Genie TZ-50 Building instructions

Genie TZ-50/30 Part No. 84577
June 2012
ii
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the Genie TZ-50/30
Operator's Manual before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting 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.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
PO Box 97030
Redmond, WA 98073-9730 USA
http://www.genielift.com
e-mail: [email protected]
Copyright © 2011 Terex Corporation
84577 Rev A November 2004
First Edition, First Printing
"Genie" and "TZ" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
other countries.
Printed on recycled paper
Printed in U.S.A.
INTRODUCTION

Part No. 84577 Genie TZ-50/30
June 2012
Serial Number Legend
Serial number
location
Serial label
location
Serial number
stamped on chassis
TZ-50 11 - 299
Model
Model year
Sequence
number
Model:
Serial number:
Model year:
Electrical schematic number:
Manufacture date:
Machine unladen weight:
Rated work load (including occupants):
Maximum number of platform occupants:
Maximum allowable side force:
Maximum allowable inclination of the chassis:
Maximum wind speed:
Maximum platform height:
Maximum platform reach:
Gradeability:
Nominal Power:
Country of manufacture:
This machine complies with:
Compliance STD #1
Compliance STD #2
Compliance STD #3
Position 4
Pos 5
Position 6
Position 7
Position 8
Position 9
Position 10
Position 11
Position 14
Position 3
Power supply voltage: Position 12
Control system voltage: Position 13
Nominal battery/design voltage power:
Position 40
Maximum hydraulic pressure: Position 27
99.999 lbs / 99.999 kg
TZ5011-299
2011 03/14/11
PN - 77055
Genie UK LTD
The Maltings
Wharf Road, Grantham, Lin
NG31 6BH United Kingdom
Manufacturer:Manufacturer:
European Representative:
TZ-50
DATE:
GVWR / PNBV:
GAWR / PNBE:
TIRES / PNEU:
RIMS / JANTE:
COLD TIRE INFLATION/
THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL
MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE
OF MANUFACTURE SHOWN ABOVE.
THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS
PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY
REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE/
CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI
LUI SONT APPLICABLES EN VERTU DU REGLAMENT SUR LA
SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN
VIGUER A LA DATE DE SA FABRICATION
V.I.N/N.I.V.:
TYPE OF VEHICLE/TYPE DE VEHICULE:TRAILER/REMORQUE
MODEL:
SERIAL NUMBER:
ELECTRICAL SCHEMATIC:
MODEL YEAR:
Position 25
Position 24
Position 26
ES0440
Position 40
99.999 lbs/ 99.99 kg
99.999 lbs/ 99.99 kg
PRESS.DE GONFL. A FROID ‘SINGLE’
TZ5011-299
2011
NOMINAL
POWER:
PN - 77172
TZ-50
Terex USA, LLC.
590 Huey Road
Rock Hill, SC 29732
USA
INTRODUCTION
iii

Genie TZ-50/30 Part No. 84577
June 2012
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.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
iv
Safety Rules
Section 1 • Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual and the Genie TZ-50/30 Operator's
Manual will result in death or serious injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
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.

Part No. 84577 Genie TZ-50/30
June 2012
SAFETY RULES
v
Section 1 • Safety Rules
Workplace Safety
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure any forklift, overhead crane or
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.
Be sure that fasteners intended for one
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 to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

Genie TZ-50/30 Part No. 84577
June 2012
Table of Contents
vi
Introduction
Important Information ......................................................................................... ii
Section 1 Safety Rules
General Safety Rules ........................................................................................ iv
Section 2 Rev Specifications
A Machine Specifications ................................................................................ 2 - 1
A Performance Specifications ......................................................................... 2 - 2
A Manifold Component Specifications ............................................................. 2 - 2
A Hydraulic Specifications ............................................................................... 2 - 3
A Machine Torque Specifications .................................................................... 2 - 4
A Honda GX160K1 Engine Specifications ....................................................... 2 - 5
A Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 6
Section 3 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
AChecklist A Procedures
A-1 Perform Pre-operation Inspection ....................................................... 3 - 6
A-2 Perform Function Tests ...................................................................... 3 - 6
A-3 Perform Engine Maintenance (if equipped)......................................... 3 - 7
A-4 Torque the Lug Bolts - CE Models ...................................................... 3 - 7
A-5 Perform Hitch Maintenance - ANSI Models ........................................ 3 - 8
A-6 Perform Engine Maintenance (if equipped)......................................... 3 - 8
A-7 Perform Axle Maintenance - ANSI Models ......................................... 3 - 9
A-8 Perform 30 Day Service ..................................................................... 3 - 9
A-9 Perform Engine Maintenance (if equipped)....................................... 3 - 10
A-10 Grease the Turntable Rotation Bearing and Rotate Gear ................. 3 - 10
A-11 Perform Engine Maintenance (if equipped) ....................................... 3 - 11

Part No. 84577 Genie TZ-50/30
June 2012
TABLE OF CONTENTS
vii
Section 3 Rev Scheduled Maintenance Procedures, continued
AChecklist B Procedures
B-1 Inspect the Batteries ......................................................................... 3 - 12
B-2 Inspect the Electrical Wiring ............................................................. 3 - 13
B-3 Test the Emergency Stop ................................................................. 3 - 13
B-4 Test the Key Switch .......................................................................... 3 - 14
B-5 Test the Manual Override ................................................................. 3 - 14
B-6 Perform Hydraulic Oil Analysis ......................................................... 3 - 17
B-7 Check the Turntable Rotation Bearing Bolts ..................................... 3 - 17
B-8 Perform Axle Maintenance - ANSI Models ....................................... 3 - 18
B-9 Service the Tongue Jack .................................................................. 3 - 19
B-10 Inspect the Parking Brake ................................................................ 3 - 19
B-11 Check the Wheel Bearings - CE Models........................................... 3 - 23
B-12 Service the Hitch - CE Models .......................................................... 3 - 24
B-13 Check the Brakes - CE Models ........................................................ 3 - 25
B-14 Perform Engine Maintenance (if equipped) ....................................... 3 - 25
BChecklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) .................. 3 - 26
C-2 Test the Platform Overload System (if equipped) ............................. 3 - 26
C-3 Perform Axle Maintenance - ANSI Models ....................................... 3 - 27
C-4 Grease the Axle Wheel Bearings - CE Models ................................. 3 - 28
C-5 Adjust the Brakes - CE Models ......................................................... 3 - 29
BChecklist D Procedures
D-1 Calibrate the Platform Overload System (if equipped) ...................... 3 - 30
D-2 Perform Axle Maintenance - ANSI Models ....................................... 3 - 31
D-3 Check the Boom Wear Pads ............................................................ 3 - 32
D-4 Replace the Hydraulic Tank Return Filter ......................................... 3 - 32
AChecklist E Procedures
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 34
E-2 Perform Engine Maintenance (if equipped)....................................... 3 - 35

Genie TZ-50/30 Part No. 84577
June 2012
TABLE OF CONTENTS
viii
Section 4 Rev Repair
Introduction .................................................................................................. 4 - 1
APlatform Components
1-1 Platform ............................................................................................. 4 - 2
1-2 Platform Rotator ................................................................................. 4 - 2
AJib Boom Components
2-1 Jib Boom ............................................................................................ 4 - 4
2-2 Jib Boom Lift Cylinder ........................................................................ 4 - 6
APrimary Boom Components
3-1 Cable Track ........................................................................................ 4 - 8
3-2 Primary Boom .................................................................................. 4 - 11
3-3 Primary Boom Lift Cylinder .............................................................. 4 - 14
3-4 Platform Leveling Cylinders.............................................................. 4 - 15
ASecondary Boom Components
4-1 Secondary Boom ............................................................................. 4 - 18
4-2 Secondary Boom Lift Cylinder .......................................................... 4 - 21
AEngine
5-1 RPM Adjustment .............................................................................. 4 - 23
5-2 Fuse Replacement ........................................................................... 4 - 23
AGround Controls
6-1 Level Sensor .................................................................................... 4 - 24
AHydraulic Pump
7-1 Function Pump ................................................................................. 4 - 28
AManifolds
8-1 Function Manifold Components ........................................................ 4 - 30
8-2 Jib Manifold Components ................................................................. 4 - 32
8-3 Drive Manifold Components (if equipped) ........................................ 4 - 34
8-4 Valve Adjustments - Function Manifold ............................................ 4 - 36
8-5 Valve Coils ....................................................................................... 4 - 39

Part No. 84577 Genie TZ-50/30
June 2012
ix
TABLE OF CONTENTS
Section 4 Rev Repair, continued
AHydraulic Tank
9-1 Hydraulic Tank ................................................................................. 4 - 41
AAxle Components
10-1 Axle .................................................................................................. 4 - 42
ATrailer Components
11-1 Hydraulic and Mechanical Brakes .................................................... 4 - 43
11-2 Parking Brake .................................................................................. 4 - 43
AOutriggers
12-1 Outrigger Components ..................................................................... 4 - 44
12-2 Outrigger Cylinder ............................................................................ 4 - 45
APlatform Overload Components
13-1 Platform Overload System ............................................................... 4 - 46
Section 5 Rev Schematics
Introduction .................................................................................................. 5 - 1
A Abbreviation Legend - Electrical Schematics ............................................... 5 - 2
A Abbreviation Legend - Wire Colors .............................................................. 5 - 3
A Ground Control Box Wiring Diagram - View 1
All Models (before serial number TZ5004-182) ............................................ 5 - 4
A Ground Control Box Wiring Diagram - View 2
All Models (before serial number TZ5004-182) ............................................ 5 - 5
A Ground Control Box Wiring Diagram - View 1
ANSI and CSA Models (from serial number TZ5004-182 to TZ5004-324) ... 5 - 6
A Ground Control Box Wiring Diagram - View 2
ANSI and CSA Models (from serial number TZ5004-182 to TZ5004-324) ... 5 - 7
A Ground Control Box Wiring Diagram - View 1
ANSI and CSA Models (after serial number TZ5004-324) ........................... 5 - 8
A Ground Control Box Wiring Diagram - View 2
ANSI and CSA Models (after serial number TZ5004-324) ........................... 5 - 9

Genie TZ-50/30 Part No. 84577
June 2012
x
TABLE OF CONTENTS
Section 5 Rev Schematics, continued
A Ground Control Box Wiring Diagram - View 1
CE Models (from serial number TZ5004-182 to TZ5004-324).................... 5 - 10
A Ground Control Box Wiring Diagram - View 2
CE Models (from serial number TZ5004-182 to TZ5004-324).................... 5 - 11
A Ground Control Box Wiring Diagram - View 1
CE Models (after serial number TZ5004-324) ............................................ 5 - 12
A Ground Control Box Wiring Diagram - View 2
CE Models (after serial number TZ5004-324) ............................................ 5 - 13
A Platform Control Box Wiring Diagram
All Models (before serial number TZ5004-182) .......................................... 5 - 14
A Platform Control Box Wiring Diagram
ANSI and CSA Models (after serial number TZ5004-181) ......................... 5 - 15
A Platform Control Box Wiring Diagram
CE Models (after serial number TZ5004-181) ............................................ 5 - 16
A Drive Control Box Wiring Diagram ............................................................. 5 - 17
A Trailer Lighting Wiring Diagram.................................................................. 5 - 18
A Honda GX160 Engine Wiring Diagram ...................................................... 5 - 19
A Electrical Symbols Legend......................................................................... 5 - 21
A Electrical Schematic -
ANSI and CSA Models (before serial number TZ5004-182) ...................... 5 - 22
A Electrical Schematic -
ANSI and CSA Models (after serial number TZ5004-181) ......................... 5 - 32
A Electrical Schematic -
CE Models (before serial number TZ5004-182) ......................................... 5 - 42
A Electrical Schematic -
CE Models (after serial number TZ5004-181) ............................................ 5 - 52
A Hydraulic Component Reference ............................................................... 5 - 62
A Hydraulic Symbols and Abbreviation Legend............................................. 5 - 63
A Hydraulic Schematic .................................................................................. 5 - 64