LEFT REAR OUTRIGGER BOOM 5 114 UP DOWN 4 OPTION TALES eS BN36 JIB A ET BOOM UP DOWN GNWH pB5 9 5 0 rt BN51 2 3 4 RIGHT REAR OUTRIGGER Q Q L15 RR LED GN WH TB24 BN57 gt BN55 TURNTABLE A SECONDARY ROTATE BN53 TB20 BOOM RIGHT FRONT X RD WH P5 3 UP DOWN OUTRIGGER L13 RF LED ORWH _ TB21 ORMH p5 5 um TB rggi GNWH __ TB25 8086 _ TB29 RD CR78A TERMINAL 87A BKWH TB27 FD TB3 n wH PA3 Ps BD TB32 H5 ALARM Jae HOUR METER BK 0 TB35 ES0440G Genie TZ 50 Part No 824982 September 2014 Section 5 Schematics D u Qa Ground Control Box Wiring Diagram ANSI CSA
75. OUTRIGGER LIMIT SWITCHES Y24 Y53 Y22 Y26 gt SR cux cog amp 1 8 3 Y52 Y21 Y25 GB 1 1 2 2 2 2 2 GCON GROUND HARNESS GROUND PLUG 4 4 4 4 gt um o o 3 d 5 6 86 5 5 5 9 S gt gt 2 2 5 8 5 5 5 gt lt OO 9 5 2 2 2 lt m Q gt lt x 5 gt 2 m 5 gt m X 2 m x 5 8 9 5 lt lt 2 V9LN AV T3G AWIL THA3 104 nV Genie Part No 824982 TZ 50 5 31 September 2014 Section 5 Schematics 0 Electrical Schematic 5 32 Section 5 Schematics September 2014 2 Hydraulic Schematic Section 5 Schematics September 2014 Hydraulic Schematic A B 0 D E F G H 6 L M N
76. POWER LOAD SENSE POWER LS19A TB3 1519 PLATFORM GROUND DOWN UP 2 1 ENABLE ENABLE 65 2 AUTOLEVEL MODULE 2 5 HALL EFFECT WITH ELECTRONIC DAMPING ME 0 79 2 3 gt 295 23299 2 0 OB gt 2 S 4 x a 5 6K 1 1 DRIVE CONTROL _ 9 eza 9 9 9 5 ET RENI n PLATFORM GROUND 7 T 5 ws 8 9 9 y 2 2 y 8 5 295 AO 5 5 5 e 3 GROUND 4188 g 9 8 3 iig 5 2 0 n D D a E 9 DD DK DGDJDH DB DN DM DL DP ol 3 m ROUND CONTROLBOX TB3 4 PE p Dy ENABLE e ENABLE CR65A 4TB9 us 4 fe ees ge CE TB BN60 BN52 BN53 BN50 51 8 TB11 UP LF O R 2 RF O R LR O R RR O R 77 ENABLE ENABLE ENABLE ENABLE e 6 TB13 BN E 7 20 21 TB23 4 24 CREEA Inoz n ENABLE 4 TB16 9 4 il 15 7 5 t Creo 7 CR61 1878 4 i l 4 J CR28 5 TB22 5 bs Cane m 1 CR65B M m 5 CR70 cres 13 H eq Cape eme Jones M EASI GCON GROUND 1835 i o 4 111 2129 1 GCON GROUND EY ay a alo 6 9 2 ge 589552 98 T E BATTERY 24V A 5 6 cg 1188 95 y gg 47 mH 2 5 AMP
77. 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 Note The hydraulic filter is mounted on the bulkhead next to the hydraulic tank 1 Clean the area around the hydraulic oil filter Remove the filter with an oil filter wrench 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 Part No 824982 CHECKLIST D PROCEDURES Apply a thin layer of fresh oil onto the gasket of the new oil filter Install the filter and tighten it securely by hand Use a permanent ink marker to write the date and number of hours from the hour meter on the new filter Clean up any oil that may have spilled during the replacement procedure Properly discard the used filter 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 Raise the platform approximately 3 ft 1 m Inspect the filter and related
78. T PROCEDURES 5 Repeat steps 3 through 4 for the other brake 6 Inspect the balance plate at the control cables Result The balance plate is at a right angle to the direction of towing 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 Note The balance plate is located beneath the diamond plate cover in front of the turntable 7 Return the outriggers to the stowed position 8 Apply the parking brake 9 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 005 KNOTT Axle Service Manual Genie part number 84443 Genie Part No 824982 GenieTZ 50 3 27 Section 3 Scheduled Maintenance Procedures September 2014 Checklist D Procedures D 1 Perform Axle Maintenance Electric and Hydraulic Axles Axle specifications require that this procedure be performed every 12 months or 12 000 miles whichever comes first Brake lining Brake cylinders
79. Y20 Y21 Y22 Y23 Y24 Y25 Y26 Y33 Y34 Y35 Y36 Y39 Y40 Y50 Y50A Y52 Y53 Y58 Y59 Y60 Y61 62 Y63 Description Resistor Function speed 0 10K ohms 1000 ohm 5600 ohm Sensor Level sensor Level sensor front rear axis auto level Level sensor left right axis auto level Electronic Component Motor controller Battery charger Time delay Drive controls printed circuit board Ignition module Valve Coil Brake release Platform down Platform up Primary down Primary up Turntable rotate left Turntable rotate right Boom retract Boom extend Left rear outrigger Right rear outrigger Left front outrigger Right front outrigger Outrigger retract Outrigger extend Drive forward reverse left Drive forward reverse right Secondary down Secondary up Proportional drive right Proportional drive left Jib boom retract Jib boom extend Platform rotate left Platform rotate right Genie TZ 50 September 2014 Wire Color Legend Description Blue ean ees Black PH Green OR ice teile ete Orange PD sciat bestie ss Red PH White BLIBK Blue Black bent Blue White BK RD seen Black Red Black White Green Black 2 22 2 Green White donet Orange Black OR RD
80. achine use a soft metal drift to tap the jib link pivot pin halfway out Lower the jib link AWARNING Crushing hazard The jib link could fall if not properly supported when the pivot pin is removed 12 Working from the ground control side of the machine use a soft metal drift to tap the jib link pivot pin out just enough to release the jib cylinder Remove the cylinder from the machine AWARNING Crushing hazard The jib cylinder could fall if not properly supported when the pivot pin is removed JIB BOOM COMPONENTS Genie Part No 824982 Genie TZ 50 Section 4 Repair Procedures September 2014 Primary Boom Components lt mid pivot primary boom lift cylinder barrel end pivot pin platform level master cylinder primary boom pivot pin platform level master cylinder rod end pivot pin extension cylinder barrel end pivot pin primary boom lift cylinder primary boom lift cylinder rod end pivot pin primary boom primary boom latch extension boom platform level slave cylinder QT 776 lt jib boom secondary boom pivot pin secondary boom link pivot pin secondary boom latch secondary boom secondary boom link secondary lift cylinder rod end pivot pin secondary boom lift cylinder secondary lift cylinder barrel end pivot pin located behind ground control box turntable secondary boom pivot pin
81. allation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the hydraulic pump AWARNING gt 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 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Genie Genie TZ 50 4 Activate the platform up function from the ground controls Result If the pressure gauge reads 3200 psi 221 bar immediately stop The pump is good Result If pressure fails to reach 3200 psi 221 bar the pump is bad and will need to be serviced or replaced Component damage hazard There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed 3200 psi 221 bar When testing the pump activate the pump in one second intervals until 3200 psi 221 bar is confirmed Do not over pressurize the pump 5 Removethe pressure gauge and reconnect the hydraulic hose Torque to specification AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to
82. below 30 F 0 C 5W 30 4 F to 100 F 20 C to 38 C 10W 30 Temperature above 50 F 10 C 30W Use oils meeting API classification SJ as they offer improved wear protection Units ship with 10W 30 SJ Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 824982 Genie TZ 50 30 2 5 Section 2 Specifications September 2014 SPECIFICATIONS Hydraulic Hose and Fitting Torque Specifications SAE O ring Boss Port tube fitting installed into Aluminum all types Your machine is equipped with Parker Seal Lok ORFS or 37 JIC fittings and hose ends SAE Dash size Torque Genie specifications require that fittings and hose 4 14 ft lbs 19 Nm ends be torqued to specification when they are removed and installed or when new hoses or fittings 23 ft lbs 31 2 Nm are installed 8 36 ft lbs 54 2 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 Nm 10 60 ft lbs 81 3 Nm m Jambnu
83. bles free of the trailer 4 Tag disconnect and plug the brake line from the back of the hub Cap the fitting 5 Clean up any brake fluid that may have spilled 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 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 50 Part No 824982 Genio Genie TZ 50 Axle Components CE models 1 Lowerthe outriggers and adjust to level the machine and raise the wheels off the ground 2 Disconnect the secondary brake cables at the tension equalizer 3 Support and secure the axle assembly to an appropriate lifting device 4 Remove the axle mounting fasteners and remove the axle from the machine AWARNING Crushing hazard The axle could become unbalanced and fall if not properly supported and secured when removed from the machine a primary brake cable b tension equalizer c secondary brake cables Section 4 Repair Procedures September 2014 Trailer Components 11 1 Hydraulic and Mechanical Brakes Hydraulic Brake System Hydraulic Axle Repair procedures and additional axl
84. ce the contactor if any damage is found Genie GenieTZ 50 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 Turntable Rotate 1 Locate the turntable rotate valve coils on the function manifold Push in and hold the red thumbscrew at the center of the valve stem Result The head of the thumbscrew should move 1 4 inch 6 mm inwards turntable rotate valve secondary boom down valve primary boom down valve primary boom up valve boom extend retract valve Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures 2 Release the red thumbscrew at the center of the valve stem to reset the valve Note The valve spool must be reset for the turntable rotate function to operate from the machine controls 3 Pull out and hold the red thumbscrew at the center of the valve stem Result The head of the thumbscrew should move 1 4 inch 6 mm outwards 4 Release the red thumbscrew at the center of the valve stem to reset the valve Note The valve spool must be reset for the turntable rotate function to operate from the machine controls Secondary Boom Down 5 Locate the secondary boom down valve coil on the function manifold Push in and turn fully in a coun
85. connect the wire harness 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 Be 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 Genie Part No 824982 Genie TZ 50 4 27 Section 4 Repair Procedures September 2014 Hydraulic Pump 7 1 Function Pump The hydraulic pumps are attached to the motor which makes up the hydraulic power unit How to Test the Hydraulic Pump Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during inst
86. ctory specifications could cause the machine to tip over resulting in death or serious injury Genie Part No 824982 Genie TZ 50 Section 4 Repair Procedures September 2014 Manifolds 8 1 Function Manifold Components The function manifold is located under the turntable cover at the ground controls side of the machine Index Schematic No Description Item Function Torque Coil nut items J 4 4800 4 5 ft lbs 7 9 Nm Hand 2 44 2 22 1 Bis Auxiliary down eene 25 27 ft lbs 34 36 Nm Relief valve 600 psi 41 bar Ban Turntable rotate circuit 18 20 ft Ibs 25 27 Nm Differential sensing valve o uiis Returns extra hydraulic fluid to tank when operating turntable rotate 25 27 ft lbs 34 36 Nm Shuttle valve 2 position 3 Turntable rotate circuit 4 5 ft lbs 6 Orifice plug 0 040 inch 1 mm Eu Restricts turntable rotate fluid flow Pott iterat tore tie oec cte doner 97 117 11 13 Nm 6 Solenoid valve 2 position 3 way with manual override Ene Secondary boom down 18 20 ft lbs 25 27 Nm Diagnostic
87. cution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications 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 Genie TZ 50 3 Tagand disconnect return hard line from the filter head Remove the hard line from the machine Cap the fitting on the filter head 4 Tagand disconnect the supply hard line from the pump Cap the fitting on the pump 5 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank and supply hard line from the machine hydraulic filter supply hard line to pump hydraulic tank return hard line from filter Torque specifications 35 in lbs 4Nm Hydraulic tank retaining fasteners dry Hydraulic tank retaining fasteners lubricated 26 in lbs 2 9 Nm Part No 824982 September 2014 Section 4 Repair Procedures 10 1 Axle How to Remove the Axle ANSI models 1 Lowerthe outriggers and adjust to level the machine and raise the wheels off the ground 2 Disconnect the secondary brake cables at the tension equalizer 3 Pullthe ca
88. d 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 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 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 26 Genie TZ 50 Part No 824982 September 2014 Section 4 Repair Procedures 5 Locate the outrigger level sensors located below the ground control panel Refer to the following illustrations tilt level sensor outrigger level sensor autolevel relay early production X indicator adjusting fastener 0 6 GROUND CONTROLS If you are not installing a new level sensor proceed to step 10 6 Tag and dis
89. e UK The Maltings Wharf Road Grantham Lincolnshire 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 yes completed N no unable to complete repaired 5 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 3 Scheduled Maintenance Procedures September 2014 p 00000 This page intentionally left blank Genie 3 4 GenieTZ 50 Part No 824982 September 2014 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
90. e consistently below 0 F 17 C Note Use Shell Tellus S2 V 46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Service Department before use Function pump models without drive option Type single section gear pump Displacement per revolution 0 244 cu in 4cc Flow rate 2 8 10 6 L min Hydraulic tank return line filter 10 micron Function pump models with drive option Type 2 section pressure balanced gear pump Displacement per revolution 0 488 cu in 8 Flow 5 6 21 2 L min Hydraulic tank return line filter 10 micron Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice SPECIFICATIONS Function manifold System 3000 psi relief valve pressure 207 bar Turntable rotate 600 psi relief valve pressure 41 bar Primary boom down 1600 psi relief valve pressure 110 bar Manifold Component Specifications Plug torque SAE No 2 36 in Ibs 4 Nm SAE No 4 10 ft Ibs 18 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm Part No 824982 Genie TZ 50 30 Section 2 Specifications September 2014 SPECIFICATIONS Machine Torque Sp
91. e 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 Mechanical Axle 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 Genie Genie TZ 50 11 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 Chock the wheels Release the 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 Engage 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 Man
92. e irae eund dee 4 40 Axle Components 1087 gt 4 41 Trailer Components 11 1 Hydraulic and Mechanical 4 42 11 2 Parking eee dades 4 42 Outriggers 7 4 43 12 2 Outrigger Cylinder 4 44 Platform Overload Components 13 1 Platform Overload System 4 45 Drive Components 14 1 Drive MOOT eyed dada Meee ea ede 4 47 14 2 Drive Control 7 4 48 Genie Xii Genie TZ 50 Part No 824982 September 2014 Section 5 TABLE OF CONTENTS Schematics 5 1 Electrical Abbreviations 5 2 Abbreviation Legend Wire Colors 5 4 Limit Switch 5 ee iim ab em ie e RR 5 5 Electrical Symbols Legend sssssssssseseeeseseeennenee ener 5 6 Abbreviation Legend Hydraulic Schematics 5 7 Hydraulic Symbols Legend 2 5 8 Honda GX160 Engine Wiring Diagram 5 9 Trailer Lighting Wiring Diagram ANSI 5 0 5 10 Trailer Lighting Wiring Diagram Mechanical Axle 5 11 Trailer Lighting Wiring Diagram Electric Axle AS
93. e yellow function enable down Fully lower the iu p and continue to oo hold the buttons while observing the pressure pets gauge Merer to Section 2 reading on the pressure gauge Refer to Section peciiications 2 Specifications a please Deby wienen to hold the 5 Release the buttons Use a wrench to hold the relief valve and remove the cap item L relief valve and remove the cap item 5 Adjust the intemal hex socket Turn it clockwise 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to to increase the pressure or counterclockwise to decrease the pressure Install the relief valve decrease the pressure Install the relief valve cap cap dove j Ponoragiust Tip over hazard Do not adjust the relier valve ighertharn the relief valve higher than specified specified 6 Repeat step 3 to confirm the relief valve 7 Repeat step 4 to confirm the relief valve pressure pressure Genie 4 36 Genie TZ 50 Part No 824982 September 2014 mnmmmmmm AAN How to Adjust the Turntable Rotate Relief Valve 1 Connect 0 to 5000 psi 0 to 350 bar pressure gauge to the test port item G on the function manifold 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
94. eberet 97 117 165 11 13 Nm 18 Solenoid valve 3 position 4 way with manual override Turntable rotate left right 18 20 ft lbs 25 27 Nm Genie 4 30 Genie TZ 50 PartNo 824982 September 2014 Section 4 Repair Procedures MANIFOLDS er 7 2 Note alpha numeric callouts 0 refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on the hydraulic schematic 9 Y22 D 9 ORS 5255 lt gt CD r cams Genie Part No 824982 Genie TZ 50 4 31 Section 4 Repair Procedures September 2014 sss MANIFOLDS 8 2 Jib Manifold Components The jib manifold is located on the jib boom Index Schematic No Description Item Function Torque nut items AA AB AD and 4 5 ft lbs 7 9 Nm 1 Solenoid valve 2 position 3
95. ecifications Platform rotator 3 4 10 center bolt lubricated 200 ft lbs 271 Nm 3 8 16 bolts lubricated Turntable rotate motor 32 ft lbs 43 Nm 1 2 13 bolts dry Turntable rotate motor pinion 60 ft lbs 81 5 8 18 bolt dry Turntable rotate bearing 180 ft lbs 244 Nm all bolts lubricated Hitch mounting bolts 195 ft lbs 264 Nm 5 8 11 bolts dry 170 ft lbs 230 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice 2 4 GenieTZ 50 30 Part No 824982 September 2014 Section 2 Specifications Honda GX160K1 Engine Displacement 9 9 cu in 163 cm Number of cylinders 1 Bore amp stroke 2 7 1 8 inches Starter motor Cooling System Ignition System SPECIFICATIONS 12 V DC Forced air Spark plug type BPR6ES NGK W20EPR U DENSO Spark plug 0 028 to 0 031 inches Horsepower 5 4 hp 3600 rpm 0 7 to 0 8 mm kW 3600 rpm Fuel unleaded gasoline 4 Engine idle no load 3400 rpm 86 octane minimum Engine idle under load alternator 3100 rpm Fuel tank capacity 0 95 gallons liters 3 6 0 Compression ratio 8 5 1 Valve Clearance cold Intake 0 006 in 0 15 mm Exhaust 0 008 in 0 20 mm Lubrication system splash Oil capacity 0 63 quarts liters 0 6 Oil viscosity requirements Temperature
96. ed 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 Inspect the following areas for burnt chafed corroded pinched and loose wires Boom to platform cable harness Primary and secondary booms Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B 3 Inspect the Electrical Contactor Genie requires that this procedure be performed every 250 hours or quarterly 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 Atthe ground controls turn the key switch to the off position and push in the red Emergency Stop button to the off position 2 Disconnect the batteries 3 Locate the electrical contactor mounted on the fuse bracket 4 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 Repla
97. ember 2014 DRIVE COMPONENTS 14 2 Drive Control Box Activating the joystick or a button on the box first sends a signal to the drive controls circuit board then to the ground controls and finally the drive manifold valve coils which ultimately activates the drive function The drive steer functions can only be operated when the machine is in the stowed position and the parking brake set Over time it may be necessary to recalibrate the drive controls The drive controls printed circuit board can be adjusted for three different functions steer left steer right and forward reverse For each function to operate correctly two side by side potentiometers Threshold and Hi range must be carefully adjusted When accurately calibrated the machine should steer and drive smoothly The drive control box consists of a printed circuit board Emergency Stop button joystick and for ANSI models buttons to operate the outriggers All of the components are replaceable Keeping the drive controls clean and defect free is essential to safe machine operation For further information or assistance consult the Genie Industries Service Department How to Remove the Drive Circuit Board 1 Tag and disconnect the drive control wire harness from the ground controls Genie Genie TZ 50 2 Remove the drive control box from the control box mount Turn the box over and remove the fasteners securing the bottom cover to the box Remove the co
98. en hydraulic Repair any machine damage or malfunction connections very slowly to allow before operating the machine the oil pressure to dissipate gradually Do not allow oil to squirt Before Troubleshooting Read understand and obey the safety rules and General Repair Process operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance or repair procedure Identify symptoms Malfunction gt Troubleshoot discovered Perform repair Be sure that all necessary tools and test equipment are available and ready for use problem still exists Return to service problem solved Genie Part No 824982 TZ 50 5 1 Section 5 Schematics 7 70 Electrical Abbreviations Legend September 2014 Description Button Function enable boom down boom retract rotate left outrigger extend Function enable boom up boom extend rotate right outrigger retract Autolevel Jib boom up down Platform rotate Capacitor Zener diode 5 1V DC Zener diode 3 3V DC Zener diode 5 1V DC 4700uF Circuit Breaker Engine 15A Controls 15A Control Relay Engine start Ignition Jib boom up down Choke Power supply Auto level system Fault ground Motor controller cutout Level sensor auto level Primary boom Secondary boom Boom extend retract Turntable rotate
99. ery two years Fuel line Required maintenance procedures and additional engine information is available in the Honda GX160 Engine Shop Manual Honda part number 61ZH700 Honda GX160 Shop Manual Genie part number 97229 Section 3 Scheduled Maintenance Procedures September 2014 p 00000 This page intentionally left blank Genie 3 34 GenieTZ 50 Part No 824982 September 2014 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Genie TZ 50 Operator s Manual on your machine Be sure that all necessary tools and parts are available and ready for use Useonly 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
100. es naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker orcomponent damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 4 3 How to Test a Coil 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 100 Genie part number 27287 Be COIL 1 w _ 10Q RESISTOR BATTERY d ANA BERE Lag 1111 1 4 Ab Ys multimeter b 9V DC battery 100 resistor Note Dotted lines in illustration indicate a reversed connection as specified in step 6 Part No 824982 A 6 Genie Genie TZ 50 MANIFOLDS 3 Setamultimeter to read DC amperage Note The multimeter when set to read DC amperage should be capable of reading up to 800 mA 4 Connectthe negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal
101. f equipped 3 22 Genie Part No 824982 Genie TZ 50 ix September 2014 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued Checklist C Procedures 0 1 Grease the Platform Overload Mechanism if equipped 3 23 C 2 Testthe Platform Overload System if 3 23 0 3 Perform Axle Maintenance Electric and Hydraulic 168 3 24 6 4 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 25 C 5 Grease the Axle Wheel Bearings Mechanical Axle 3 25 C 6 Adjust the Brakes Mechanical Axle 3 26 Checklist D Procedures D 1 Perform Axle Maintenance Electric and Hydraulic 3 28 D 2 Check the Boom Wear 2 22 4 0 0 00 3 28 0 3 Replace the Hydraulic Tank Return Filter 3 29 D 4 Check the Turntable Rotation Bearing Bolts 3 30 D 5 Inspect for Turntable Bearing 3 31 Checklist E Procedures E 1 Testor Replace the Hydraulic Oil 3 32 E 2 Perform Engine Maintenance if equipped 3 33 Genie Genie TZ 50 Part No 824982 September 2014 Section 4 TABLE OF CONTENTS Repair S 4 1 Platform Components
102. fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 1 1 How to Remove the Platform 2 Raise the jib boom 4 to 5 feet 1 2 to 1 5 m 3 Lowerthe jib boom until the platform mount rests on sawhorses or a work table of sufficient capacity 4 Tagand disconnect the wire harness from the platform control box 5 Tagand disconnect the wires from the jib manifold 6 Remove the wire harness from the platform mount and the jib boom 7 Pullthe all harness cables through the jib boom 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 Genie 4 4 Genie TZ 50 8 platform mount b boom cylinder barrel end pivot pin jib link pivot pin d e boom lift cylinder f boom g jib boom cylinder rod end pivot pin h jib boom pivot pin i jib mount pivot pin j platform level slave cylinder rod end pivot pin 8 Tag disconnect and plug the hydraulic hoses to the platform rotator Cap the fittings on the rotator 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 9 Tag disconnect and plug
103. fitting to properly tighten the joint after it has been loosened Figure 2 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 Part No 824982 Genie 2 50 30 Section 2 Specifications 2014 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 18 140 158 18 13 175 24 14 19 27 366 16 23 312 44 596 24 26 352 35 474 37 501 49 664 37 501 49 664 50 678 70 947 29 a 555 55 145 eo 3 1084 6 or 43 57 773 75 1016 20 1084 110 149 20 64 567 85 115 90 122 242 80 1084 6 12 41 110 149 210 284 18 130 176 40 200 271 270 366 280 379 380 515 220 298 300 so sio 420 420 55 ___560 __ 759 E EREHE 640 867 680 922 990 1342 _9 14 2 z EE a 142 670 _ 890 1206 1080 1464 140 1952 1220 1654
104. for continued scheduled maintenance 1 Perform the following maintenance procedures A 11 Grease the Turntable Rotation Bearing and Rotate Gear A 10 Perform Engine Maintenance if equipped Engine specifications require that this procedure be performed every 50 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Air filter Required maintenance procedures and additional engine information is available in the Honda GX160 B 10 Inspect the Parking Brake Engine Owner Manual 0 3 Replace the Hydraulic Tank Honda part number 312 7630 Return Filter 0 4 Check the Turnable Rotation Honda GX160 Owner s Manual Bearing Bolts Genie part number 97228 Genie 3 10 GenieTZ 50 Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures A 11 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 below the ground control box 3 Pump multipurpose grease into the turntable rotation bearing Rotate the turntable in increments of 4 t
105. ged if they are kinked or pinched 21 Remove the pin retaining fasteners securing the secondary boom pivot pin to the turntable 22 Using a soft metal drift remove the secondary boom pivot pin Crushing hazard The secondary AWARNING boom could become unbalanced and fall if not properly supported when the pin is removed 23 Remove the secondary boom from the machine Remove the secondary link 24 Working at the ground controls remove the power to platform wiring from the ground control box 25 Remove the ground controls from the machine 26 Rotate the rod end of the secondary boom lift cylinder approximately 90 27 Attach a lifting strap of suitable capacity from an overhead crane to the rod end of the lift cylinder Raise the cylinder slightly remove the block and lower the cylinder through the secondary link and onto the front bulkhead Part No 824982 September 2014 Section 4 Repair Procedures 28 Remove the pin retaining fasteners securing the secondary link pivot pin to the turntable 29 Using a soft metal drift remove the secondary link pivot pin AWARNING Crushing hazard The secondary link could become unbalanced and fall if not properly supported when the pin is removed 30 Release the latch at the tongue end of the machine 31 Remove the secondary link from the machine AWARNING Crushing hazard The secondary link could become unbalanced and fall if not properly supported whe
106. heel brakes until the wheel turns with difficulty Genie GenieTZ 50 CHECKLIST B PROCEDURES 12 Engage and release the parking brake 4 times 13 Tighten the nuts on the tension equalizer bracket until the bracket is balanced Securely tighten the lock nuts 14 Adjust the linkage until it is free of play and without initial tension 15 Lower the machine and return the outriggers to the stowed position 16 Engage the parking brake Attempt to move the machine in both directions Result The parking brake should prevent the machine from moving If the parking brake does not prevent the machine from moving repeat steps 5 through 16 until adjustment is correct OR see B 13 Perform Axle Maintenance Mechanical Axles Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B 9 Check the Wheel Bearings Mechanical Axle 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 Res
107. hted For operational specifications refer to the Operators Manual 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 Ill 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 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 componentdamage Continuous improvement of our products isa Genie policy Product specifications are subject to change without notice Genie 2 50 30 Part No 824982 September 2014 Section 2 Specifications Note Use Chevron Aviation A hydraulic fluid when ambient temperatures ar
108. ight Drive forward reverse right Check valve drive circuit Drive forward reverse left Proportional valve left Outrigger left rear Outrigger right rear Outrigger left front Outrigger right front Parking brake release drive option Part No 824982 TZ 50 Section 5 Schematics September 2014 Hydraulic Symbols Legend o Filter Q Check valve pilot to open NVM Brake release Pilot operated 2 position 2 way pressure compensator normally closed Solenoid operated 2 position 3 way directional valve with manual override Double acting cylinder lt gt Shuttle valve C3 Motor Fixed displacement hand pump Ald Solenoid operated 2 position 3 way directional valve HET Adjustable relief valve WEE Y40 Y39 Solenoid operated 3 position 4 way directional valve Genie TZ 50 Fixed displacement pump Solenoid operated 2 position 4 way directional valve Counterbalance valve Y53 Y52 Solenoid operated 3 position 4 way directional valve with manual override 0 090 inch 2 3
109. il the axle is off the ground and the machine is level Release the boom hold down latch Turn the key switch to platform control Level the platform amp Determine the maximum platform capacity Refer to the machine serial plate 6 Using 8 suitable lifting device place an appropriate test weight equal to that of the maximum platform capacity in the center of the platform floor O Result The platform overload indicator light should be off at both the ground and platform controls Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST C 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 Test all machine functions from the ground controls Result All ground control functions should not operate 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 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 al
110. imary boom Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Part No 824982 Genie Genie TZ 50 JIB BOOM COMPONENTS 18 Attach a lifting strap of suitable capacity from an overhead crane to the jib link at the ground control side of the machine Support the jib link Do not apply any lifting pressure 19 Working from the ground control side of the machine use a soft metal drift to tap the jib link pivot pin halfway out Remove the jib link from the machine Crushing hazard The jib link could AWARNING fall if not properly supported when the pivot pin is removed 20 Attach a lifting strap of suitable capacity from an overhead crane to the remaining jib link Support the jib link Do not apply any lifting pressure 21 Working from the side of the machine opposite the ground controls use a soft metal drift to tap the jib link pivot pin halfway out Remove the jib link from the machine Crushing hazard The jib link could AWARNING fall if not properly supported when the pivot pin is removed 22 Attach a lifting strap of suitable capacity from an overhead crane to the jib cylinder Support the cylinder Do not apply any lifting pressure 23 Using a soft metal drift remove the jib cylinder pivot pin Remove the cylinder from the machine AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed 24 Attach a lifting strap of s
111. ine 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 824982 Genie GenieTZ 50 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 FUTT ndiates an imminently hazardous 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 September 2014 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols
112. inued 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 on a firm level surface and the boom in the stowed position 1 Grease the turntable bearing See A 11 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 Startthe 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 the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing 5 Atthe dial indicator adjust it to zero the indicator Part No 824982 Genie GenieTZ 50 CHECKLIST D PROCEDURES turntable dial indicator drive chassis turntable rotation bearing oo 0 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 W Resu
113. istributor 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 1 Test or Replace the Hydraulic Oil Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures B 6 Perform Axle Maintenance Electric and Hydraulic Axles 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 Manual CHECKLIST B PROCEDURES B 7 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 Jack specifications require that this procedure be performed quarterly or every 3000 miles whichever comes first 1 Remove the cap from the top of the jack housing and using automotive grease lightly grease the internal gears Rotate the handle to Genie part number 89219 evenly distribute the lubricant the internal gears 2 Securely install
114. ivot pin gt Genie TZ 50 A Genie Part No 824982 September 2014 Section 4 Repair Procedures 4 1 Secondary Boom How to Remove the Secondary Boom AWARNING This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 1 1 How to Remove the Platform 2 Remove the jib boom See 2 1 How to Remove the Jib Boom 3 Removethe primary boom See 3 2 How to Remove the Primary Boom Remove the mid pivot 4 Attach a lifting strap of suitable capacity from an overhead crane to the rod end of the primary lift cylinder Raise the cylinder to a horizontal position Part No 824982 Genio Genie TZ 50 SECONDARY
115. l axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number 84376 Genie part number 84443 Genie 3 8 Genie TZ 50 Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures A 7 Perform Hitch Maintenance Hydraulic Axle 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 20023 Demco Model 91 Owner Operator Manual Genie part number 84592 Part No 824982 Genie GenieTZ 50 3 9 CHECKLIST A PROCEDURES A 8 Perform Engine Maintenance if equipped Engine specifications require that this procedure be performed initially at 20 hours or 30 days whichever comes first Replace engine oil Required maintenance procedures and additional engine information is available in the Honda GX160 Engine Owner Manual Honda part number 31ZH7630 Honda GX160 Owner s Manual Genie part number 97228 Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST A PROCEDURES A 9 Perform 30 Day Service The 30 day maintenance 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
116. l 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 13 1 Calibrate the Platform Overload System if equipped Genie GenieTZ 50 C 3 Perform Axle Maintenance Electric and Hydraulic Axles Axle specifications require that this procedure be performed every 6 months or 6000 miles whichever comes first Brake Magnets Brake Controller 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 Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures C 4 Replace the Hydraulic Tank Breather 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 824982 Genie GenieTZ 50 CHECKLIST C PROC
117. l sensor activates 5 Locate the tilt level sensor beneath the ground an alarm will sound making the operator aware of a control panel Refer to the following illustrations potentially hazardous situation 4 Turn the key switch to the off position The tilt alarm sounds when the incline of the chassis exceeds 2 5 in any direction 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 How to Install and Calibrate the 69 Tilt Level Level Sensor tilt level sensor outrigger level sensor autolevel relay early production X indicator adjusting fastener Tip over hazard Failure to install or calibrate the 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 Install the level sensor procedure If you are not installing new level sensor proceed to step 10 6 Tag and disconnect the wire harness from the 1 Perform this procedure with the machine tilt level sensor firm level surface that is free of obstructions 7 Remove the three level sensor retaining faste
118. light control cable at the front of the platform 2 Remove the platform control box retaining fasteners Remove the platform control box from the platform and set it to the side Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 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 lower side of the platform mount 5 Remove the fasteners and pin securing the platform to the platform mount Crushing hazard The platform AWARNING could become unbalanced and fall if not properly supported when the pin is removed 6 Remove the platform from the platform mount Genie 4 2 Genie TZ 50 1 2 Platform Rotator The platform rotator is a hydraulically operated helical gear assembly used to rotate the platform 160 How to Remove the Platform Rotator if equipped 1 Remove the platform See 1 1 How to Remove the Platform 2 Raise the jib boom 4 to 5 feet 1 2 to 1 5 m 3 Lower the jib boom until the platform mount rests on sawhorses or a work table of sufficient capacity 4 Remove the wire harness from the platform mount Set the platform controls and wire harness cables to the side 5 Tag disconnect and plug the hydraulic hoses to the platform rotator Cap the fittings on the rotator Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin
119. lt The measurement is more than 0 025 inch 0 635 mm The bearing is worn and needs to be replaced 8 Fully retract the primary boom Raise the 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 909 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 Section 3 Scheduled Maintenance Procedures September 2014 Checklist E Procedures 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 When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then t
120. lve spool must be reset for the primary boom up function to operate from the machine controls Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES Boom Extend Retract 11 Locate the boom extend retract valve coils on the function manifold Push in and hold the red thumbscrew at the center of the valve stem Result The head of the thumbscrew should move 1 4 inch 6 mm inwards 12 Release the red thumbscrew at the center of the valve stem to reset the valve Note The valve spool must be reset for the turntable rotate function to operate from the machine controls 13 Locate the boom extend retract valve coils on the function manifold Pull out and hold the red thumbscrew at the center of the valve stem Result The head of the thumbscrew should move 1 4 inch 6 mm outwards 14 Release the red thumbscrew at the center of the valve stem to reset the valve Note The valve spool must be reset for the turntable rotate function to operate from the machine controls Genie GenieTZ 50 B 5 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 d
121. metallic ring at either end of the coil 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 0 mA and are different by a minimum of 20 The coil is good W Result If one or both of the current readings 0 mA or if the two current readings do not differ by a minimum of 2095 the coil and or its internal diode are faulty and the coil should be replaced Section 4 Repair Procedures September 2014 Hydraulic Tank 9 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during operation It has an external return line filter How to Remove the Hydraulic Tank Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electro
122. n removed from the machine 32 Tag disconnect and plug the hoses from the secondary lift cylinder Cap the fittings on the cylinder 33 Attach a lifting strap of suitable capacity from an overhead crane to the secondary lift cylinder Raise the cylinder to a horizontal position 34 Remove the pin retaining fasteners securing the secondary lift cylinder pivot pin to the mid pivot 35 Using a soft metal drift remove the secondary lift cylinder pivot pin Remove the cylinder from the machine AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed Part No 824982 Genie Genie TZ 50 SECONDARY BOOM COMPONENTS 4 2 Secondary Boom Lift Cylinder The secondary boom lift cylinder raises and lowers the secondary boom The secondary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure 1 Release the boom latch at both the tongue end and turntable end of the boom 2 Raise the secondary boom to a horizontal position 3 Attach a lifting strap of suitable capacity from an overhead crane to the mid pivot Support the mid pivot Do not apply any lifting pressure 4 Attach a lifting strap of suitable capacity from an overhead crane to the lift cylinder Support the cylinder Do not apply any lifting pressure 5 Remove the pin retaining fasteners securing the lift cylinder rod end pivot pin 6 Place a woode
123. n block between the secondary link and the lift cylinder 7 Using a soft metal drift remove the lift cylinder pivot pin AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed 8 Lowerthe cylinder onto the wooden block 9 Rotate the rod end of the secondary boom lift cylinder approximately 90 10 Raise the cylinder slightly remove the block and lower the cylinder through the secondary link and onto the front bulkhead Section 4 Repair Procedures September 2014 SECONDARY BOOM COMPONENTS 11 Tag disconnect and plug the hydraulic hoses on the lift 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 Note Place rags beneath the barrel end of the lift cylinder before loosening the hydraulic lines Note It may be helpful to remove the turntable rotate motor 12 Remove the pin retaining fasteners securing the lift cylinder barrel end pivot pin 13 Using a soft metal drift remove the lift cylinder barrel end pivot pin Crushing hazard The cylinder AWARNING could fall if not properly supported when the pivot pin is removed 14 Carefully remove the cylinder from the machine Crushing hazard The lift cylinder AWARNING could become unbalanced and fall if n
124. nable platform controls Level sensor Limit switch fault Down enable Lift cut out Sequencing Platform rotate Alternator Fuse Function 275A Alternator 50A Engine starter 50A Flashing Beacons option Ground Gauge Hour meter Battery charge indicator option Horn or Alarm Horn Multifunction alarm Joystick Keyswitch Item 14 4 112 L13 L14 L15 L33 L34 L35 L36 L58 LS LS12 LS13 LS14 LS15 LS18 LS18A LS19 M3 M5 N C NCHO N O NOHC P1 P2 P3 Q7 Genie Part No 824982 Section 5 Schematics 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 License plate light Limit Switch Left front outrigger Right front outrigger Leftrear outrigger Right rear outrigger Boom down Boom down Load sense Motor Engine starter 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 Emergency Stop button at drive controls Choke Solenoid TZ 50 Section 5 Schematics ds Electrical Abbreviations Legend Item R14 R22 R22B S7 59 510 U6 U16 U24 U26 Y11 Y19
125. nder 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 Part No 824982 PRIMARY BOOM COMPONENTS Genio Genie TZ 50 a platform level master cylinder b platform level slave 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 Remove the pin retaining fastener from the rod end pivot 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 Section 4 Repair Procedures September 2014 eee PRIMARY BOOM COMPONENTS 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
126. ners Remove the level sensor from the machine 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 Genie 4 24 Genie TZ 50 Part No 824982 September 2014 Section 4 Repair Procedures 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 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 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 bee
127. not driving 25 27 ft lbs 34 36 Nm 7 Counterbalance valve BG Drive circuit right side 25 30 ft Ibs 34 41 Nm 8 Shuttle valve 2 position way BH Drive CIrCUlt 4 5 ft lbs 6 9 Solenoid valve 2 position 2 way Brake release 18 20 ft lbs 25 27 Nm 10 Differential sensing valve BJ Maintains traction equal to BA 25 27 ft lbs 34 36 Nm 11 Proportional valve 2 position 2 way BK Drive circuit right side 18 20 ft lbs 25 27 Nm 12 Solenoid valve 2 position 4 way BE Drive circuit right side 18 20 ft lbs 25 27 Nm 13 Check valve 10 psi 0 7 bar BM Pump 2 2 2 2 18 20 ft Ibs 25 27 Nm 14 Solenoid valve 2 position 4 way BN Drive circuit left side 18 20 ft Ibs 25 27 Nm 15 Proportional valve 2 position 2 way BO Drive circuit left side 18 20 ft Ibs 25 27 Nm Genie 4 34 Genie TZ 50 Part No 824982 September 2014 Section 4 Repair Procedures MANIFOLDS Note alpha numeric callouts refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes
128. o 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 underthe turntable Grease type Multipurpose grease Part No 824982 Genie GenieTZ 50 CHECKLIST A PROCEDURES A 12 Perform Engine Maintenance if equipped Engine specifications require that this procedure be performed every 6 months or every 100 hours whichever comes first Perform this procedure more often if dusty conditions exist Replace engine oil Clean fuel sediment cup Check clean spark plug Required maintenance procedures and additional engine information is available in the Honda GX160 Engine Owner Manual Honda part number 31ZH7630 Honda GX160 Owner s Manual Genie part number 97228 Section 3 Scheduled Maintenance Procedures September 2014 Checklist B Procedures B 1 Inspect the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water
129. o 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 NN 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 7 sure to properly dispose of old oil or 3 other fluids Use an approved container Please be environmentally safe sure that your workshop or work area E is properly ventilated and well lit Genie Part No 824982 Genie TZ 50 vii September 2014 Table of Contents Introduction Section 1 Section 2 Section 3 Important Information li Revision aoo i c teri ee rr t ed prd reg a uda erie odo lii Serial Number 1 nennen nennen nnne nnne nnns Safety Rules General Safety 06 da
130. om extension from the primary boom 17 Remove the pin retaining fasteners from the primary boom extension cylinder rod end pivot pins 18 Using a soft metal drift remove the primary boom extension cylinder rod end pivot pins 19 Remove the primary boom extension cylinder from the boom extension Section 4 Repair Procedures September 2014 eee PRIMARY BOOM COMPONENTS 3 3 5 Lower the cylinder onto the secondary boom Primary Boom Lift Cylinder 6 Remove the pin retaining fastener from the lift cylinder barrel end pivot pin How to Remove the 7 Using a soft metal drift remove the lift cylinder Primary Boom Lift Cylinder barrel end pivot pin The primary boom lift cylinder raises and lowersthe AWARNING 2 dod primary boom The primary boom lift cylinder is whenthe SUR 22 equipped with counterbalance valve to prevent pivot p movement the event of a hydraulic line failure 8 Carefully remove the cylinder from the machine Note When removing a hose assembly or fitting AWARNING Crushing hazard The lift cylinder the O ring if equipped on the fitting and or the could become unbalanced and fall hose end must be replaced All connections must if not properly supported when be torqued to specification during installation Refer removed from the machine to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses
131. on the hydraulic schematic BN QUOMEORO A BJ 9 0 7 Before After Serial Number Serlal Number 25004 152 TZ5004 151 Genie Part No 824982 Genie TZ 50 Section 4 Repair Procedures MANIFOLDS 8 4 Valve Adjustments Function Manifold How to Adjust the September 2014 How to Adjust the Primary Boom Down Relief Valve 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port item G on the function manifold System Relief Valve 2 the key switch to ground control and pull out red Emergency Stop button to the on Note Perform this procedure with the outriggers in position at both the ground and platform the stowed position controls 1 Connect a 0 to 5000 psi O to 350 bar pressure Push and hold the yellow function enable button gauge to the test port item G on the function Push and hold the auto level button manifold Result The outriggers will lower and adjust to keyswinehito greurid contro pull level the machine and raise the wheels off the out the red Emergency Stop button to the on ground position at both the ground and platform controls 4 Push and hold the yellow function enable button Push and hold the primary boom down button 3 Push and hold th
132. on the lift 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 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 Using a soft metal drift remove the lift cylinder rod end pivot pin AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed Genie 4 14 Genie TZ 50 Part No 824982 September 2014 Section 4 Repair Procedures 3 4 Platform Leveling Cylinders 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 if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cyli
133. ondary 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 Attach a lifting strap of suitable capacity from an overhead crane to the secondary boom Support the secondary boom Do not apply any lifting pressure 15 Remove the pin retaining fasteners securing the lift cylinder pivot pin to the secondary boom 16 Place a wooden block between the secondary link and the secondary lift cylinder 17 Using a soft metal drift remove the lift cylinder pivot pin from the secondary boom Crushing hazard The cylinder AWARNING could fall if not properly supported when the pivot pin is removed 18 Lower the cylinder onto the wooden block 19 Raise the secondary boom to a horizontal position Genie Genie TZ 50 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 dama
134. or future printings of this and all other manuals Contact Us http www genielift com e mail awp techpub 6 terex com Genie Copyright 2004 Terex Corporation 824982 Rev A June 2013 Second Edition First Printing Genie and TZ are registered trademarks of Terex South Dakota Inc in the USA and many other countries 6 Printed on recycled paper Printed in U S A Genie 7 50 824982 September 2014 Revision History Revision Date Section Procedure Schematic Page Description 62019 __________ m 004 s Scem s Honda Engine_Section 2_Specifications Electronic Version A 6 B 3 C 7_Section 3_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 highlighted in blue to view the update Genie Part No 824982 Genie TZ 50 iii September 2014 REVISION HISTORY CONTINUED Procedure Schematic Description Honda Engine Section 2 Specifications Electronic Version 6 3 7 Section 3 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 highlighted in blue to view the update Genie iv Genie TZ 50 Part No 824982 September 2014 INTRODUCTION Serial Number Legend Geni A TEREX BRAND
135. or controller Battery charger Level sensor TZ 50 Part No 824982 September 2014 O I1 Hydraulic Abbreviations Legend Item lt gt 00 7 2 gt Description Auxiliary pump Relief valve turntable rotate Pilot operated relief valve Shuttle valve turntable rotate Orifice turntable speed Secondary boom down with override Primary boom down with override Relief valve primary boom Primary boom up with override Boom extend retract with override System relief Outrigger counterbalance Outrigger extend retract Check valve outrigger circuit Secondary boom up Orifice primary secondary boom down speed Turntable rotate left right with override Jib boom extend Jib boom retract Relief valve platform level circuit Platform rotate left right option Platform level up down Platform level counterbalance Pilot operated relief valve Orifice platform rotate speed Orifice jib boom up speed Orifice jib boom down and platform level speed Shuttle valve platform level circuit Genie Section 5 Schematics Description Pilot operated directional valve left Orifice drive speed Pilot operated pressure compensator Orifice drive speed Counterbalance valve Pilot operated pressure compensator Counterbalance valve Shuttle valve Brake Dump Pilot operated directional valve right Proportional valve r
136. orqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the machine in the stowed position 1 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 50 2 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container Refer to Section 2 Specifications for capacity information AWARNING sta injury hazard Spraying ydraulic can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Tag and disconnect the hydraulic return line from the filter head to tank 4 Tag and disconnect the hydraulic inlet line to the filter head Cap the fitting on the line 5 Remove the filter head from the machine 6 Tag and disconnect the hydraulic line from the tank to the pump Cap the fitting on the pump 7 Remove the hydraulic tank mounting fasteners Remove the hydraulic tank from the machine 8 Clean the inside of the hydraulic tank using a mild solvent 9 Install and tighten the hydraulic tank drain plug using thread sealer on the threads Torque to specification Torque specifications Hydraulic tank drain plug dry 150 in Ibs 16
137. ot properly supported when removed from the machine Genie 4 22 Genie TZ 50 Part No 12 September 2014 Section 4 Repair Procedures Engine 5 1 Fuse Replacement The electric engine starter circuit is protected by both 5 amp and 50 amp fuse If either fuse burns out the electric starter will not operate The engine can however still be manually started Additional engine information is available in the Honda GX160 Engine Owner Manual Honda part number 31ZH7630 OR the Honda Engines Shop Manual Honda part number 61ZH700 Honda GX160 Owner s Manual Genie part number 97228 Honda Engines Shop Manual Genie part number 97229 Se 6 5 fuse starter circuit inside cover 50 amp fuse starter circuit 50 amp fuse alternator circuit Genie Part No 824982 Genie TZ 50 4 23 Section 4 Repair Procedures September 2014 Ground Controls 6 1 3 Push and hold the yellow function enable button Push and hold the auto level button Level Sensor Result The outriggers will lower and adjust to Each machine is equipped with two types of level level the machine and raise the wheels off the sensors ground Use the bubble level located below the ground controls to confirm that the machine is Tilt level sensor level One level sensor monitors the incline of the turntable after the outriggers are deployed and the machine is level When this leve
138. ow 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 extension boom cable bridge cable track track support platform level slave cylinder jib boom 6 Tag disconnect and plug the hydraulic hoses at the lower end of the cable track Cap the fittings on the hydraulic hard lines Refer to YY in the illustration above 7 Place blocks between the cable bridge and the cable track and secure them together Crushing hazard If the cable AWARNING bridge and the cable track are not properly secured together the combination could become unbalanced and fall when removed from the machine Section 4 Repair Procedures September 2014 PRIMARY BOOM COMPONENTS 8 Attach a lifting strap of suitable capacity from an overhead crane to the rod end of the primary lift cylinder Support the cylinder Do not apply any lifting pressure 9 Remove the pin retaining fastener from the primary lift cylinder rod end pivot pin 10 Using a soft metal drift remove the primary lift cylinder rod end pivot pin AWARNING Crushing hazard The cylinder will fall if not properly supported when the pivot pin is removed 11 Lower the cylinder onto the secondary boom 12 Remove
139. performed Daily or 8 hours Inspection A Quarterly or 250 hours or 3000 mile 4800 km Inspection 500 hours 6000 mile 9600 km Inspection A B C Annually or 1000 hours or 12 000 mile 19 300 km 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 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 N no remove from service R repaired Comments Checklist A Checklist B Y NR A 1 Manuals and Decals B 1 Batteries 2 Pre operation inspect B 2 Electrical wiring A 3 Function tests B 3 Electrical Contactor A 4 Engine maintenance if equipped A 5 Lug bolts Electric and Hydraulic Axles 6 Lug bolts Mechanical Axle A 7 Hitch maintenance A 8 Engine maintenance if equipped Perform after 40 hours A 9 Perform 30 day service Perform every 50 hours A 10 Engine maintenance if equipped Perform every 100 hours A 11 Grease rotate bearing A 12 Engine maintenance if equipped Genie Part No 824982 B 4 Manual override B 5 Hydraulic oil analysis
140. ps 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 Part No 824982 Genio Genie TZ 50 GROUND CONTROLS 15 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 16 Using a digital level lower the ground control side of the machine until the turntable is 2 4 out of level O 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 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 19 Using a digital level lower the pla
141. rs or every 6000 miles 9600 km A B C Annually or every 1000 hours or every 12 000 miles 19 300 km 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 824982 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 Geni
142. s available in the Honda GX160 Engine Owner Manual Honda part number 31ZH7630 Honda GX160 Owner s Manual Genie part number 97228 Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST A PROCEDURES A 5 Torque the Lug Bolts Electric and Hydraulic Axles 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 Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual A 6 Torque the Lug Bolts Mechanical Axle 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 additiona
143. t Non adjustable 12 85 ft lbs 115 Nm 2 fitting Non adj Adjustable 16 110 ft Ibs 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 SAE Dash size Torque JIC 37 Fittings 4 ORFS 37 Adj 15 ft lbs 20 3 Nm swivel nut or hose connection ORFS Non adj 37 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 g 14 1 10 ORFS Adj Non adi 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 1 1 116 12 1 12 All types 135 ftlbs 183 Nm 5 16 16 1 516 12 1 16 All types 200 ft lbs 271 2 Nm 1 5 8 12 1 20 All types 250 ft lbs 339 Nm 24 24 All types 305 ft lbs 413 5 Nm 2 6 Genie TZ 50 30 Part No 824982 September 2014 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 used in the Parker Seal Lok fittings and hose ends are custom si
144. t No 824982 Section 4 Repair Procedures September 2014 MANIFOLDS Models with Platform Rotate Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Models without Platform Rotate Genie TZ 50 38 Part No 824982 Section 4 Repair Procedures September 2014 MANIFOLDS 8 3 Drive Manifold Components if equipped The drive manifold is located next to the function manifold Index Schematic No Description Item Function Torque nut items BK BL BN and 4 5 ft lbs 7 9 Nm 1 Differential sensing valve BA Maintains traction equal to 25 27 ft lbs 34 36 Nm 2 Orifice plug 0 090 inch 2 3 mm BB Drive circuit 3 Differential sensing valve Maintains torque while driving 25 27 ft lbs 34 36 Nm 4 Orifice plug 0 090 inch 2 3 mm BD Pump 2 circuit Ports Plug iiio era inp ID e iD Dn 97 117 11 13 Nm 5 Counterbalance valve BE Drive circuit left side 30 35 ft lbs 41 47 Nm 6 Differential sensing valve BF Returns pump 2 hydraulic fluid to tank when
145. ter clockwise direction the red thumbscrew at the center of the valve stem Result The head of the thumbscrew should rotate one quarter turn in a counter clockwise direction 6 Push in and turn fully in a clockwise direction the red thumbscrew at the center of the valve stem to reset the valve Note The valve spool must be reset for the secondary boom down function to operate from the machine controls Part No 824982 Genie GenieTZ 50 CHECKLIST B PROCEDURES Primary Boom Down 7 Locate the primary boom down valve coil on the function manifold Push in and turn fully in a counter clockwise direction the red thumbscrew at the center of the valve stem Result The head of the thumbscrew should rotate one quarter turn in a counter clockwise direction 8 Push in and turn fully in a clockwise direction the red thumbscrew at the center of the valve stem to reset the valve Note The valve spool must be reset for the primary boom down function to operate from the machine controls Primary Boom Up 9 Locate the primary boom up valve coil on the function manifold Push in and turn fully in a counter clockwise direction the red thumbscrew at the center of the valve stem Result The head of the thumbscrew should rotate one quarter turn in a counter clockwise direction 10 Push in and turn fully in a clockwise direction the red thumbscrew at the center of the valve stem to reset the valve Note The va
146. tform 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 Repeatthis procedure beginning with step 6 Section 4 Repair Procedures September 2014 GROUND CONTROLS 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 WP 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 replace
147. the cap onto the jack Genie Part No 824982 GenieTZ 50 3 17 Section 3 Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B 8 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 Models with Hydraulic or Electric Axles 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 Set the parking brake Note If the brake cables are too tight the parking brake assembly will be difficult to apply If the brake cables are too loose the brakes will not activate when the lever is set Genie GenieTZ 50 Attempt to manually push the machine Result The machine should not move Result The machine moves Proceed to step 5 Chock the wheels Release the parking brake Loosen the set screw at the side of the parking brake handle 8 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 9 Tighten the set screw Do not overtighten 10 Engage the parking brake Attempt to move the machine in both directions Result
148. the hydraulic hoses to the jib cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 824982 September 2014 Section 4 Repair Procedures 10 Attach a lifting strap of suitable capacity from an overhead crane to the platform mount Support the mount Do not apply any lifting pressure 11 Remove the pin retaining fasteners securing the platform mount pivot pins 12 Using a soft metal drift remove the platform mount pivot pins Remove the platform mount from the machine Crushing hazard The platform AWARNING mount could fall if not properly supported when the pivot pin is removed 13 Remove the jib manifold retaining fasteners Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 14 Attach a lifting strap of suitable capacity from an overhead crane to the jib boom Support the jib boom Do not apply any lifting pressure 15 Remove the pin retaining fasteners securing the jib boom pivot pins 16 Using a soft metal drift remove the jib boom pivot pins Remove the jib boom from the machine AWARNING Crushing hazard The platform mount could fall if not properly supported when the pivot pin is removed 17 Lay the jib manifold and hoses off to the side of the pr
149. the wire harness cables from the bottom of the primary boom Secure the hydraulic hard lines to the boom 13 Place blocks between the cable bridge and the cable track Secure the cable bridge and the cable track together Crushing hazard If the cable AWARNING bridge and the cable track are not properly secured together the combination could become unbalanced and fall when removed from the machine 14 Attach a lifting strap from an overhead crane to the cable track 15 Remove the mounting fasteners that attach the lower cable track to the boom 16 Remove the cable track from the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The cable track could become unbalanced and fall if not properly attached to the overhead crane Genie Genie TZ 50 How to Repair the Cable Track Component damage hazard The cable track can be damaged if it is twisted 1 Visually inspect the cable track and determine which 7 link section needs to be replaced 2 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 3 Using a flat blade screwdriver at one side of the link 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 4 Repeat step 3 for the other end of the section to be replaced
150. tings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Attach a lifting strap of suitable capacity from an overhead crane to the platform mount Support the mount Do not apply any lifting pressure 5 Attach a lifting strap of suitable capacity from an overhead crane to the jib boom Support the jib boom Do not apply any lifting pressure Part No 824982 September 2014 Section 4 Repair Procedures 6 Place a wooden block between the jib cylinder and the jib links 7 Removethe pin retaining fasteners securing the jib boom cylinder barrel end pivot pin 8 Using a soft metal drift remove the jib boom cylinder barrel end pivot pin Lower the cylinder onto the wooden block AWARNING Crushing hazard The jib cylinder could fall if not properly supported when the pivot pin is removed AWARNING Crushing hazard The jib boom could fall if not properly supported when the pivot pin is removed 9 Install the jib boom onto the platform mount Install the pivot pin securing the jib boom to the platform mount 10 Attach a lifting strap of suitable capacity from an overhead crane to the jib link at the ground control side of the machine Support the jib link Do not apply any lifting pressure 11 Working from the ground control side of the m
151. to the limit switch Section 4 Repair Procedures September 2014 eee 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 4 46 Genie TZ 50 Part No 12 September 2014 Section 4 Repair Procedures The TZ 50 drive option allows the operator to move the machine into another position without having to use a tow vehicle to do so This option package includes drive controls a brake cylinder and a drive motor for each axle wheel When a drive function is activated at the drive control box a signal is sent to one or more of the drive manifold valve coils enabling the machine to move The drive controls will function only when
152. ual Genie part number 84443 Part No 824982 September 2014 Section 4 Repair Procedures 12 1 Outrigger Components How to Remove an Outrigger Outriggers are essential to safe machine operation and machine stability Operating a machine with 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 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 5 Remove the pin retaining fasteners from the outrigger cylinder rod end pivot pin 6 Attach a lifting strap of suitable capacity from an overhead crane to the rod end of the outrigger cylinder Support the cylinder Do not apply any lifting pressure Part No 824982 Genio Genie TZ 50 Outriggers 7 Place a wooden block under the cylinder 8 Lowerthe outrigger enough to remove the outrigger cylinder rod end pivot pin 9 Using a soft metal drift remove the outrigger cylinder rod end pivot pin
153. uitable capacity from an overhead crane to the jib mount Support the mount Do not apply any lifting pressure Section 4 Repair Procedures September 2014 JIB BOOM COMPONENTS 25 Remove the pin retaining fasteners securing the jib mount pivot pin and the platform level slave cylinder rod end pivot pin 26 Place a wooden block between the primary boom and the platform level slave cylinder 27 Using a soft metal drift remove the platform level slave cylinder rod end pivot pin Rest the cylinder on the block AWARNING Crushing hazard The cylinder could fall if not properly supported when the pivot pin is removed 28 Using a soft metal drift remove the jib mount pivot pin Remove the jib mount from the machine Crushing hazard The jib mount AWARNING could fall if not properly supported when the pivot pin is removed Genie 4 6 Genie TZ 50 2 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or the hose end must be replaced All connections must be torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom 4 to 5 feet 1 2 to 1 5 2 Lower the jib boom until the platform mount rests on sawhorses or a work table of sufficient capacity 3 disconnect and plug the hydraulic hoses to the jib cylinder Cap the fit
154. ult 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 Mechanical Axle 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 Service the Hitch Mechanical Axle 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 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 Genie part number 84443 Genie 3 20 Genie TZ 50 Part No 824982 September 2014 Section 3 Scheduled Maintenance Procedures 5 Lightly grease the ball mount 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
155. umm UE eo OUTRIGGER OUTRIGGER F iL J 3000 3000 3000 BN 1 CYLINDER CYLINDER M a 1 M 4 207 207 207 N X 11 X 1 3000 3000 3 1 4 5 1 ___ A Q 207 bar 207 bar 3 1 f 1000 i ER 1 eu ba x x 59 69 bar 451 1 51 t F4 3 1 ae 4 W psi X 5 ry parker Lis 1 WEE z h 11 41101 0 037 0 037 in f 3 RS BJ uc m TP L ESPRIME 1 mere LN HER 0 7 bar E AL 8 7 7 7 7 R gt dm BL 7 E i 4 4 i d pem DRIVE SHa at Bn MANIFOLD 909 N TP 1 tee Mr md J600 psi Sorter 13000 psi H H ne 41 ber ma 2 4 207 bar I Al 1 le 3 1 4 z T 4 8 9 090 BD BUM X passes 2 3mm 0 090 in t t to i m T EO Ee r E 1 3 gt Ld z H 2
156. us injury and significant component damage Dealer service is required Follow the disassembly steps to the point required to complete the repair Then re assemble the secondary boom by following the disassembly steps in reverse order 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 Remove the jib boom See 2 1 How to Remove the Jib Boom 3 Remove the wire harness cables from the bottom of the secondary boom Secure the hydraulic hard lines to the boom 4 Tagand disconnect the wire harness cables from the ground controls Pull the cables to the mid pivot Component damage hazard Cables and hoses can be damaged if they are kinked or pinched For ease of assembly pay close attention to how the cables are routed when pulling the cables to the mid pivot Section 4 Repair Procedures September 2014 PRIMARY BOOM COMPONENTS 5 Remove the harness clamps inside the mid pivot Pull the wire harness cables through the mid pivot 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 6 Tag disconnect and plug the hoses from the platform level master cylinder Cap the fittings on the cylinder
157. ver 3 Locate the 6 pin Deutsch connector between the circuit board and the 14 wire main cable Note The 6 pin connector and wiring originates from the circuit board nearest the B SIDE potentiometer Note On the circuit board side seven wires are installed into the 6 pin connector with two red wires installed into terminal 1 b 14 wire main cable 4 Tagand disconnect the circuit board from the 14 wire main cable Component damage hazard ACAUTION Electrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when handling printed circuit boards 5 Tag and disconnect the joystick from the circuit board 6 Remove the circuit board mounting fasteners and remove the circuit board from the box Part No 824982 September 2014 Section 5 Schematics Schematics About This Section There are two groups of schematics in this section Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits Observe and Obey could result in death or serious injury Remove all rings watches Troubleshooting and repair procedures shall be and other jewelry completed by a person trained and qualified on the repair of this machine Hydraulic Schematics Immediately tag and remove from service a AWARNING P o4ily injury hazard Spraying damaged or malfunctioning machine hydraulic oil can penetrate and burn skin Loos
158. vernmental regulations You have the appropriate tools lifting equipment and a suitable workshop Genie vi Genie TZ 50 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 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 Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Part No 824982 September 2014 Section 1 Safety Rules SAFETY RULES Workplace Safety Be sure t
159. zards 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 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 50 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 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 824982 September 2014 Section 3
160. ze 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 2 Make reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 SPECIFICATIONS 9 Figure 1 8 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 marks indicate that the correct tightening positions have been determined Use the second mark on the body hex

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