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

Part No.84577 GenieTZ-50/30 2 - 1
Section 2 • Specifications
REV A
November 2004
Specifications
Machine Specifications
Batteries, models without drive option
Type 6V DC
Group T-105
Quantity 4
Battery capacity 225AH
Reserve capacity @ 25A rate 447 minutes
Batteries, models with drive option
Type 6V DC
Group T-145
Quantity 4
Battery capacity 244AH
Reserve capacity @ 25A rate 530 minutes
Fluid capacities
Hydraulic tank 4.75 gallons
18 liters
Hydraulic system 8 gallons
(including tank) 30 liters
For operational specifications, refer to the
Operators Manual.
Tires and wheels - ANSI and CSA models
Axle
Tire size 225/75R15
Load range D
Lug nut torque, dry 80 ft-lbs
108 Nm
Tire pressure, maximum (cold) 65 psi
4.48 bar
Tires and wheels - CE models
Axle
Tire size 215/70R14
104/102N
Load range C
Lug bolt torque, dry 192 ft-lbs
260 Nm
Tire pressure, maximum (cold) 66 psi
4.55 bar
Tongue jack - all models
Tire size 12 x 3.25
Type Polyolefin with rubber tread
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.

2 - 2 GenieTZ-50/30 Part No.84577
Section 2 • Specifications
REV A
November 2004
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Valve Coil Resistance
Description Specification
Solenoid valve, 2 position 3 way 25 to 27Ω
20V DC with diode
(schematic items F, G, I, AA and AB)
Solenoid valve, 3 position 4 way 25 to 27Ω
20V DC with diode
(schematic items J, M, Q, AD and AE)
Solenoid valve, 2 position 4 way 25 to 27Ω
20V DC with diode
(schematic item Bl and BN)
Solenoid valve, 2 position 2 way N.C. 25 to 27Ω
20V DC with diode (schematic item BI)
Proportional valve, 2 position 2 way N.C. 25 to 27Ω
20V DC with diode (schematic item BK and BO)
Solenoid valve, 2 position 2 way N.C. 29 to 31Ω
24V DC with diode
(schematic items CA, CB, CC and CD)
Performance Specifications
Boom function speeds, maximum
from platform controls
(no weight in platform)
Primary boom up 17 to 21 seconds
Primary boom down 17 to 21 seconds
Primary boom extend 13 to 17 seconds
Primary boom retract 14 to 18 seconds
Secondary boom up 18 to 22 seconds
Secondary boom down 15 to 19 seconds
Jib boom up 16 to 20 seconds
Jib boom down 16 to 20 seconds
Turntable rotate - 359° 94 to 98 seconds
Airborne noise emissions 80 dB
Maximum sound level at normal operation workstations
(A-weighted)
For operational specifications, refer to the
Operators Manual.
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.
SPECIFICATIONS

Part No. 84577 Genie TZ-50/30 2 - 3
Section 2 • Specifications
REV A
November 2004
SPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalent
Approximate SAE grade 5W-20
Viscosity index rating 200
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
rating of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Premium ECO 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
Function pump (models without drive option)
Type: single section gear pump
Displacement per revolution 0.244 cu in
4 cc
Flow rate 2.8 gpm
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
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

2 - 4 GenieTZ-50/30 Part No.84577
Section 2 • Specifications
REV A
November 2004
SPECIFICATIONS
Machine Torque Specifications
Platform rotator
3/4-13 center bolt, lubricated 200 ft-lbs
271 Nm
3/8-16 bolts, lubricated 32 ft-lbs
43 Nm
Turntable rotate motor
1/2-13 bolts, dry 60 ft-lbs
81 Nm
Turntable rotate motor pinion
5/8-18 bolt, dry 180 ft-lbs
244 Nm
Turntable rotate bearing
all bolts, lubricated 195 ft-lbs
264 Nm
Hitch mounting bolts
5/8-11 bolts, dry 170 ft-lbs
230 Nm

Part No.84577 GenieTZ-50/30 2 - 5
Section 2 • Specifications
REV A
November 2004
Honda GX160K1 Engine
Displacement 9.9 cu in
163 cm2
Number of cylinders 1
Bore & stroke 2.7 x 1.8 inches
68 x 45 mm
Horsepower 5.4 hp @ 3600 rpm
4 kW @ 3600 rpm
Engine idle - no load 3400 rpm
Engine idle - under load (alternator) 3100 rpm
Compression ratio 8.5:1
Valve Clearance, cold
Intake 0.006 in (0.15 mm)
Exhaust 0.008 in (0.20 mm)
Lubrication system splash
Oil capacity 0.63 quarts
0.6 liters
Oil viscosity requirements
Temperature below 30°F / 0°C 5W-30
-4°F to 100°F / -20°C to 38°C 10W-30
Temperature above 50°F / 10°C 30W
Use oils meeting API classification SJ as they offer
improved wear protection. Units ship with 10W-30 SJ.
Starter motor 12 V DC
Cooling System Forced air
Ignition System
Spark plug type BPR6ES (NGK)
W20EPR-U (DENSO)
Spark plug gap 0.028 to 0.031 inches
0.7 to 0.8 mm
Fuel unleaded gasoline
86 octane minimum
Fuel tank capacity 0.95 gallons
3.6 liters
SPECIFICATIONS

2 - 6 GenieTZ-50/30 Part No.84577
Section 2 • Specifications
REV A
November 2004
SPECIFICATIONS
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications
require that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 40 ft-lbs / 54.2 Nm
-10 69 ft-lbs / 93.6 Nm
-12 93 ft-lbs / 126.1 Nm
-16 139 ft-lbs / 188.5 Nm
-20 172 ft-lbs / 233.2 Nm
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm
Seal-Lok®Fittings
(hose end)
SAE Dash size Torque
-4 18 ft-lbs / 24.4 Nm
-6 27 ft-lbs / 36.6 Nm
-8 40 ft-lbs / 54.2 Nm
-10 63 ft-lbs / 85.4 Nm
-12 90 ft-lbs / 122 Nm
-16 120 ft-lbs / 162.7 Nm
-20 140 ft-lbs / 190 Nm
-24 165 ft-lbs / 223.7 Nm
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.
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.
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.

Part No. 84577 GenieTZ-50/30 3 - 1
November 2004 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.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantialdamage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Keep records on all inspections for three years.
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
followingconfiguration:
· Machine disconnected from tow vehicle
· Machine parked on a firm, level surface
· Boom in the stowed position with both
latches secured
· Key switch in the off position with the
key removed
· Wheels chocked
· Parking brake applied
AboutThis 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.
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 cause
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.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

3 - 2 GenieTZ-50/30 Part No.84577
November 2004Section 3 • Scheduled Maintenance Procedures
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
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold motor or pump will
be required to perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Pre-delivery Preparation Report
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation report
to use for each inspection. Store completed forms
as required.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
perform a scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours or
every 3000 miles / 4800 km A + B
Semi-annually or every 500 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. Store completed forms
for three years.

Part No. 84577 GenieTZ-50/30 3 - 3
November 2004 Section 3 • Scheduled Maintenance Procedures
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
[phone]
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie
Industries. Rev A
Genie UK
The Maltings, Wharf Road
Grantham,Lincolnshire
NG31- 6BH England
(44)1476-584333
Pre-DeliverPre-Deliver
Pre-DeliverPre-Deliver
Pre-Delivery Preparationy Preparation
y Preparationy Preparation
y Preparation
Pre-Delivery Preparation Y N R
Pre-operationinspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
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
N = no, unable to complete
R = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
The Pre-delivery Preparation is performed prior to
each delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it
is put into service.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged
and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer'sspecifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians, according
to the manufacturer's specifications and the
requirements listed in the responsibilities manual.

3 - 4 GenieTZ-50/30 Part No.84577
November 2004Section 3 • Scheduled Maintenance Procedures
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