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Service Manual - Genie Industries

1. 40 86 9 86 WH MANIFOLD HARNESS gw pk 87 87 Gane TERMINAL BASE 87 ee PN t SICH TB22 DRIVE MANIFOLD HARNESS PIN 8 t MANIFOLD HARNESS GN 85 OUTRIGGERS PLATFORM 85 LIFTCUTOUT BK PIN K TB35 2 Rp m LEVEL 87 87 MANIFOLD HARNESS 87 HSH u BD MANIFOLD HARNESS WH BK 27 g5 a CR70 Q Q 35 Q Q 85 PIN
2. 40 86 9 86 WH MANIFOLD HARNESS 87 87A Gane TERMINAL BASE 87 3 4 5 CR72 DRIVE MANIFOLD HARNESS PIN 8 tsar 9 MANIFOLD HARNESS GN __ __ PIN 85 OUTRIGGERS PLATFORM 85 a HARNESS 8 2 TERMINAL MANIFOLD HARNESS wH 87 87A HHH SAKE Y PIN P 3 TB31 35 MANIFOLD HARNESS WH BK gc CR70 Q Q P 5 PIN
3. 0 TERMINAL BASE 9 mo TEMA MANIFOLD HARNESS 87 87 87 8 PD SNB GN BK RD 66872 TB22 DRIVE MANIFOLD HARNESS PIN 8 a GH7gA MANIFOLD HARNESS GN 85 OUTRIGGERS PLATFORM 85 LIFTCUTOUT HARNESS 4 n5 TB35 S TERMINAL PA 8 86 LEVEL 87 87 MANIFOLD HARNESS wH 87 87A HEH AHHH BD 7617 T w MANIFOLD HARNESS 7 CR70 5 85 518 P3
4. BIRD CR15 TERMINAL 86 ED RD 4 TERMINAL 86 RD MODELS POWER CABLE PIN 1 WITH RD TURNTABLE HARNESS ENGINE PINE BD CR8 TERMINAL 87 Do TERMINAL 30 CR15 TERMINAL 30 KS1 KEY SWITCH P1 emercency stop 55 rS S FUNCTION ENABLE WH TB10 START BOOM UP EXTEND ROTATE RIGHT AND OUTRIGGER RETRACT 9 7 f RD TURNTABLE HARNESS
5. 9 TERMINAL BASE mp TBA MANIFOLD HARNESS gw pk 87 87 87 PD 55 GNEK GN BK RD sl 22 DRIVE MANIFOLD HARNESS PIN 8 CR78A MANIFOLD HARNESS GN 85 OUTRIGGERS PLATFORM 85 LIFTCUTOUT BK n HARNESS e 1 BD 1835 A TERMINAL PA O 86 1 MANIFOLD HARNESS wH 87 87A HEHESSHHEH v 87 87 RD PIN P WHIBK 3 TB17 MANIFOLD HARNESS WH BK 5 2 CR70 Q 3 Q 85 AH PIN N PLATFORM ROTATE 6 35
6. gt 1 PLATFORM CONTROLS mm mw w w m s sr gt DRIVE CONTROLS NOTE MACHINE SHOWN IN C gt j STOWED POSITION WITH AUTO LEVEL THE POWER OFF 2 Bd T LS18 NOTE FLASHING BEACON DOWN 5 v OPTION STOWED POSITION WITH ele sg 7 gp 2 s al a e le THE POWER OFF z 8 i 8 5 5 1 5 8 2 2 9 8 8 E t 8 8 1 2
7. BK RD RD RD MODELS FD WITH m 1 5 BN68 N 19 OI BN60 FUNCTION ENABLE START 7 E G RIGHT OUTRIGGER 1 N KEY SWITCH CN BN59 FUNCTION ENABLE BN90 BOOM DOWN T lene AND OUTRIGGER WH eed RD WH BN58 Q BN56 PLATFORM BN49 EXTEND RETRACT UPIBGUN 5 AUTO LEVEL BLWH _ BN52 pee LE
8. 1 PLATFORM CONTROLS PLATFORM CONTROLS mm E NE mw sar B gt DRIVE CONTROLS DRIVE CONTROLS NOTE MACHINE SHOWN IN gt STOWED POSITION WITH AUTO LEVEL THE POWER OFF 2 1 57 1518 FLASHING BEACON BOOM DOWN MACHINE SHOWN IN OPTION NEKO STOWED POSITION WITH slo 2 gt LS18A zx g 2 p o THE POWER OFF 2 2 2 x A m s 5 z 2 2 8 a 2 f B00M DOWN 3 1 2 DA 3 PA1 PA2 DB 4 DC CD10 CD9 DE DF DG DH DJ DK PA7 PA8 PA9 Hz DL T lt Us 34 TB1 3 Y B
9. A B C D E F G H 9 L WHT 1 GRN BLK BLK BLK RED Page 3 of 3 WHT RED ORG RED REDAWHT g BLU 5 m e DOWN LIMIT SWITCHES BANBLK 2 3 SHOWN IN STOWED POS B m 2 2 2 D 9 2 5 D B 9 m 9 ag 2 2 Mon z pssB e B 5 gt 1 2 1 PA2 DB PAS PAS cg DF DG DH DU DK PA7 DP 9 GROUND CONTROL BOX m Ui A TB4A 182 n TB4 lt 3 1 i E TB3 BN59 BN60 BN68 BN90 zi ian NP FUNCTION ENABLE ENGINE CHOKE E P ALAR START Y 0788 9 7 Tag 7810 B12
10. 1 PLATFORM CONTROLS PLATFORM CONTROLS w w w Oo B gt DRIVE CONTROLS DRIVE CONTROLS NOTE MACHINE SHOWN IN STOWED POSITION WITH gt AUTO LEVEL THE POWER OFF 2 1 o LS18 NOTE FLASHING BEACON 3 BOOM DOWN MACHINE SHOWN IN Jg OPTION STOWED POSITION WITH slo mw o gt gt LS18A z 2 v o THE POWER OFF 2 2 5 z S S 8 3 8 f S 8 8 8 amp RB g 1 2 DA 3 PA10 11 1 2 DB PA4 PAS DC pp CD10 CD9 CD11 DE DF DG DH DJ DK 7 TB1 ug 4 3 Y l
11. PLATFORM CONTROLS PLATFORM CONTROLS mO eee gt DRIVE CONTROLS DRIVE CONTROLS NOTE MACHINE SHOWN IN STOWED POSITION WITH F AUTO LEVEL THE POWER OFF NOHC 1 1518 22 FLASHING BEACON BOOM MACHINE SHOWN IN N CHO NOHC STOWED POSITION WITH g p s s S 112121 P THE POWER OFF 227 5 i 5 5 BOOMDOWN 3 B8 8 8 1 2 3 PA10 PA1 PA2 DB PA3 4 5 CD10 CD9 CD11 DE DF DG DH DJ DK PA7 PA9 4 gt 1 Y Pablas lt 1 1189
12. R14 BN65 BN67 R22B WS Boom PLATFORM 58K OHM 8220 FUNCTION EXTEND RETRACT LEVEL SPEED 4 5 6K OHM 10K OHM LED RD EMERGENCY LIMIT SWITCH HARNESS _OR STOP TERMINAL 3 98 1 8 wn RD pOWERCABLEPIN 1 po 4 _ OR BK BN97 BN63 8 MODELS ENGINE JIB BOOM PRIMARY BOOM PLATFORM N WITH START UP DOWN UP DOWN ROTATE OPTION PN ENGINE BN62 FUNCTION ENABLE TURNTABLE AND CELUM 1 lo RIGHT 1 1 8 gt BL CR 9 TERMINAL 30 AND 2 6 9 f BN64 BN66 BD ENGINE
13. Section 5 Schematics srctrrr r ria Ground Control Box Wiring Diagram AS CE from serialnumber TZ5010 145to TZ5011 131 O 86 9 86 WH MANIFOLD HARNESS gw pk 87 87A anne TERMINAL BASE 87 ED e amp CHI 22 DRIVE MANIFOLD HARNESS PIN 8 2 1 0H MANIFOLD HARNESS GN 85 OUTRIGGERS PLATFORM 85 LIFTCUTOUT BK P3 K HARNESS mp 1885 AUTO 8
14. 40 86 9 86 WH MANIFOLD HARNESS GN BK 9 87A TERMINAL BASE 87A TO o oos PIN t SICH SNBK DRIVE MANIFOLD HARNESS PIN 8 cHmA MANIFOLD HARNESS GN 85 FATE PLATFORM 85 tem BK PIN K TB35 HARNESS BD AUTO 86 TERMINAL PA O 1 LEVEL MANIFOLD HARNESS wH 87 87A HHH SAKE 87 87 RD PIN P 1 30 MANIFOLD HARNESS WH BK 7 CR70 Q Q 39 Q Q 85 Terg PIN PLATFORM ROTATE 2 2 35 2 U16B 35 9 86 35 4 7 WH MANIFOLD HARNESS gi 87 87A Q Q C Q y ivoc 87 87A PIN S BUBK 505 35 0 rt MANIFOLD HARNESS _ CREB C e C 85 CR28 PIN R O 33 POWER SUPPLY Gs Cu Q 32 12 MANIFOLD HARNESS RD 87 ADEK og 2 32 2 87 Tee 30 31 30 CR77 MANIFOLD m a 67 e 2 5 i 50 2 1 3 ds DOWN ERABLE
15. R14 BN65 BN67 R22B PLATFORM 5 6K OHM R22C FUNCTION EXTEND RETRACT LEVEL 5 6K OHM 10K OH 10K OHM 2 LED RD EMERGENCY LIMIT SWITCH HARNESS s STOP TERMINAL 3 1 8 RD POWER CABLE PIN 1 BK WH P2 4 1 lt ORBK 196 BN2 BN97 BN63 BN98 MODELS JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UP DOWN ROTATE OPTION BN62 FUNCTION ENABLE TURNTABLE AND Pues Q RIGHT I 7 1 1_ BL CR 9 TERMINAL 30 AND 2 6 9 f BN3 G7 BN64 BN66 tpg ENGINE CHOKE BATTERY CHARGE SECONDARY BOOM TURNTABLE J INDICATOR UP DOWN ROTATE MX RD TB1 BN61 O D FUNCTION ENABLE BOOM DOWN BOOM RETRACT
16. gt ZENER DIODE 5 1V DC R14 BN65 BN67 R22B w BOOM BOOM PLATFORM 5 6K OHM 22 EXTEND RETRACT LEVEL SPEED 5 6K OHM 10K OHM 14 2 LED 1 O EMERGENCY LIMIT SWITCH HARNESS _ STOP TERMINAL 3 b PA4 WH BD POWER CABLE PIN 1 pg d TREE im 12 ORE DE DT MORE MET BN97 BN63 BN98 MODELS ENGINE UP DOWN WITH START 254 ENGINE BN62 O C OO FUNCTION ENABLE BOOM UP EXTEND TURNTABLE AND D RIGHT I PA1 z BL CR 9 TERMINAL 30 AND 6 SN A gt d G7 BN64 BN66 gt RD SECONDARY TURNTABLE M UP DOWN ROTATE S Bp 1 BN61 2 FUNCTION ENABLE BOOM DOWN
17. J WHT GRN 1 BLK BLK BLK RED From Page 1 of 3 EU WHT RED ORG RED RED WHT BLU GRN BLK 5 WHT BLK BLU BLK From Page 2 of 3 ATE ORG BLK GRN GRNMHT m 2 2 E m pr m amp S sx 5 g 2 x 2 m x 2 m o a B 2 8 a 8 88 5 5 5 3 1 PA2 PA3 PA4 PAQ PA6 PBI PB2 PB3 __ PB5 PB6 PB7 zb Ui j EMERGENCY G7 STOP 2 yle BNe1 2 DOWN _ UP FUNCTION FUNCTION x ENABLE ENABLE eo 5 4 ELI m BN66 ERES BN67 m VE ange X 2 3002 86 PLATFORM d ROTATE TBS s 166 8 8783 al 87 jz 85 C BN2 START CHOKE 4 sec 7 BN64V BN63 BN65 BN97 OPTION up ME p PRIMARY BOOM JIB a 54V BOOM BOOM EXTEND BOOM UP D
18. 40 86 9 86 WH TB34A MANIFOLD HARNESS gw pk 87 87 Gane TERMINAL BASE 87 PD 5 PN t SICH TB22 DRIVE MANIFOLD HARNESS PIN 8 tsar 9 MANIFOLD HARNESS GN 85 OUTRIGGERS PLATFORM 85 LIFTCUTOUT BK PIN K HARNESS c TB35 Hy TERMINAL PA MANIFOLD HARNESS wH 87 87A HEHEISSHHEH PIN WHIBK lee 30 MANIFOLD HARNESS 4 CR70 Q PIN 0 O 3 Q es OO o 0 D MANIFOLD HARNESS PIN s 8 QUA BUBK C C 35 C C svoe 87 U MANIFOLD HARNESS _ CR68 Q Q 34 Q Q 85 P CR28 PNR 85 SECONDARY BOOM C B 33 AP POWER SUPPLY 34 DIODE E 86 C O 3 3V DC 86 MANIFOLD HARNESS mp 87 87A OB 87 WH PIN U gt TB26 H gt lt 5 RD BK CR67 MANIFOLD HARNESS 85 Q 85 DOWN ENABLE 44 RD O 5 E 5 lt BL TB15 MANIFOLDHARNESS pk 87 BKMH
19. 9 TERMINAL BASE 9 mo TEMA MANIFOLD HARNESS gw pk 87 87 ik 87 0 Bus PIN L TB22 DRIVE MANIFOLD HARNESS PIN 8 roaa B 30 CR72 30 CR78A MANIFOLD HARNESS GN _ PIN K 85 OUTRIGGERS PLATFORM 85 e FTCUT OUT 635 HARNESS RDL AUTO TERMINAL PA 86 LEVEL 8 88 H H MANIFOLD HARNESS 87 SHH 4 7 BD 7617 WH BK 20 70 a 35 Q gt gt WH MANIFOLD HARNESS NN So O 35 5 O 85 U16B 0 0 rz C4 WH MANIFOLD HARNESS gi e Q Q 55 C2 Q s PIN S BUBK 1625 cl iJ 35 Q DU orgia MANIFOLD HARNESS _BLBK CR68 Q Q 3 e C 85 CR28 PIN R SECONDARY BOOM 33 C4A L POWER SUPPLY T 34A S MANIFOLD HARNESS RD 87 ADEK ng 5 5 5 87 7 w 2 cRez OQ Q 31 6 2 77 MANIFOLD HARNESS 85 C 57 C 85 DOWN ENABLE Q 2 Ga 86 RD 86 BL MANIFOLD HARNESS gk 87A s
20. BKRD CR15 TERMINAL 86 BD CR1 TERMINAL 86 TURNTABLE HARNESS eee EM PIN E MODELS POWER CABLE PIN 1 WITH RD TB3 BD CR6 TERMINAL 30 CR15 TERMINAL 30 RD 1 5 RD Ho G TURNTABLE HARNESS BN68 BN6O ENGINE FUNCTION ENABLE WH TB10 START 7 E G RIGHT AND OUTRIGGER RETRACT 1 N KEY SWITCH D OR 7 59 1 4 FUNCTION ENABLE BOOM DOWN 90 14 r AND OUTRIGGER LED EXTEND WH TB9 dL AD TB17 WH TB18 BN58 BN56 PLATFORM BOOM LEVEL BN49 UP DOWN 1 AUTO LEVEL EXTEND RETRACT Go gt 35 ff Ko 0 0 CG BL WH BNE TB23 BL WH fe m LEFT FRONT OUTRIGGER 5 7 O BN54 BNe3 L12 BN50 PRIMARY PLATFORM LFLED LEFT REAR OUTRIGGER BOOM ROTATE
21. M L K G F E D C B A PLATFORM CONTROL BOX PLATFORM CONTROL BOX 1 PLATFORM E STOP POWER LOAD SENSE POWER LS19A TB3 LS19 PLATFORM GROUND DRIVE CONTROL BOX DOWN UP COE IV ENABLE ENABLE 9 AUTOLEVEL MODULE 2 DRIVE E STOP POWER 55 H 53 3 3 8 LL EFFECT WITH ELECTRONIC DAMPING 98838 9 lt i 583 3 8 2 CR55 cr71 2222552 m 6 9 gt a 9 4449 66 PLATEORM GROUND a Oe IR EAT OORT OOM E z URN y y EA z 2 7 AGE B al S 5 x 3 222 8 8 8 8 382 2 i GROUND CONTROL BOX PRY DO D AURA E ay GROUND CONTROL BOX TB3 e BN59 BN60 1 DOWN ee 7 sTB9 m 4 u 2 BN60 BN50 BN51 ENABLE P ENABLE ENABLE Y 6 TB5 lt 46 1813 BN49 2 CR65A T AUTOLEVEL e TB23 TB24 e 1KOHM ej 15 e TB14 i 5 7 18 u 5 lt
22. BD CR1 TERMINAL 86 TURNTABLE HARNESS 4 eo PIN E MODELS POWER CABLE PIN 1 WITH RD TB3 ENGINE CR6 TERMINAL 30 OPTION 7 CR15 TERMINAL 30 P1 EMERGENCY STOP G 5 5 RD TURNTABLE HARNESS FUNCTION ENABLE TB10 START BG L p RIGHT AND OUTRIGGER RETRACT mE KS1 KEY SWITCH d BN59 CB1 CB2 FUNCTION ENABLE 1 90 15 15 DOWN CHOKE Q BOOM RETRACT ROTATE LEFT 2 OUTRIGGER WH 1 AD TB17 WH TB18 58 BN56 PLATFORM BN49 LEVEL tr 1 AUTO LEVEL EXTEND RETRACT UP DOWN 5 BK TB35 BL WH p lt ka TB23 gt E LEFT FRONT OUTRIGGER i 5 3 L12 00 BN50 PRIMARY O LF LED lt LEFT REAR OUTRIGGER BOOM ROTATE Q UP DOWN OPTION O I I I i I BN36 S S 1 JIB m Sce BOOM UP DOWN GNWH BN51
23. L K J PLATFORM CONTROL BOX PLATFORM CONTROL BOX 1 PLATFORM E STOP POWER LOAD SENSE POWER LS19A TB3 LS19 PLATFORM GROUND DOWN UP JANIE ENABLE ENABLE AUTOLEVEL MODULE 2 DRIVE E STOP POWER 509 j gt x 54338 EFFECT WITH ELECTRONIC DAMPING 98838 9 9 2 iem ra R14 4 I 1414 8 55 CR55 16K POT epar z 5 2 2 2 3 5 I P S lt P M 8220 DRIVE CONTROL BOX 8 49998588 IU 1 T a s PLATFORM GROUND E 9 z X voz 5 9 9 BR WR RY 2 2 ABE E al e amp x 3 333 g g a 8 i 2 u GROUND CONTROL BOX DO PS DN PL DG PN 9 8 8 5 N GROUND CONTROL BOX TB3 BN59 60 1 DOWN UP ENABLE ENABLE CR65A i 9 t t t i 4 BN60 BN52 BN53 BN50 BN51 1 UP LF O R O R LR O R RR O R He TB8 11 ENABLE 7A ENABLE 74 ENABLE cnz7 L e d TB13 BN49 1 e Le 4 9 CR65A R22 TB21
24. TERMINAL BASE ap BSA 87 87A 1 BN55 DRIVE MANIFOLD HARNESS PIN 8 5 Pi PLATFORM 85 LIFT CUT OUT BK TB35 HARNESS BD 28 TERMINAL 6 LEVEL HHOH M A RD gi 9 Q 35 O P WH H 35 2 U16B 5 35 5 C4 35 O ZENER mE 0 _ 95 920 gia Q 0 CRe8 33 85 POWER SUPPLY lt LI 2 6 86 WH gio 5 b 32 e h e 87 gt TB8 2 D T 2 85 CNTT 2 29 3 28 S A BL TURNTABLE HARNESS QE COO 27 1 wn 25 86 Q Q 0 0 em 5 cresa T C 85 CUT OUT WH O C O WH BK Q Q 079 E e I 19 O O 4 87 87 2 2 B T 85 Bac Q C 0 0 2 3 12 C 87 87A RD Ces 5 47 CR64 lt n b 85 FAULT GROUND O 2 2 Q a a 12 Q 2 DC 1 86 WH TB4A Bes In P e kau i 7 5 30 CR75 PIN 7755 lt T3 85 LEVEL SENSOR AS c go 6 Qo Hs o Q OQ Q O Q NOTE DIODES ARE 2 AMP H H UNLESS OTHERWISE MARKED OQ Q HU O O I Part 84577
25. 0 TERMINAL BASE 9 mo TEMA MANIFOLD HARNESS 87 87 87 3 PD 55 PIN pa L RD gu 36 CR72 DRIVE MANIFOLD HARNESS PIN 8 CR78A JN Io 85 OUTRIGGERS PLATFORM 85 HFTCUFOUT HARNESS RD AUTO TERMINAL PA 8 89 LEVEL MANIFOLD HARNESS wH 87 WEEK pH S5 87 CR70 35 18 po 85 PLATFORM ROTATE H 35 2 2 z U16B L 35 WH MANIFOLD HARNESS e Q 35 Q Q b P3 S BUBK 505 2 0 35 Q ae 30 i MANIFOLD HARNESS BUBK 85 CREB com Q Q ty Q gt 85 CR28 PIN P3 R pi 33 POWER SUPPLY C 34A DIODE 86 M 3 8V DC 86 WH MANIFOLD HARNESS RD 87A TE 32 JEL 87 WH P3 U p 32 3 Bg CR67 O O gt O CR77 MANIFOLD HARNESS RUBK 85 PRIMARY BOON 3 Cj 1130 e 85 DOWN ENABLE 4 B Q Q Q 14 TB42 P 28 5 gt B TB15 MANIFOLD HARNESS 67 87A C CN 5 A 87 4 BL TURNTABLE MANIFOLD HARNESS BKWH 85 2 CR69 b 27 CR65B PIN H PIN P3 V BOOM EXTEND C
26. 3 s i 2 e g fs e g E E 8 2 E 9 8 8 8 58 8 JUPE PA a DE DM LPP IPB l DL XH alps al pk po AM 2 3 PA2 PA1 5 PA4 PA9 PA3 PA6 1 12 5 7 PB4 PB3 PB2 PB6 P3 3 EMERGENCY EMERGENCY G7 H1 STOP STOP BATTERY N ALARM CHARGE AN N 2 3 4 5 6 N p INDICATOR MEE 5 14 TTB1 JOYSTICK D RIVE 1 CONTROLLER P LATFORM BN2 fee W oss see ce ce n ra CONTROL CONTROL BN61 BN62 8 BOX BOX FUNCTION ENABLE FUNCTION ENABLE us DOWN UP Soom RETRACT BOOMEXTEND 4 TURNTABLE AND TURNTABLE AND ROTATE CHOKE PLATFORM ROTATE PLATFORM ROTATE LEFT RIGHT SAP 8228 66 CR78B BN67 BN98 MODELS TURNTABLE LIFTCUT OUT PLATFORM PLATFORM WITH 5 6K OHM ROTATE LEVEL ROTATE TBS 30 2 485 hes 4 pea V 8 87 Jer 85 5 R14 RESISTOR m BN97 BN97 BN64 BN63 4 BN65 22 JIB JIB SECONDAR
27. _ BKRD CR15 TERMINAL 86 BD CR1 TERMINAL 86 RD TURNTABLE HARNESS a if 5 MODELS POWER CABLE PIN 1 WITH ENGINE CR6 TERMINAL 30 7 CR15 TERMINAL 30 4 1 EMERGENCY STOP RD 175 lt P ____ TURNTABLE HARNESS 9 Oj BN60 PINB ENGINE FUNCTION ENABLE WH TB10 START E G x RIGHT AND OUTRIGGER RETRACT V 1 Z KEY SWITCH D OR 7 59 X o PA4 c CB2 FUNCTION ENABLE 15 BOOM DOWN 90 CHOKE ROTATE LEFT 14 a OUTRIGGER LED EXTEND WH Ee 17 WH TB18 BN58 N 5 PLATFORM BOOM LEVEL BN49 EXTEND RETRACT UP DOWN G 1 AUTO LEVEL 2 TB35 BUWH TB23 E IIS 11 BN52 x F gt LEFT FRONT OUTRIGGER O BN54 BNe3 L12 BN50 PRIMARY PLATFORM OR Prien LEFT REAR OUTRIGGER BOOM ROTATE UP DOWN 0 4 114 L N LRLED I j I BN36 i JIB N UA BOOM UP DOWN m
28. M L K J 1 WHT BLK BLU BLK RED BLK To Page 3 of 3 BLKWHT 5 ORG BLK E m GRN T 5 5 D 2 D o 2 E EH m GROUND CONTROL BOX PBI PB PB3 2 2 2 zuo c o 24 42 6 ics CR78A BN57 BN93 DRIVE CONTROL BOX OPTION E TURNTABLE 3 PLATFORM b 3079 86 ROTATE ROTATE 8193 OPTION 1 1 JG5 TB31 4 315 s cM BN96 BN95 BN96 JOYSTICK 3 Y S TB33 DOWN UP AUTO E EMERGENCY ENABLE ENABLE CONTROLLE t STOP 00 TTT ss Y BN55 BN54 BN56 BN36 0 Sm A Bou i UPIDOWN UP DOWN POENDRETRACT UP DOWN Y TB25 5 TB27 9 29 l 4 1832 T Y T TB28 TB12 1828 TB22 zi CR72 CR70 CR68 CR67 CR69 DE DF DD DK 06 DH DJ DN DM DC DP DB DL Ber Bons Became SI iS 0 95 4H 86 02 3 2 3 a 85 fc E 288 B 3 8 99 29 Es 9 Bs 5 gA 85 lt 87 7 Jos 87A 87 lt E s va gb 5 Y 5 gy 17 m 5 5 m PE Be 2 2 8 2
29. A B C D E F G H L 4 1519 1 34 V PLATFORM CONTROL BOX PLATFORM E STOP POWER P2 LOAD SENSE POWER t 5 LOAD SENSE POWER BN3 BN2 PLATFORM 4 LS19A t 4 START Hi Y 7 CHOKE CONTROLS FAULT LED Ld 9 PLATFORM GROUND N N 2 v v v v z x 21 2 2 2 4 DRIVE CONTROLS EA b ENGINE OPTION gt ele DRIVE E STOP POWER lt 9 m HORN OPTION amp 1618 a 4 I 8 2 5 3 3 E 1518 gt gt 8105 202 DE QP Ae y GROUND CONTROL BOX TB3 e e e TB3 CB2 ier e iau P KS TB2 TB RD RD H5 x BN90 BN68 FAULT i EE ele Toro ACHOKE START ALARM E 15 L4 GROUND ge is y 2 CONTROLS G7 1 112 113 114 115 4 d 76 CR15 9168 3 15 T7 6 LOAD CR75 CR75 9 0 GCON GRO 4 N GROUND 2 ki 18 Ki 9 m 9 Mi 4 P 2 OUTRIGGER m Rg a 2T 1 1 1 1 D 1 1 1 1 x 6 w Rs e
30. Section 5 Schematics M L J 1 PLATFORM POWER i BN61 BN62 DOWN DOWN ENABLE ENABLE PLATFORM GROUND 7l TB2 UP e m AUTOLEVEL MODULE B3 2 DRIVE E STOP POWER 1159 1 3 f 59335 EFFECT WITH ELECTRONIC DAMPING 8228 44 5 6K 928338 8 cre 5o x m F lt gt 9 R14 4 Tot f eg ee 28825229225 R22C e 4 Po fo lt 5 6K o o as m peo gt o pee gt e Sivi d PLATFORM GROUND 5 5 2 eee u 7 gt TU m o gt 31355 RBE Po 2 i 3 882 3 3 3 3 2 9 DR DK DODA DH DM DLY DG DR E 3 GROUND CONTROL BOX TB3 BN59 BN60 7 DOWN ENABLE ENABLE CR65A s B9 4 4 ee eas BN60 UP i REO RON 8 1811 ENABLE 6 TB13 BN49 CR65A R2
31. Section 5 Schematics September 2014 Ground Control Box Wiring Diagram AS CE from serial number TZ5004 182to TZ5004 324 _ CR15 TERMINAL 86 BD CR1 TERMINAL 86 VICE POWER CABLE PIN 1 MODELS RD TURNTABLE HARNESS TURNTABLE HARNESS RD PINB j OPTION a CR6 TERMINAL 30 KS1 CR15 TERMINAL 30 5 KEY SWITCH P1 stop X n BN68 CF ane D Q UP EXTEND ROTATE RIGHT AND OUTRIGGER RETRACT V RD 59 CB2 tid FUNCTION ENABLE gt 1 90 15 15 DOWN 5 5 4 EXTEND LED RD 17 WH TB18 58 BN56 PLATFORM BN49 EXTEND RETRACT EN 1 LEVEL BK TB35 7 BL WH TB23 BN52 eo LEFT FRONT OUTRIGGER s cor O BN54 112 bjo BN50 PRIMARY PLATFORM 5 LEFT OUTRIGGER BOOM ROTATE I L14 UP DOWN OPTION t J j LRLED BN36 j
32. MANIFOLD HARNESS 87 87 PIN L 1 i B22 MANIFOLD Bi GN 7 2 5 MANIFOLD HARNESS wH 87 87 PIN P WHIBK MANIFOLD HARNESS WH BK CR70 PIN N PLATFORM ROTATE MANIFOLD HARNESS BL 87 PIN S gt BUBK BL BK MANIFOLD 85 SECONDARY BOOM MANIFOLD HARNESS RD 87 87 5 TB26 MANIFOLD HARNESS _RD BK 85 CR67 PIN T PRIMARY BOOM 44 5 12 MANIFOLD HARNESS 87 87 BK WH PIN W 3 TB27 BKWH R69 MANIFOLD BKWH 77 BOOM EXTEND 86 45 RD 87 87A 8 CR8 85 IGNITION BK 86 MODELS g i BK 87 87A WITH 30 0j OPTION 85 ENGINE START BK RD PA2 2 5 1 BKIRD akan 87 27 RD PD10 P1 CR15 85 24 STARTING AID i 1 86 18 TB15 87 87A WH BK TB16 TURNTABLE HARNESS WH BK a CR86 Qu 85 PIN J SEQUENCING BK TB35 R22 1000 OHM TERMINAL BASE HHS HH Q Q Q Q Q 3 Q Q 2 OQ 34 O Q Q Li 0 Q H QO He QAO CO X 28 Ee ELLAS
33. A B C D E F G H J K L 1 Ej mm PLATFORM E STOP POWER P2 pens PLATFORM 7 CONTROLS 4 FAULT TB9 PLATFORM GROUND v v v B 215 7 2 x 3 3 DRIVE CONTROLS 3 m 5 ele DRIVE E STOP POWER ENTE 9 g g 2 HORN OPTION J 1518 z 2 m z 5 5 iz 2 115184 79 U 3 5 i 3 ES PAL DE Q7 GROUND CONTROL BOX TB3_ z ie TB2 TB4 15AMP Ex PLA RD Hs SN BN90 BN6 FAULT BI RD GRD STAR ALARM a 15 TEMA 4 CR64 GROUND 2 CONTROLS dd CR65A BC G7 4 112 L13 L14 L15 L 4 L_ TB7 5 CR76 CR8 CR15 U16B 3 T as A Pie LOAD QUE 75 7 l i i l i i i GCON GROUND 5 g 79 Ts 215 12 3 E 3T 2 OUTRIGGER m 9 9 2 9 9 bv o 9 E gt 5 x SWITCHES 9 9 gt E E gt 5 a m m m m F6 gt o ODR1 oA 6 5 5 dis i BATTERY 24V 275AMP F
34. A C D E F G H 9 L M LEFT FRONT RIGHT FRONT OUTRIGGER OUTRIGGER 1 CYLINDER CYLINDER EXTENSION SECONDARY BOOM PRIMARY BOOM CYLINDER LIFT CYLINDER LIFT CYLINDER LEFT RIGHT 1 TURNTABLE JIB PLATFORM OPTION RELEASE DRIVE MOTOR DRIVE MOTOR ROTATE BOOM LEVEL O 1 SLAVE G 2 0 037 in CYLINDER El 0 94 Y es Yi e sl x D1 D2 4 o WBESTBAMeERENWeS 12 3 gt 24 9 CU IN REV S Y EARS Y PA RIGHT REAR x mme 3000 8000 psi 8000 psi L i US OUTRIGGER Lii Li Li 207 bar OUTRIGGER 1 LEN 207 l 207 b 69 X X me __ CYLINDER 3000 psi 3000 psi 23 T2s004 218 4 dioe T x h a h x pd pi BE FROM a y ese dx 5 es of gt yes wl di MSS __ 3 vn d poH you R RU E Nn LA 101 0 037 in 0 037 in X T A Jas 0 94 mm L_ B 10 pal s 0 7
35. 2 R14 BN65 BN67 H22B BOOM BOOM PLATFORM 5 6K OHM pleno FUNCTION EXTEND RETRACT LEVEL 1 SPEED L4A 10K OHM MODELS 2 O EMERGENCY STOP i E POWER CABLE BN97 BN63 BN98 MODELS JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UP DOWN ROTATE ENGINE BN62 FUNCTION ENABLE S n DIO PLATFORM ROTATE RIGHT pai BK BL CR87 TERMINAL 86 AND CR 9 TERMINAL 30 AND 6 SN G7 BN64 BN66 RD CR78B TERMINAL 30 AND ENGINE CHOKE BATTERY CHARGE SECONDARY BOOM TURNTABLE CR74 TERMINAL 87 EL INDICATOR _ UP DOWN ROTATE S BN61 FUNCTION ENABLE DOWN D D BOOM RETRACT TURNTABLE AND 5 D LEFT RDWH pag PA2 sumo 8 CR74 TERMINAL 86 u WHIBK cR78B TERMINAL 86 AND POWER CABLE PB POWER CABLE GNWH C887 TERMINAL 30 AND CR 78B TERMINAL 87A PP PB2 _ RDBK ppg aue RD WH D 9 l BL pA RD 87 87 BN66 4 RB TBI CR74 FUNCTION ENABLE O 87 87 30 CR78B 80
36. J WHT GRN 1 BLK BLK BLK RED WH From Page 1 of 3 ORG WHT RED ORG RED REDWHT BLU GRN BLK RED 2 WHT BLK BLU BLK RED BLK From Page 2 013 BLK WHT ORG BLK GRN GRNMHT p B 2 2 2 9 ge 4 s 5 5 9 2 3 S 8 9 2 52 m i a Bg Es 2 7 5 5 A 5 8 1 PA2 PA3 PA4 PAO Pas PAT PAB 2 PB3 __ 5 12 6 PB7 EMERGENCY 67 STOP pi VAY BN61 BN62 447 DOWN UP FUNCTION FUNCTION x 4A CR78B BN67 4 Bl BN66 PLATFORM 1 LED TURNTABLE E LEVEL BN98 C 2 8002 86 f PLATFORM 183 T BE TB2 L 4 gt BN2 BN3 i 87 5 OPTION is PLATFORM ROTATE EE BN64 BN63 BN65 BN97 OPTION ge L 4 ai 5 PRIMARY BOOM JIB K5AV BOOM BOOM EXTEND BOOM UP DOWN UP DOWN UP DOWN 71 CR9 CR87 T be aj 5 SO 256 E E lt 7 9 amp lr 85 Jer 85 3 ZA 87 85 5 m TB9 PLATFORM CONTROL BOX 7 r m h ie Sie
37. ACCES m ES 3 pese fopsio7 bar 10 pl L Sa i T pum eim Lewy ow orba _ A2 __ __ __ __ Pn _______ _ __ LS RL ___ LL eR M 1 Ip E 5 af OCT MANIFOLD TIS XN PX M cmo DU 4 ISI E bar E 41 bar 3 1 T H P p ril X J Pa i XW t X cor Y 4 BB 9 090 in Ai 0 090 I 0 046 e odo ii 0000 1 0 035 vaio in 1 1 ri __ 23 3000 Te s 1 7 2 Timm mm 14mm 80psi 1 lt 1mm ix 80 psi ls 207 T 5 5 Y 5 5 l 14 uk MMMM F j Nt S a 1 L a eee 20710 PPT 7 7 4 i 71 Ej x s HYDRAULIC MODELS WITH 1280 HMS JIB POWER UNIT DRIVE OPTION MANIFOLD MANIFOLD 1 11 SEC2 EL eee uu 1
38. BIRD CR15 TERMINAL 86 ED RD 4 TERMINAL 86 RD MODELS POWER CABLE PIN 1 WITH RD TURNTABLE HARNESS ENGINE PINE BD CR8 TERMINAL 87 Do TERMINAL 30 CR15 TERMINAL 30 KS1 KEY SWITCH P1 emercency stop 55 rS S FUNCTION ENABLE WH TB10 START BOOM UP EXTEND ROTATE RIGHT AND OUTRIGGER RETRACT 9 7 f RD TURNTABLE HARNESS S Z BN59 PINB FUNCTION ENABLE 1 5 1 2 DOWN 90 15 15 ROTATE LEFT SHORE 3 G AND OUTRIGGER 14 u EXTEND LED Wa TB9 17 WH TB18 58 MEC BN56 PLATFORM BN49 EXTEND RETRACT UPDOWN r G 1 AUTO LEVEL ES 2 BK TB35 LIC BL WH BN52 sa rr LEFT FRONT OUTRIGGER 7 BN54 0 12 BNSO PRIMARY PLATFORM LFLED lt LEFT REAR OUTRIGGER 6 ROTATE 5 114 LRLED I j I BN36 JIB RN ANA BOOM UP DOWN GNWH 9 f BN51 gt RIGHT REAR OUTRIGGER G L15
39. Section 5 Schematics EI Electrical Schematic ANSI CSA 2 of 3 from serial number TZ5005 211 to TZ5005 284 M L K J WHT BLK 1 BLU BLK RED BLK BLK WHT To Page 3 of 3 ORG BLK 2 m GRN 5 5 5 5 GRNWHT 5 9 2 GROUND CONTROL BOX A PBS Z po 3 par 2 CR78A BN57 BN93 DRIVE CONTROL BOX OPTION MEN 3075 86 WO OPTION 1 JC5 TB31 4 8 c Teo BN96 BN95 BN96 JOYSTICK 9 33 DOWN UP AUTO ENABLE ENABLE LEVEL CONTROLLER 3 TB34A STOP ry i eme c P3 l Y BN55 BN54 BN56 BN36 RM 0 N UP DOWN UPDOWN UP DOWN Y TB25 e TB26 TB27 TB29 4 5 7 TB28 DU DH D obN DM DO DB DB CR72 CR70 CR68 CR67 CR69 9 mo m c 30 10 86 oc 30 86 Om 30 12 86 m 30
40. BD CR1 TERMINAL 86 RD TURNTABLE HARNESS I X m PINE MODELS RD POWER CABLE PIN 1 WITH RD OPTION CR6 TERMINAL 30 7 CR15 TERMINAL 30 P1 EMERGENCY STOP RD V LPD TURNTABLE HARNESS EIS E 2 1 BNeo BINE Sur 5 ER T 1 V RIGHT AND OUTRIGGER RETRACT KEY SWITCH D OR 7 BN59 V o 5 c CB2 wv FUNCTION ENABLE BN90 15 BOOM DOWN BOOM RETRACT CHOKE ROTATE LEFT d L4 r gt AND OUTRIGGER LED Wa TB9 1 4 RD TB17 WH TB18 BN58
41. A C D F 9 L M PLATFORM CONTROL BOX 1 ele e PLATFORM E STOP POWER Y PLATFORM CONTROLS PLATEORM GROUND r 5 5 5 5 ENGINE OPTION DRIVE CONTROLS 2 HORN ORTON m z a l i 2 1518 p 4 2 z o 2 4 I z 5 5 La T LS18A f gt me 2 3 31 5 8 x NS E ES S GROUND CONTROL BOX TB3 CB2 KS1 B TB2 4 RD e H5 2 4 GRD BN90 FAUL i CR65A eje TB4A 4 1SAMP CHOKE ALARM EA GROUND uot CONTROLS cr ____________ 112 113 114 5 R8 CR15 U16B CR76 8 15 17 LOAD cR75 EE 4 t GCON GROUND RS v y y 3 X 240 lt dT Gd al a EE 9 gt D a CR20 e oe 2 OUTRIGGER OB 996 ae SB 6 m w gs Sis 5 LIMIT ES 2 m D o m ODR1 2 SWITOHES aa aa gars o X I o E o T I X o 9 3 BATTERY 24V 27 d zi 4 BEL n 5 E ALTERNATOR 1 3 gt DEB QD1 i 50 AMP T T a O ski Eg E Has 118 5 m x e o Q 1 5 mpe
42. 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 Ibs 204 7 Nm 6 30 ft Ibs 40 7 Nm 24 184 ft Ibs 249 5 Nm 8 40 ft lbs 54 2 Nm 10 60 ft Ibs 81 3 Nm m Jambnut 2 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 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 Ibs 39 3 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 Ibs 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 type
43. BN36 JIB BOOM UP DOWN A w es 9 0 L15 RR LED pm N R o BN51 RIGHT REAR OUTRIGGER 55 SECONDARY BOOM UP DOWN TURNTABLE BN53 RDWH ROTATE RIGHT FRONT _ RD WH OUTRIGGER L13 RF LED WH BK GN WH BL BK RD BK GN RD BK WH RD pa RD 5 ALARM 2 Jae HOUR METER ES0440D 5 42 TB33 CR15 TERMINAL 86 CR1 TERMINAL 86 TURNTABLE HARNESS PINE POWER CABLE PIN 1 TB3 CR6 TERMINAL 30 CR15 TERMINAL 30 TURNTABLE HARNESS PINB TB10 TB7 CB2 59 on 1 4 9 17 18 TB35 TB23 PB5 7 PB5 9 TB24 TB4A TB20 5 3 21 5 5 11 1 0 25 26 29 CR78A TERMINAL 87A TB27 TB3 PA3 TB32 TB35 Genie TZ 50 Part No 84577 September 201 4
44. 135 Platform Wiring Harness GR x ag WH BL SC 1 RD BK RD BK Eod 2 BL 3 WH WH BK TR 4 GN m 5 OR A I 6 RD Sub 7 BK c 8 WH BK L36 LEFT SIDE MARKER TURN RUN LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT ad 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 84577 TZ 50 5 15 Section 5 Schematics September 2014 m vSCsssssrr rri Ground Control Box Wiring Diagram ANSI CSA to serial number TZ5004 181 _
45. September 2014 2 yo ZENER DIODE 5 1V DC 14 BN65 BN67 R22B w BOOM BOOM PLATFORM 5 6K OHM R22C FUNCTION EXTEND RETRACT LEVEL SPEED LAA 5 6K 10K OHM P2 LED O EMERGENCY LIMIT SWITCH HARNESS STOP TERMINAL 3 b 4 pAg WH HD POWER CABLE PIN 1 2 4 AUR OR BK BN97 BN63 I TES MODELS ENGINE JIB BOOM PRIMARY PLATFORM N WITH START UP DOWN UP DOWN ROTATE OPTION ER ENGINE l BN62 O C FUNCTION ENABLE TURNTABLE AND iege eeu D
46. extension boom cable bridge cable track track support platform level slave cylinder jib boom p Q OQ 0M 6 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 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 cabl
47. M L K J D C B A PLATFORM CONTROL BOX PLATFORM CONTROL BOX 1 PLATFORM E STOP POWER BN61 BN62 DOWN DOWN ENABLE ENABLE TB3 PLATFORM GROUND TB2 Uu DOWN UP E e tel ENABLE ENABLE m AUTOLEVEL MODULE TB3 2 DRIVE E STOP POWER 5 5 3 2 i 543 8 5 EFFECT WITH ELECTRONIC DAMPING ings do Sg 2 5 6K 7 2988 R14 CRo v 2 8 8 8 5 10 cart 18 58 cant oee gt o gt o P228 PLATFORM GROUND E 258 8 9 7 TA 5 5 amp 5 3 i Bs 8 8 2 3 809 GROUND CONTROL BOX 09 DK PAPAL DR DL V M 8008 TB3 e BN59 BN60 7 DOWN UP ENABLE ENABLE CR65A fe BO TB4A E i I me 4 BN60 BN52 BN53 BN50 BN51 LF O R RF OR LR O R RR O R 8 p BU TB11 ENABLE ENABLE ENABLE ENABLE Tad 54 BN9 CR65A GROUND CONTROL BOX AUTOLEVEL 7e TB21 TB23 e 822 ENABLE 1 gt 47817 2 CR65B b i 5 CR61 5 X 41818 4 8 22 7 CR28 e C5 TB32 TB32 CR72 i 96 10 MU Chee 6 TB35 GCON GROUND
48. OR BK BK RD RD RD tf MODELS FD WITH RD IF NE E 1 stop O Gy ae ENABLE START E G G BOOM UP EXTEND ROTATE Nom D RIGHT AND OUTRIGGER RETRACT KS1 KEY SWITCH M BN 1 2 ENABLE BN90 15AMP 15AMP BOOM DOWN ge O G8 pum gt AND OUTRIGGER C EXTEND WH i RD WH BN58 56 PLATFORM BN49 LEVEL AUTO LEVEL UP DOWN 5 K V BLWH CA BN52 LEFT FRONT OUTRIGGER BN54 6 BN93 L12 50 PRIMARY PLATFORM OX LFLED lt LEFT REAR OUTRIGGER iom cie 514 LRLED BN36 1 7 LL JIB mm ovs Hf G BN51 RIGHT REAR OUTRIGGER 115 RRLED BN57 BN WH BN53 RIGHT FRONT RD WH UP DOWN OUTRIGGER L13 RF LED GEH ORMWH RD WH BK GN WH BL BK RD BK GN RD BK WH RD WH RD C H5 ALARM 6 HOUR METER xd d m c cC CMM c LN ESI T 5 24 TB33 CR15 TERMINAL 86 CR1 TERMINAL 86 TURNTABLE HARNESS PINE POWER CABLE PIN 1 TB3 CR6 TERMINAL
49. 3 26 B 14 Perform Engine Maintenance if equipped 3 26 Genie Part No 84577 Genie TZ 50 ix September 2014 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures continued Checklist C Procedures C 1 Grease the Platform Overload Mechanism if equipped 3 27 2 Test the Platform Overload System if equipped 3 27 C 3 Perform Axle Maintenance Electrical and Hydraulic 3 28 C 4 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 29 C 5 Grease the Axle Wheel Bearings Mechanical Axle 3 29 C 6 Adjust the Brakes Mechanical 3 30 Checklist D Procedures D 1 Perform Axle Maintenance Electrical and Hydraulic Axles 3 32 D 2 Check the Boom Wear Pads nennen 3 32 D 3 Replace the Hydraulic Tank Return Filter 3 33 0 4 Check the Turntable Rotation Bearing Bolts 3 34 D 5 Inspect for Turntable Bearing Wear see 3 35 Checklist E Procedures E 1 Testor Replace the Hydraulic Oil 3 36 E 2 Perform Engine Maintenance if equipped 3 37 Genie Genie TZ 50 Part No
50. 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 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 84577 September 2014 Section 5 Schematics er Honda GX160 Engine Wiring Diagram BATTERY STARTER SOLENOID BK WH WH CONTROL BOX WH CIRCUIT S NM RECTIFIER BK RD OIL LEVEL TRANSISTORIZED WH SWITCH IGNITION UNIT 1 SPARK PLUG CHARGING COIL Genie Part No 84577 TZ 50 5 9 Section 5 Schematics September 2014 n X 1 T
51. 35 Q Q 3 Q MANIFOLD HARNESS Q Q Q e PERI BL 87 87A rN Cy 87 87 PIN 5 BUBK c X 35 OQ MANIFOLD HARNESS _ CR68 Q Q 34 Q Q gt CR28 PIN R T INS 85 SECONDARY BOOM 33 caaPt 85 POWER SUPPLY 34 ZENER DIODE MANIFOLD HARNESS 8 Q A 87 PU ADK 1826 O Q 32 OPO WH MANIFOLD HARNESS _RD BK 2 CR67 OQ Q 31 910 CR77 PIN T 85 PRIMARY BOOM 30 es 85 DOWN ENABLE OQ 4 86 RD 86 BL MANIFOLD HARNESS 87A ids Q Q 28 QE PIN w BKWH Q oc 28 Ke ZN ET HARNESS MANIFOLD HARNESS 85 a CR69 Q 3 27 X s 39 CR65B PINH PIN V BOOM EXTEND U6 CUT OUT Wl las 15 86 RD TB2 2 H 24 a 2 86 87 4 e O 23 87 87 WH CRB 788 CO Ode 3 9 CR65A is 85 IGNITION 22 5 85 4 U6 CUT OUT WH 7 O 9 6 BK anes 4 N 3 oio MODELS INI 5 O Q 20 6 2 87 WITH re 4700uF Q Q 19 9 9 1 30 CR1 18 e a FAULT ENGINE START 85 BKRD OQ Q 17 920 16 7 BK RD poo 2 H 2 2 WH 87 87A 87 87A pB10 BRD AD 14 RD pas 3 15 OO 30 CR64 85 STARTING AID E
52. TB3 1 1 M 7 I Y BN59 BN60 FUNCTION ENABLE GROUND Hund GROUND js BOOM RETRACT ROTATE RIGHT ENGINE CHOKE G ROTATE LEFT AND OUTRIGGER CONTROL SIAHT gt AND OUTRIGGER RETRACT CONTROL _ 1 Y A Cee eee caw BOX BOX 4 ALARM LED S 411819 4 l 3 6 45 6A 6A r E e CR64 I BN52 14 i 1 BNSO 3 2 Tet LEFT RIGHT LEFT RIGHT 5 MODELS RES fe This l FRONT l l REAR REAR 8 5 WITH Y ourniGERn OUTRIGGER SIS ENGINE Zer PEST EI ere dis A Hu ayl KS1 DOWN R22 BN49 ay 5 9 an s 30 86 1000 Auto LeveL SWITCH 4 17 112 L13 L14 115 eM fs e SE a RFLED RR LED 5 TB32 CR65A 4 eS CUTOUT TEE 222 CR28 POWER SUPPLY 22 P1 E EMERGENCY 4 2 2 les STOP 5 30 86 30 86 30 86 30 86 30 45 86 30 46 86 30 42 86 8 30 86 47 48 p U16A 5 1 i ps i TIME DELAY Lia n 9 0 TO i0 SECONDS TB20 24 4 21 87A Jer 85 87A 87 85 87 85 U1
53. TURNTABLE AND PLATFORM Pp ax LEFT RD RD WH TBI POWER CABLE PIN 2 PP WH BK rgo GNWH_ tpg CR 78B TERMINAL 87A 80 M bg BL BK PB2 e OU COM caves BN64 RD 85 LIFT CUT OUT 3 u m 9 8 7 6 5 4 2 Tp oa NS JIB HARNESS PIN TB6 HARNESS 85 a 5 S gt O O O OJO OO O19 OJOO QOJ Q OO 4 86 ig See k 87 87 GN PB6 JIB HARNESS PIN 5 GN GN BN97 PA6 30 JIB HARNESS PIN 4 GNBK 85 a UP DOWN G7 5 HARNESS PIN 7 BL 8 GN WH TB8 30 JIB HARNESS PIN 6 BUBK 85 CR87 PLATFORM ROTATE OPTION BK 5 250 Genie Part No 84577 TZ 50 5 47 Section 5 Schematics Platform Control Box Wiring Diagram AS CE from serial number TZ5005 285to TZ5010 144
54. Ao dE ec gt 5 zi SWITCHES 2 2 gt m p F6 zz m m I gt 6 e C I A BATTERY 24V 275 gt v Y Na m nue 1 8 E 50AMP 8 1 8 3 Y 2 0 o A O 2 4 L X e Q7 4 8 3 3 3 Bs iind bm pis 5 8 5 5 57 FB1 5 L gt m 5 m MA REGUATOR o i D im m i 7 5 m 9 S lt 7 1 2 2 BATTERY GROUND 6 gt 55 gt i En 25 40 55 ES0440D 2 329 3 gt 2 Omm Br go of o o E 025 E dE cm U om gt gt 2 S 7 gt 2 m 29 9 8 5 855 5 m 19 6 B E m lt gt 9 5 V 29 8 8 2 m lt 2 er 9 a 5 m ENGINE OPTION i Genie 5 78 TZ 50 Part No 84577 September 2014 Electrical Schematic ANSI CSA 2 of 3 from serial number TZ5010 145 to TZ5011 131
55. 5 40 Ground Control Box Wiring Diagram AS CE from serial number TZ5010 145 to 25011 131 5 42 Ground Control Box Wiring Diagram AS CE from serial number 75011 132 5 44 Platform Control Box Wiring Diagram AS CE to serial number TZ5004 181 5 46 Platform Control Box Wiring Diagram AS CE from serial number TZ5004 182 to 25005 284 5 47 Platform Control Box Wiring Diagram AS CE from serial number TZ5005 285 to TZ5010 144 5 48 Platform Control Box Wiring Diagram AS CE from serial number TZ5010 145 to TZ5011 131 5 49 Platform Control Box Wiring Diagram AS CE from serial number 75011 13 5 50 Drive Control Box Wiring Diagram AS CE to serial number TZ5004 284 sse 5 51 Genie Part No 84577 Genie TZ 50 XV September 2014 TABLE OF CONTENTS Section 5 Schematics continued Electrical Schematics ANSI CSA Electrical Schematic ANSI CSA to serial number TZ5004 181 5 54 Electrical Schematic ANSI CSA from serial number TZ5004 182 to 25005 210 5 60 Electrical Schematic ANSI CSA from serial number TZ5005 211 to TZ5005 284
56. sss 5 9 Trailer Lighting Wiring Diagram ANSI CSA 5 10 Trailer Lighting Wiring Diagram Mechanical Axle CE to SN TZ5012 215 eati rere ica i PRI RR S 5 11 Trailer Lighting Wiring Diagram Mechanical Axle CE from SN 75012 216 5 12 Trailer Lighting Wiring Diagram Electric Axle AUS to SN TZ5012 252 a u u una eet 5 13 Trailer Lighting Wiring Diagram Electric Axle AUS from SN 25012 253 teen n s nue ere 5 14 Trailer Lighting Wiring Diagram Hydraulic Axle AUS TZ5012 2106 eer D P 5 15 Genie Part No 84577 Genie TZ 50 Xiii September 2014 TABLE OF CONTENTS Section 5 Schematics continued Control Box Wiring Diagrams ANSI CSA Ground Control Box Wiring Diagram ANSI CSA to serial number TZ5004 181 seen 5 16 Ground Control Box Wiring Diagram ANSI CSA from serial number TZ5004 182 to TZ5004 324 5 18 Ground Control Box Wiring Diagram ANSI CSA from serial number TZ5004 325 to TZ5005 284 5 20 Ground Control Box Wiring Diagram ANSI CSA from serial number TZ5005 285 to TZ5010 144 5 22 Ground Control Box Wiring Diagram ANSI CSA from serial number TZ5010 145 to TZ5011 131
57. 9 WH 87 RD gwss E RD _pN58 30 CR78A 85 4 2 LIFT CUT OUT BK TB35 WH 87 WH 30 CR73 85 FUNCTION ENABLE Ca WH 5 7 86 WH 87A 5 1V DC t WH 1816 gt CR28 POWER SUPPLY ZENER DIODE 3 3V DC 6 86 WH 1812 87 WH WH 30 CR77 85 DOWN ENABLE Ox 87 4 BL TURNTABLE 3 HARNESS _ CR65B PINH 85 U6 CUT OUT om 87 WH lus 30 CR65A 85 gt CUT OUT WH TB7 3 86 WHIBK 87 30 CR76 85 LIMIT SWITCH FAULT 2 86 WH 87 87 30 CR64 85 FAULT GROUND N 1 WH 87 87A WH TURNTABLE HARNESS 30 CR75 PIN C 85 LEVEL SENSOR ES TZ50A
58. B E m m 2 2 z 9 m 2 m 9 o DF DA DE DN DM DC DL DB DP DH DJ DG DK DD 1 2 3 PA2 PA1 5 PA4 PA9 1 5 7 4 2 6 2 M 1 2 I uU 3 EMERGENCY EMERGENCY E Gy STOP STOP BATTERY k _ 74 ee 5450 SN INDICATOR FUNCTION ALARM ENABLE oe DRIVE ed E PLATFORM n r CONTROLLER BN2 LEDs l Nee eh CONTROL CONTROL T n BN61 BN62 wA far B OX B OX FUNCTION ENABLE FUNCTION ENABLE BOOM DOWN BOOM UP 4 BN3 BOOM RETRACT BOOM EXTEND queen TURNTABLE AND TURNTABLE AND PLATFORM CHOKE PLATFORM ROTATE PLATFORM RIGHT ROTATE OPTION R22B 66 78 BN98 MODELS TURNTABLE LIFT CUT OUT PLATFORM ITE 5 6K OHM ROTATE e e ROTATE ENGINE 30 5 42 1 J EN Y 8 87A 85 5 WH 14 RESISTOR m 4 0 10K OHM 1 BN97 1 BN64 4 BN63 1 65 JIB SECONDARY PRIMARY BOOM BOOM BOOM BOOM EXTEND UP DOWN UP DOWN UP DOWN ZENER DIODE 5 1V DC i er 6 t 30 86 30 86 30 86 CR9 53 ge 48 87 CR71 JIB BOOM 50 21
59. 1 12 5 4 2 MES ye k w 2 el rr 3 P3 P2 EMERGENCY EMERGENCY G7 E d H1 STOP STOP BATTERY E AR ALARM CHARGE ZEN 2 4 5 6 7 S amp JC5 Shi DRIVE 1 x CONTROL CONTROL 57 po one BOX BOX FUNCTION ENABLE FUNCTION ENABLE 5s pu BOOM DOWN BOOM UP j BN94 BN95 BN3 Soom RETRACT Boomen gs PLATFORM 4 FUNCTIONENABLE ____ 22 4 FUNGTION CHOKE PLATFORM ROTATE PLATFORM ROTATE ROTATE BOOM RETRACT e ROTATE RIGHT LEFT piam ROTATE LEFT AND OUTRIGGER 9A AND OUTRIGGER RETRACT R22B BN66 CR78B BN67 BN9
60. Pu BN59 BN60 FUNCTION ENABLE FUNCTION ENABLE GROUND sys NEL OM her CONES I GROUND s ROTATE LEFT AND OUTRIGGER CONTROL ENGINE CHOKE i pos CONTROL BOX H5 0471 dy i BOX ALARM 10 9 1 es P 2 Y e t x 15 52 14 BN53 I 1 50 BN51 3 Tet LEFT RIGHT LEFT RIGHT Q MODELS 1 41789 fer 25 _ abis FRONT FRONT REAR z 5 WITH Y outriccer outriacer OUTRIGGER d i 2 CR77 e lig 1 GROUND DOWN R22 BN49 __ 9 4 30 86 1000 OHM AUTO LEVEL KEY OPTION 87 87 85 4 S I SWITEH 814 17 112 L13 114 115 A fer m ELED RFLED URLED RRLED 4 Bre 4 CROA me CR28 1 POWER SUPPLY TB22 gt 5 EMERGENCY 4 5 STOP 30 5 488 30 86 304 7 486 48 309 3 30 86 3 30 7 4 U16A Te E COCA 5 E a 0 129 10 SEGONDS 2 1 85 87 85 Ta 0168 85 87 87 85 87 87 85 87 87 85 87 87 85 TB28 ICB1 TIME DELAY CR86 10
61. 5 66 Electrical Schematic ANSI CSA from serial number TZ5005 285 to TZ5010 144 5 72 Electrical Schematic ANSI CSA from serial number TZ5010 145 to 25011 131 5 78 Electrical Schematic ANSI CSA from serial number TZ501 1 132 to TZ5011 310 5 84 Electrical Schematic ANSI CSA from serial number TZ5011 311 5 90 Electrical Schematics AS CE Electrical Schematic AS CE to serial number TZ5004 181 5 96 Electrical Schematic AS CE from serial number TZ5004 182 to TZ5005 210 5 102 Electrical Schematic AS CE from serial number TZ5005 211 to 25005 284 5 108 Electrical Schematic AS CE from serial number TZ5005 285 to TZ5010 144 5 114 Electrical Schematic AS CE from serial number TZ5010 145 to 25011 131 5 120 Electrical Schematic AS CE from serial number TZ5011 132 to 25011 310 5 126 Electrical Schematic AS CE from serial number TZ5011 311 5 132 Hydraulic Schematics Hydraulic Schematic to serial number 25006 510 5 138 Hydraulic Schemat
62. 5 5 5 9 aS o lt lt 28 2 00 2 2 X m az o 8 gt m mm 9 o c 0 20 Su Z 98 5 T ID 3 5 27 2 2D my m m m 2 ad m xm 2 2 2 m 2 m o r E m Oo gt Om gt gt z lt 2 2 2 2 ce g 5 Genie Part No 84577 TZ 50 5 115 September 2014 Section 5 Schematics k aww Electrical Schematic AS CE from serial number TZ5005 285 to TZ5010 144 5 115 5 116 September 2014 Section 5 Schematics Electrical Schematic AS CE 3 of 3 from serial number TZ5005 285 to TZ5010 144 PLATFORM CONTROL BOX 1 TB3 J BN67 BN98 2 ROTATE PLAT PLAT ENABLE LEVEL ROTATE ENABLE ENABLE CR78B ME 1 CRBS 2 BNGS anes BN97 A 1 SECA EXTA JIB e ENABLE ENABLE ENABLE ENABLE E s 2 CR71 CR9 87 7 H o amp PLATFORM GROUND X To D e 3 w g8 B g 998 gee 5 o z A ARA A T z 8 9 8 0 9 o mg ROUND NTROL BOX 2 2 2 s A s x MANI
63. OR BK pw RD gt 2 OR BK DM YL gt 3 OR WH BK gt 4 WH BK WH BK DC WH RD 2 5 BK gt 6 BK 175221 BL BK DP BK DB U24 DRIVE CONTROLS PRINTED CIRCUIT BOARD FROM TZ5005 285 REFER TO THE ELECTRICAL SCHEMATIC FOR YOUR MODEL AND SERIAL NUMBER Genie Part No 84577 TZ 50 5 51 Section 5 Schematics September 2014 r rTsO This page intentionally left blank Genio 5 52 TZ 50 Part No 84577 53 Section 5 Schematics September 2014 Electrical Schematic ANSI CSA to serial number TZ5004 181 Section 5 Schematics September 2014 Electrical Schematic ANSI CSA 1 of 3 to serial number TZ5004 181 B C D E F G H K L M
64. _ 85 JIB UP DOWN 5 86 JIB HARNESS 6 7 BL 87 g GNWH uo 30 JIB HARNESS PIN Pe 6 PUBK 77 65 ROTATE BK 504400 Genie Part No 84577 TZ 50 5 31 Section 5 Schematics sec Platform Control Box Wiring Diagram ANSI CSA from serial number TZ501 1 132 September 2014 CR 78B TERMIN 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 ZENER DIODE 5 1V DC R14 BN65 BN67 R22B
65. BN49 j AUTO LEVEL BN52 Q LEFT FRONT OUTRIGGER L12 LFLED BK BL WH BL WH BN50 LEFT REAR OUTRIGGER K L14 LR LED 2 GN WH L15 RRLED BN51 RIGHT REAR OUTRIGGER GN WH BN53 RIGHT FRONT OUTRIGGER 113 RF LED WH RD WH RD WH OR WH OR WH RD WH BK GN WH BL BK RD BK GN BK WH RD 5 22 P 6 HOUR METER 50440 TB33 CR15 TERMINAL 86 CR1 TERMINAL 86 TURNTABLE HARNESS PINE POWER CABLE PIN 1 TB3 CR6 TERMINAL 30 CR15 TERMINAL 30 TURNTABLE HARNESS PINB TB10 9 17 18 TB35 TB23 CC7 CC9 TB24 TB4A TB20 CC3 TB21 CC5 TB11 TB31 TB30 TB25 TB26 TB29 CR78A TERMINAL 87A TB27 TB3 PA3 TB32 TB35 Part No 84577 September 2014 Section 5 Schematics ssrss n v rs Drk s irs xsmT O so ic rtr Ground Control Box Wiring Diagram ANSI CSA from serialnumber TZ5005 285to TZ5010 144
66. G sam m S Tam a Da x css mimi AB182235 1 2 3 4 _ 5 8s 71 pa gt 9 s 9 m moz gt Let lt do gt mu g MS OF 1519 mx 49 22 joo 5 29 ing lt Ex P2 958 Ea 2 YI9T 5 60 vei Y62 8 d d d LIMIT SWITCH SHOWN Y20 IN UNLOADED POSITION S ld 84577 2 50 5 111 September 2014 Section 5 Schematics kw Electrical Schematic AS CE from serial number TZ5005 211 to TZ5005 284 5 111 ses Section 5 Schematics 2014 2 Electrical Schematic 5 from serial number TZ5005 285 to TZ5010 144 5 113 5 114 Section 5 Schematics September 2014 Electrical Schematic AS CE 1 of 3 from serial number TZ5005 285 to TZ5010 144 A B C D E J K PLATFORM CONTROL BOX 1 5 PLATFORM E STOP P2 BN3 BN2 5 819 SENSE G7 CHOKE START LIMIT SWITCH T 210 2 E RJ i gt z zm e e DRIVE CONTROLS 2 ele DRIVE E STOP
67. 25 RD 2 C RE Q 72 87 87 O ao 30 CR8 55 30 CR65A 85 IGNITION Q 24 22 9 85 U6 CUT OUT WH 7 C N gt 22 t C G gt MODELS 9 4 BNe8 C5 O FI 120 9 5 WHIBK WITH BK 8 O e O e 87 87 30 CR1 Q 18 T E OPTION ENGINE START O O 17 C 85 BKRD py Wie 2 2 1 BK RD 2 H 22 WH 87 5 87 1 BD p 37 14 O RD pas 30 CR15 MS 30 CR64 85 STARTING AID 35 C ru C 85 FAULT GROUND 4 H 12 8 86 BL 1815 a 2 Q 2 DC 86 WH 1 2 2 TURNTABLE HARNESS 97 1 6 es 11 Mes PIN P3 J 30 CR86 2 10 4 3 CH75 PIN C 85 SEQUENCING BK TB35 EX 9 A C 857 LEVEL SENSOR 1 I i Q Hs Q Hl R22 1000 OHM 3 NOTE DIODES ARE 2 AMP T 3 UNLESS OTHERWISE MARKED 2 eso HHOH 04400 Genie Part No 84577 TZ 50 5 25 Section 5 Schematics X rr Ground Control Box Wiring Diagram ANSI CSA from serial number TZ501 1 132
68. Genie 5 132 TZ 50 Part No 84577 September 2014 Section 5 Schematics rOsr Electrical Schematic AS CE 2 of 3 from serial number TZ5011 311 M L K J PLATFORM NTROL BOX 1 PLATFORM E STOP POWER LOAD SENSE POWER BN62 ENABLE 1 519 1519 M PLATFORM GROUND TBAQ DOWN 2 ENABLE ENABLE 65 2 AUTOLEVEL MODULE TB3 2 as a 2 5 HALL EFFECT WITH ELECTRONIC DAMPING m 32858 79 58 3 gt R14 L i 228 55 9 CR55 CR55 10K POT 967 y 5 9 lt gt SS BEC CR87 66666 5 PLATFORM GROUND DRIVE CONTROLBOX 2 9 Pag 5999655 z D 92 8 9 E 9 y 2 y y x 4 AOT 3 GROUND 29 3 3 g 3 9 8 DD DK DGDJDH DB DN DM DL DG DP MOS A ou gt T z zx ROUND CONTROL BOX TB3
69. STOWED POSITION WITH THE POWER OFF m 2 gt m o 2 21 5 5j 3 5 2 2 2 5 2 E 2 3 2 2 E 8 pP PB1 PB2 PB3 12 5 4 7 6 DL DM DN 2 3 1 4 8 1 6 5 wh k gt r S1 0 S9 1 4 LEFT RIGHT AXIS FRONT REAR AXIS AUTO LEVEL 3 LEVEL SENSOR LEVEL SENSOR ____ 1 1 lel h BN58 BN93 E EC 4 57 30 9 488 PLATFORM PLATFORM 1 PN TURNTABLE S LEVEL ROTATE L i UP DOWN r OPTION J E 1 87 Jor 85 E 2 3 1 l4 2 3 11 L S 1 40 4 I CR78A il GROUND urrcuroUT r I eee 4 4 4 1 CONTROL CR66 1 TB34A e LEVEL SENSOR RELAY l BOX t 55 BN54 BN56 BN36 4 CR61 SECONDARY PRIMARY BOOM JIB BOOM f 24 AUTO LEVEL UP DOWN UP DOWN UP DOWN al SYSTEM RELAY 25 26 27 TB29 __87 185 5 TB32 30 86 Y Y RD ME RD F TB28 2 YL GN 1 87 87 85 30 86 30 86 30 86 30 86 30 86 788 7848 788 x 2254 274 271 14 5
70. aeu HYDRAULIC TANK MODELS WITHOUT HSTZ50 G PLATFORM ROTATE MODELS WITH PLATFORM ROTATE MODELS WITHOUT DRIVE OPTION Genie Part No 84577 TZ 50 5 139 September 2014 Section 5 Schematics nwu voI f Hydraulic Schematic from serial number TZ5006 511 5 139 5 140 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 36436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 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
71. e z f f f 18 POR gen I BN52 BN53 BNSO BN51 gt A 85 CR7 Tr Por 4 o OUTRIGGER ourRIGGER OUTRIGGER OUTRIGGER CR64 heH 1K OHM BN90 PE 7 l ull x KS1 3 LEUTE LN REI 300286 5 OE 17 112 113 1 1 114 115 d LF LED RF LED LR LED RRLED D ZI Z TBI m ITB32 lt 87 85 al Bra 95 g 7 168 2 S CR65A B16 t 5 TB22 or Sr tr B S Borgy56 30 307786 30 U16A 1 pae 3 588 9 Maal jal m 91 o s 95 Ok 7 Oje E 0 110 SEC P1 a f gJ IN 2 mg E E O TIME DELAY TB20 21 TB24 f S 5 e m 7A 87 5 8 7 85 87 85 87 87 Bo 7 7 85 Bs ls CR8 CR15 F CR76 L 4 CR28 cet gt 5 0 CR65B CR86 2 1 1 mE i 7 7 T CAPACITOR 4700 5 T T T 15 AMP RESISTOR 5 OHM 33V 51 CD 006 6 BT Ef DJ PB8 PBS 077 PBT2T e FT H T C x 0 04 8 ccto i m BLK RED 6 A 2 9 B IB
72. sess a OD 28 27 OOO 25 24 23 N D gt 1 22 2 2 c5 4700uF 19 Q Q O Ox 0 5 246 O Une C xu 9 His 00 o o o D Fan O 23 aus 34000001 x O9 mdi N N Section 5 Schematics n a O aw X L rrrr r i Ground Control Box Wiring Diagram to serial number TZ5004 181 AS CE woes 24000222502 ees Part No 84577 Genie TZ 50
73. 5 24 Ground Control Box Wiring Diagram ANSI CSA from serial number 75011 13 5 26 Platform Control Box Wiring Diagram ANSI CSA to serial number TZ5004 181 5 28 Platform Control Box Wiring Diagram ANSI CSA from serial number TZ5004 182 to 25005 284 5 29 Platform Control Box Wiring Diagram ANSI CSA from serial number TZ5005 285 to TZ5010 144 5 30 Platform Control Box Wiring Diagram ANSI CSA from serial number TZ5010 145 to 25011 131 5 31 Platform Control Box Wiring Diagram ANSI CSA from serial number TZ5011 132 2 5 32 Drive Control Box Wiring Diagram ANSI CSA to serial number TZ5004 284 5 33 Genie xiv Genie TZ 50 Part No 84577 September 2014 Section 5 TABLE OF CONTENTS Schematics continued Control Box Wiring Diagrams AS CE Ground Control Box Wiring Diagram AS CE to serial number TZ5004 181 5 34 Ground Control Wiring Diagram AS CE from serial number TZ5004 182 to TZ5004 324 5 36 Ground Control Box Wiring Diagram AS CE from serial number TZ5004 325 to 25005 284 5 38 Ground Control Box Wiring Diagram AS CE from serial number TZ5005 285 to TZ5010 144
74. Gi Ai 2 Bi B2 PE PR SD PU PD LS RL RR JU JD PLU PLD PRL PRR 168 715 T Ms sce G DRIVE mig 02 708 MANIFOLD i941 BELLES 69 veg P __ 800 psi ene oy OE se 59 3000 psi i 8 41 bar 4 x d 11 52 TlY21 TIY61 1 135 psi 9 3 bar N S OF ALE HEX 0 Y40 I IX Y39 Y26 Y25 Y24 Y23 1 hive os nm T 7 ON Coossi 2 5 I 7 i eo 3000 psit 80 psi 046m 0401 0 89 mm Timm lt 80 psi 207 bar 5 5 2mm 5 5 5 ar 1 L HE b GEM AERE aru m RI m bm i i i L 69 5 TOP I c C O eee HYDRAULIC JIB POWER UNIT MANIFOLD MANIFOLD MODELS WITH 2 8 9pm 10 6 L min 4 M D a ee L a ae a SS ee _ MODELS WITHOUT HSTZ50DC F 47 FROM TZ5005 274 l 5508 a SEG T HYDRAULIC TANK PLATFORM ROTATE MODELS WITH PLATFORM ROTATE gt FROM 25005 430 6
75. RR LED GNWH TB24 BN55 zd TORIA TURNTABLE BN RD WH SECONDARY ROTATE 53 TB20 BOOM RIGHT FRONT RD WH CC3 UP DOWN OUTRIGGER L13 RF LED ORWH _ 21 OR WH ccs M BD CR73 TERMINAL 87 CR78A TERMINAL 30 WH BK TB31 GNWH _ BUBK 25 RDBK GN TB29 BD CR78A TERMINAL 87 BKWH _ wH PA3 RD TB32 5 66 ALARM _ 1 ES TZ50A Genie 5 16 TZ 50 Part No 84577 September 2014 MANIFOLD HARNESS 87 87 PIN L 1 i B22 MANIFOLD Bi GN 7 2 5 MANIFOLD HARNESS wH 87 87 PIN P WHIBK MANIFOLD HARNESS WH BK CR70 PIN N PLATFORM ROTATE MANIFOLD HARNESS BL 87 PIN S gt BUBK BL BK MANIFOLD 85 SECONDARY BOOM MANIFOLD HARNESS RD 87 87 5 TB26 MANIFOLD HARNESS _RD BK 85 CR67 PIN T PRIMARY BOOM 44 5 12 MANIFOLD HARNESS 87 87 BK WH PIN W 3 TB27 BK WH R69 MANIFOLD BKWH 77 BOOM EXTEND 86 45 RD 87 87A 8
76. U16B 35 j a B oo D MANIFOLD HARNESS BL 87 BUBK E 4 35 pew 87 87 WH ceu MANIFOLD HARNESS _BLBK 2 CREB C e 3 e C 85 CR28 PIN R a 33 SUPPLY 34 DIODE 86 132 42 2 3 3V DC 86 gt MANIFOLD HARNESS RD 87 87 ADEK Q e 87 cUm 31 77 MANIFOLD HARNESS n 2 m 37 H 85 DOWN ENABLE 2 29 4 86 12 2 H 28 2 5 8 Bb TB15 MANIFOLD HARNESS 87 BKWH C 6 28 2 A 87 87 F BL TURNTABLE MANIFOLD HARNESS _BK WH 85 CR69 C5 Q Q 27 2 m CR65B PIN H PIN V BOOM EXTEND 4700 E oe SS eS cd 25 45 86 RD TB2 7 2 H 24 O 2 2 86 87 4 Bk O O 23 87 87 WH CRB O 5561722 eae 1 85 IGNITION 5 OHM e FSi 22 FA E 85 CUT OUT WH TB7 t 2 0 Cam MODELS de BK 105 O 50 j y WHIBK WITH 9 O 0 9 0 ier 30 TT 7 85 CRI START H 18 N 85 LIMIT SWITCH FAULT OPTION O 17 BK RD x 86 Q 6 WS 86 WH 4 pugo C TL O O 2 sump 5 7 RD Cy ua O gt 87 Bb 5 15 c C 85 STARTING AID 85 FAULT GROUND
77. get ete e ER rer aee dene eec 4 38 Genie Part No 84577 Genie TZ 50 September 2014 TABLE OF CONTENTS Section 4 Repair continued Hydraulic Tank 9 1 Hydraulic Tank e eem rn eee eee d tb re irae eund dee 4 40 Axle Components 1087 icri tt t ee RN at et a e sa 4 41 Trailer Components 11 1 Hydraulic and Mechanical 4 42 11 2 Parking eee dades 4 42 Outriggers 12 1 Outrigger Components enne 4 43 12 2 Outrigger Cylinder e rcd e mets 4 44 Platform Overload Components 13 1 Platform Overload System 2 444 0000 4 45 5 14 1 Dive MOOT Z Da aa Ree Le ea ede 4 47 14 2 Drive Control 4 48 Genie Xii Genie TZ 50 Part No 84577 September 2014 TABLE OF CONTENTS Section 5 Schematics eio 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 5 6 Abbreviation Legend Hydraulic Schematics 5 7 Hydraulic Symbols Legend 5 8 Honda GX160 Engine Wiring Diagram
78. PE p Dy ENABLE e ENABLE CR65A TB9 TB4A T li 4 4181 BN60 BN52 BN53 BN50 BN51 UP LF O R 2 O R LR O R 7 RR O R 77 ENABLE ENABLE ENABLE ENABLE e 6 TB13 2 20 218 23 24 1 US 16 lt 15 2 Creo 7 CR61 U gt 1818 J CR28 5 e TB22 bs TB32 thea TEZ TB32 CR65B A cnm I T e 70 creat 13 H PER 5 ons 509448 4089 Gs TB35 10 18 87 GROUND i 4 ee 11100 GCON GROUND XU RT RT BTR 2181 BIST 3 S o lt alo 6 2 alc 519889 g 98 L1 BATTERY 24V A A 1188 98 S 9g 925 47 mH 2 5 0 034 OHM _ gt 1 1 nS gt 58 Y50A I 069 5 s 5 v 2 cok 124 12 12 212 8B A 1 1 1 1 Md z 2 B 5 3 2 9 Yso Y11 IRL 17 28 5 da Y39 fy Y Y MOTOR E m 35 36 33 Y34 MIS 2 E lt lt 2 ms 25 7 22 2 P 9 5 524 22088 8882 DS t1 ig BBS 2 ee 5 GCON GROUND UB 6 Di M5 MOTOR 598 232 g HARNESS GROUND PLUG BATTERY GROUND 4 5044 m 5 3 gt 2 c o B 3 S0440G 1955 2 cc m
79. Electrical Schematic ANSI CSA 3 of 3 from serial number TZ5011 132 to TZ5011 310 Section 5 Schematics J PLATFORM CONTROL BOX TB3 J BN67 BN98 ROTATE PLAT PLAT ENABLE LEVEL ROTATE ENABLE ENABLE CR78B 1 CR78B 0 s BN64 BN63 BN65 97 3 SECA PRI A JIB 8 ENABLE 5 1 71 1 9 CR87 3 7 4 5 PLATFORM GROUND ZN INN 7 7 U UU u D 5 79 N N o N o o m 9 8 8 5 988 222 28 amp A AR 7 7 U 5 5 T y o o o o w o GROUND CONTROL BOX v M 2 5 A A JIB MANIFOLD 1 x1 1 yi BN93 BN57 BN58 BOTATE Y20 Y61 Y63 Ead EE ENABLE eg pus TB11 19 62 Cx L L 1 31 Pes 3 SE 5 Ter TB34A CR78A CR78A 9 ENABLE ENABLE ENABLE AME 9 2 2 2 2 2 2 BN55 547 56 BN36 e T TB32 TB25 5 w o TB29 I m 26 27 r m 4 m CR61 T8284 mm zm 940 8 U16A 40870411 42868 12 4CRE7 10 28691 m m gt 2 SIT 4 m 4 DD LOAD x 9 9 GCON GR
80. merce room 2 cem n s 4 1 2 3 1 4 5 6 7 2 3 o 2 2 E g E 7 60 Y62 Y19 JIB PLATFORM PLATFORM BOOM ROTATE LEVEL RETRACT LEFT DOWN Yei 1 Ex vea Y20 JIB PLATFORM PLATFORM BOOM ROTATE LEVEL EXTEND RIGHT UP eg Ex S 8 4 ES TZ50A Part No 84577 TZ 50 5 57 September 2014 Section 5 Schematics ss mrwsrv rssEr Electrical Schematic ANSI CSA to serial number TZ5004 181 58 59 Section 5 Schematics September 2014 R w rrsrn m cr mm HrU Or Vy Electrical Schematic ANSI CSA from serial number TZ5004 182 to TZ5005 210 Section 5 Schematics September 2014 m Iui I Electrical Schematic ANSI CSA 1 of 3 from serial number TZ5004 182 to TZ5005 210 A B G H K L M
81. CM 87 BL TURNTABLE HARNESS MANIFOLD HARNESS _BK WH 85 a CR69 Q H CR65B PIN H PIN V BOOM EXTEND C Q EL 15 86 RD TB2 2 86 Q OL 87 4 ION PES O O 87 87 WH a 80 CR8 30 CR65A 85 IGNITION Q 5 54 85 U6 CUT OUT WH 7 PAN e t MODELS dg 2 4 pN68 3 e 3 WHIBK Coo WITH 95 9 65 6 3 CRI xm S D aff CR76 5 OPTION 85 ENGINE START O O 85 2 H 9 BKRD queo 2 H 2 87 87A 87 87A BK RD RD 377 RD 10 1 3 15 APIS MW T 30 CR64 85 STARTINGAID 6 2 85 FAULT GROUND is 1 r gt 18 86 BL 15 a a NN D 87 97 WH BK 1 87 87 TURNTABLE TURNTABLE HARNESS TB16 1 CX HARNESS PIN J 30 CR86 SA Y T 3 _ 75 PIN C 85 SEQUENCING BK TB35 6 LCS 857 LEVEL SENSOR i Xe CD 1 N R22 t2 XJ 1000 OHM O NOTE DIODES 2 s 2 UNLESS OTHERWISE MARKED 5 Q Q O O ll de T 1 ES TZ50C Genie Part No 84577 TZ 50 5 37 Section 5 Schematics September 2014 _ Ground Control Wiring Diagram 5 from serial number TZ5004 325to TZ5005 284 _ CR15 TERMINAL 86
82. Electrical Schematic AS CE 1 of 3 from serial number TZ5010 145 to TZ5011 131 A B C D E F G H 9 tS19 LOAD SENSE WAY y LIMIT SWITCH PLATEORM CONTROL BOX les PLATFORM E STOP POWER ROAD SENSE POWER LOAD SENSE POWER BN2 PLATFORM 14 f LS19A CHOKE START 2 Y LED 1819 ALARM BR PLATFORM GROUND 2 gt x x 3 x DRIVE CONTROLS a m ENGINE OPTION x ele DRIVE E STOP POWER 2 2 8 m LS18 E 2 8 25 8154 DRIVE CONTROL BOX 1518 3 7 v 7 gt e gt Wa __ DRAP TB3 n A TB3 CB2 P1 KS1 15 u PLAT TB2 TB4 RS 5 90 BN68 FAULT 65 x ED ele GRD CHOKE START ALARM d CRG A 4 15AMP Iz 14 LOAD CR64 sENsE 5 GROUND 2 UD CONTROLS GROUND CONTROL BOX CRESA 4 112 113 114 115 L_e 5 TB7 s CR76 CR8 CR15 CRI U16B 3 T 15 T 7 06 LOAD cms 75 l 1 G
83. Genie 5 60 TZ 50 Part No 84577 September 2014 Section 5 Schematics Electrical Schematic ANSI CSA 2 of 3 from serial number TZ5004 182 to TZ5005 210 D c gt 1 PLATFORM CONTROLS PLATFORM CONTROLS w m X DRIVE CONTROLS DRIVE CONTROLS ww m A m m m u AUTO LEVEL NOTE MACHINE S
84. Genie ES0440G gt FROM TZ505011 311 TZ 50 Section 5 Schematics September 2014 Platform Control Box Wiring Diagram AS CE to serial number TZ5004 181 ZENER DIODE 5 1V DC 4 2 R14 BN65 BN67 H22B BOOM BOOM PLATFORM 5 6K OHM pleno FUNCTION EXTEND RETRACT LEVEL 1 SPEED L4A 10K OHM MODELS 2 O EMERGENCY STOP i E POWER CABLE 4 2 BN97 BN63 BN98 MODELS JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UP DOWN ROTATE ENGINE BN62 FUNCTION ENABLE
85. Genie TZ 50 A Genie Part No 84577 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 84577 Genio Genie TZ 50 SECONDARY BOOM COMPONENTS 5 Remove the pin retaining fasteners securing the primary lift cylinder barrel end pivot pin
86. LIFT CUT OUT BL BN67 86 pre 87 87 JIB HARNESS PIN 28 ORBK 30 JIB HARNESS PIN 2 SEAM 4 eT GN 87 87 GN 6 JIB HARNESS PIN 5 GN __ pug GN BK CR9 JIB HARNESS PIN 4 NPK 5 JIB BOOM UP DOWN BNe2 B BN98 ps 87 87 JIB HARNESS PIN 7 GNWH pp7 30 JIB HARNESS PIN 6 BUBK gs CRB ae TB3 ES TZ50A BK Genie TZ 50 Part No 84577 September 2014 Section 5 Schematics D i Platform Control Box Wiring Diagram ANSI CSA from serial number TZ5004 182to TZ5005 284 zener nione 5 1v pc R14 BN65 BN67 R22B WV Boom BOOM PLATFORM 5 6K OHM 8220 FUNCTION EXTEND RETRACT LEVEL SPEED ay et S 5 6K OHM 10K OHM an mS P2 9 EMERGENCY STOP O c WH RD POWER CABLE PIN 1 ORBK wW O xil 1 BN97 BN63
87. m E 3 2 8 a gsi 929 ger B 4 8 3 GROUND CONTROL BOX 5 9 g g lt GROUND i BN93 CONTROLS BN57 BN58 PLAT 1 1 1 1 1 LEVEL ROTATE ENABLE ENABLE ENABLE 7 Y20 Y61 Y63 TB31 i TB34A SEC PRI EXT JIB CR78A ENABLE ENABLE ENABLE CR78A Y19 Y60 Y62 9 55 54 56 BN36 9 TB32 6 1826 47827 i i 2 2 2 2 2 2 m JIB MANIFOLD LL 5 5 ICR61 U16A CR70 CR68 CR67 CR69 4 Fon a a 33 7 7 7 7 m A 2 LOAD m m 26 6 GROUND 2 4 2 Ta 2 p xl xl xl 70 E ES0440G gt gt U 2 2 9 9 e v m J gt 2 Zz gt gt p lt 5 9 o 1813 1515 e RFO R RROR z Ea ES 2 ms a 1512 1514 r I LF O R LR O R A A 1 m OUTRIGGER LIMIT SWITCHES Y24 Y53 Y22 Y26 gt SR cux z amp 1 2 Y52 Y21 Y25 v2 2 2 2 2 GCON GROUND HARNESS GROUND PLUG 4 q 4 4 1 4 gt gt um o o z 90 gt x 6888 m 4 gt 2 2 6 6 2 2 8 m lt lt m cm gt gt mr Q 2 7 82 Z Z gt lt lt 375m m Z m
88. t t t T PT 51514 31515 E 88 8 He 3 3 6 v gt o A rl A N E 9 2 5 9 L1 E BATTERY 24V 2A 5 5 5 95 8 5 25 47 mH 2 5 0 034 OHM M 2 2 Y40 7 f 9 58 50A 12 12 102 12 g Qa X3 ma 2 d OQ Cj i 2 2 2 1 1 5 8 z gt m 59 Y50 11 gt 9 lt l gt I vas ees pT aa 9 2 42 42 42 42 e mnm mnnm Dd D5 ee lt lt EE mm m ji NHS 2 k k b 605220202255 mg GCON GROUND DVS OD HARNESS GROUND PLUG BATTERY GROUND 228 30 UC o o 50440 5 cc gt 50 70 gt Js 992 lt or lt lt 11 554 o c n 55 d 4 4 9 o o lt lt 98 gt 8 lt 00 2 2 2 m o 9 8 5 T 223 BE 20 DD E D m m m m m m lt 5 23 D m x m 2 2 2 D m B zo b Lom gt lt wx zo gt lt Zaa a ERE 8 vA Genie Part No 84577 TZ 50 5 85 September 2014 Section 5 Schematics 1 Electrical Schematic ANSI CSA from serial number TZ5011 132 to TZ5011 310 86 September 2014
89. 3 10 11 1 2 DB PA3 4 5 DC pp Pas CD10 CD9 DF DG DJ 7 PA9 4 3 4 1782 ABEST Kea 1 pe SELLE 59 60 FUNCTION ENABLE GROUND a CIONES E GROUND BN 68 B N 90 x ROTATE RIGHT ROTATE LEFT AND OUTRIGGER CONTROL ENGINE 5 Z7 SN V C NTROL L Cs l 42220204 BOX H5 res BOX 4 ALARM us Leo 30 6 4 6A 6A a CR64 li BN52 14 i BN50 3 9 TB LEFT RIGHT LEFT RIGHT 8 8 MODELS GUN Sad fon Jor FRONT REAR REAR WITH outriaceR ouTRIGGER ourRiGGER eje 4 0 5 Tes 9 CR77 1 JH DOWN R22 BN49 wW x 9 ts m 30 4 86 1000 AUTO LEVEL MA WY SWITCH 4 K 14 L12 L13 114 115 3 a fer us PT sa LF LED RFLED 945 RR LED x 2 91s CR65A lt 4 Se U6 CUTOUT CR28 TB12 1 POWER SUPPLY 22 a 5 ies EMERGENCY 4 STOP n 30 86 30 86 304 Ga 86 304 gt 86 L L 4 ane dg dg 485 90 47
90. 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 secondary link pivot pin at the mid pivot Crushing hazard The secondary AWARNING link could become unbalance
91. 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 hours 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 84577 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
92. OPTION pum Y 38 Bg 2 2 AS Ad A g gt 112 PAI DB PAS DC DD PA6 cos DF DGDH DJ GROUND CONTROL BOX TB4A 3 182 TB4 T 5 5 T ET gt BN68 BN90 siz FUNCTION ENABLE ENGINE CHOKE ALAR R START LA 61788 12 7810 gt 4 gt 6 r r r r ENGINE KO 18 52 BN50 3 51202 1 cM 4 a amp 87 87 85 OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER oye m AUTO CR64 TBS 1 Z BN9O TA 1 2 7 P P l 26 S m 17 12 quts o F 1 FLED LRD RRLED Er m Cc B32 O BA 87 85 87A 87 85 g T TB7 g I _ 28 U16B 8 CR65A 17816 s 5 _ 5 t U16A 0 6 6 6 2r 909588 0486 o 0458 S JELO 5 5 OK 307 86 WOLI P1 2 fo 9 9 gt e re 9 DELAY ITB20 21 8 23 8 TB24 H 65 Br 87 85 87a 87 85 gl m 87 87 85 5 85 g 87A 87 85 87 87
93. P 4 86 Controlrelay We Resistor ES Z Hm Alarm EX Solenoid valve with diode e e Quick disconnect Genie 6V Battery e 1 5 Power unit or motor Motor controller Battery charger Level sensor TZ 50 Part No 84577 September 2014 Item UOZzr A4c rommoouo 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 Abbreviation Legend
94. i s x s z x s AUTO LEVEL NOTE MACHINE SHOWN IN STOWED POSITION WITH THE POWER OFF zl 2 9 a 2 2 z 5 5 5 2 z 2 z g 7 x 1 2 5 4 PB7 Pee DL DM DN RENE EE PNIS 4 LEFT RIGHT AXIS FRONT REAR AXIS AUTO LEVEL 3 LEVEL SENSOR LEVEL SENSOR BN57 BN58 BN93 30 86 3 9 486 TURNTABLE LEVEL ROTATE ROTATE UP DOWN OPTION 87A 87 85 1 87 85 1 4 CR73 CR78A Y GROUND FUNCTION LIFT CUT OUT CONTROL TB34A BOX BN55 BN54 BN56 BN36 CR61 SECONDARY PRIMARY BOOM JIB BOOM BOOM AUTO LEVEL UP DOWN UP DOWN UP DOWN SYSTEM RELAY TB25 2 7827 H e TB29 5 30 86 I ne 87 85 30 86 30 86 30 86 30 86 30 86 Wes A Seg Ei bend EE d See 87 87 85 87 87 85 87 87 85 87 87 85 87 87 85 6 G6 CR72 CR70 CR68 CR67 CR69 HOUR OUTRIGGER TURNTABLE SECONDARY PRIMARY BOOM METER ROTATE BOOM BOOM EXTEND TB35 E gt 4 TB34 ry F Y K M N P R 5 2 1 3 5 7 8 2 2 5 2 x d p
95. y 85 FAULT GROUND j 4 C 12 C fis 86 2 C LJ 12 C DC 1 86 WH aaa 5 0 11 E d 87 87A TURNTABLE TURNTABLE HARNESS 1816 n C 11 A HARNESS PIN J 30 CH86 1 BS P 30 CH75 PIN C 85 SEQUENCING BK 1635 a AES 9 5 85 LEVEL SENSOR gt Hs TO OQ Ot I D 0 9 ile o Hi Q R22 741 1000 OQ O 3 57 60 NOTE DIODES 2 OQ Q 3 Q UNLESS OTHERWISE MARKED O Q 2 6 9 d 2 OQ O 1 HL pe m 1 5 250 Genie Part No 84577 TZ 50 5 19 Section 5 Schematics September 2014 ssTs Ground Control Box Wiring Diagram ANSI CSA from serial number TZ5004 325to TZ5005 284 _ 133 CR15 TERMINAL 86
96. 1 1 1 1 MG coo z w9 ppo y1 a 5 5 5 E S Ss RS m CONTROLLER oag 2 5 mm o F 7 2 2 2 2 2 272 m mmm zz til 1 Seo CP mm 22 lt lt lt gt gt gt 5 o 225555 id GCON GROUND UB 6 D M5 MOTOR nrg HARNESS GROUND PLUG BATTERY GROUND 5 m 5 2 3 gt 2 c 2 5 ES0440G 419887 2 ado ba 5 5 A EE m lt OI 2 lt lt S 4 S oM o 2 lt lt 0 88 3 902 a2 29 m m m o m 2 gt 2 8 9 9 o n gt 22 DD gt 3 9 2 5 S9 x3 EF 4 m ax 20 59 z gt gt lt lt 2 Genie Part No 84577 TZ 50 5 91 September 2014 Section 5 Schematics 22 2 Electrical Schematic ANSI CSA from serial number TZ5011 311 92 September 2014 Section 5 Schematics Electrical Schematic ANSI CSA 3 of 3 from serial number TZ5011 311
97. 85 PLATFORM ROTATE BK TB9 ES0440G Genie TZ 50 Part No 84577 September 2014 Section 5 Schematics Drive Control Box Wiring Diagram ANSI CSA to serial number TZ5004 284 BK GN DA ab RDBK pe BKWH pr JC5 JOYSTICK BN95 CONTROLLER P3 D FUNCTION ENABLE EMERGENCY OUTRIGGER RETRACT G9 STOP F Go o c dl s o BN94 a a FUNCTION ENABLE 5556 2455 2151518 OUTRIGGER EXTEND A A 25 75651 E pog bog z GNK RD WH gt DD BON ae 1 AUTO LEVEL 2 OR BK jO 3 I OR WH BK 2 4 WH BK Q D WH RD 5 BK gt 6 s DH DJ BL DRIVE CONTROLS Da PRINTED CIRCUIT BOARD pw DM we Bk DP DB FROM TZ5005 285 REFER TO THE ELECTRICAL SCHEMATIC FOR YOUR MODEL AND SERIAL NUMBER Genie Part No 84577 TZ 50 5 33 Section 5 Schematics September 2014 eee Ground Control Box Wiring Diagram 5 to serial number TZ5004 181 _
98. 87 87 gt 87 87 B 0 2 cong 85 STARTING AID p H 3 gt C 85 FAULT GROUND 4 NP 4 H 12 8 2 BL 1815 a 2 Q C DC D WH TURNTABLE HARNESS WHIBK 7 _ uic es 11 A 87 87 TURNTABLE PIN P3 J 30 7 gt CR86 1 SS 2 2 3 CH75 PIN P3 C 85 SEQUENCING BK i PS EX Ts lt 85 7 LEVEL SENSOR I mu OO Hr OQ OQ 1 0 Q POD i 5 6 OQ 3 R22 lt 1000 OHM 3 NOTE DIODES ARE 2 2 3 2 UNLESS OTHERWISE MARKED 2 B p 1 HHHHSHH be 804400 Genie Part No 84577 TZ 50 Section 5 Schematics September 2014 A Ground Control Box Wiring Diagram AS CE from serial number TZ501 1 132 _
99. BJ Before After Serial Number sena NUNDEL TATT le TZ5004 151 Genie Part No 84577 Genie TZ 50 35 Section 4 Repair Procedures msc Ts s lt i MANIFOLDS 8 4 Valve Adjustments Function Manifold How to Adjust the September2014 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 the 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 010 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 unsi y w n 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 Pushand hold the yellow function enable button Push and hold the primary boom down button 3 Push and hold the yellow function enable down Fully lower the iu p and continue to S o hold the buttons while observing the pressure peus gauge Merer to Section 2 reading on the pressure gauge
100. Electrical Schematic ANSI CSA 1 of 3 from serial number TZ5005 211 to TZ5005 284 A B C D E F G H 9 L WHT 1 GRN BLK BLK BLK RED AHT To Page 3 of 8 WHT RED ORG RED z 3 RED WHT 3 m DOWN SWITCHES ET 219 i 2 9 SHOWN STOWED POS 2 1407 2 3 9 NES 8 92e B FB1 FLASHING BEACON 9 2 cm mm c o 2
101. PLATFORM 35 Q O U16B 9 86 2 2 H C4 7 MANIFOLD HARNESS 87 87 5 Yeivoc 87 87A BL BK 35 C WH PIN S t TB14 MANIFOLD HARNESS _ 85 Q H 2 Q gt 85 2 on PIN 133 4 34 ZENER DIODE 43 86 O 5 32 C C 3 3V DC 86 TB12 MANIFOLD HARNESS 87 87 PIN U P i gt RDIBK e E 2 5 52 CRW WH i MANIFOLD m 67 aii C O T 3D C 6 85 DOWN ENABLE 44 RD H E 5 lt BL TB15 MANIFOLD HARNESS BK 87 87A BON e 28 80 87A 1 4 BL TURNTABLE PIN W 3 cR TB27 PS 5 O 3 CH65H HARNESS MANIFOLD HARNESS BKWH o CROO n 5 C 3 5 0 0 3 87 4 87 87 BK WH 23 WH 37 CRB 788 7722 5 977 CR65A m 85 IGNITION v v 85 Us CUT OUT WH Bk 4 2 gt TB7 OQ 627 0 MODELS 9 4 pN68 C5 C C 20 WHIBK WITH ppg aoe O G 9 87 20 18 O 30 CR76 OPTION 85 ENGINE START O 17 85 LIMIT SWITCH BK RD 00 8 i er 2 H in D da 2 WH 87 5 5 87 pB10 BRD 5 AD Qd 14 OQ RD pas 85 EC NE p Q 2 Q 85 ZE ees 111 OO 0 87 ge 87 87 TURNTABLE H
102. PLATFORM CONTROL BOX 1 TB3 BN67 BN98 2 BN66 PLAT PLAT ROTATE LEVEL ROTATE ENABLE ENABLE ENABLE 0 CR78B 1 2 BNo4 P BN65 BN SEC e PHI e e JIB ENABLE ENABLE ENABLE ENABLE 4 CR71 CR9 CR87 68 JQ 2 16 7 7 7 PLATFORM GROUND z NN 8 gd d N gt a m a gt 3 8 8 93383 Bee ger B 5 x y y N gt GROUND CONTROL BOX AL Oy 9 9 9 E 0 E 5 BN57 BN58 BN93 S E x 4 5s BN93 PLAT 1 1 1 1 1 1 ROSE LEVEL ROTATE ENABLE ENABLE ENABLE Ta Y20 Yet Y63 5 TB31 1 oe P m P wm CR78A ENABLE ENABLE ENABLE ENABLE CR78A Y19 Y60 5 9 55 54 56 BN36 9 TB32 25 I Ber NI 2 RI 2 2 2 2 JIB MANIFOLD gt ES vs E cSCR61 U16A ores QCR67 Bm m 2 gt 8 12 97 mx a a LOAD SA 2 75 UO GROUND 2m d 8 6 m X P 3 3 4 a 9 3 2 3 504400 2g 5 2 5 o amp lt 1 5 1813 1515 RF O R RROR gt T I w 2 S al 9 1612 1814 P RA SES LF O R LR O R A A 1 m OUTRIGGER LIMIT SWITCHES Y24 Y53 Y22 Y26 uu 2 2 7 Y23 Y52
103. Part No 84577 PRIMARY BOOM COMPONENTS Genie 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 mnmmmmm I 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 valves to prevent movement in the event of a a platform level master cylinder hydraulic line failu
104. gt i SWTCHES gt E 2 5 m F6 g ODRI xz UT m SATE 8 3 8 o I S A IT 3 275AMP F9A 9 Di BATTERY 24V P amp hy HAM eg peser X E g F 2 5 z 1 4 A m D 4 L S A e 2 e e Q7 c tr 11 I UR c S 4 4 S s pepe 1 Vv m 4 E 2 2 2 5 No 2 B g B m f Ec 87 1 50 2 D 2 4 i r r r 7 e _ IND g ES Ee T E BATTERY GROUND 3 8 829 4 9 98 50440 r 5 5 5 65 1 5 gt 59 28 o o A 4 a eg e oO gt gt 2 mm m z gt m c mm o ao gt gt 2 8 lt lt 3 oS gt 22 gt lt gt 2 r Zo D Q gt gt 20 2 m x A 9 a 2 m ENGINE OPTION Genie 5 126 TZ 50 Part 84577 September 2014 Section 5 Schematics Electrical Schematic 2 of 3 from serial number TZ5011 132 to TZ5011 310
105. 15 While activating the function enable switch adjust the A SIDE HI RANGE potentiometer until the voltage is 22V DC Release the joystick Section 4 Repair Procedures September 2014 DRIVECOMPONENTS 16 Repeat this procedure beginning with step 14 17 Activate the function enable switch and move the joystick fully in the left direction The voltage is 3V DC Proceed to step 20 The voltage is less than or greater than DC Proceed to step 18 18 While activating the function enable switch and holding the joystick fully in the left direction adjustthe A SIDE THRESHOLD potentiometer until the voltage is 3V DC Release the joystick 19 Repeat this procedure beginning with step 17 20 Disconnect the positive lead Adjust both SW DC potentiometers 21 Without disconnecting the wire harness connect the positive lead of the multimeter to the blue black wire of the 14 wire main cable 22 Activate the function enable switch and move the joystick fully in the forward direction The voltage is 4 9V DC Proceed to step 25 The voltage is less than or greater than 4 9V DC Proceed to step 23 23 While activating the function enable switch and holding the joystick fully in the forward direction adjust the SW DC HI RANGE potentiometer until the voltage is 4 9V DC Release the joystick 24 Repeat this procedure beginning with step 22 25 Activate the function enable switch and move the joystick fu
106. 2 5 D 5 9 2 P 9 PLATFORM GROUND DRIVE CONTROLBOX 2 9 888 5999585 gt z g ume b w 5 5 gt gt gt 3 8 2 p AU GROUND CONTROL BOX TB3 4 BN59 BN60 DOWN UP ENABLE ENABLE CR65A sTB9 i m 4 EE BN50 BN51 B11 ENABLE 74 ENABLE 6 TB5I e 6 1 ee ee CR65A I TB23 TB24 1K OHM 47816 15 8TB14 1 5 t 5 GROUND CONTROL BOX gt 822 J CR28 gt e 65 TB32 TB32 CR65B 06 CR28 5 7 Br GCON GROUND d Lil GROUND CONTROLS GROUND eT ETT dd dd Tx Te 6 R amp S g 2 2 24 E 9 L1 5 a 2 47 mH 2 5 0 034 OHM 2 3 5 1 31 2 e a m DRIVE OPTION d 1 z 1 2 606 54 9 2 3 s o TO o Z 2 z 2 m 3 2 1 1 Coo 2 2 7 11 MOTOR ma go lt gt wd Y33 CONTROLLER ons zi m 5 m 5 m 5 2 J 2 fea mm mmm s 22 52 gt lt lt lt lt lt gt m AT M moron Ama 22 5 5 5 GCONGROUND 3200 2 N amp HARNESS GROUND PLUG BATTERY GROUND 00 4 T Jm gm gt ir m o 225 ee T D 2 do gt 99 2 qa o Hm
107. 207 bar AC aes Platform level circuit 18 20 ft Ibs 25 27 Nm 4 Solenoid valve 3 position 4 way AD 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 PortUBI0Qu u hee eibi iei ide ned 97 117 11 13 Nm 9 Orifice plug 0 055 inch 1 4 mm Bliss Jib boom up circuit cede eR kc uu aus M 97 117 11 13 Nm 10 Orifice plug 0 040 inch 1 mm AJ Jib boom down circuit Port Plug u u 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 Part No 84577 Section 4 Repair Procedures September 2014 MANIFOLDS Models with Platform Rotate Note alpha callouts refer to corresponding no
108. 23 1 gt e 41817 4 t CR65B 7 n s CR61 1 5 41818 8 TB22 J CR28 hd ie L ts oii TB32 CR65B G6 Tonos CR86 NN TM 0 GROUND GCON GROUND 1835 2 2 E CONTROLS GROUND gate 8 i 3 3 6 E z Xx o E l a 5 gp L1 8 BATTERY 24V A 5 5 51 51 55 1199 FRx Fs 47 2 5 0 034 2 2 2 40 E 9 39 Qo g y a Y58 12 1 2 1 2 12 0 2 E ES i tm S 3 z 35 e P P FA i f poe S 6 sr 7 59 Y50 Yt glY39 MOTOR Ooms 22350 2 Ya Y33 sm 332005 mo 2 je je je Je 2 mmm 25 s bb b k b 11 PERS T gt GROUND AMS mmo 22223 m MOTOR 9 2 K oz BB HARNESS GROUND PLUG BATTERY GROUND gt E o3 ES0440E 219 882 804 5 39 TE S zz g m 5 55 EIUS 289 2 2 2 8 2 95 24 932 15 9 9 Lr gt 52 DD gt 39 2 m m m m lt 94 2 5 o3 m xm 2 gt 5 29 m 2 40 zo gt gt m o dis E g core UU Genie Part No
109. 3000 psi i F BN 1 CYLINDER CYLINDER 4 4 Vip 207 207 207 X X 3000 psi 3000 psi 3 1 4 51 2u A 1000 psi i 207 bar 207 bar 3 1 3 MS e sn d 4 69 L 4 5 1 1 5 1 i 2 1B 3 1 1 n4 so L 4 psi 00 psi X R MASTER 207 bar Ti 207 bar Nai CYLINDER
110. ANSI CSA from serial number TZ5004 182to TZ5004 324 _ BKRD CR15 TERMINAL 86 BD CR1 TERMINAL 86 viU POWER CABLE PIN 1 MODELS HARNESS RD TURNTABLE HARNESS PINB RD CR6 TERMINAL 30 CR15 TERMINAL 30 KEY SWITCH P1 emercency stop ES T BN68 o LO WH START x FUNCTION ENABLE Q RIGHT AND OUTRIGGER RETRACT MN l C BD TB3 59 15 15 DOW
111. 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 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 outrigger BN54 Primary boom up down BN55 Secondary boom up down C5 BN56 Boomextend retract CB BN57 Turntable rotate 1 58 Platform level up down 2 BN59 Function enable down boom retract rotate left outrigger extend CR BN60 Function enable boom up boom extend CRI rotate right outrigger retract CR8 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 BN66 Turntablerotate CR67 BN67 Platform level up down CR68 BN68 Engine start CR6
112. OO Section 5 Schematics Ground Control Box Wiring Diagram ANSI CSA to serial number TZ5004 181 SO aod E ees Genie Part No 84577 9 WH 87 PD 55 X B RD 30 CR78A 85 4 2 LIFT CUT OUT BK TB35 s WH 87 WH 30 CR73 85 FUNCTION ENABLE Ca WH 5 7 86 WH 87A 5 1V DC t 5 WH gig CR28 POWER SUPPLY ZENER DIODE 3 3V DC 6 86 WH 1812 87 WH WH 30 CR77 85 DOWN ENABLE Ox 87 4 BL TURNTABLE 5 HARNESS _ CR65B PINH 85 U6 CUT OUT om 87 WH lus 30 CR65A 85 gt CUT OUT WH TB7 3 86 WHIBK 87 30 CR76 85 LIMIT SWITCH FAULT 2 86 WH 87 87 30 CR64 85 FAULT GROUND N 1 WH 87 87A WH TURNTABLE HARNESS 80 CR75 PIN C 85 LEVEL SENSOR ES TZ50A TZ 50 Section 5 Schematics September 2014 Ground Control Box Wiring Diagram
113. WH BL WH E BN BL BL FOG 1 YL Bk 29 ok BK RUN 2 BK uH WH GROUND 3 WH YL YL RD BRAKE 4 GN LEFT REAR YL n TU RN 5 BL m 6 RD 7 BN L36 LEFT SIDE MARKER LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT Genie Part No 84577 1 TURN SIGNAL 2 FOG LIGHT 3 REFLECTOR 4 BRAKE RUNNING LIGHT 7 50 Section 5 Schematics September 2014 Trailer Lighting Wiring Diagram Electric Axle AUS from SN TZ5012 253 Trailer Chassis Wiring Harness ELECTRIC BATTERY CHARGER 35 5 35 BK WH RIGHT SIDE MARKER ELECTRIC BREAK AWAY KIT rh YL A 1 RD 5 WH e e e IL 2 K 7 R 4 o 1 YL zs 2 7 PIN PLUG INSTALLED BY CUSTOMER u u 3 WH 1 YL LEFT TURN SIGNAL 4 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 MAR
114. g m m 2 E E mm amp BA E c i m B zoo EE go oU go 2 i pie 3 x d 5852 4 351 AYse 5 1 43 NOS 2 x f FAX x P 0 5 VDC 07 if cs EL SIGNAL AUTO LEVEL e el c F9 44 7 z pe qp E gt i E 5 Ura OUTRIGGER LIMIT SWITCHES 1512 LS13 514 PR5 52 OUTRIGGERS SHOWN STOWED LEFT FRONT RIGHT FRONT LS REAR 1515 a B5 PE Be POSITION FORCED OPEN OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER BI 250AMP 1 ind CONTROLLER Uu i MOTOR 8 Genie 5 108 TZ 50 Part No 84577 ES TZ50F September 2014 Section 5 Schematics ZI Electrical Schematic 2 of 3 from serial number TZ5005 211 to TZ5005 284
115. gt MODELS WITHOUT DRIVE OPTION 8 3 1 TO TZ5005 273 4 5 1 FROM TZ5005 274 7 8 Genie 5 138 TZ 50 Part No 84577 September 2014 Section 5 Schematics Hydraulic Schematic from serial number TZ5006 511 N M L K J H G F E D C B A LEFT RIGHT DRIVE MOTOR DRIVE MOTOR LEFT FRONT RIGHT FRONT EXTENSION SECONDARY BOOM PRIMARY BOOM 1 OUTRIGGER OUTRIGGER CYLINDER CYLINDER CYLINDER LIFT CYLINDER LIFTCYLINDER _ 1 pog TURNTABLE JIB PLATFORM PLATFORM ROTATE BOOM LEVEL ROTATE 2 DE E MERC NN OPTION Icd co 1 RECRUIT 4 R i L SLAVE 3 0 037 0 037 lt gt CYLINDER QX E 0 94 mm 200 psi 522 s 4 4 13 8 8 7 5 B 1 D2 D3 04 2 3mm gt 1 24 9 CU IN REV 4l IF Al a LEFT REAR RIGHT REAR ED a 2E OUTRIGGER OUTRIGGER E 3000 psi 3000
116. z 2 2 5 3 E 5 8 3 5 DR PBI PB2 PBS PBS PB4 PB7 6 DM DN 2 1 4 8 7 6 5 510 59 7 LEFT RIGHT AXIS FRONT REAR AXIS AUTO LEVEL 3 REVEL SENSOR REVEL SENSOR 1 t t 4 t m BN57 BN58 BN93 EC 4 39 8 456 304 9 486 PLATFORM PLATFORM pis TURNTABLE LEVEL L L ROTATE UP DOWN OPTION GF O a 5 87A 87 85 87 Jor 85 14 2 31111 4 2 3 11 4 L LT 4 CR73 Y CR78A Y GROUND FUNCTION UFTCUTOUT TT C 7 T a 4 4 4 i m CONTROL CR66 TB34A e LEVEL SENSOR RELAY z BOX E BN55 BN54 BN56 BN36 CR61 SECONDARY PRIMARY BOOM JIB BOOM BOOM EXTEND RETRACT BOOM E AUTO LEVEL UP DOWN UP DOWN UP DOWN SYSTEM RELAY 87 gt 85 5 H TB26 TB27 TB29 2 30 86 x Y RD 2 i Aen TB28 GN YL GN 87 87 85 30 86 30 86 30 86 30 86 30 86 742 742 788 x uri ird 22 E NO 7 4 7 A 87 87 85 87 87 85 87 87 85 87A 87 85 87 87 85 6 G6 CR72
117. 2 D v gt gt d Eee o H or ys lt A D 5 N m uz mm oo 9 omn om 9 lt lt lt 0 D So iz 8 ag m m m m 2 gt 2 5 s r 223 e gt 20 DD gt 39 2 m m m m lt 589 m 3 ma E m gt gt gt 2 lt 265 gt gt lt gt E 1 oO Part 84577 2 50 5 133 September 2014 Section 5 Schematics kwa ww Ms s _swGsa lt ecs Electrical Schematic AS CE from serial number TZ5011 311 5 133 5 134 September 2014 Section 5 Schematics Electrical Schematic AS CE 3 of 3 from serial number TZ5011 311 PLATFORM CONTROL BOX 1 TB3 j BN67 BN98 BN66 PLAT PLAT ROTATE LEVEL ROTATE ENABLE ENABLE ENABLE 78 0 CR78B 1 2 BN64 BN63 BN65 SEC PRI e EXT Kd ENABLE ENABLE ENABLE ENABLE 71 CR9 CR87 3 9 5 7 7 7 E PLATFORM GROUND ox S S 5119 5808
118. 21 Engage both drive motors 22 Working from the front end of the parking brake cylinder adjust the drive motor brake cables by hand until they have zero play and zero resistance Be sure the brake cylinder balance bar is square to the parking brake input cable 23 Disengage both drive motors 24 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 this procedure beginning with step 5 Genie GenieTZ 50 B 11 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 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Result There is side to side or up and down movement See C 5 Grease the Axle Wheel Bearings Mechanical Axle Required maintenance procedures and additional axle information is a
119. 22 zz 5 x A JBMANIFOLD a cs BN93 BN57 BN58 20 Y61 Y63 TB11 BOTATE ENABLE ENABLE 4 4 19 Y60 Y62 nw 78318 Pes E T TB34A 7 CR78A 1CR78A 9 ENABLE ENABLE ENABLE WAE 9 2 R2 2 72 2 2 2 5 89 5 BN36 m E 5 5 v g gt gt gt TB29 m 26 27 m x 1 CRe1 es m m 919 8 U16A 7 1 2868 4CR67143 CR69 14 m m gt 2 o T T 7 T Lc m 88 LOAD m x GCON GROUND i 2 gt gt R M 5 oj lt 5 1513 1915 T RF O R O R T g m 8 a 2 g 2200 amp A 1512 1614 iS LF O R ris I MP 22 26 OUTRIGGER LIMIT SWITCHES Yo3 1 Voi 1 Y25 m ES0440C 2 2 2 2 2 2 2 GCON GROUND HARNESS GROUND PLUG e e gt ez 2888833909 4 8 8 m m LI muB m m m 2 2 o o gt gt O O m om o02207g mzz s 2 02885 5 2 m 3 gt 234 5 o m zs D m 4 gt 2 m gt 2 9 B 5 Bm gt Genie Part No 84577 TZ 50 September 2014 Section 5 Schematics Electrical Schematic ANSI CSA from serial number TZ5005 285 to TZ5010 144 77 Section 5 Schematics September 2014 2 Electrical Schematic ANSI CSA from serial numbe
120. 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 circuit 18 20 ft Ibs 25 27 Nm 14 Solenoid valve 2 position 4 way BN Drive circuit left side 18 20 ft lbs 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 84577 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 on the hydraulic schematic BO QUOMEORO
121. 35 214 3 501 49 664 44 49 664 so 678 947 29 a 555 ss 145 eo 213 ao 10848 or 43 57 773 75 1016 20 108 4 110 149 20 64 567 85 115 90 122 12_ 80 1084 s 12 41 110 149 210 284 18 130 176 10 200 271 270 366 280 379 380 515 220 298 300 so f 420 420 se ___560 759 EREHE eso 867 680 922 990 1342 9 zx 2 z EE 142 670 890 1206 1080 L 1464 140 1952 120 1654 ere 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 Nm inibs Mm inibs Nm in Ibs Nm in Ibs Nm intbs Nm in tbs Mm inibs 5 16 18 2 24 463 54 61 55 663 78 775 91 103 6 19 3 05 36 4 07 69 787 105 100 11 3 132 15 116 132 155 176 7 45 542 683 116 132 155 176 167 189 223 252 195 221 260 254 ft Ibs Nm ft l
122. 5 Torque the Lug Bolts Electrical and Hydraulic Axles 3 8 A 6 Torque the Lug Bolts Mechanical 3 8 A 7 Perform Hitch Maintenance Hydraulic Axle 3 9 8 Perform Engine Maintenance if equipped 3 9 A 9 Perform 30 Day 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 3 12 B 2 Inspect the Electrical 3 13 B 3 Test the Electrical Contactor 3 14 B 4 Test the Emergency 3 14 B 5 Test the Key 3 15 B 6 Test the Manual 3 15 B 7 Perform Hydraulic Analysis 3 17 B 8 Perform Axle Maintenance Electrical and Hydraulic Axles 3 18 B 9 Service the Tongue Jack 3 18 B 10 Inspect the Parking 2 3 19 B 11 Check the Wheel Bearings Mechanical Axle 3 24 B 12 Service the Hitch Mechanical 3 25 B 13 Perform Axle Maintenance Mechanical
123. 84577 September 2014 Section 4 TABLE OF CONTENTS Repair S 4 1 Platform Components Platforms sies Ret eis tt dein iui euet 4 2 1 2 PlathOrm ROOM eee ct eta et 4 2 Jib Boom Components 2 4 Jib BOOM ciet reete e e teet Ee Ee te atte cett nat ele 4 4 2 2 Jib Boom Lift Cylinder 4 6 Primary Boom Components 3 1 Cable Track xiii eet e eee 4 9 3 2 Primary BOON EO ede E ree tef ier 4 11 3 3 Primary Boom Lift Cylinder essen 4 14 3 4 Platform Leveling Cylinders 4 15 Secondary Boom Components 4 1 Secondary BOOM eee tea T te 4 18 4 2 Secondary Boom Lift 4 21 Engine 5 1 4 23 Ground Controls 6 1 Level Sensor 4 24 7 1 Function PUMP is ects 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
124. 84577 TZ 50 5 127 September 2014 Section 5 Schematics Electrical Schematic 5 from serial number TZ5011 132 to TZ5011 310 5 127 5 128 September 2014 Section 5 Schematics Electrical Schematic AS CE 3 of 3 from serial number TZ5011 132 to TZ5011 310 1 TBS J BN66 2 BN67 BN9B ROTATE PLAT PLAT ENABLE LEVEL ROTATE ENABLE ENABLE 1 78 1 2 PNET a BN63 65 BN97 7 SECA PHI JIB ENABLE ENABLE ENABLE ENABLE CR71 CR9 CR87 7 7 6 PLATFORM GROUND y Xx y du us o o m 3 8 988 899 gee x 5 A x x y y y y y 3 v P N Oo m 4 m e EE 9 9 2 2 qr D m A A JIB MANIFOLD 4 1 1 1 1 1 yl BN93 BN58 PLAT Y20 Y61 Y63 RNa LEVEL ROTATE ENABLE ENABLE ENABLE TB11 e 2 1 Y19 Y60 Y62 Bo nw PI pes uid ter T CR78A CR78A 5 78 1CR78 9 ENABLE ENABLE ENABLE 9 2 2 2 2 2 2 TB32 rgo P N59 54 BN56 B
125. Blue BK acce eain Black GIN ua sa PH Green OR PD a bestie ss Red PH White BLIBK Z S Blue White BK RD seen Black Red aeree Black White Green Black GNAWH 2 22 2 Green White donet Orange Black OR RD Orange Red iiio ette Orange White Red Black RDWH etie id Red White de White Black WARD ziii White Red Part 84577 September 2014 Section 5 Schematics Limit Switch Legend Item Description a Boom limit switches b Outrigger limit switch C Boom limit switch d Outrigger limit switch 22 Part 84577 Schematic 1518 L818A LS12 LS13 LS14 LS15 to TZ5006 159 518 to 25006 159 LS12 LS13 LS14 LS15 from TZ5006 160 Genie TZ 50 5 5 Section 5 Schematics September 2014 NN CNN UG I Electrical Symbols Legend TB1 Terminal gt Diode 1 KS1 KEY SWITCH Key switch 1 EMERGENCY STOP e Emergency stop button normally closed 15 Circuit breaker 1 i O 7 fae NOHC Limit switch M Toggle switch
126. CR8 85 IGNITION BK 86 MODELS g i BK 87 87A WITH 30 0j OPTION 85 ENGINE START BK RD PA2 2 5 1 BKIRD akan 87 27 RD PD10 P1 CR15 85 24 STARTING AID i 1 dg 6 87 87A WH BK TB16 TURNTABLE HARNESS WH BK a CR86 Qu 85 PIN J SEQUENCING BK TB35 R22 7 1000 OHM TERMINAL BASE D 2 6988827 7 2 Ee HHS HH 135 35 Q 35 uc 35 Ups C 32 031 30 OD Stesee 29 28 28 27 Bo j OOO 25 gt Q Q Q Q 23 6 4422 20 Q Hs 5 c0 ge Q Q 16 OZO 15 poyo Inm gt 112145 O 11 O Liu NE Q 9 Q 1 o o o OOOOOOO D Fan d 4 945 9i O N 600000680 O9 00
127. D TURNTABLE AND PLATFORM ROTATE SQ LEFT RD WH 8D lt o oo POWER CABLE PIN 2 2 WHIBK GNWH CR 788 TERMINAL 87A NS RDIBK po _ 86 RD 9 D COM p 87 87 k wa 619 BN64 RD p 85 LIFT CUT OUT 10000090909909090900 8 7 6 5 3 214 JIB HARNESS P6 3 n uf JIB HARNESS 6 2 ORAK 6 85 2 CAL LeveL E _ x pm x 7 M K oolooloolooleolooloo GN 87 87 8 PAG JIB HARNESS P6 5 GN GN BK 90 CR9 7 JIB HARNESS PIN 6 4 JIB UP DOWN 5 86 87 87A JIB HARNESS PIN 6 7 BL GNWH Los 30 JIB HARNESS PIN 6 6 L BK 65 CR87 PLATFORM ROTATE OPTION BK 504400 Genie Part No 84577 TZ 50 5 49 Section 5 Schematics September 2014 Platform Control Box Wiring Diagram AS CE from serial number TZ501 1 132
128. 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 94958 evenly distribute the lubricant to the internal gears 2 Securely install the cap onto the jack Genio 3 18 Genie TZ 50 Part No 84577 September 2014 Section 3 Scheduled Maintenance Procedures B 10 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 ANSI models without drive option 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 W Result The mac
129. Grease the Turntable Rotation Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification See D 2 Check the Turntable Rotation Bearing Bolts 3 Start the machine from the ground controls and raise the primary and secondary booms to full height Do not extend the primary boom 4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place 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 84577 Genie GenieTZ 50 CHECKLIST D PROCEDURES turntable dial indicator drive chassis turntable rotation bearing ao oo 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 Result 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 d
130. N NO ENGINE 62 OIO FUNCTION ENABLE UP EXTEND TURNTABLE AND RIGHT 1 1_ S BE 4 CR 9 TERMINAL 30 2 6 G7 BN64 BN66 RD TB3 ENGINE BATTERY CHARGE SECONDARY BOOM TURNTABLE 22 INDICATOR UP DOWN ROTATE E S RD TB1 BN61 O FUNCTION ENABLE BOOM DOWN BOOM RETRACT Q gt O TURNTABLE AND PLATFORM ROTATE BK RD LEFT p1 2 gt RD WH PP ses TB2 POWER CABLE PIN 2 80 85 tpg BK pg CR78B TERMINAL 87A PP Na RDIBK_ 55 3 P2 2 _ O RD 87 87 C AR 7 ool ool joo loo o j oo loo oo BN64 I7 85 LIFT CUT OUT a Bt 4 L gt 9 8 7 6 5 4 3 2 1 JIB HARNESS PIN 84 ORIBK ps 30 OR BK CR71 JIB HARNESS 6 2 _ 65 Q O 3j 5 GN 87 87 Fee P1 6 JIB HARNESS PIN P6 5 GN BN97 GN BK CR9 G7 JIB HARNESS PIN 6 4
131. O c WH RD POWER CABLE PIN 1 ORBK 556 BN97 BN63 BN98 MODELS ENGINE JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UPDOWN OPTION C 2 ENGINE BN62 OIO FUNCTION ENABLE UP EXTEND TURNTABLE AND EI Q D RIGHT pai BK S 77 BE CR 9 TERMINAL 30 G7 BN64 BN66 RD TB3 ENGINE BATTERY CHARGE SECONDARY BOOM TURNTABLE 2274524 INDICATOR UP DOWN ROTATE E S RD TB1 BN61 9 O FUNCTION ENABLE BOOM DOWN D TURNTABLE AND D PLATFORM ROTATE LEFT 2 RD WH PP gt POWER CABLE PIN 2 80 WHIBK gp BK GNWH_ tpg CR 78B TERMINAL 87A PP RD BK pgs ppo _ 2 BD gt 87 87 f N gt 3 ee OOl 6o o oo o lo oo oo BN64 Ie 85 LIFT CUT OUT BL 4 D 9 8 7 6 5 4 3 2 1 87 JIB HARNESS PIN P ORBK 166 30 OR BK CR71 JIB HARNESS PIN 2 1 85 PLATFORM LEVEL glo Y GN 87 87 PB6 JIB HARNESS PIN 5 98 GN BN97 6 GN BK CR9 JIB HARNESS 4 85 JIB BOOM UP DOWN 87 JIB HARNESS PIN 7 BL We GNWH os
132. Perform Axle Maintenance Electrical 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 84577 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 84577 Genie GenieTZ 50 CHECKLIST C PROCEDURES 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 machin
133. 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 Repeatthis procedure beginning with step 6 23 Continue to lower the tongue end of the machine until the turntable is 2 7 out of level Result The tilt alarm will sound at 180 beeps per minute W Result The tilt alarm does not sound The level sensor is faulty and must be replaced Repeat this procedure beginning with step 6 24 Return the outriggers to the stowed position Push and hold the yellow
134. 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 personnelto 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 O 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 Tagand disconnect the taillight 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 damage
135. 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 dud 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 not properly supported when removed from the machine Genie 4 22 Genie TZ 50 Part No 84577 Septemb
136. 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 as required Part No 84577 September 2014 Section 3 Scheduled Maintenance Procedures 9 Connectthe 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 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 co
137. 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 Raisethe boom enough to access the turntable bearing 2 Before serial number TZ5004 391 Locate the grease fitting on the inside of the turntable rotation bearing After serial number TZ5004 390 Locate the grease fitting below the ground control box 3 Pumpmultipurpose grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm ata time and repeat this step until the entire bearing has been greased 4 Apply grease to each tooth of the drive gear located underthe turntable Grease type Part No 84577 Multipurpose grease 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
138. 3 of 3 from serial number TZ5010 145 to TZ5011 131 1 3 J 866 BN67 BN98 ROTATE PLAT PLAT ENABLE LEVEL ROTATE ENABLE ENABLE PLATFORM L 1 CRIBB 2 CONTROLS BNGS P BN63 5 BN97 1 e PRI 4 JIB 8 ENABLE ENABLE ENABLE ENABLE 8 2 jCR71 1 9 7 P je e 176 PLATFORM GROUND y X xl A Te so To Io foie cur D m _ 3 w w 2 8 8 5 Jg ger 4 4 2 7 y y U U 9 9 GROUND CONTROL BOX N 7 A 3 2 amp s A JIB MANIFOLD 4 GROUND 1 1 1 yl 1 CONTROLS T PLAT 20 Y BN57 PLAT ROTATE of ROTATE LEVEL wk na TB11 ENABLE ENABLE 4 19 60 Y62 Freee wk Ter 4 5 CR78A 1CR78A 9 ENABLE ENABLE ENABLE 9 2 2 2 2 2 2 TB32 rgo P NSS 8 59 BN36 4 33 38 27 mx d d A CR61 U16A ie m m m m 3 m 8 6 70 4 68 412 CR6715 CR69 14 m m gt 2
139. 30 BL BK CR87 JIB HARNESS PIN 6 85 9 50440 Genie TZ 50 Part No 84577 September 2014 Section 5 Schematics F s TO c r r h Platform Control Box Wiring Diagram ANSI CSA from serialnumber TZ5010 145to TZ5011 131 zener nione 5 1v pc R14 BN65 BN67 R22B WV Boom BOOM PLATFORM 5 6K OHM 8220 FUNCTION EXTEND RETRACT LEVEL SPEED P ss E 5 6K OHM 10K OHM mS P2 9 EMERGENCY STOP q 1 8 RD POWER CABLE PIN 1 p2 4 ORBK 556 3 BN2 BN97 BN63 BN98 MODELS JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UPDOWN OPTION
140. 44 RD 2 H a 2 5 lt BL TB15 V MANIFOLD HARNESS gk 87 87A 5 CN 28 C 87 8A BL TURNTABLE m HARNESS MANIFOLD HARNESS _ Con 2 H 27 e 39 CR65B PIN H PIN V x x3 87 4 87 87 BK WH 23 WH ZB Bea 85 IGNITION 5 OHM 24 55 5 85 4 U6 CUT OUT WH 7 BK pat lir 211 MODELS 9 4 pN68 2 H 20 75 9 gt WHIBK WITH PD9 O CO 4 DETON 85 Lens l Q Q OQ Q 85 ii OPTION Es o OQ 16 0 4 BK RD_ pugo 2 H m 2 WH 87 87A 87 87A al chu RD py 14 H 3 RD e 13 85 STARTING AID 3 e C RETO Cj C A 85 FAULT GROUND i ME Q 2 48 86 BL mus 2 C Lj 12 C C DC 1 86 WH Grae f 87 87A TURNTABLE TURNTABLE HARNESS 1 C Os 11 HARNESS PIN J 30 CR86 1 Y 1o 7 gt 3 CH75 PIN C 85 SEQUENCING BK 535 H T0 lt S 85 LEVEL SENSOR S E d 1 i D 8 1 e 8 A P R22 j 4 R 1000 O 3 NOTE DIODES 2 2 3 Q 2 UNLESS OTHERWISE MARKED 2 5 i 50440 Genie Part No 84577 TZ 50 5 41 Section 5 Schematics September 2014 Ground Control B
141. 5 PLATFORM BOOM LEVEL BN49 EXTEND RETRACT UP DOWN 1 AUTO LEVEL 35 7 BL WH BN52 TB23 BL WH XL LEFT FRONT OUTRIGGER SS f BN54 Liz 50 PRIMARY PLATFORM irie LEFT OUTRIGGER BOOM ROTATE UP DOWN 0 4 114 L N LRLED I j I BN36 M JIB UA BOOM UP DOWN GNWH cg BN51 RIGHT REAR OUTRIGGER G L15 RR LED GNWH 55 BN57 WH TB4A TURNTABLE SECONDARY ROTATE BN53 RDWH _ 7820 RIGHT FRONT RD WH UP DOWN OUTRIGGER 113 RF LED ORWH _ 21 OR WH ccs WHIBK _TB31 GNWH _ BUBK TB25 _TB26 GN TB29 AD CR78A TERMINAL 87A BKWH TB27 BD WH 2 H5 ALARM 06 Bk NC TB35 ES TZ50F Genie 5 38 TZ 50 Part No 84577 September 2014 Section 5 Schematics n i Ground Control Box Wiring Diagram AS CE from serial number TZ5004 325to TZ5005 284
142. 7822 J CR28 gt TB32 TB32 at CR65B G6 CR28 5 GCON GROUND tll l GROUND CONTROLS GROUND 5275 8 44875 88 dz H2 3 3 6 amp L N z 2 8 BATTERY 24V Z 9 8 2 L1 8 24 9 3 8 47 mH 2 5 0 034 OHM 12 1 3 2 23 8335 2 T LL LL T e us 2855556 8 E 7 z Y33 Y34 CONTROLLER 2 m lt 2 m 5 gt 5 me lt lt mm 52 lt lt lt lt lt 2m at Aan 22 222 lt 4 GCON GROUND 5 MOTOR 2210 o gt 9 D HARNESS GROUND PLUG BATTERY GROUND F 5 228 es gt Q o om o ES0440D mo E ie ie D 2 gt gt 4 A o m lt lt lt JIA m a BN 2 2 m om 9 98 lt lt 5 2 2 om 8 18 E poe 3 p a SUE 59 2 m m m mox 599 20 m x m 2 2 m 2 uo m gt zo gt x7 lt c PPP RE PRUNUS DAR ti 9 Part 84577 2 50 5 121 September 2014 Section 5 Schematics k aww Electrical Schematic AS CE from serial number TZ5010 145 to TZ5011 131 5 121 5 122 September 2014 Section 5 Schematics Electrical Schematic AS CE
143. 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 84577 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 on a 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 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 liftin
144. 85 bza 87 las 87 5 85 bza 87 185 6 hd hd G6 CR72 CR70 CR68 CR67 CR69 HOUR OUTRIGGER TURNTABLE SECONDARY PRIMARY BOOM BOOM BOOM EXTEND I TB35 TB34 L 1 N P R 8 U 2 1 3 s 8 2 B E z z 9 9 z a 50 58 11 7 DRIVE PROPORTIONAL BRAKE FWD REV DRIVE RELEASE 40 Y23 Y52 21 Y25 rwo m OUTRIGGER ROTATE SECONDARY PRIMARY BOOM EXTEND LEFT DOWN DOWN RETRACT SEN Ee py dex ox cox AEX Y50A Y59 Y39 EX Y24 i Y53 i Y22 Y26 DRIVE PROPORTIONAL OUTRIGGER ROTATE SECONDARY PRIMARY BOOM FWD REV DRIVE RETRACT RIGHT UP UP EXTEND RIGHT LEFT kX EX X EAX ES TZ50D 4 4 8 Genie Part No 84577 TZ 50 5 61 September 2014 Section 5 Schematics 1 Electrical Schematic ANSI CSA from serial number TZ5004 182 to TZ5005 210 62 September 2014 Section 5 Schematics Electrical Schematic ANSI CSA 3 of 3 from serial number TZ5004 182 to TZ5005 210 L K J H G F E D z 8 8 ga 2 g 2 gs g 8 2 8 9 2 8 8 P 3 8 8 E DA DE DN DM DC DP DB DL DH DJ DK DD 2 3 PA2 1 PA5 PA4 PAQ
145. 86 o 30 14 86 E 32 m 99 KE m w alto m3 EH mda 2995 z g Fe ks 187A 87 85 87 85 G SA 87 85 lt 87 87 gt lt 87 85 2 5 2 3 90 do 5 r m 5 5 d ka d d 2 TB35 KL My NF P RT ST T 3r DN 7 8 o o 2 m ow oz 2 2 S 5 9 3 22 28 2 gg x 2 6 vis Y23 Y52 Y21 Y25 2 3 3 Fox EX z 5 gt AX 5 Xm E 2 o9 lt Y39 Y24 Y53 Y22 REX XS 8 gt gt 5 d e d d um N g 8 8 a m 3 2 8 8 0 58 7 2 2 gt gt ES TZ50F 5 5 2 X gt m gt lt lt m m m 2 2 2 D 7 9 lt lt 2 m m m 5 5 g m 5 gt 9 2 gt 5 2 8 Genie Part No 84577 TZ 50 5 67 September 2014 Section 5 Schematics 1 Electrical Schematic ANSI CSA from serial number TZ5005 211 to TZ5005 284 68 September 2014 Section 5 Schematics Electrical Schematic ANSI CSA 3 of 3 from serial number TZ5005 211 to TZ5005 284
146. 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 bar Lust System relief 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 circuit 25 30 ft Ibs 34 41 Nm 16 Solenoid valve 2 position 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 uicit enu t ute tap et edit deberet 97 117 165 11 13 Nm 18 Solenoid valve 3 position 4 way with manual override Euer Turntable rotate left right 18 20 ft Ibs 25 27 Nm Genie 4 30 G
147. A 2 Pre operation inspect B 2 Electrical wiring A 3 Function tests B 3 Electrical Contactor A 4 Engine maintenance if equipped 5 Lug bolts 6 Lug bolts 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 84577 B 4 Emergency Stop B 5 Key switch B 6 Manual override B 7 Hydraulic oil analysis B 8 Axle maintenance B 9 Tongue jack B 10 Parking brake B 11 Wheel bearings B 12 Hitch B 13 Axle maintenance Perform every 300 hours B 14 Engine maintenance if equipped Checklist C YNR 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 E 1 Hydraulic oil E 2 Engine maintenance if equipped Y NR GenieTZ 50 Section Scheduled Maintenance Procedures September 2014 Checklist A Procedures A 1 Inspect the Manuals and Decals Genie s
148. 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 84577 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 is available in the Honda GX160 Engine Owner Manual Honda part number 31ZH7630 Honda GX160 Owner s Manual Genie part number 97228 Section Scheduled Maintenance Procedures September 2014 CHECKLIST A PROCEDURES A 5 Torque the Lug Bolts Electrical 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 Man
149. BATTERY CHARGER CONTROLLER ES TZ50A Genie 5 54 TZ 50 Part No 84577 September 2014 Section 5 Schematics e a Electrical Schematic ANSI CSA 2 of 3 to serial number TZ5004 181 L K J D C B A 1 PLATFORM CONTROLS PLATFORM CONTROLS DRIVE CONTROLS DRIVE CONTROLS w M n
150. CHARGER CONTROLLER ES TZ50D Genie 5 102 TZ 50 Part 84577 September 2014 Section 5 Schematics LS Electrical Schematic AS CE 2 of 3 from serial number TZ5004 182 to TZ5005 210 D C B A c gt 1 PLATFORM CONTROLS m w gt DRIVE CONTROLS u u w w Ll oou
151. CR70 CR68 CR67 CR69 HOUR OUTRIGGER TURNTABLE SECONDARY PRIMARY BOOM 1 METER ROTATE BOOM BOOM EXTEND TB35 4 l N P R 5 2 1 3 5 7 8 8 5 9 5 i Y50 Y58 7 DRIVE PROPORTIONAL BRAKE Y40 Y23 Y52 Y21 Y25 ET NE OUTRIGGER ROTATE SECONDARY PRIMARY BOOM EXTEND LEFT DOWN DOWN fy kX kX EAX X X ZX Y50A Y59 Y39 Y24 Y53 Y22 Y26 DRIVE PROPORTIONAL OUTRIGGER ROTATE SECONDARY PRIMARY BOOM FWD REV DRIVE RETRACT RIGHT uP uP EXTEND RIGHT LEFT cox X RAX AX 5 250 i jew 4 if L 1 iL i 14 i 8 Genie Part No 84577 TZ 50 5 97 September 2014 Section 5 Schematics Electrical Schematic AS CE to serial number TZ5004 181 98 September 2014 Section 5 Schematics r TF Electrical Schematic AS CE 3 of 3 to serial number TZ5004 181 L K J D C B A
152. Maintenance Unless 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 governmental 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
153. N Y50 Y58 Y11 7 DRIVE PROPORTIONAL BRAKE Y40 Y23 Y52 Y21 Y25 terr FIGHT DAVE OUTRIGGER ROTATE SECONDARY PRIMARY BOOM EXTEND LEFT DOWN DOWN RETRACT kX EX EX X RAX AX ZX Y50A Y59 Y39 Y24 Y53 Y22 Y26 DRIVE PROPORTIONAL OUTRIGGER ROTATE SECONDARY PRIMARY BOOM FWD REV DRIVE RETRACT RIGHT RIGHT LEFT X AX RAX cox X ES TZ50A 4 Genie Part No 84577 TZ 50 5 55 September 2014 Section 5 Schematics ss mrwsrv rssEr Electrical Schematic ANSI CSA to serial number TZ5004 181 56 September 2014 Section 5 Schematics SSS SSS eee Electrical Schematic ANSI CSA 3 of 3 to serial number TZ5004 181 L K J D C B A 8 3 39 s E e aif P 2 8 g s 8 P 2 5 8 8 3 14 DA DE DN DM DL DB DP DH DJ DG DK DD 1 2 3 PA2 1 PAS 4 5 7 4 2 44 ATA EA 2 bis ll P3 P2 I 3 EMERGENCY EMERGENCY E STOP STOP BATTERY N CHARGE CR74 2 3 4 5 6 7 INDICATOR H1 FUNCTION E cie cm ALARM ENABLE JC5 e e DRIVE ide aM PLATFORM WEN x w um CONTROL
154. Q T 13 0 85 FAULT GROUND x 8 76 48 86 BL 12 SF DC 1 86 WH 87A bs e 1 87A Wa TURNTABLE HARNESS WH BK 1816 1 CX 11 5 c I HARNESS PIN P3 J 30 CR86 i 559 Es 1o 7 C 30 CR75 PIN C 85 SEQUENCING T lt 9 IX 85 LEVEL SENSOR 1 XN G Q 0 He 0 Q PO 9 1878 WS Ban poo lt LI Q 3 1000 OHM Q 3 NOTE DIODES ARE 2 AMP 2 UNLESS OTHERWISE MARKED 2 4 5 O 2 O O fn Pli eee 226 E 200 OHM HEHE CHEE ES0440G INDICATOR r gt 2505011 311 BK TB35 G7 E RD P1 E STOP Genie Part No 84577 TZ 50 5 27 Section 5 Schematics September 2014 Platform Control Box Wiring Diagram ANSI CSA to serial number TZ5004 181 C4A ZENER DIODE 5 1V DC
155. RIGHT REAR OUTRIGGER C L15 RR LED GNWH BN55 REU raaa TURNTABLE BN53 RD WH SECONDARY ROTATE TB20 BOOM RIGHT FRONT RD WH UP DOWN OUTRIGGER L13 RF LED ORWH _ TB21 OR WH ccs Bo rggi GNWH _ BUBK TB25 RD BK GN TB29 BD CR78A TERMINAL 87A BKWH _ ED wH PA3 HD 2 ALARM 6 i TB35 ES TZ50F 5 20 2 50 Part No 84577 September 2014 Section 5 Schematics ss r m rsE sm ni Ground Control Box Wiring Diagram ANSI CSA from serialnumber TZ5004 325to TZ5005 284
156. RUN BACKUP L34 LEFT REAR TAIL LIGHT TZ 50 Part No 84577 September 2014 Section 5 Schematics Trailer Lighting Wiring Diagram Electric Axle AUS 5 25012 252 Trailer Chassis Wiring Harness ELECTRIC BATTERY CHARGER 135 35 BK RIGHT SIDE MARKER etectrric 7 BREAK AWAY KIT YL 2 1 a RD 5 5 aS S 3 WH e i 2 I 4 2 1 7 4 1 YL zs 2 7 PIN PLUG INSTALLED BY CUSTOMER E 3 WH 1 YL LEFT TURN SIGNAL 4 GN 2 BK REVERSE LIGHT 5 BL 2 BK BREAK AWAY BATTERY CHARGER 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 L35 p sas Platform Wiring Harness RIGHTREAR GN TURN GN aN RD BRAKE BN w 8 RUN e GY FOG ua i GREEN PLUG WH E GROUND RD
157. S Z BN59 PINB FUNCTION ENABLE 1 5 1 2 DOWN 90 15 15 ROTATE LEFT SHORE 3 G AND OUTRIGGER 14 u EXTEND LED Wa TB9 17 WH TB18 58 MEC BN56 PLATFORM BN49 EXTEND RETRACT UPDOWN r G 1 AUTO LEVEL ES 2 BK TB35 LIC BL WH BN52 sa rr LEFT FRONT OUTRIGGER 7 BN54 0 12 BNSO PRIMARY PLATFORM LFLED lt LEFT REAR OUTRIGGER 6 ROTATE 5 114 LRLED I j I BN36 JIB RN ANA BOOM UP DOWN GNWH 9 f BN51 gt RIGHT REAR OUTRIGGER G L15 RR LED GNWH TB24 BN55 zd TORIA TURNTABLE BN RD WH SECONDARY ROTATE 53 TB20 BOOM RIGHT FRONT RD WH CC3 UP DOWN OUTRIGGER L13 RF LED ORWH _ 21 OR WH ccs M BD CR73 TERMINAL 87 CR78A TERMINAL 30 WH BK TB31 GNWH _ BUBK 25 RDBK GN TB29 BD CR78A TERMINAL 87 BKWH _ wH PA3 RD TB32 5 66 ALARM _ 1 ES TZ50A Genie 5 34 TZ 50 Part No 84577 September 2014
158. S n DIO PLATFORM ROTATE RIGHT pai BK BL CR87 TERMINAL 86 AND CR 9 TERMINAL 30 AND 6 SN G7 BN64 BN66 RD CR78B TERMINAL 30 AND ENGINE CHOKE BATTERY CHARGE SECONDARY BOOM TURNTABLE CR74 TERMINAL 87 EL INDICATOR _ UP DOWN ROTATE S BN61 FUNCTION ENABLE DOWN D D BOOM RETRACT TURNTABLE AND 5 D LEFT RDWH pag CR74 TERMINAL 86 u WHIBK cR78B TERMINAL 86 AND POWER CABLE PB POWER CABLE GNWH C887 TERMINAL 30 AND CR 78B TERMINAL 87A PP _ RDK ppg RDWH awe RDAWH _ pac D 5 Lig BL pi RD 87 87 BN66 4 RB TBI CR74 FUNCTION ENABLE 2 WH 87 87 30 CR78B 80 LIFT CUT OUT BL BN67 86 ESSA 87 87A JIB HARNESS PIN 28 ORBK 30 JIB HARNESS PIN 2 85 SEAM iee 4 eT GN 87 87 SN PB6 JIB HARNESS PIN 5 GN BE GN BK CR9 JIBHARNESS PIN 4 GNBK 65 JIB BOOM UP DOWN BNe2 B BN98 ots 87 87 JIB HARNESS PIN 7 GNWH pp7 30 JIB HARNESS PIN 6 BUBK gs CRB 5 750 Genie TZ 50 Part No 84577 2014 Section 5 Schematics r Platform Control Wiring Diagram AS CE from serial number TZ5004 182to TZ5005 284
159. TO 30 SECONDS CR8 1 15 75 76 CR65B SEQUENCING CAA IN C4 5 1 e IGNITION ENGINE START STARTINGAID LOAD LEVEL SENSOR LIMIT SWITCH U6 CUTOUT ZDIODE 8 7 La 3 3V DC 5 DC 7 4 4 tie 4 4 4 te 2 7 TB35 GN WH TB35 15 D 8 PB9 PB10 12 J H 1 2 4 5 6 7 8 CC2 CD1 CD2 CC3 CC4 CD3 CD4 CC5 CC6 CD5 CC7 8 CD7 C gt y 8 8 3 z z 8 o e 8 g 2 8 D1 ALTERNATOR 4 83 NO 7 Ct M5 EX 8 44X Q7 D i 57 4 AUTO LEVEL CHOKE F9 NA 5 Y36 Y33 SOLENOID LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR A1 OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER 771 j i OUTRIGGER SHOWN IN tU P dele EE STOWED POSITION FAM E S al ud U26 M3 po Pr po Eos INPUT B 10 1512 1513 1514 1515 IaniTion STARTER gt LEFT FRONT RIGHT FRONT LEFT RIGHT REAR i IN L U9 06 OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER MOTOR 4 2 J 4 BATTERY CHARGER CONTROLLER INNAM ERREUR ES TZ50A Part No 84577 September 2014 Section 5 Schematics EE te r a Electrical Schematic 2 of 3 to se
160. 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 F H J K 4 5 ft lbs 7 9 Nm Hand 2 44 2 22 1 Bis Auxiliary down 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 function 25 27 ft lbs 34 36 Nm Shuttle valve 2 position way Turntable rotate circuit 4 5 ft lbs 6 Orifice plug 0 040 inch 1 mm Eu Restricts turntable rotate fluid flow Pott iterat tore 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 nipple Testing Solenoid valve 2 position 3 way with manual override Primary boom down 18 20 ft Ibs 25 27 Nm
161. ZF 20 1 8 8 T 2 oF gt i Genie 5 114 TZ 50 Part 84577 PLATFORM CONTROL BOX PLATFORM E STOP POWER September 2014 Section 5 Schematics So Electrical Schematic AS CE 2 of 3 from serial number TZ5005 285 to TZ5010 144 F E D PLATFORM CONTROL BOX 1 PLATFORM GROUND E E e 61 BN62 DOWN DOWN ENABLE ENABLE 4 TB3 TB4 DOWN UP 2 e aa IE RO x ENABLE ENABLE 5 8 AUTOLEVEL MODULE T aE l B3 2 DRIVE E STOP POWER 5 9 L EFFECT WITH ELECTRONIC DAMPING SWT 4 885 B ia a C 9 9 lt R14 669 L Er 9 8 o 4 pee 12 10K 08710 epe 2 T 27 6 2 2 2 2 ere gt PLATFORM GROUND DRIVE CONTROLBOX 2 9 599956 __________ ___ _____ ____ 1 z 2 UR 5 7 B 3 15 am
162. beginning with step 5 Genie GenieTZ 50 CE models with drive option 1 Visually inspect the parking brake cables and components for damage 2 Visually inspect the parking brake cables to ensure all are properly secured and installed into the brake backing plate and parking brake balance bar 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 W 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 7 Pull out the nose of the hitch as far as it will go 8 Remove the parking brake cylinder inspection cover Part No 84577 September 2014 Section 3 Scheduled Maintenance Procedures 9 Visually inspect the parking brake cables to ensure all are properly secured and installed into the brake backing plate and tension equalizer bracket Models to TZ5006 510 2 4 9 0 rear chassis parking brake cable cylinder output rod threaded rod tension equalizer bracket parking brake cyli
163. damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Genie UK The Maltings Wharf Road Grantham 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 Y yes completed 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 s
164. 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 on a 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 84577 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 GROUND CONTROLS If you are not installing a new level sensor proceed to step 10 6 Tagand disconnect the wire harness from the outrigger level sensor 7 Remove the three level sensor retaining fasteners Remove the level s
165. gradually Do not allow oil to squirt or spray Part No 84577 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 primary boom Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Part No 84577 Genie Genie TZ 50 COMPONENTS 18 Attach lifting strap of suitable capacity from an overhead c
166. 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 COIL MULTI METER 100 9V RESISTOR BATTERY Lon f VN fece b 9V DC battery 100 resistor Note Dotted lines illustration indicate reversed connection as specified in step 6 Part No 84577 o Genio 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 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 Resul
167. such moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Part No 84577 September 2014 Section 1 Safety Rules SAFETY RULES Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage 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 sure to properly dispose of old or Ge other fluids Use an approved container Please be environmentally safe sure that your workshop or work area E E is properly ventilated and well lit Genie Part No 84577 Genie TZ 50 September 2014 Table of Contents Introduction Section 1 Section 2 Section 3 Important Information u eer ante HALLE li Revi
168. tests may also depend on national regulations AWARNING Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine 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 machine in the following configuration Machine disconnected from tow vehicle Machine parked on a firm level surface Boomin the stowed position with both latches secured Key switch in the off position with the key removed Wheels chocked Parking brake applied Part No 84577 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 ndicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situa
169. y m m A 5 om gt Z lt 9 50 gt 2 a S z 4 E gt Genie Part No 84577 TZ 50 5 135 September 2014 Section 5 Schematics kwa ww Ms s _swGsa lt ecs Electrical Schematic AS CE from serial number TZ5011 311 5 135 5 136 Section 5 Schematics September 2014 Hydraulic Schematic to serial number TZ5006 510 5 137 5 138 Section 5 Schematics PK Hydraulic Schematic to serial number TZ5006 510 September 2014
170. 11 311 September 2014 E A B C D E F G H L M 5 1819 1 LS19A LOAD SENSE 1733 2 LIMIT SWITCH PLATFORM CONTROL BOX ele e 2 EGAD SENSEPOWEH LOAD SENSE POWER BN2 PLATFORM see 1 CHOKE START CONTROLS H1 i L4 TB9 FAULT ALARM PLATFORM GROUND 79 79 7 79 7 5 a 2 5 ENGINE OPTION z ee ele DRIVE E STOP POWER 2 5 ES m 1518 E 13 3 8 2 55 5 S LN DRIVE CONTROL BOX 3 E LS18A P T 2 2o 3 3 5 a f CAE N 2 DA D DE SS ROUND CONTROL BOX TB3 e e e M TB3 1 t d ED lt lt lt denis 1 KS1 TB2 TB4 RD P RD PLAT Y A RD GRD BN90 BN68 FAUL icr a eje 4 CHOKE ALARM TB4A 15AMP 4 14 GROUND ia d 598 CONTROLS CR65A T 200 L 10W L12 L13
171. 2 lt 1 BN59 BN60 Y FUNCTION ENABLE FUNCTION ENABLE DOWN ROU N D BN68 90 Y Y RIGHT G ROU N D ROTATE LEFT AND OUTRIGGER CO NTR O L PE norm e L EXTEND EN BOX 5 L4 et B BOX 4 1 1 ALARM LED l Kat 9 alls ET Y e 1 BN52 I IA BN53 14 BN50 BNS1 11 3 MOBEUS loe gu a BC QNIN MEN 8 5 Y ourniGGER ourniGGER OUTRIGGER 11 WITH 5 77 1 pa FAULT 0 x L SAY KS1 ENGINE GROUND 1 DOWN R22 BN49 __ Y Y Y 30 86 ENABLE 1000 OHM AUTO LEVEL 43 7 45 45 87 87 85 775 I SWITGH Pes 14 17 112 L13 114 115 87 87A Jor 85 280 BE Li 5 i pte R65A 4 4 RE lE 28 POWER SUPPLY TB22 P1 5 SOP a 30 86 30 86 86 30 86 ess 904 48 485 30 dg 425 30 D 86 30 86 9 gt 5 4700uF 9 U16A A 263 unt das 72 1 TIME DELAY 1 TB23 TB24 if U16B eza Tas far Tos fa
172. 2 AUTOLEVEL GROUND CONTROL BOX ENABLE 7 TB20 TB21 TB2 TB2 4 To 1K OHM 4 7817 Y Y Y Y TRIS CR65B s 716 7 CR61 1 5 818 8 J CR28 cs TB32 e TB32 m 65 I CR28 6 10 7 0 cnag tv GCON GROUND 1835 zt Lil i GROUND CONTROLS GROUND ay ay ay WD p 8 88 32 8 6 S gt X r e 40 A amp i w 2 c w L1 24 Boss B g 8 p 9 8 g 47 mH 2 5 0 034 m 2 2 g Y40 7 5 fF m 9 DRIVE OPTION Maas a ck 12 1 2 102 102 06 9 3 2 2 2 2 2 1 1 ROS Q 2 3 gt 59 Y50 Y11 m ipit iri C I 9 m 5 gt 5 m m 7 ROLLER c vas 33 com TEREE 2 412 j 12 k 5 lt lt AD 52 4 m DIZ 55 555 x Ms MOTOR 38 g E d BGCON GROUND HARNESS GROUND PLUG BATTERY GROUND 55 223 egg 005 2 3o g m 2 gt lt I YE x lt I vi DIDM 9 z c e o 5 83 2520 m cg 2 5 o2 32 8 50 99 5 5 2 m 5m 3 o 5 Oe AE DD 4 2 m m m mR 3 5 99 2 o d m m 2 2 m 2 m D 4 E m zo gt 2 lt Zs zo 5 2 r 8 9 Genie PartNo 84577 TZ 50 5 79 September
173. 2 Y25 gt 2 2 2 2 2 2 2 2 GCON GROUND HARNESS GROUND PLUG 4 j 4 4 4 4 z 22 88992229 dd 35888 r gt gt gt gt 2 2 m 2m mm 5 6 2 92 5 oS o gt gt lt lt B gp 9 g 22 8 2 gt m m m xw 2 m gt 13 6 lt gt 2 2 gt 2 gt E gt Genie Part 84577 TZ 50 5 93 September 2014 Section 5 Schematics 22 2 Electrical Schematic ANSI CSA from serial number TZ5011 311 94 95 Section 5 Schematics September 2014 2 7 Electrical Schematic AS CE to serial number TZ5004 181 Section 5 Schematics Electrical Schematic AS CE 1 of 3 to serial number TZ5004 181 C A B September 2014
174. 2014 Section 5 Schematics kwa ww Electrical Schematic ANSI CSA from serial number TZ5010 145 to TZ5011 131 80 September 2014 Section 5 Schematics Electrical Schematic ANSI CSA 3 of 3 from serial number TZ5010 145 to TZ5011 131 J 1 TB3 J BN66 2 BN67 ROTATE PLAT PLAT ENABLE LEVEL ROTATE ENABLE ENABLE 2 BNG4 anes BN657 BN97 1 SEC PHI A JIB 8 ENABLE ENABLE ENABLE ENABLE d 3 1 71 jCR9 1 87 3 LJ 4 LJ 5 PLATFORM GROUND Y 9 UU 11717 12 Uu 79 Y n iele joje 4 m A 3 8 998 gee gee 8 x RR GROUND CONTROL BOX RA D 2 5 JIB MANIFOLD 4 1 1 1 vi 1 3 BN57 BN58 PLAT 20 Y61 Y63 TB11 ESI ENABLE ENABLE P 4 T 19 60 Y62 r DN Pes iu jer T CR78A dcs CR78A 5 7 CR 9 ENABLE ENABLE ENABLE 9 2 2 2 2 2 2 TB32 5 BN56 BN36 5 5 e Tez frez rezo mx CR61 IE i 9
175. 30 CR15 TERMINAL 30 TURNTABLE HARNESS PINB TB10 9 17 18 TB35 TB23 PB5 7 PB5 9 TB24 TB4A TB20 P5 3 21 5 5 11 TB31 TB30 TB25 TB26 TB29 CR78A TERMINAL 87A TB27 TB3 PA3 TB32 TB35 Part No 84577 September 2014 Section 5 Schematics D X ss M Ground Control Box Wiring Diagram ANSI CSA from serial number TZ5010 145 to TZ501 1 131
176. 4 GN x LEFTREAR YL TURN 5 BL 6 RD 7 BN LEFT SIDE MARKER LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT B 1 TURN SIGNAL TERR 7 2 FOG LIGHT 3 REFLECTOR V 4 BRAKE RUNNING LIGHT Genie Part No 84577 TZ 50 5 11 Section 5 Schematics n Trailer Lighting Wiring Diagram Mechanical Axle CE from SN TZ5012 216 RIGHT SIDE MARKER Trailer Chassis Wiring Harness GR I I GR OR e OR WH WH Rp ss Mis RD BL BL Z BK e e 1 RD BK RD BK RD BK 2 BL 1 RD BK 3 WH 2 BL WH BK WH BK 4 CN 8 WH 5 OR 4 GN 8 6 RD 5 OR 97 7 7 6 j 8 WH BK s 9 272 97 L36 8 29 4 LEFT SIDE MARKER 1 9 5 e b 12 13 135 RIGHT SIDE MARKER September 2014 L33 RIGHT REAR TAIL LIGHT Platform Wiring Harness GR x e WH RD BL BK e RD BK RD BK BL WH WH BK GN w I RD BK WH BK L36 LEFT SIDE MARKER LEFT REAR TAIL LIGHT RIGHT REAR TAIL LIGHT 1 SIDE MARKER 2 TURN SIGNAL 3 FOG LIGHT 4 RED REFLECTOR 5 REVERSE LIGHT 6 BRAKE LIGHT Genie GND TURN
177. 440C m 2 3 3 2 OoJ 29 gI lt E o mm m Q gt E 25 2 g z z Piu m 20 p mm gt I Z m9 mee mo gt gt m L3 m lt lt m m oS 25 gt gt gt gt gt zo o 8 3 5 gt 28 8 gt El ENGINE OPTION 3 Genie 5 72 TZ 50 Part No 84577 PLATFORM CONTROL BOX PLATFORM E STOP POWER September 2014 Section 5 Schematics F Electrical Schematic ANSI CSA 2 of 3 from serial number TZ5005 285 to TZ5010 144 F E D PLATFORM CONTROL BOX 1 Ld BN61 BN62 DOWN DOWN ENABLE ENABLE Te le Te TB3 PLATFORM GROUND TB2 t DOWN UP 2 c ENABLE ENABLE AUTOLEVEL MODULE B3 2 DRIVE E STOP POWER ee 5 1 2 f 5 8 8 5 LL EFFECT WITH ELECTRONIC DAMPING imm d 5 6K 8 8 5 5 f 2 0 9 PET 9 8 mE d CR87 Z Z
178. 5 A J 4 2 4 4 4 35 1834 K z R 5 U vy W 1 2 DL 3r DM 5 DNI 7 8 D w oz ET E 2 s 3 55 z 2 5 29 2910 5 5 E 5 i Y23 Y52 Y21 Y25 E a 2 2 40 EX EX EX EX 5 5 gt 5 2 99 on f Y26 2 m 31 2 lt kx Y24 22 Y53 Y22 EX ES HeexX S 59 gt gt n ES TZ50F i BRN i 11 13 eis J E m 7 n 9 8 m m 2 Y50 58 2 m gt gt g gt gt 6 6 m m 0 gt gt 262056 m m m gt zio 2 D 9 2 3 T om mi a I gt 2 at lt 9 4 g v 2 m m z z gt 9 Genie Part No 84577 TZ 50 5 109 September 2014 Section 5 Schematics kw Electrical Schematic AS CE from serial number TZ5005 211 to TZ5005 284 5 109 5 110 September 2014 Section 5 Schematics Electrical Schematic AS CE 3 of 3 from serial number TZ5005 211 to TZ5005 284
179. 6 TERMINAL PA 86 LEVEL MANIFOLD HARNESS WH 87 8 WHK cess HHHOH 87 s RD ion 30 MANIFOLD HARNESS WH BK a CR70 C Q gt Q Q 85 w Terg PIN P3 N PLATFORM ROTATE D 35 U16B O Q 3 Q Q 86 C4 86 WH MANIFOLD HARNESS e 87A Q O 35 Q Q Sav oc 87A P3 S BUBK 35 WH OO 0 O 5 MANIFOLD HARNESS _ PS 4 gt 85 CR28 PIN POWER SUPPLY 3 ZENER DIODE 86 3 3V DC 6 86 WH MANIFOLD HARNESS 87 87A E 2772 Q 87 WH P3 U 5 TB26 Q 3 WH MANIFOLD HARNESS RUBK 85 CR67 2 Cj 2 85 DOWN ENABLE 14 Q a 2 7 5 88 B TB15 MANIFOLD HARNESS pk 87 C Cel 28 A 87 8A 4 TURNTABLE MANIFOLD HARNESS _ __ 85 2 CR69 C5 21 3 30 CR65B PINH PIN BOOM EXTEND 4700uF U6 CUT OUT gsm 0 87 4 87 87 BK WH 23 WH f CRB ins 22 2 2 917 E 85 IGNITION 5 OHM He 22 85 U6 CUT OUT WH 7 pia MODELS 6 i BK anes 2 C Q 3 2 WITH 87 87 d P 4 87 30 1 C Q L 19 Q 1 CR76 85 ENGINE START 18 85 LIMIT SWITCH BK RD 9 17 OQ gi zA 1 BK RD BN90 c 9 2 2 WH
180. 6B 87A Jer 85 87A 87 85 87A 87 85 87 87 85 87 87 85 TB28 x 1 1 TIME DELAY CR86 4 E 6 ee CR8 CRI 15 CR75 CR76 CR65B samona 04 IGNITION ENGINE START STARTINGAID LOAD LEVEL SENSOR LIMIT SWITCH U6 CUTOUT DIODE DIODE FAULT 3 3V DC 5 1V DC l w 1 Ld 9 Ld Ls rey CB2 TB35 GNWH 5 4 15 1 D 8 PB9 PB10 PB11 PB12 J ne 1 4 3 5 8 8 CC1 CD1 CD2 CC3 cs CCe CD5 CC7 CC8 CD7 CD8 CC10 8 8 R 8 z 8 8 e oe um d 8 8 2 3 g 222 8 9 r m SURE EIE 1 i 7 7 7 SA ame t cl ER EX EX i AUTO LEVEL CHOKE F9 NU STI Y35 Y36 Y33 Y34 SOLENOID 50AMP LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR E F9A 3 bal 7 SENSOR S2 OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER i 50 AMP OUTRIGGERS SHOWN E D a UN ry 4 STOWED POSITION ae oe ae N 1 N M3 0 5V DC 512 1513 1514 1515 IGNITION If STARTER sS LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR IN MOTOR L U6 OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER L J 09 4 4 BATTERY CHARGER CONTROLLER ES TZ50D
181. 8 BN96 MODELS TURNTABLE LIFT CUT OUT PLATFORM PLATFORM Y Y Y Y AUTOLEVEL WITH 5 6K OHM ROTATE LEVEL ROTATE 5 30 gj 48 thes OPTION poe Y 8 87 Jor 85 5 r 4 2 R14 meq WH Pahad RESISTOR 0 10K OHM 4 i BN97 BN97 BN64 6 65 R22C JIB JIB V PRIMARY BOOM 5 6K OHM BOOM BOOM BOOM EXTEND C4B UP DOWN UP DOWN UP DOWN UP DOWN 9 RETRACT ZENER DIODE 5 1V DC i i 6 CR9 4 30 488 87 4 71 JIB BOOM eld UN d PLATFORM srl PLATFORM UP DOWN ROTATE LEVEL 87A 87 85 87A 87 86 87A 87 86 7 1 7 TNCS 1 4 5 7 2 3 g 2 g LS19 3 3 E 7 LOAD SENSE Y60 Y62 Y19 JIB PLATFORM PLATFORM NOS lg BOOM ROTATE LEVEL LEFT DOWN N Y61 45 20 SWITCH SHOWN IN JIB PLATFORM PLATFORM UNLOADED POSITION BOOM ROTATE LEVEL RIGHT UP 44 FX 8 zem 4 ES TZ50D Part No 84577 TZ 50 5 63 September 2014 Section 5 Schematics 1 Electrical Schematic ANSI CSA from serial number TZ5004 182 to TZ5005 210 64 65 Section 5 Schematics September 2014 a rr rrrrrrrrrsnrrrr y r Electrical Schematic ANSI CSA from serial number TZ5005 211 to TZ5005 284 Section 5 Schematics September 2014 m nv 5 2
182. 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 Manual Genie part number 84443 Part No 84577 September 2014 Section 4 Repair Procedures 12 1 Outrigger Components How to Remove an Outrigger Outriggers are essenti
183. 85 48 2 i y rur D 6 Ut 6 0 1 10 SECONDS 24 1 87 Jor 85 87 85 87 87 85 0168 m 87 Jor 85 87 87 85 87 87 85 87 87 85 87 87 85 Ey i 5 2 1 TIME DELAY CR86 2 E 6 15 CR8 CR1 CR15 VOTOS SECONDS CR75 CR76 CR65B SEQUENCING 5 m i IGNITION ENGINE START STARTINGAID Loa LEVEL SENSOR LIMIT SWITCH CUTOUT DIODE DIODE 5 7 ec FAULT 3 3V DC 5 1V DC M Ld m 2 TB35 GNWH TB35 15 AMP 4 1 4 7 B E D 8 PB9 PB10 PB12 l ni J P 2 4 3 5 6 8 CD1 CD2 CC3 CC4 CD4 5 mo CD5 CC8 CD7 CD8 CC9 CC10 8 8 R 5 5 8 8 EE 8 s 2 7 5 os 4 6V d EX EX ex EX gt I Q7 AUTO LEVEL CHOKE F9 5 Y36 Y33 Y34 SOLENOID 50AMP LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR F9A OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER z gt 5 E OUTRIGGERS SHOWN x x N CHO 8 f n STOWED POSITION Le M wa ME 02611 3 27 1512 1513 1514 515 STARTER LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR i MOTOR OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER 2 1 l
184. 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 N MOTOR M STANDARDS REGULATIONS IN ON 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 NG31 6BH United Kingdom MODEL 7 50 SERIAL NUMBER 25011 299 MODEL YEAR 2011 ELECTRICAL SCHEMATIC 50440 77172 NOMINAL Position 40 R POWER M Serial label location location We PN 77055 stamped on chassis Genie Part No 84577 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
185. 9 8 U16A 2870 2868 28611 28621 m m gt 5 n ao 4 8B LOAD GCON GROUND i gt gt 6 97 T d d a 3 a x dz 4 8 8 5 9 5 i 4 ES0440D 1813 1515 O R RROR T gB g 8 8 E E 7 presi d Bw 4 A e 1812 1514 mer Tir W 22 26 3 14 wy 1 OUTRIGGER LIMIT SWITCHES 23 2 voi Y25 1 2 ye 2 ye ye ve 8 7 GCON GROUND HARNESS GROUND PLUG i 4 4 6 2 8 8 m 5520 3 Se O O Z o gt gt gt gt 2 2 m of m7 5 G222 O lt gt gt om 2 Z gt 27343 z m x mm x 358284 lt Domo gt 2 8 gt gt 5 4 x gt Genie Part No 84577 TZ 50 5 81 September 2014 Section 5 Schematics kwa ww Electrical Schematic ANSI CSA from serial number TZ5010 145 to TZ5011 131 82 83 Section 5 Schematics 2014 Electrical Schematic ANSI CSA from serial number TZ5011 132 to TZ5011 310 Section 5 Schematics September 2014 m R R a Rr s8 Electrical Schematic ANSI CSA 1 of 3 from serial number TZ5011 132 to TZ5011 310
186. 9 BN90 Choke CR70 93 Platform rotate Genie 5 2 TZ 50 Part No 84577 September 2014 Trn rr Electrical Abbreviations Legend CR71 CR72 CR73 CR74 CR75 CR76 CR77 CR78 CR86 CR87 D1 F6 F9 F9A FB1 GND G6 G7 H5 JC5 KS1 Description Control Relay Platform level Outrigger Function enable ground controls Function enable platform controls Level sensor Limit switch fault Down enable Lift cut out 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 4 112 113 114 115 133 134 135 136 158 LS LS12 LS13 LS14 LS15 LS18 LS18A LS19 5 P1 P2 P3 Q7 Genie Part No 84577 Section 5 Schematics Description Light or LED Load sense at ground load sense option Load sense at platform load sense option Left front outrigger Right front outrigger 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 p
187. 92 87A 87 85 87 87 85 87 87 85 87 87 85 87A 87 85 4 4 4 i 6 G6 CR72 CR70 CR68 CR67 CR69 HOUR OUTRIGGER TURNTABLE SECONDARY PRIMARY BOOM BOOM EXTEND TB35 4 TB34 L 4 L M N P R s T uy w 2 1 3 sy 7 Z 2 5 E z 8 8 50 58 Y11 7 DRIVE PROPORTIONAL BRAKE Y40 Y23 Y52 21 Y25 t d RIGHT DAVE OUTRIGGER ROTATE SECONDARY PRIMARY BOOM EXTEND LEFT DOWN DOWN RETRACT AX cox X Y50A Y59 Y39 Y24 Y53 Y22 Y26 DRIVE PROPORTIONAL OUTRIGGER ROTATE SECONDARY PRIMARY BOOM FWD REV DRIVE RETRACT RIGHT UP UP EXTEND RIGHT LEFT EX EX EX EX FX ES TZ50D 4 pe 2 4 i 8 Genie Part No 84577 TZ 50 5 103 September 2014 Section 5 Schematics 1 Electrical Schematic AS CE from serial number TZ5004 182 to TZ5005 210 5 103 5 104 September 2014 Section 5 Schematics Y Electrical Schematic AS CE 3 of 3 from serial number TZ5004 182 to TZ5005 210 K J H G F E D
188. 9A y D1 of e gt ra PR5 c ALTERNATOR 1 3 50AMP 8 1 8 3 5 gt 2 9 EXCT 2 D D Di i LES js m e 2 e e Q7 mi Sum E 3 3 3 i 026 INO 9 STA T 5 m 5 9 9 Lm L d 97 FB1 50 2 5 2 E i i p 7 5 1 1 Y2 2 i BATTERY GROUND a 5 9 599 9 o gt m ez 50440 2 55 gt lt 4 49 45 5 5 5 2 2 gt o2 m oJ OI lt mm m 5 52 gt m 2 2 nmn m 2 2 ons 2 5 gt mm 053 2 28 m 7 mz wo 5 22 P m 8 9 23 x x zo 2 lt 8 m 5 gt ac 9 a 5 2 m ENGINE OPTION Genie 5 84 TZ 50 Part No 84577 September 2014 Section 5 Schematics LLL SLE Electrical Schematic ANSI CSA 2 of 3 from serial number TZ5011 132 to TZ5011 310
189. ABLE 05 F 2 2 AUTOLEVEL MODULE 2 DRIVE E STOP POWER E 338 x 44 5 5 HALL EFFECT WITH ELECTRONIC DAMPING 253 m R22B 3 8 lt 5 6 299 me R14 9834359 8 n 4 CB 12 15 9 9 WW 820 Dill 5 1V eeo we 4 5 DRIVE CONTROL BOX 2 Fes 798 PLATFORM GROUND 5 D o gx e 2 E 2 22 3 7 7 7 7 7 eo 5 GROUND CONTROL BOX DR DGDJDH DRON DM DIPPER ANA 8 GROUND CONTROL BOX TB3 4 P e ENABLE CR65A 9 og 1 tus 4 4 BN60 BN52 BN53 BN50 51 trom LROR BRO 77 ENABLE ENABLE ENABLE TB5 6 TB13 A C TB20 4 21 23 24 i ui a 1K OHM 67816 h 4 e 7814 15 11 CRESB CR61 t 1818 8 J CR28 5 22 bs TB32 Sank 464 2 Sey 4 H cra cp LI 7CR86 YOP 5 es GCON GROUND 1838 4 s 2 4 791 1109 GROUND ii 52 o 1 7 8 2 F g 6 B d w L1 BATTERY 24V A d TTA x 5 m 1158 95 eae gt 1 1 n a 58 Y50A 7069 2 m 9 vov Chal Chal Qa bb 25 8355
190. ALARM T uU A T i gt z gt e e DRIVE CONTROLS 2 ele DRIVE E STOP POWER 92 gig 5 L m 1518 p 2 A Lat is E LS18A 12 x 3 E 5 gt 8559 DAJDF GROUND CONTROL BOX TB3_ i i TB3 CB2 P1 KS1 et e ELS 15AMP 2 PLAT TB2 4 NOT n RD T RD H5 FA 90 BNG FAULT Aggy Dele GRD ACHOKE ALARM FEARS 15 4 CR64 GROUND 2 CONTROLS eno 112 113 114 115 caze G CR76 5 CR15 CR1 U16B 3 15 7c 17 f T6 LOAD 1 4 i GCON GROUND AN N AN A gt 8 as 8 58 3 5 emee 01 8 5881 SR 8 58 D gt SWITCHES 2 2 E 2 gt 2 2 5 56 25 SONO APA BATTERY 24V 6 275AMP EAM E gt gt PRE gg E 5 8 3 5 8B 1 A 7 S g 2 e Q7 M 50AMP mI o 3 5 S 5 AP 5 5 5 5 B5 059 NO 5 S T E 5 8 Ls Ww lj D D ru 3 2 2 M3 l 4 41 8 7 _ 1 m gt T 1 2 T ae 24 509 o 9 ede FE oz om BATTERY GROUND 2 5 2 55 gt gt gt lt E 59 ES0
191. ARNESS _WH BK 1 TURNTABLE PIN J 30 CR86 SA Y T C 30 CH75 PIN C 85 SEQUENCING BK TB35 LCS lt j 857 LEVEL SENSOR OG 2 Q H 2 0 52 LE 1 e AAS OTT 2 R22 O 7 1000 OQ NOTE DIODES 2 Q 9 UNLESS OTHERWISE MARKED Q Q 6 9 I OQ OQ TS 50440 Genie Part No 84577 TZ 50 5 23 Section 5 Schematics September 2014 m ss rs QI Ground Control Box Wiring Diagram ANSI CSA from serialnumber TZ5010 145to TZ5011 131
192. BN98 MODELS ENGINE JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UPDOWN OPTION zx mm BN62 OIO FUNCTION ENABLE BOOM UP EXTEND 2 TURNTABLE AND Ett in D PLATFORM RIGHT 1 _ siZ BL CR 9 TERMINAL 30 6 i 4l G7 BN64 BN66 RD TB3 ENGINE BATTERY CHARGE SECONDARY BOOM TURNTABLE 2274524 INDICATOR UP DOWN ROTATE E S RD TB1 BN61 9 O FUNCTION ENABLE BOOM DOWN TURNTABLE AND 0 2 PLATFORM ROTATE BK RD pA BKRD gt RD WH 80 o TB2 RD WH BK POWER CABLE PIN 2 TB5 BK GNWH CR 788 TERMINAL 87A RD BK 2 BD TB7 87 87 CR78B T BNe4 PP 85 LIFT CUT OUT OA lt ool6olo6o lo ool ojloloo o JIB HARNESS PIN 8 81 97 ORBK 30 JIB HARNESS PIN 2 OR BK 71 9 8 7 6 5 4 3 2 1 PLATFORM
193. 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 weighted 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 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 Optionalfluids Petro Canada Environ MV 46 Statoi
194. CHOKE SECONDARY BOOM TURNTABLE f UP DOWN ROTATE S HD TB1 BN61 5 oO FUNCTION ENABLE BOOM DOWN BOOM RETRACT D TURNTABLE AND PLATFORM ROTATE B mm E LEFT RDWH WHIBK 5 BK GNWH 78 TERMINAL 87A M RDIBK_ po _ 2 BD 7 87 87 k LEA ees oo o ojoojoooo ooloo oo BN64 85 LIFT CUT OUT as BE TBA 9 9 8 7 6 5 4 3 2 1 87 JIB HARNESS PIN 08 s II 30 OR BK CR71 JIB HARNESS PIN 26 2 25981 e 5 5 PLATFORM LEVEL CN m r5 oolooloolooleoloologo olo 4 86 GN 87 87 GN PB6 JIB HARNESS PIN P6 5 GN BN97 PAG 30 CR9 fash JIB HARNESS PIN 6 4 gs JIB BOOM UP DOWN 5 25 87 JIB HARNESS PIN 6 7 BL GNWH 30 JIB HARNESS PIN 6 gs CR87 PLATFORM ROTATE OPTION BK ES0440G Genie 5 50 TZ 50 Part No 84577 September 2014 Section 5 Schematics Drive Control Box Wiring Diagram AS CE to serial number TZ5004 284 BK 71 GNWH pi EN DA RD RD BK DE BKWH pF JOYSTICK w CONTROLLER P3 GO GO STOP x Z G L 1 69
195. CON GROUND TN vf 3 818 zy 51818 z 3 eme P fs 2 9 3 Fy FT je W o gt 5 SWITCHES m E 2 m g m gt gate Ba 6 o r6 o E gt 5 275AMP 3 X 5 BATTERY 24V SANE P8 1 AME 1 B 3 gt 50AMP 14 m ro xf 2 02 o S 5 UT Q7 EDAMP BATI m I e 5 B5 M 2 3 3 DO FB o o lt 1 U26 NO tsp a 8 P 8 67 FB1 3 b 2 3 D 5 7 ae u gt z l 1 2 z 5 _ 5 o3 BATTERY GROUND o E 8 55 gt 3 5 Sg x ES0440D poco 1 90 2 2 gt omm m oo o2 A po 3 a oJ 2 QI lt O mm m m ors gt 2 m 205 Z 2 2 2 ons do S 5 5 2 6 m55 m 2 a 2 amp r m 22 3 8c gt m gt 2 5 gt 8 Y 2 a m ENGINE OPTION Genie 5 120 TZ 50 Part 84577 September 2014 Section 5 Schematics mr Electrical Schematic 2 of 3 from serial number TZ5010 145 to TZ5011 131
196. D 28 Q 5 9 87A bi BK WH 28 ET eT BL TURNTABLE 3 27 4 HARNESS MANIFOLD HARNESS BKWH CR69 Q 27 CR65B PINH PIN V BOOM EXTEND C 88 B 87 87 IT BKWH ppg e 123 lt WH 37 9 Ow 90 CR65A 85 IGNITION O 22 O 85 CUT OUT WH TB7 5 ts Fite MODELS 6 2 4 BK_ Beg 6 0 20 y v WHIBK BK 87 C5 2 87 87 WITH PD9 19 4700uF 7 ENGINE 30 ORI S C 18 C C 85 K i OPTION V OQ BKRD lt C 9 i BIRD uoo M 4 2 86 87 87 4 6 Q Q 87 87 BK RD RD T RD PB10 B CR15 P1 C 14 e 7 CR64 PA3 85 STARTING AID 7 3 a 3 e 85 FAULT GROUND is 8 86 2 12 Q DC 1 86 gt EA Das Pa 87 87A TURNTABLE TURNTABLE HARNESS 1816 1 CX 11 gt HARNESS PIN J 30 CR86 1 153 7 30 CR75 PIN C 85 SEQUENCING BK O 4 85 LEVEL SENSOR i H PF O 1 H z Q 0 2 R22 SN 1000 OHM O Ta NOTE DIODES ARE 2 AMP 2 4 UNLESS OTHERWISE MARKED V PAS 2 O L ES TZ50F gt 25005 211 Genie Part No 84577 TZ 50 5 21 Section 5 Schematics
197. FOLD 4 1 yi 1 i 1 BN93 BN57 BN58 POE Y20 Y61 Y63 TB11 ESI ENABLE ENABLE p Y19 Y60 Y62 Bo 1 Dx 78319 Pes 2 T TB34A t 5 CR78A 1CR78A 9 ENABLE ENABLE ENABLE 9 2 2 2 2 2 2 TB32 89 5 BNse BN36 5 va Iro 29 2 2 2m 3 mm 27 m lt lt CR70 CR68 JCR6743 2869 2 8 UA 70 e 29 fase 14 5 OAD a z 3 GCON GROUND 4 2 m 5 gt 6 m m ar 8 lt x wd c lt ES0440C 88g z 1513 1815 RF O R RROR X g a gi AAF d LS12 LS14 c T I 22 26 OUTRIGGER LIMIT SWITCHES Y23 1 Y25 m gt 2 2 3 2 2 ve X 2 7 GCON GROUND HARNESS GROUND PLUG 1221 02 11 2z ZRRRBESS a g og nagossme m m m r 2 o o lt lt oo lt m om 5 2 zz 2 rz mr Z Z m x 2 gaymzmmsx x gt z 2 2 99 2 On gt 8 8 8 lt gt Genie Part No 84577 TZ 50 5 117 September 2014 Section 5 Schematics k aww Electrical Schematic AS CE from serial number TZ5005 285 to TZ5010 144 5 117 5 118 Section 5 Schematics September 2014 Rw rr r nm cr r Electrical Schematic AS CE from serial number TZ5010 145 to TZ5011 131 5 119 5 120 Section 5 Schematics September 2014
198. FT FRONT OUTRIGGER 5 BN54 3 L12 50 LFLED LEFT OUTRIGGER BOOM 5 114 UP DOWN q OPTION leien 5 BN36 s mi _ ___ UPIDOWN GN WH 5 BN51 2 Q lt 115 REAR OUTRIGGER Q RR LED 55 BN57 lt WH SECONDARY BN53 RD WH BOOM RIGHT FRONT RD WH UP DOWN OUTRIGGER L13 RFLED ORMWH OR WH RD WH BK GN WH BL BK RD BK GN RD I BK WH RD WH Ps RD H5 ALARM Jae HOUR METER BK Genie ES0440G September 2014 TB33 CR15 TERMINAL 86 CR1 TERMINAL 86 TURNTABLE HARNESS PINE POWER CABLE PIN 1 TB3 CR6 TERMINAL 30 AQ _ CR15 TERMINAL 30 BCI TURNTABLE HARNESS PINB TB10 9 17 18 TB35 TB23 PB 7 PB5 9 TB24 TB4A TB20 P5 3 21 5 5 11 TB31 TB30 TB25 TB26 TB29 CR78A TERMINAL 87A TB27 TB3 PA3 TB32 TB35 TZ 50 Part No 84577 September 2014 Section 5 Schematics rFrs O T mwsssrssmhsW Ground Control Box Wiring Diagram ANSI CSA from serialnumber TZ5011 132
199. GNWH BN51 RIGHT REAR OUTRIGGER Q Q 115 RR LED GNWH BN55 zn TURNTABLE BN53 RD WH SECONDARY ROTATE TB20 BOOM RIGHT FRONT RD WH UP DOWN OUTRIGGER L13 RF LED ORWH _ 21 OR WH ccs rggi GNWH _ BUBK TB25 _TB26 GN TB29 AD CR78A TERMINAL 87A BKWH TB27 BD WH RD TB32 H5 ALARM 26 HOUR METER BE TB35 gt gt was moved top position FROM TZ5005 343 _ z 50440 5 40 Genie TZ 50 Part No 84577 September 2014 Section 5 Schematics n rr Ground Control Box Wiring Diagram AS CE from serial number TZ5005 285to TZ5010 144
200. Genie A TEREX BRAND Service Manual Serial Number Range M from 25004 1 to TZ5012 253 Part No 84577 Rev B1 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 c
201. HOWN IN STOWED POSITION WITH THE POWER OFF g 2 2 m 2 2 2 o 2 481 8 75 8 x A PBI PA12 5 4 DM DN 2 3 4 8 6 5 T LEFT RIGHT AXIS FRONT REAR AXIS AUTO LEVEL 3 LEVEL SENSOR LEVELSENSOR 30 86 ae TURNTABLE LEVEL L UP DOWN m OPTION aa p L 6 87 85 TB33 14 2 3 41 4 fm E SIE y CR78A Y GROUND l po J po pe 4 4 4 CONTROL CR66 LEVEL SENSOR RELAY BOX t 55 BN54 BN56 BN36 Yt SECONDARY PRIMARY BOOM JIB s ee CR61 BOOM BOOM EXTEND RETRACT BOOM W 4 24 AUTO LEVEL UP DOWN UP DOWN UP DOWN SYSTEM RELAY Y Y za z les 5 TB25 27 29 2 30 86 Y Y Y q TB28 GN YL GN 87 87 85 1 1 1 7 86 ay 4 7 42 48 7 99 4 86 30 86 P 86 30 86 30 86 11 61 Et i 23 c 1 Di 87 85 87A 87 85 87 87 85 87 87 85 87A 87 85 87
202. Honda part number 31ZH7630 Honda GX160 Owner s Manual Genie part number 97228 Section 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 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 Puton protective clothing and eye wear 2 Be 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
203. Hydraulic Schematics Description Pilot operated directional valve left Orifice drive speed Pilotoperated pressure compensator Orifice drive speed Counterbalance valve Pilotoperated pressure compensator Counterbalance valve Shuttle valve Brake Dump Pilot operated directional valve right Proportional valve right 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 84577 TZ 50 Section 5 Schematics September 2014 Hydraulic Symbols Legend 9 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
204. KER Boom Harness 6 RD BRAKE LIGHTS ELECTRIC 7 BN SIDE MARKERS FOG LIGHTS RUN BRAKE L33 RIGHT REAR TAIL LIGHT BY BACKUP L35 RIGHT SIDE MARKER Platform Wiring Harness GN A TURN BN e e BL WH GND WH stop WH RD e lt a L FoG WH BL BR Bi FoG 1 YL BK 2 A 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 RED REFLECTOR REVERSE LIGHT BRAKE LIGHT Part No 84577 September 2014 Section 5 Schematics m Trailer Lighting Wiring Diagram Hydraulic Axle AUS from SN TZ5012 216 RIGHT SIDE MARKER Trailer Chassis Wiring Harness GR A I GR OR e OR WH WH RD RD BL 77 BK e e 1 RD BK RD BK RD BK 2 BL 1 RD BK 3 WH 2 BL WH BK WH BK AGN 3 wH m z m z 5 OR 4 GN 8 amp T 5 OR 9 P nk 6 RD e e 10 8 m 9 e L36 29 94 LEFT SIDE MARKER L33 RIGHT REAR TAIL LIGHT
205. L14 L15 5 fo TB7 p U16B 5476 CR8 CR15 cn 76 16 1 3 15 17 CR75 CR75 1 1 E GCON GROUND x y y X X x bd d arate aT dT d 5 2 3 CR20 aig OUTRIGGER 1 d 1o Y m d 6 m m ga o i x SM m 2 3 gt ODR1 gt 2 2 gt gt 45 ES 5 g 3 AE x 5 8 5 BATTERY 24V 275AMP F9A d 2 2 Di 7 ATI 1 3 U6 B A SOAMP P8 1 8 3 AN I m m 20 gt 3 RS MODE m ee 5 s 5 5 5 Ei ass LFB E E d gt 7 ca U26 INO gt gt sm gt 5 D 5 E CHARGER quet 4 57 1 9 m E m peus e gt 2 5 ESAE Rn EE B B 5 m x LOL 2 4 4 4 4 ES0440G BATTERY GROUND n od Te a c i 555 5 5 5 81 5 daz m oU gt 295 9585 d 9 282 ok 8 88 8 m D 2 z oso gt m 29 o 8 S BEF 2 85 a mg 9 o m gt 2 Ons On gt 5 lt lt OS zm o gt gt lt m 9 z L za lt 2 gt lt gt 58 gt 20 T 4 m lt 2 lt ac o m ms 2 5 D
206. LEVEL 4 s eN r Jie HARNESS PIN 8 9 9 87 3 BN97 GN BK CR9 ig JIB HARNESS 4 85 JIB BOOM UP DOWN PAG 5 86 G7 BL 87 87 JIB HARNESS 7 GNWH BL BK CR87 JIB HARNESS PIN 6 PLATFORM ROTATE BK ES TZ50F Genie Part No 84577 TZ 50 5 29 Section 5 Schematics n rr v Vm RUIN Platform Control Box Wiring Diagram ANSI CSA from serialnumber TZ5005 285to TZ5010 144 September2014 ZENER DIODE 5 DC h 2 14 BN65 BN67 R22B WV Boom BOOM PLATFORM 5 6K OHM 8220 FUNCTION EXTEND RETRACT LEVEL SPEED 2 9 EMERGENCY STOP
207. N 0 C BOOM RETRACT e CHOKE O ROTATE LEFT AND OUTRIGGER WH a 1 TB9 n TB17 Wit 18 58 H BN56 PLATFORM BN49 UPIDGUN lo 6l AUTO LEVEL 2 TB35 f BL WH S BN52 TB23 u 7 BL WH LEFT FRONT OUTRIGGER X BN54 BN93 BN50 PRIMARY PLATFORM LF LED LEFT REAR OUTRIGGER p umow llo OPTION L14 L LRLED cDNA BN36 DO JIB V BOOM UP DOWN ALL GNWH BN51 Z RIGHT REAR OUTRIGGER 5 115 E RR LED TB24 BN55 BN57 lt lt TORIA TURNTABLE BN RD WH SECONDARY ROTATE 53 TB20 BOOM RIGHT FRONT RD WH UP DOWN OUTRIGGER 113 RF LED ORWH _ 21 OR WH ccs HD WHIBK _TB31 GNWH __ TB25 RDIBK__ 1826 TB29 BD CR78A TERMINAL 87A BKWH TB27 BD TB3 pa RD TB32 H5 ALARM 06 HOUR METER RC TB35 ES TZ50C Genie 5 18 TZ 50 Part No 84577 September 2014 Section 5 Schematics D Ground Control Box Wiring Diagram ANSI CSA from serial number TZ5004 182to TZ5004 324
208. N PLATFORM ROTATE 35 U16B O 0 3 Q Q 4 ss 35 O 5 ce 7 86 WH MANIFOLD HARNESS 87 BUBK C O as 6 jsivbo 87 87 MANIFOLD HARNESS _ CR68 Q 54 Q Q l CR28 oN ESR 7 85 SECONDARY BOOM pi 33 gt 85 POWER SUPPLY M C D ZENER DIODE 43 86 17 COM 83V DC 86 WH MANIFOLD HARNESS RD 87A 3 32 Pw 87 WH TE PIN P3 U RDIBK O Q Ule WH CR67 O Q ms 30 77 MANIFOLD HARNESS RD BK 85 E Cj 30 C 85 DOWN ENABLE 56 RD 2 2 s 2 2 5 gt Bb TB15 2 MANIFOLD HARNESS pk 87 es 87 TURNTABLE MANIFOLD HARNESS BK WH jg CR69 Q Li 27 CR65B PINH PIN P3 V BOOM EXTEND C M D cmu L l 5 OC fas oO 45 86 RD gt 4 86 E d S Q Q 124 Q 87A CRS BKWH pog 0 23 C CHESA WH 85 IGNITION 6 Q 22 C d 3 85 U6 CUT OUT WH Q Q 22 O TB7 BK p4 4 3 e 79 B Sie 3 5 MODELS 9 4 pN68 C5 O O 20 C 5 WHIBK WITH P29 w Hie 0 1 uF a CRI 2125 5 fie 8 CR76 OPTION 85 ENGINE START 5 2 G 17 O 85 LIMIT SWITCH FAULT BK RD_ py O O ais 2 BKRD 4 H 2 WH 87 87 c Q Q Q 87 87 3 RD 2 14 3 RD pas 85 STARTING AID
209. N36 EE 5 5 2 TB29 m 4 26 27 Bx ud 28 m m sb zi lt 61 U1 le lt lt m gt 8 6A 0870 11 42868 12 CRG7 13 4CRG9 m m gt 2 1 E DD 7 7 zm LOAD m 4 GCON GROUND 4 2 A n 6 7 7 X AN GNE GS h 5 2 95 558 5t PS04401 527 5 1513 1515 RF O R RROR T E 8 E 3 A RA 1512 1514 Y24 Y53 22 26 d LF O R LR O R wa 50 wa wk gt OUTRIGGER LIMIT SWITCHES Ql AR Y 1 m Y23 Y52 Y21 Y25 P3 lt 7 gt 2 2 42 2 2 2 2 v2 GROUND HARNESS GROUND PLUG ez 5 9 ESOS Ema gt gt gt Z gg Z z 0 m om gt an gt gt T Z Z lt lt m x gt Oz m mim 4 2 3 32 6 zm 8 lt g 9 2 gt m 6 5 gt lt gt Genie Part No 84577 TZ 50 5 129 September 2014 Section 5 Schematics Electrical Schematic 5 from serial number TZ5011 132 to TZ5011 310 5 129 5 130 Section 5 Schematics September 2014 o x Electrical Schematic AS CE from serial number TZ5011 311 5 131 5 132 Section 5 Schematics Electrical Schematic AS CE 1 of 3 from serial number TZ50
210. NN O C 12 2 2 2 1 gt 8 86 _ 2 L 12 Q 2 DC 1 86 WH 7 87 1 WH TURNTABLE HARNESS 1816 5 CX 11 2 il EIL HARNESS PIN J 30 CH86 1 mho 7 gt 30 CR75 PIN 85 SEQUENCING B usb i TA 4 lt 85 LEVEL SENSOR Bs Gy C 8 A PQ o 2 0 5 1 C d R22 NT 1000 Q NOTE DIODES ARE 2 AMP OQ Q UNLESS OTHERWISE MARKED Q OQ PA5 ES TZ50F gt FROM 75005 191 FROM TZ5005 211 Genie Part No 84577 TZ 50 5 39 Section 5 Schematics September 2014 ssssiisin xr vr msm Ymc r Ground Control Box Wiring Diagram 5 from serialnumber TZ5005 285to TZ5010 144
211. NOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number Genie GenieTZ 50 84443 Section Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B 13 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 B 14 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 KNOTT Axle Service Manual Genie part number 84443 Honda GX160 Owner s Manual Genie part number 97228 Honda GX160 Shop Manual Genie part number 97229 Genie 3 26 Genie TZ 50 Part No 84577 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 whicheve
212. OIG PLATFORM ROTATE RIGHT pai b BL CR 9 TERMINAL 30 AND 6 SN A gt f G7 BN64 BN66 gt RD SECONDARY TURNTABLE Z INDICATOR ES UP DOWN ROTATE 227 MA BD TB1 BN61 e FUNCTION ENABLE BOOM DOWN TURNTABLE AND PLATFORM RD WH 8D 2 POWER CABLE PIN 2 80 _ GNWH CR 788 TERMINAL 87A M RDIBK ppg ppo _ gt RD 87 87A DD LL I res SO OO SO DOO POO OoOo oo BN64 i 85 LIFT CUT OUT ELI 7 4 2 1 E 87 6 i JIB HARNESS PIN 3 2 7 ORBK 30 ME M rare WY 2 MV M 4 8 zi 87 87 PB6 PAG JIB HARNESS PIN 5 GN 80 CR9 JIB HARNESS PIN 4 SNBK 65 JIB BOOM UP DOWN Sy 5 JIB HARNESS 7 80 87 GNWH 30 BL BK CR87 MIBIHARNESSPINIG T 85 TB ES0440C Genie TZ 50 Part No 84577 2014 Section 5 Schematics Platform Control Box Wiring Diagram AS CE from serial number TZ5010 145 to TZ501 1 131 C4A ZENER DIODE 5 1V DC
213. OUND l 2 gt 5 gt m m 8 5 37 9 9 3 2 5 5 3 l 50440 1513 1515 5 RFO R RROR B P 8 E A AR AE 1512 1514 in METS Y59251 vee 26 A 12 mS 44 OUTRIGGER LIMIT SWITCHES Y23 52 21 Y25 J 2 2 V2 2 2 2 2 2 8 GCON GROUND HARNESS GROUND PLUG ez 88882222 o o 824048 9 x gt O O S m m gt 2 2 Z lt lt Q ox gt gt 2 lt 566 m om 2 2 0 2 z mr lt lt m 5 zm m x gt 24 0 lt g 3 m gt 2 9 gt 2 2 m o 9 ud gt E z gt Genie Part No 84577 TZ 50 September 2014 Section 5 Schematics 1 Electrical Schematic ANSI CSA from serial number TZ5011 132 to TZ5011 310 88 89 Section 5 Schematics September 2014 Electrical Schematic ANSI CSA from serial number TZ5011 311 Section 5 Schematics September 2014 Electrical Schematic ANSI CSA 1 of 3 from serial number TZ5011 311
214. OWN UP DOWN UP DOWN 6 71 CR9 CR87 ro S Be 27 9 5 6K 7 gt 9 S 7 87 5 1 2 87 B 85 2 2 9 7 m m 4010253 9 1 2 3 4 5 6 7 o iio 0 9 me a moz 2 c 288 248 48 1519 lea xo mo 33 T 922 127 co BB 19 Y1 58 Y60 weg 15 8 d LIMIT SWITCH SHOWN X Y20 63 IN UNLOADED POSITION ES TZ50F 1 Part 84577 TZ 50 5 69 September 2014 Section 5 Schematics kwa ww Electrical Schematic ANSI CSA from serial number TZ50005 211 to TZ5005 284 71 Section 5 Schematics 2014 3 Electrical Schematic ANSI CSA from serial number TZ5005 285 to TZ5010 144 Section 5 Schematics m roi Electrical Schematic ANSI CSA 1 of 3 from serial number TZ5005 285 to TZ5010 144 September 2014 A B C D E F G H PLATFORM CONTROL BOX 1 5 PLATFORM E STOP P2 BN3 BN2 G7 CHOKE START H1 FAULT 46c
215. PLATFORM UP DOWN ROTATE LEVEL 87A 87 85 87 87 85 87 87 85 4 4 4 P 7 7 1 4 E 1 E 4 r 2 2 2 2 9 8 1519 l 3 2 7 LOAD r _ Y60 Y62 Y19 JIB PLATFORM PLATFORM a BOOM ROTATE LEVEL LEFT DOWN PIE amp EX Y61 X 20 SWITCH SHOWN IN JIB PLATFORM PLATFORM UNLOADED POSITION BOOM ROTATE LEVEL x e EXTEND RIGHT UP ES TZ50A 8 Genie Part No 84577 TZ 50 5 99 September 2014 Section 5 Schematics 1 Electrical Schematic 5 to serial number TZ5004 181 5 100 Section 5 Schematics September 2014 Electrical Schematic 5 from serial number TZ5004 182 to TZ5005 210 5 101 5 102 Section 5 Schematics September 2014 ms v Tri Electrical Schematic AS CE 1 of 3 from serial number TZ5004 182 to TZ5005 210 A B G H K L M
216. POWER 9 gig 5 L fi 9 1518 o z 5 iz DRIVE CONTROL BOX E LS18A 12 2 3 d gt E 2 gt 5 2 599 E amp Ae GROUND CONTROL BOX TB3_ i i TB3 P1 KS1 15 2 PLAT TB2 4 RD BN90 BN6 CR65A CBI ele GRD STAR F TBA 15AMP 4 GROUND CONTROLS L12 L14 Lie e kc L 4 15 CRI 15 h qan 5 T6 LOAD em i GCON GROUND AN N AN A Bu cam 28 d 29 9 z omen 8 Biz 8 8 8e 8 de 52 5 N SWITCHES 2 a E a gt a gt m m F6 z 2 A m U AL SADE VASE 6 BATTERY 24V 27 i mE 5 PR5 DEGREE A 2 2 4 L 9 9 Qzd pl 5 SLE i E 3 3 B5 f 2048 8 8 8 5 026 gt 8 8 R el K A 97 2 i 0 002002 Ms 4 E 8 5 7 md 1 A lt 2 4 4 4 4 5 9 99 o E oz on BATTERY GROUND P 2655 E z5 go 135 ES0440C m d 3 2 8 E eg oz 7 9 m m gt 25 2 Fs iu m m es mm z m gt z o mee mz e gt gt 54 m lt lt m m oS 25 gt d lt S
217. Refer to Section peciiications 2 Specifications a please 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 I 5 Adjust the internal 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 higher the relief valve higher than specified specified 6 Repeat step to confirm the relief valve 7 Repeat step 4 to confirm the relief valve pressure pressure Genie 4 36 Genie TZ 50 Part No 84577 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 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 Ra
218. SS Rp 87 87 PIN P3 U RDIBK 30 MANIFOLD HARNESS _RD BK 85 CR67 PIN P3 T PRIMARY BOOM 64 86 MANIFOLD HARNESS BK 87 87 PIN P3 W BKWH 07 39 CR69 C5 BK WH MANIFOLD HARNESS _ PIN P3 V BOOM EXTEND TODE as 87 87 1 BKWH pg CR8 85 IGNITION 5 OHM pia 86 MODELS Re anes WITH PK ENGINE 0 1 85 ENGINE START OPTION 2 1 BK RD ako j RD P2 10 1 15 T 85 STARTING AID 1 l 86 H 18 PL 15 87 87 TURNTABLE HARNESS WH BK WHBK 1 PIN P3 J 30 CR86 85 SEQUENCING BK TB35 H 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 R22 1000 OHM BATTERY CHARGE 5 BK TB35 G7 BD P1 E STOP Y Section 5 Schematics r mr si Ground Control Box Wiring Diagram 5 from serialnumber TZ5011 132 WH
219. September 2014 v a Ground Control Box Wiring Diagram ANSI CSA from serial number TZ5005 285 to TZ5010 144 MODELS WITH ENGINE OPTION P1 EMERGENCY STOP V 7 T BN68 9 ENGINE START 1 KEY SWITCH f 1 90 CB1 15 BN56 BOOM EXTEND RETRACT BN58 PLATFORM LEVEL UP DOWN BN54 PRIMARY BOOM UP DOWN L 3 PLATFORM OPTION BN36 JIB BOOM UP DOWN 55 SECONDARY BOOM UP DOWN BN57 TURNTABLE ROTATE Ex A CB2 15 AMP RIGHT AND OUTRIGGER BN59 FUNCTION ENABLE BOOM DOWN BOOM RETRACT ROTATE LEFT AND OUTRIGGER EXTEND RD WH Q
220. Stop button at the ground controls will stop all machine operation without regard to the position of the key switch 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at the ground controls 4 Push down the red Emergency Stop button at the platform controls to the off position Result No machine functions should operate Models with drive option 5 Pull out the red Emergency Stop button to the on position at the platform controls 6 Push down the red Emergency Stop button at the drive controls to the off position Result The drive function should not operate Part No 84577 September 2014 Section 3 Scheduled Maintenance Procedures B 5 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause ahazardous operating situation Note Perform this procedure from the ground using the platform controls Do not stand in the platform 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls Pull out the red Emergency Stop button to the on position at the drive controls if equipped 2 Turn the key switch to platform control 3 Check the machine functio
221. TS Confirmthe 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 O 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 O 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 O 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 O Result All ground control functions should not operate Genie 4 46 Genie TZ 50 Part No 84577 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 the machine is in the stowed position the parking brake is set and both wheel motors are in place agains
222. UP DOWN 0 OPTION L14 L LRLED BN36 M A LL JIB TN BOOM UP DOWN _ GNWH pB5 9 5 R BN51 G RIGHT REAR OUTRIGGER Q Q L15 RR LED GNWH TB24 BN57 lt WH BN55 TURNTABLE RD WH _ SECONDARY ROTATE BN53 TB20 BOOM RIGHT FRONT _ RD WH PB5 3 UP DOWN OUTRIGGER L13 RF LED ORWH _ 21 OR WH PB5 5 um rggi GNWH _ TB30 BUBK 25 RDBK 1826 TB29 BD CR78A TERMINAL 87A BK WH TB27 BD TB3 pa RD TB32 H5 ALARM Jae HOUR METER RC TB35 ES0440G Genie 5 44 TZ 50 Part No 84577 September 201 4 io 8 MANIFOLD HARNESS GN BK 87 87 PIN PL p22 30 CR72 MANIFOLD HARNESS _GN PIN 85 OUTRIGGERS 86 MANIFOLD HARNESS wH 87 87A PIN P3 P WHIBK 30 MANIFOLD HARNESS WH BK CR70 PIN P3 N PLATFORM ROTATE Ka MANIFOLD HARNESS BL 87 PIN P3 S BUBK 39 CR68 MANIFOLD HARNESS BL BK 7 85 PIN P3 R SECONDARY BOOM 3 MANIFOLD HARNE
223. WV Boom BOOM PLATFORM 5 6K OHM 822 FUNCTION EXTEND RETRACT LEVEL SPEED a em 5 6K OHM 10K OHM 52042 2 EMERGENCY 5 1 O 8 RD POWER CABLE PIN 1 NER 186 BN2 BN97 BN63 BN98 MODELS ENGINE JIB BOOM PRIMARY BOOM PLATFORM WITH START UP DOWN UPDOWN J ROTATE option Kc BN62 OPTION FUNCTION ENABLE TURNTABLE Q D RIGHT 1 1_ p BL TER CR 9 TERMINAL 30 AND P2 6 9 TR BN64 BN66 RD TURNTABLE TB1 22 UP DOWN ROTATE S BD TB1 BN61 D FUNCTION ENABLE BOOM DOWN BOOM RETRACT D TURNTABLE AND PLATFORM ROTATE LE LEFT RD WH jus TB2 WHIBK BK AL 87 RDBK P2 2 _ D RD TB7 87 87 f Y TB3 C 2 cues 85 LIFT CUT OUT BE 4 D 9 8 7 6 5 4 3 2 1 C OR 87 87 ORK us 30 ORBK 7 ss CR71 Fou 9 O 86 4 7 4 2 GN 87 87 _ Fee 1 6 GN BN97 80 CR9 m 85 JIB BOOM UP DOWN 67 5 _ BL 87 BL BK 59 CR87
224. Y PRIMARY BOOM 5 6K OHM BOOM BOOM BOOM EXTEND C4B UP DOWN UP DOWN UP DOWN UP DOWN 9 RETRACT ZENER DIODE 5 1V DC 1 i 6 486 304 486 CR87 l s 486 CR71 JIB BOOM icem 71 5 UP DOWN 4 5 LEVEL 87A 87 85 87A 87 85 7 t 1 4 sT 7D 2 Ef 12 2 2 2 519 E 7 LOAD enum SENSE Y60 Y62 Y19 JIB PLATFORM PLATFORM NO is BOOM ROTATE LEVEL LEFT DOWN No 14 15 Y61 vea 145 Y20 SWITCH SHOWN IN JIB PLATFORM PLATFORM UNLOADED POSITION BOOM ROTATE LEVEL EXTEND RIGHT UP X Hx Es TZ50D 8 4 Part 84577 2 50 5 105 September 2014 Section 5 Schematics 1 Electrical Schematic AS CE from serial number TZ5004 182 to TZ5005 210 5 105 5 106 Section 5 Schematics September 2014 2 7 Electrical Schematic 5 from serial number TZ5005 211 to TZ5005 284 5 107 5 108 Section 5 Schematics m Electrical Schematic AS CE 1 of 3 from serial number TZ5005 211 to TZ5005 284 September2014
225. aa gf 3 8 5 026 sta u o O 5 7 m CHARGER LUIS 9 9 p gu 7 gt 2 2 2 5 Y LUE L os B B B Lf 4 AY lt 2 pe 4 4 4 4 BATTERY GROUND t 5 9 gt i 888 P P gu oS s m X 2 ow QU gt 8 B 2 222 B B 2 8 8 p gt m m b Ox 2 85 mes 5 m gt 059 6 m2 lt lt 3 ie zm 24 lt m gt zo o ES 8 g 3 4 m gt go 2 20 9 a 2 m S 2 5 90 TZ 50 PartNo 84577 September 2014 Section 5 Schematics RR R s rsi Electrical Schematic ANSI CSA 2 of 3 from serial number TZ5011 311 M L K J PLATFORM CONTROLBOX PLATFORM CONTROL BOX 1 PLATFORM E STOP POWER BET DOWN ENABLE PLATFORM GROUND TB2 DOWN UP ENABLE EN
226. aining 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 Disconnectthe 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 Replace the contactor if any damage is found Genie GenieTZ 50 B 4 Test the Emergency Stop A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting ina hazardous situation 1 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 Pull out the red Emergency Stop button to the on position at the drive controls if equipped 2 Push in the red Emergency Stop button at the ground controls to the off position Result No machine functions should operate Note The red Emergency
227. ake balance bar 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 W Result The machine moves Proceed to step 5 Part No 84577 September 2014 Section 3 Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 5 Adjustthe brakes See B 8 Perform Axle Modelsto TZ5006 510 Maintenance Electrical and Hydraulic Axles 6 Chockthe wheels 7 Releasethe parking brake RE 8 Loosen the set screw at the side of the parking m brakehandle 9 Adjustthe handle just to the point where it is t difficult to apply the parking brake then rotate the top of the parking brake handle counterclockwise one full turn 10 Tighten the set screw Do not overtighten 11 Atthe ground controls extend the outriggers until the axle is off the ground and the machine Models from TZ5006 51 1 is level 12 Engage the parking brake 13 Remove the parking brake cylinder inspection cover 14 Adjust the parking brake cylinder input cable until the cylinder flange just contacts the cylinder slider assembly rear chassis parking brake cable cylinder output rod threaded
228. al 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 84577 Genie GenieTZ 50 4 43 Outriggers 7 Place a wooden block under the cylinder 8 Lower the 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 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 p
229. all rings watches and other jewelry 1 Tagand disconnect the wire harness from the coil to be tested 2 Testthe 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 1 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 BI 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 84577 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 spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker
230. ally 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 84577 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 cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray
231. aman CONTROL s eni dd BOX DAE pensas 4 BN94 BN95 BN3 TURNTABLE AND TURNTABLE AND IPLATFORM FUNCTION ENABLE FUNCTION ENABLE CHOKE PLATFORM ROTATE PLATFORM ROTATE BOOM DOWN 4 BOOM UP EXTEND LEFT RIGHT ROTATE BOOM RETRACT ROTATE RIGHT ROTATE LEFT 7 AND OUTRIGGER e OPTION AND OUTRIGGER RETRACT roe 8228 66 CR78B BN67 BN98 BN96 MODELS TURNTABLE LIFTCUT OUT PLATFORM PLATFORM Y Y Y Y AUTOLEVEL WITH 5 6K OHM ROTATE LEVEL ROTATE 30 2 486 4 4 44 DE 8 87A 85 5 WH RESISTOR g 4 0 10K OHM 1 BN97 BN64 BN63 BN65 JIB SECONDARY PRIMARY BOOM BOOM BOOM BOOM EXTEND UP DOWN UP DOWN UP DOWN RETRACT ZENER DIODE DC LIlol i 6 s 486 39 5 456 87 8 4 CR71 JIB BOOM son of PLATFORM zm PLATFORM UP DOWN ROTATE LEVEL 87A 87 85 87A 87 85 87 87 85 hd d hd hd hd dec b SCC M Ku EN c ms
232. 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 Part No 84577 Genio Genie TZ 50 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 Models with Drive 8 option n 3 wW primary brake cable parking brake cylinder models with drive option tension equalizer d secondary brake cables om Section 4 Repair Procedures September 2014 Trailer Components 11 1 Hydraulic and Mechanical Brakes Hydraulic Brake System Hydraulic Axle Repair procedures and additional axle information is available the Dexter Axle Operation Maintenance Service Manual Dexter part number LIT 001 00 Dexter Axle Operation Maintenance Service Manual Genie part number
233. arged 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 Loosen hydraulic Repair any machine damage or malfunction connections very slowly to allow before operating the machine the oil pressure to dissipate M 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 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 84577 TZ 50 5 1 Section 5 Schematics M a os Electrical Abbreviations Legend September 2014 Description Button Function enable down boom retract rotate left outrigger extend
234. atform 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 a platform mount b boom cylinder barrel end pivot pin jib link pivot pin d e boom lift cylinder f jib 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 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
235. bs Nm ft Ibs Nm ft lbs Nm ft Ibs Nm ft Ibs Nm_ ft lbs Nm ft lbs Nm 8 54 741 72 9 88 14 19 1 188 25 5 20 1 273 269 365 23 6 32 314 426 10 10 8 147 144 196 279 378 372 505 39 9 541 53 2 722 467 63 3 623 84 4 12 189 256 251 341 486 66 649 88 697 945 922 125 81 110 108 147 14 301 408 40 543 774 105 103 140 110 150 147 200 129 175 172 234 16 46 9 63 6 62 5 848 125 170 166 226 173 235 230 313 202 274 269 365 48 545 875 882 117 171 233 229 311 238 323 317 430 278 377 371 503 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 84577 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
236. cedure beginning with step 6 Part No 84577 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 platform end of the machine until the turntable is 2 4 out of level Result The tilt sensor alarm should not sound
237. d 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 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 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 mo
238. d 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 damaged if they are kinked or pinched 21 Remove the pin retaining fasteners securing the secondary boom pivot
239. d 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 COMPONENTS Genio Part No 84577 Genie TZ 50 Section 4 Repair Procedures September 2014 Primary Boom Components 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 c 7o o0o0053 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 Genie TZ 50 Genie Part No 84577 September 2014 Section 4 Repair Procedures 3 1 Cable T
240. d 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 9 14 wire main cable 4 Tagand disconnect the circuit board from the 14 wire main cable Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Use a grounded wrist strap at all times when handling printed circuit boards 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 84577 September 2014 Section 4 Repair Procedures How to Calibrate the Drive Circuit Board to SN TZ5008 532 1 Remove the blue wire from terminal 1 of the motor controller U6 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 cover 3 Turn the key switch to platform controls and pull out the Emergency Stop button to the on position at the ground platform and drive controls Adjust both B SIDE potentiometers 4 Without disconnecting the wire harness connect the negative lead of the multimeter to the black wire of the 14 wire main cable 5 Without disconnecting the wire harness connect the positive lead of the multi
241. 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 Cleanthe 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 2 Apply a thin layer of fresh oil onto the gasket of the new oil filter CHECKLIST D PROCEDURES 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 components to be sure that there are no leaks Genie Part No 84577 GenieTZ 50 3 33 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 Turntab
242. e T T 3 LOAD m GCON GROUND J m gt x 2 6 IN ZN AN ES0440D 9 z d gt d lt z J 1513 1515 a RF O R RR O R I g g AT AR AG 1512 1514 Y24 Y53 Y22 Y26 S LF O R LR O R E A OUTRIGGER LIMIT SWITCHES Y23 1 t Y21 1 Y25 m Gu L DX gt 2 2 2 Ye 2 2 2 E 7 GCON GROUND HARNESS GROUND PLUG 1 4 j z 2 3 S368 S Z mm 4 3 gt gt Fe 2 mm 5 9 0 02 lt gt lt lt m 5 2 lt lt m 24 2 m m m omm x gt 2m m x gt gt lt 3 8 2 2 m lt gt Genie Part No 84577 TZ 50 5 123 2014 Section 5 Schematics Electrical Schematic AS CE from serial number TZ5010 145 to TZ5011 131 5 123 5 124 Section 5 Schematics September 2014 2 7 Electrical Schematic 5 from serial number TZ5011 132 to TZ5011 310 5 125 5 126 Section 5 Schematics September 2014 i i iia pGsx s i Electrical Schematic AS CE 1 of 3 from serial number TZ5011 132 to TZ5011 310
243. e 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 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 cabl
244. e 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 84577 September 2014 INTRODUCTION Serial Number Legend Geni A TEREX BRAND gt Model 7 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 lg Lir LT x 2j Model Sequence 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
245. e 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 Plugtorque 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 84577 GenieTZ 50 30 Section 2 Specifications September 2014 SPECIFICATIONS Machine Torque Specifications 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 Nm 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 84577 September 2014 Section 2 Specifications Honda GX160K1 Engine Displacement 9 9 cu in 163 5 1 Bore amp stroke 2 7 x 1 8 inches Starter motor Cooling Syste
246. e 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 84577 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 84577 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 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 remo
247. e 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 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 axle Install and torque the lug bolts to specification Refer to Section 2 Specifications 10 Perform steps 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 i
248. enie TZ 50 Part No 84577 September 2014 Section 4 Repair Procedures MANIFOLDS J 7 2 Note alpha numeric callouts SS th refer to corresponding notes on the electrical schematic Note alpha callouts refer to corresponding notes on the hydraulic schematic Y22 D 83 ORS 5255 ssp lt gt lt gt r 5 9 z cams Genie Part No 84577 Genie TZ 50 4 31 Section 4 Repair Procedures September 2014 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 way 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
249. ensor 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 84577 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 installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydra
250. er 2014 Section 4 Repair Procedures Engine 5 1 Fuse Replacement The electric engine starter circuit is protected by both a 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 ysa 5 amp fuse starter circuit inside cover 50 amp fuse starter circuit 50 amp fuse alternator circuit o Genie Part No 84577 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 O 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 level sensor activates 5 Locate the tilt level sensor beneath the ground an alarm will sound making the operator aware o
251. es 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 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 become unbalanced a
252. f 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 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 a new level sensor proceed to step 10 6 Tagand disconnect the wire harness from the 1 Perform this procedure with the machine on a tilt level sensor firm level surface that is free of obstructions 7 Removethe three level sensor retaining fasteners Remove the level sensor from the machine 2 Turn the key switch to ground control and pull out the red Emergency S
253. 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 84577 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 wooden block between the secondary link and the lift cylinder 7 Using a soft metal drift remove the lift cylinder
254. g device place an appropriate test weight equal to that of the maximum platform capacity at the center of the platform floor Part No 84577 Genie 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 onto the limit switch Section 4 Repair Procedures September 2014 mnmmmm 1 PLATFORM OVERLOAD COMPONEN
255. gs 87 87 85 87 87 85 1 JA 11 CR8 CR1 CR15 CR76 28 CR61 gt m CR65B CR86 4 x CB2c 1 CAPACITOR 27000 CA eu i T T 1 5 AMP 415 AMP 33V 5 CD3 605 CD6 6 BT 1E DT TPB8 PBS Pete H J 1 x 0 5064 67 cco 4 2 S l wr m m gt D ji 5 mm 2m oz A ES m m 2 GU 2 A K s 5852 jas 3 4 9 7 m 2000 og ypc AUTOLEVEL 2222 Eg EX EX Q7 f LEVEL SIGNAL 5285 7 SENSOR 2 C 29 4 z 9 EC 2 7 6 E 5 B PR5 E s2 OUTRIGGER LIMIT SWITCHES LS12 LS13 1514 1515 OUTRIGGERS SHOWN IN STOWED LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR B5 ai xs gt POSITION FORCED OPEN OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER 1 250 ES TZ50F 2 MGE S oim uu tec MOTOR 8 Genie 5 66 TZ 50 Part No 84577 32 28 12 22 September 2014
256. hine moves Proceed to step 5 5 Chock the wheels 6 Releasethe parking brake Part No 84577 Genie GenieTZ 50 CHECKLIST B PROCEDURES 7 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 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 Electrical and Hydraulic Axles CE models without drive option 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 4 Attempt to manually push the machine Result The machine should not move W Result The machine moves Proceed to step 5 Section Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES 5 Atthe ground control
257. ial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90 apart 11 Lower the primary and secondary booms to the stowed position and turn the machine off 12 Remove the dial indicator from the machine Section 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 torqued 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 c
258. ic from serial number 25006 511 5 139 Genie Xvi Genie TZ 50 Part No 84577 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 Ibs tit 4 108 Battery capacit 225AH EUM Tire pressure maximum cold 65 psi Reserve capacity 25 rate 447 minutes 4 48 bar Batteries models with drive option Tires and wheels Mechanical Axle Type Axle Group T 145 Tire size 215 70R14 104 102N Quantity 4 Load range C Battery capacity 244AH Lug bolt torque dry 192 ft Ibs 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 TZ5005 204 including tank 30 liters Tire size 12 x 3 5 x 0 75 From TZ5005 205 Tire size 10x3x0 75 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 84577 Genie TZ 50 30 2 1 Section 2 Specifications September 2014 SPECIFICATIONS Performance Specifications
259. ico 12 ol L Q out cog dd M BN51 RIGHT REAR OUTRIGGER ol 115 ILT RR LED GN WH TB24 WH us BN53 aa oit BOOM RIGHT FRONT RD WH UP DOWN OUTRIGGER cca L13 OR WH TB21 OR WH ccs WHIBK _TB31 GNWH _ BL BK TB25 _TB26 GN TB29 AD CR78A TERMINAL 87A BKWH TB27 BD WH 2 H5 ALARM _ 06 Bk T DOCCT T UU UE UU Genie TZ 50 Part No 84577 September 2014 Section 5 Schematics cs lt mCmwvmIIrai Ground Control Box Wiring Diagram 5 from serialnumber TZ5004 182to TZ5004 324
260. ighten 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 84577 GenieTZ 50 3 31 Section 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 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 Ope
261. ignature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures September 2014 p J1 c er This page intentionally left blank 3 4 Genie TZ 50 Part No 84577 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 performed Daily or 8 hours Inspection A Quarterly or 250 hours or 3000 mile 4800 km Inspection Semi annually 500 hours or 6000 mile 9600 km Inspection Annually 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 A 1 Manuals and Decals B 1 Batteries
262. in 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 ee injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie Genie TZ 50 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
263. intenance Procedures September 2014 CHECKLIST B PROCEDURES 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 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 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 Genie GenieTZ 50 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 b
264. ion boom 6 Remove the fasteners and hose clamp securing the platform level slave cylinder hoses to the extension boom Part No 84577 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 boom 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 p
265. ircuits 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 9 Nm Hydraulic tank drain plug lubricated 112 in Ibs 12 6 Nm Part No 84577 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 specificati
266. ise 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 84577 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 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
267. l 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 Note Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in component damage Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice GenieTZ 50 30 Part No 84577 September 2014 Section 2 Specifications Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below 0 17 Note Use Shell Tellus S2 V 46 hydraulic 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 4 Flow 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 cc Flow rate 5 6 gpm 21 2 L min Hydraulic tank return line filter 10 micron Continuous improvement of our products is a Geni
268. lace 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 Scheduled Maintenance Procedures September 2014 CHECKLIST C PROCEDURES 7 Add an additional 44 Ibs 20 kg of weight to overload the platform O Result The platform overload indicator light should be flashing at both the ground and platform controls 8 Testall 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 O Result All ground control functions should not operate Lift the test weight off the platform floor using a suitable lifting device O 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 O Result All ground control functions should operate normally 13 Turn the key switch to platform control 14 Test all machine functions from the platform controls Result All platform control functions should operate Note If the platform overload system is not operating properly referto Repair Procedure 13 1 Calibrate the Platform Overload System if equipped Genie GenieTZ 50 C 3
269. le Rotation bolt is torqued in sequence to specification Bearing Bolts Refer to Illustration 2 Maintaining propertorque onthe 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 Besurethat each turntable rotation bearing 9 O 7 mounting bolt above the turntable is torqued in O i sequence to specification Refer to Illustration 1 5 4 NC Tongue 8 2 9 5 1 Illustration 2 O ___ 11 Bearing to chassis bolt torque sequence 2 2 Turntable rotation bearing bolt torque specifications 8 O 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 34 GenieTZ 50 Part No 84577 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 Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine on a firm level surface and the boom in the stowed position 1 Grease the turntable bearing See A 13
270. lly in the reverse direction The voltage is 4 9V DC Proceed to step 28 The voltage is less than or greater than 4 9V DC Proceed to step 26 Genie Genie TZ 50 26 While activating the function enable switch and holding the joystick fully in the reverse direction adjust the SW DC HI RANGE potentiometer until the voltage is 4 9V DC Release the joystick 27 Repeatthis procedure beginning with step 25 28 Confirm the forward and reverse settings Repeatthis procedure beginning with step 22 Adjusting the SW DC THRESHOLD potentiometer will determine where the voltage begins as you move the joystick in either forward or reverse 29 Disconnect the positive and negative leads 30 Push in the red Emergency Stop button to the off position at the ground platform and drive controls 31 Apply SentrySeal to the screws of the potentiometers which were adjusted 32 Install the cover onto the box Install and securely tighten the fasteners 33 Install the drive control box onto the machine Secure with the control box latch 34 Securely connect the blue wire to terminal 1 of the motor controller 35 Perform the function tests Refer to the Operators Manual on your machine Part No 84577 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 ch
271. lt or 25 lt vi DDA c e m BN mm oo 9 lt lt 2 2 50 2 2 2 Az o 8 m mm o 5 m gt om z 98 5 r O23 20 DD 5 2g 2 m m m m lt 5 94 2 m gt 2 D 2 zo gt OD gt E gt 2 lt 29 zJ lt 2 a kasus Genie Part No 84577 TZ 50 5 78 September 2014 Section 5 Schematics Electrical Schematic ANSI CSA from serial number TZ5005 285 to TZ5010 144 74 September 2014 Section 5 Schematics Electrical Schematic ANSI CSA 3 of 3 from serial number TZ5005 285 to TZ5010 144 TB3 J BN66 BN67 8 PLAT PLAT ENABLE LEVEL ROTATE ENABLE ENABLE R78B 1 BNGS 7 BNS BN97 A 1 PRI JIB 8 ENABLE ENABLE ENABLE ENABLE 8 71 1 9 1 87 4 5 PLATFORM GROUND Xx gt aya E g e v g 8 m w o 1 Bp d g 388 222 gpp AR 2 v v v v z S 9 8 9 o w m ROUND NTROL BOX V
272. m Ignition System SPECIFICATIONS 12 V DC Forced air Spark plug type BPR6ES NGK W20EPR U DENSO 68 x45 mii Spark plug gap 0 028 to 0 031 inches Horsepower 5 4 hp 3600 rpm 0 7 to 0 8 mm 4 kW 3600 rpm Fuel unleaded gasoline Engine idle no load 3400 rpm 86 octane minimum Engine idle under load alternator 3100 rpm Fuel tank capacity 0 95 gallons 3 6 liters Compression ratio 8 511 Valve Clearance cold Intake 0 006 in 0 15 mm Exhaust 0 008 in 0 20 mm Lubrication system splash Cil capacity 0 63 quarts 0 6 liters Cil viscosity requirements Temperature below 30 F 0 5W 30 4 F to 100 F 20 to 38 10W 30 Temperature above 50 F 10 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 84577 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
273. meter to the orange wire of the 14 wire main cable 6 Squeeze the joystick to activate the function enable switch SW5 The voltage is 21 9 to 22 1V DC Proceed to step 9 W The voltage is less than 21 9 or greater than 22 1V DC Proceed to step 7 7 While activating the function enable switch adjust the B SIDE HI RANGE potentiometer until the voltage is 22V DC Release the joystick 8 Repeatthis procedure beginning with step 6 9 Activate the function enable switch and move the joystick fully in the right direction Q The voltage is 3V DC Proceed to step 12 The voltage is less than or greater than DC Proceed to step 10 Part No 84577 Genio Genie TZ 50 DRIVECOMPONENTS A side potentiometers SW DC potentiometers c PB side potentiometers om 10 While activating the function enable switch and holding the joystick fully in the right direction adjust the B SIDE THRESHOLD potentiometer until the voltage is 3V DC Release the joystick 11 Repeat this procedure beginning with step 9 12 Disconnect the positive lead Adjust both A SIDE potentiometers 13 Without disconnecting the wire harness connect the positive lead of the multimeter to the orange black wire of the 14 wire main cable 14 Squeeze the joystick to activate the function enable switch SW5 The voltage is 21 9 to 22 1V DC Proceed to step 17 The voltage is less than 21 9 or greater than 22 1V DC Proceed to step 15
274. n 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 84577 September 2014 Section 3 Scheduled Maintenance Procedures t CHECKLIST PROCEDURES 5 Repeat steps 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 T
275. nd 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 84577 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 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 extens
276. nder cylinder flange slider assembly drive motor brake cable cylinder input cable parking brake cable threaded rod 720700009 Part No 84577 Genie GenieTZ 50 CHECKLIST B PROCEDURES 10 Loosen the lock nuts at the tension equalizer bracket 11 Turn the wheel in a forward motion adjusting the wheel brakes until the wheel turns with difficulty or not at all 12 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 13 Repeat steps 11 and 12 for the other wheel 14 Engage and release the parking brake 4 times 15 Engage the parking brake 16 Adjust the parking brake cylinder input cable until the cylinder flange just contacts the cylinder slider assembly 17 Release the parking brake 18 Adjust both rear parking brake cables at the tension equalizer bracket until when turning the wheel in the direction of travel a slight rubbing noise can be heard from the brakes Loosen the cables just until no noise can be heard when turning the wheels Note Be sure a minimum of one full thread of the cable end is showing through the adjustment nut at the tension equalizer bracket Section Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES 19 Tighten the nuts on the tension equalizer bracket until the bracket is balanced Securely tighten the lock nuts 20 Engage the parking brake
277. ns from the ground controls Result The machine functions should not operate 4 Checkthe machine functions from the drive controls Result The drive functions should operate 5 Turn the key switch to ground control 6 Checkthe machine functions from the platform controls Result The machine functions should not operate 7 Checkthe machine functions from the drive controls Result The drive functions should operate 8 Turn the key switch to the off position Result No function should operate Part No 84577 Genie GenieTZ 50 CHECKLIST B PROCEDURES B 6 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 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 Section Scheduled Ma
278. ntact Genie Product Support Part No 84577 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 red Emergency Stop button to the on position at both the ground and platform controls 3 Raise the secondary boom until the platform is approximately 10 feet 3 m off the ground 4 Inspect the boom storage area for burnt chafed and pinched cables 5 Lowerthe boom to the stowed position and turn the machine off 6 Inspect the following areas for burnt chafed corroded pinched and loose wires Boom to platform cable harness Primary and secondary booms Section 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 Maint
279. nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 SPECIFICATIONS Figure 1 a hex nut b reference mark hex fitting 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Figure 2 Note Use the 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position Note The marks indicate that the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Figure 2 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 84577 Genie 2 50 30 Section 2 Specifications September 2014 SPECIFICATIONS SIZE 1 4 546 3 8 7 16 1 2 9 16 SAE FASTENER TORQUE CHART THREAD 0 SIE 20 80 9 100 113 110 124 140 158 10 147 28 s 101 120 135 120 135 160 18 I 140 158 18 13 175 24 14 19 27 366 16 23 312 44 596 24 26 352
280. on 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 84577 September 2014 Section 3 Scheduled Maintenance Procedures A 2 Perform Pre operation Inspection Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is 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
281. ons 35 in Ibs 4 Nm Hydraulic tank mounting fasteners dry Hydraulic tank mounting fasteners lubricated 26 in lbs 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 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 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 84577 Genie GenieTZ 50 CHECKLIST E PROCEDURES E 2 Perform Engine Maintenance if equipped Engine specifications require that this procedure be performed every 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 Sep
282. onsidered for future printings of this and all other manuals Contact Us http www genielift com e mail awp techpub terex com Genie Copyright 2004 Terex Corporation 84577 Rev B May 2013 First Edition Second 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 ii Genie TZ 50 Part No 84577 September 2014 Revision History Revision Date Section Procedure Schematic Page Description a quum 5 2013 Introduction Revision History Added Hydraulic Specifications SAE and Metric Fastener Torque Chart int Added Specific maintenance to all axle procedures Revised procedures Revised procedures Revised all schematics and grouped by Markets Bi 9 2014 5 138 5 139 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 st highlighted in blue to view the update Genie Part No 84577 Genie TZ 50 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 pag
283. oom down function to operate from the machine controls Primary Boom Up 9 Locate the primary boom up valve coil on the function manifold Push 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 valve spool must be reset for the primary boom up function to operate from the machine controls Part No 84577 September 2014 Section 3 Scheduled Maintenance 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 fo
284. 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 84577 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 machine 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 groun
285. ower 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 w nr Fr Ege Electrical Abbreviations Legend Item R14 R22 R22B S7 59 510 U6 U16 U24 U26 Y11 Y19 Y20 Y21 Y22 Y23 Y24 Y25 Y26 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 gt M
286. ox Wiring Diagram AS CE from serial number TZ5010 145 to TZ501 1 131 OR BK BK RD RD MODELS WITH ENGINE OPTION ENGINE FUNCTION ENABLE BOOM UP EXTEND ROTATE o o N a 60 N KEY SWITCH BN90 CHOKE 14 A LED RIGHT AND OUTRIGGER RETRACT V 1 5 RD p OR FUNCTION ENABLE BOOM DOWN BOOM RETRACT ROTATE LEFT AND OUTRIGGER EXTEND WH 15 1 56 EXTEND RETRACT Q BN58 PLATFORM LEVEL UP DOWN qo 49 1 AUTO LEVEL 2 ULL fe o BN52 LEFT FRONT OUTRIGGER O BN54 PRIMARY BOOM UP DOWN n IBN93 L12 50 PLATFORM LF LED LEFT REAR OUTRIGGER
287. p 3 05 3 ay RY GROUND CONTROL BOX TB3 1 J BONN 0900 ENABLE ENABLE CR65A 9 ones m 4 EE lg BN50 BN51 TBS ENABLE ENABLE ENABLE 5 eu I 5 8 9 1 cm ere CR65A m AUTOLEVEL S 21 TB23 TB24 2 J15 OHM gt e 15 65 TB14 GROUND CONTROL BOX TB18 t 1 5 gt i i 41822 CR28 L ts 32 2 CR65B 06 CR86 e 18 GCON GROUND d Lil i GROUND CONTROLS GROUND eT ETT dd dd Tx Te 6 N A NI 5 9 BATTERY 24V is 95 P LI 5 gt i A F4 g FR FSB 47 2 5 0 034 E 2 3 50 n 3 Qo d 1 1 1 P 1 o u6 5 9 2 2 He 91 99481135 cols 25352925 7 Y35 Y36 Y33 Y34 20075 me 2 42 2 22 2 52 lt lt c mm m gt gt gt mms lt lt lt lt lt gt 4 PECUMMM 555 1 5 2 z 5 5 XA GCONGROUND 2002002 om HARNESS GROUND PLUG BATTERY GROUND 25255 gt gt 3 50440 mo E c c c m m 2 D 22 9 9 gt a d ot 2 lt 228 S c em os BN 5
288. pecifications 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 84577 September 2014 Section 4 Repair Procedures Axle Components 10 1 CE models Axle 1 Lower the outriggers and adjust to level the 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 cables 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
289. pecifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Checkto 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 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 inspecti
290. 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 84577 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 when removed from the machine 32 Tag disconnect and plug the hoses from the secondary lift cylinder Cap the
291. 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 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 for continued scheduled maintenance 1 Performthefollowing maintenance procedures 11 Greasethe 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 7 Checkthe Turnable Rotation Engine Owner Manual Bearing Bolts Honda part number 312 7630 B 10 Inspect the Parking Brake 0 4 Replace the Hydraulic Tank Honda GX160 Owner s Manual Return Filter Genie part number 97228 Genie 3 10 Genie TZ 50 Part No 84577 September 2014 Section 3 Scheduled Maintenance Procedures A
292. r UE TOO SECONDS TB28 1 87 87 85 87 87 85 87 87 85 87 87 85 A i r TIME DELAY ICB1 10 TO 30 SECONDS 86 4 4 6 Reet 1 15 CR75 CR76 CR65B SEQUENCING 7 C4 5 e IGNITION ENGINE START STARTINGAID LoAD LEVEL SENSOR LIMIT SWITCH U6 CUTOUT DIODE DIODE 8 1 3VDC 51V DC 1 4 4 ie 4 4 4 e 4 CB2 TB35 GNWH TB35 15 T n meyer et rem emnt CEA gt D 8 PB9 PB10 11 12 J H 1 2 4 3 5 6 d CC1 CD1 CD2 CC3 CC4 CD3 CD4 CC5 CC6 CD5 CC7 CC8 CD7 CD8 CC9 CC10 8 8 8 8 md ud 8 9 2 8 28 25 Fes 8985 3 7 ALTERNATOR 3 Oe E M NE B5 4 6V BATERY cox EAX kX Q7 AUTO LEVEL CHOKE Y35 Y36 Y33 Y34 LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR pm OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER F9A T gt 6 i 50 AMP ADT OUTRIGGERS SHOWN IN hun gt SINE gt gt ar N E 8 STOWED POSITION M 097 026 M3 T INPUT 1 1512 1513 1514 1515 IGNITION STARTER LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR i MOTOR U6 OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER T 09 1 4 4
293. r 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 84577 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 until 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 a suitable lifting device p
294. r TZ5010 145 to TZ5011 131 Section 5 Schematics R tk Electrical Schematic ANSI CSA 1 of 3 from serial number TZ5010 145 to TZ5011 131 September 2014 A B C D E F G H 1 po ESO BN3 H1 CONTROLS FAULT PLATFORM GROUND 70 5 5 4 DRIVE CONTROLS 2 S 9 ele DRIVE E STOP POWER 8 413 5 L m 5 LS18 gt E I 25 De fe 9 55 gt 5 3 E 2 929 DADR DE 8 AS GROUND CONTROL BOX m n 7 TB3 CB2 ier MEAM T KST TB2 RD RD 5 BN90 BN68 FAULT R65A pne e GRD START ALARM d ER 15AMP TB4A 4 CR64 GROUND 2 CONTROLS Se CR65A 4 L12 113 114 115 e e tel G CR76 5 815 R1 U16B 3 17 706 LOAD GCON GROUND Bal al 5 3 did 2 M omes 37 2 3 go 2 5 21 Fo 1 1 1 h 2 b M 1 1 1 u LIMIT om ag
295. r 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 84577 September 2014 Section 4 Repair Procedures mn p M Tt This page intentionally left blank Genie Part No 84577 Genie TZ 50 4 17 Section 4 Repair Procedures September 2014 Secondary Boom Components 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 c7 0 5 00023 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 SPA
296. r the turntable rotate function to operate from the machine controls Part No 84577 Genie GenieTZ 50 CHECKLIST B PROCEDURES B 7 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See 1 Test or Replace the Hydraulic Oil Section Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES B 8 Perform Axle Maintenance Electrical 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 B 9 Service the Tongue Jack Maintaining the tongue jack in good condition is essential to safe operation and good machine performance
297. rack 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 84577 Genio 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 below 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
298. railer Lighting Wiring Diagram ANSI CSA 135 WH RIGHT SIDE MARKER QD12 TRAILER PLUG C BN BN T GN L33 BN YL BN RIGHT REAR TAIL LIGHT YL BN BK 4 YL PD BK _ BN L36 Wa LEFT SIDE MARKER L34 LEFT REAR EN TAIL LIGHT Genie 5 10 TZ 50 Part No 84577 September 2014 Section 5 Schematics Trailer Lighting Wiring Diagram Mechanical Axle CE Trailer Chassis Wiring Harness to SN TZ5012 215 RIGHT SIDE MARKER i w w GR I x GR BR WH cdi WH Ct fih ES RS I BL BL BK BK 227 1 YL fa VE e e 2 BL YL YL 3 WH 2 BL 1 4 GN 5 BN 3 Ve EC 6 RD 4 GN C L36 7 5 BN 59 LEFT SIDE MARKER 6 Boom Harness Platform Wiring Harness DEN GN m zi RIGHT GN TURN BN Pi w BN RUN GY GY FOG WH lt GREEN PLUG WH GROUND RD e BL YELLOW PLUG BL FOG WH 1 YL BK 2 BK B WH GROUND 3 WH YL 3 YL RD BRAKE
299. rane 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 suitable capacity from an overhead crane to the jib mount Support the mount Do not apply any lifting pressure Section 4 Repair Procedures September 2014 COMPONENTS 25 Remove the pin retaining fasteners sec
300. ration 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 32 Genie TZ 50 Part No 84577 September 2014 Section 3 Scheduled Maintenance Procedures D 3 Replace the Hydraulic Tank Return Filter Replacement of the hydraulic tank return filter element is essential for good machine performance and service life A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage Extremely
301. re 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 Raisethe 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 Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate The maste
302. rial number TZ5004 181 L K J H G F E D C B A A gt 1 PLATFORM CONTROLS PLATFORM CONTROLS m s m w r u ee To B DRIVE CONTROLS DRIVE CONTROLS w w s AUTO LEVEL NOTE MACHINE SHOWN IN STOWED POSITION WITH THE POWER OFF 2 g 2 g m o z 5 5 o EJ
303. rimary boom extension cylinder from the boom extension Section 4 Repair Procedures September 2014 1 3 3 5 Lowerthe 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 pA dod primary boom The primary boom lift cylinder is whenthe SUR 22 equipped with counterbalance valve to prevent pivot p i 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 on the lift cylinder Cap the fittings on the cylinder AWARNING ses injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradu
304. rod tension equalizer bracket parking brake cylinder cylinder flange slider assembly drive motor brake cable cylinder input cable parking brake cable threaded rod a b 9 Genie Part No 84577 GenieTZ 50 3 21 Section Scheduled Maintenance Procedures September 2014 CHECKLIST B PROCEDURES 15 Release the parking brake 16 Adjust both rear parking brake cables at the tension equalizer bracket until when turning the wheel in the direction of travel a slight rubbing noise can be heard from the brakes Loosen the cables just until no noise can be heard when turning the wheels Note Be sure a minimum of one full thread of the cable end is showing through the adjustment nut at the tension equalizer bracket 17 Tighten the nuts on the tension equalizer bracket until the bracket is balanced Securely tighten the lock nuts 18 Engage the parking brake 19 Engage both drive motors 20 Working from the front end of the parking brake cylinder adjust the drive motor brake cables by hand until they have zero play and zero resistance Be sure the brake cylinder balancebar is square to the parking brake input cable 21 Disengage both drive motors 22 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 this procedure
305. s 135 ftlbs 183 Nm s 5 46 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 types 305 ft Ibs 413 5 2 6 GenieTZ 50 30 Part No 84577 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 size O rings They are not standard SAE size O rings They are available in the O ring field service kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks JIC 37 fittings 1 Align the tube flare hex nut against the nose 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
306. s 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 o Turn the wheel in a forward motion adjusting the wheel brakes until the wheel turns with difficulty 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 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 Lowerthe machine and return the outriggers to the stowed position Genie GenieTZ 50 16 Engage the parking brake Attempt to move the machine in both directions Result The parking brake should prevent the machine from moving W 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 ANSI models with drive option 1 Visually inspect the parking brake cables and components for damage 2 Visually inspect the parking brake cables to ensure all are properly secured and installed into the brake backing plate and parking br
307. slort HIStOLy cia oes i c teri e ir t ed n pred acne a uda bee ete vore ndo lii Serial Number Legend Safety Rules uite eed vi Specifications Machine Specifications 2 enne nennen enne nnn 2 1 Performance Specifications 2 2 Hydraulic Specifications ie aes e t its P ERR Pere 2 2 Manifold Component Specifications 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 E 3 1 Pre delivery Preparation 3 3 Maintenance Inspection 3 5 Checklist A Procedures A 1 Inspectthe Manuals and Decals em 3 6 2 Perform Pre operation Inspection 3 6 A 3 Perform Function Tests u u u 3 7 4 Perform Engine Maintenance 3 7 Genie 7 50 84577 September 2014 Section 3 TABLE OF CONTENTS Scheduled Maintenance Procedures continued
308. t Both current readings are greater than mA and are different by a minimum of 20 The coil is good W Result If one or both of the current readings 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 Electrocution 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 S
309. t 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 84577 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 Removethe drive wheel 3 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Removethe drive motor mounting fasteners and remove the drive motor from the machine Section 4 Repair Procedures September 2014 DRIVECOMPONENTS 14 2 Drive Control Box Drive Control Box Circuit Board Activating
310. tember 2014 p J1 c er This page intentionally left blank Genie 3 38 GenieTZ 50 Part No 84577 September 2014 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate Genie 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 Wheels chocked Parking brake applied Part No 84577 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
311. tes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the electrical schematic Models without Platform Rotate GenieTZ 50 33 Part No 84577 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 and 4 5 ft lbs 7 9 Nm 1 Differential sensing valve BA Maintains traction equal to BJ 25 27 ft lbs 34 36 Nm 2 Orifice plug 0 090 inch 2 3 mm BB Drive circuit 3 Differential sensing valve BC 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 Returns pump 2 hydraulic fluid to tank when not driving 25 27 ft lbs 34 36 Nm 7 Counterbalance valve BG Drive circuit right side
312. 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 ofthe 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 Genie Genie TZ 50 How to Remove the Drive Circuit Board 1 Tagand disconnect the drive control wire harness from the ground controls 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 cover 3 Locate the 6 pin Deutsch connector between the circuit board an
313. tion 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 Scheduled Maintenance Procedures September 2014 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to performthis 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 E a 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
314. top buttons to the on position at both the ground and platform controls Genie 4 24 Genie TZ 50 Part No 84577 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 beeps per minute W Result The tilt alarm does not sound The level sensor is faulty and must be replaced Repeat this pro
315. ual 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 Checkeach lug bolt for proper torque Refer to Section 2 Specifications Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number 84376 Genie part number 84443 Genie 3 8 Genie TZ 50 Part No 84577 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 BH20023 Demco Model 91 Owner Operator Manual Genie part number 84592 Part No 84577 Genie GenieTZ 50 3 9 CHECKLIST A PROCEDURES A 8 Perform Engine Maintenance if equipped Engine specifications require that this
316. ulic hose from the hydraulic 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 2 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 dissipate gradually Do not allow oil to squirt or spray Part No 84577 September 2014 Section 4 Repair Proced
317. unt Do not apply any lifting pressure Part No 84577 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 84577 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 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 Pl
318. ures 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 xis 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 factory specifications could cause the machine to tip over resulting in death or serious injury Genie Part No 84577 Genie
319. uring 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 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
320. vailable in the KNOTT Axle Service Manual KNOTT part number P005 KNOTT Axle Service Manual Genie part number 84443 Part No 84577 September 2014 Section 3 Scheduled Maintenance Procedures B 12 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 Part No 84577 N CHECKLIST B PROCEDURES 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 does not move 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 K
321. ving 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 Note 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 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 hos

Service Manual - Genie Industries

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