Terex Genie TZ-50 User manual

Genie TZ-50 Part No. 824982
January 2016
ii
Introduction
Copyright © 2004 Terex Corporation
824982 Rev B3 August 2016
Second Edition, Second 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
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate operator's
manual on your machine before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting fault
codes and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures. However,
several procedures require specialized skills,
tools, lifting equipment and a suitable workshop.
In these instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
http://www.genielift.com
e-mail: awp[email protected]

Part No. 824982 Genie TZ-50
January 2016
Revision Date Section Procedure / Schematic Page / Description
A 6/2013 New release
A1 9/2014 Schem. 5-34
B 11/2014 Updated manual for EN280 certification
B1 11/2015 Schem. 5-21,5-22, 5-23, 5-25, 5-28, 5-29, 5-31, 5-34, 5-35,
5-37 and 5-40
B2 1/2016 3 3-30 updated turntable rotation bearing bolt torque spec's
B3 8/2016 1 Updated the Serial Number Legend artwork
Revision History
iii
REFERENCE EXAMPLES:
Honda Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
5-35, 5-56, 5-104_Section 5_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.

Genie TZ-50 Part No. 824982
January 2016
iv
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
Honda Engine_Section 2_Specifications.
A-6,B-3,C-7_Section 3_Maintenance Procedure.
3-2, 6-4, 9-1_Section 4_Repair Procedure.
5-35, 5-56, 5-104_Section 5_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.

Part No. 824982 Genie TZ-50
January 2016
Serial Number Legend
INTRODUCTION
v

Genie TZ-50 Part No. 824982
January 2016
vi
Safety Rules
Section 1 • Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
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.
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.
Indicates an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
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
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.

Part No. 824982 Genie TZ-50
January 2016
SAFETY RULES
vii
Section 1 • Safety Rules
Workplace Safety
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 Part No. 824982
January 2016
Table of Contents
viii
Introduction
Important Information ...................................................................................................... ii
Revision History ............................................................................................................. iii
Serial Number Legend .................................................................................................... v
Section 1 Safety Rules
General Safety Rules ..................................................................................................... vi
Section 2 Specifications
Machine Specifications ..............................................................................................2 - 1
Performance Specifications........................................................................................2 - 2
Hydraulic Specifications .............................................................................................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 Chart......................................................................2 - 8
Section 3 Scheduled Maintenance Procedures
Introduction.................................................................................................................3 - 1
Pre-delivery Preparation Report.................................................................................3 - 3
Maintenance Inspection Report .................................................................................3 - 5
Checklist A Procedures
A-1 Inspect the Manuals and Decals.......................................................................3 - 6
A-2 Perform Pre-operation Inspection.....................................................................3 - 7
A-3 Perform Function Tests .....................................................................................3 - 7
A-4 Perform Engine Maintenance (if equipped) ......................................................3 - 7

Part No. 824982 Genie TZ-50
January 2016
TABLE OF CONTENTS
ix
Section 3 Scheduled Maintenance Procedures, continued
A-5 Torque the Lug Bolts - Electric and Hydraulic Axles.........................................3 - 8
A-6 Torque the Lug Bolts - Mechanical Axle ...........................................................3 - 8
A-7 Perform Hitch Maintenance - Hydraulic Axle ....................................................3 - 9
A-8 Perform Engine Maintenance (if equipped) ......................................................3 - 9
A-9 Perform 30 Day Service..................................................................................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 Wiring ...........................................................................3 - 13
B-3 Test the Electrical Contactor...........................................................................3 - 14
B-4 Test the Manual Override................................................................................3 - 14
B-5 Perform Hydraulic Oil Analysis .......................................................................3 - 16
B-6 Perform Axle Maintenance - Electric and Hydraulic Axles..............................3 - 17
B-7 Service the Tongue Jack.................................................................................3 - 17
B-8 Inspect the Parking Brake...............................................................................3 - 18
B-9 Check the Wheel Bearings - Mechanical Axle................................................3 - 20
B-10 Service the Hitch - Mechanical Axle ...............................................................3 - 20
B-11 Perform Axle Maintenance - Mechanical Axle ................................................3 - 21
B-12 Perform Engine Maintenance (if equipped) ....................................................3 - 22

Genie TZ-50 Part No. 824982
January 2016
TABLE OF CONTENTS
x
Section 3 Scheduled Maintenance Procedures, continued
Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped)................................3 - 23
C-2 Test the Platform Overload System (if equipped) ...........................................3 - 23
C-3 Perform Axle Maintenance - Electric and Hydraulic Axles..............................3 - 24
C-4 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil.................................................................3 - 25
C-5 Grease the Axle Wheel Bearings - Mechanical Axle ......................................3 - 25
C-6 Adjust the Brakes - Mechanical Axle ..............................................................3 - 26
Checklist D Procedures
D-1 Perform Axle Maintenance - Electric and Hydraulic Axles..............................3 - 28
D-2 Check the Boom Wear Pads...........................................................................3 - 28
D-3 Replace the Hydraulic Tank Return Filter .......................................................3 - 29
D-4 Check the Turntable Rotation Bearing Bolts ...................................................3 - 30
D-5 Inspect for Turntable Bearing Wear.................................................................3 - 31
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ...................................................................3 - 32
E-2 Perform Engine Maintenance (if equipped) ....................................................3 - 33

Part No. 824982 Genie TZ-50
January 2016
xi
TABLE OF CONTENTS
Section 4 Repair
Introduction.................................................................................................................4 - 1
Platform Components
1-1 Platform ............................................................................................................4 - 2
1-2 Platform Rotator................................................................................................4 - 2
Jib Boom Components
2-1 Jib Boom...........................................................................................................4 - 4
2-2 Jib Boom Lift Cylinder.......................................................................................4 - 6
Primary Boom Components
3-1 Cable Track .......................................................................................................4 - 9
3-2 Primary Boom.................................................................................................4 - 11
3-3 Primary Boom Lift Cylinder.............................................................................4 - 14
3-4 Platform Leveling Cylinders ............................................................................4 - 15
Secondary Boom Components
4-1 Secondary Boom............................................................................................4 - 18
4-2 Secondary Boom Lift Cylinder........................................................................4 - 21
Engine
5-1 Fuse Replacement..........................................................................................4 - 23
Ground Controls
6-1 Level Sensor...................................................................................................4 - 24
Hydraulic Pump
7-1 Function Pump ...............................................................................................4 - 28
Manifolds
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 - 38

Genie TZ-50 Part No. 824982
January 2016
xii
TABLE OF CONTENTS
Section 4 Repair, continued
Hydraulic Tank
9-1 Hydraulic Tank ................................................................................................4 - 40
Axle Components
10-1 Axle.................................................................................................................4 - 41
Trailer Components
11-1 Hydraulic and Mechanical Brakes ..................................................................4 - 42
11-2 Parking Brake .................................................................................................4 - 42
Outriggers
12-1 Outrigger Components ...................................................................................4 - 43
12-2 Outrigger Cylinder ..........................................................................................4 - 44
Platform Overload Components
13-1 Platform Overload System..............................................................................4 - 45
Drive Components
14-1 Drive Motor .....................................................................................................4 - 47
14-2 Drive Control Box............................................................................................4 - 48
Section 5 Schematics
Introduction.................................................................................................................5 - 1
Electrical Abbreviations Legend .................................................................................5 - 2
Abbreviation Legend - Wire Colors.............................................................................5 - 4
Limit Switch Legend ...................................................................................................5 - 5
Electrical Symbols Legend .........................................................................................5 - 6
Abbreviation Legend - Hydraulic Schematics.............................................................5 - 7

Part No. 824982 Genie TZ-50
January 2016
Section 5 Schematics, continued
Hydraulic Symbols Legend.........................................................................................5 - 8
Honda GX160 Engine Wiring Diagram.......................................................................5 - 9
Trailer Lighting Wiring Diagram - ANSI / CSA ..........................................................5 - 10
Trailer Lighting Wiring Diagram - Mechanical Axle, CE ............................................5 - 11
Trailer Lighting Wiring Diagram - Electric Axle, AS...................................................5 - 12
Trailer Lighting Wiring Diagram - Hydraulic Axle, AS................................................5 - 13
Control Box Wiring Diagrams - ANSI/CSA
Ground Control Box Wiring Diagram - ANSI/CSA ....................................................5 - 14
Platform Control Box Wiring Diagram - ANSI/CSA...................................................5 - 16
Control Box Wiring Diagrams - CE
Ground Control Box Wiring Diagram - CE................................................................5 - 18
Platform Control Box Wiring Diagram - CE...............................................................5 - 20
Control Box Wiring Diagrams - AS
Platform Control Box Wiring Diagram - AS...............................................................5 - 21
Electrical Schematics - ANSI/CSA
Electrical Schematic - ANSI/CSA .............................................................................5 - 22
Electrical Schematics - CE
Electrical Schematic - CE ........................................................................................5 - 28
Electrical Schematics - AS
Electrical Schematic - AS .........................................................................................5 -34
Hydraulic Schematics
Hydraulic Schematic ................................................................................................5 - 40
TABLE OF CONTENTS
xiii

Genie TZ-50 Part No. 824982
January 2016
xiv
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Section 2 • SpecificationsJanuary 2016
Part No. 824982 Genie TZ-50 2 - 1
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 4.75gallons
18 liters
Hydraulic system 8 gallons
(including tank) 30 liters
Tires and wheels - Electric and Hydraulic Axles
Axle
Tire size ST225/75R15
Load range D
Lug nut torque, dry 80 ft-lbs
108 Nm
Tire pressure, maximum (cold) 65 psi
4.48 bar
Tires and wheels - Mechanical Axle
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 10 x 3 x 0.75
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.

Section 2 • Specifications January 2016
2 - 2 Genie TZ-50 Part No. 824982
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rando HD equivalent
Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rando HD oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Chevron Aviation A
Arnica 32
Continued use of Chevron
Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Performance Specifications
Boom function speeds, maximum
from platform controls
(no weight in platform)
Primary boom up 18 to 26 seconds
Primary boom down 17 to 26 seconds
Primary boom extend 13 to 20 seconds
Primary boom retract 16 to 24 seconds
Secondary boom up 17 to 25 seconds
Secondary boom up 20 to 30 seconds
(with drive option)
Secondary boom down 16 to 24 seconds
Jib boom up 16 to 22 seconds
Jib boom down 16 to 22 seconds
Platform rotate (if equipped) 8 to 12 seconds
Turntable rotate - 359° 110 to 140 seconds
Airborne noise emissions 80 dB
Maximum sound level at normal operation workstations
(A-weighted)
SPECIFICATIONS
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
For operational specifications, refer to the
Operators Manual.

Section 2 • SpecificationsJanuary 2016
Part No. 824982 Genie TZ-50 2 - 3
SPECIFICATIONS
Note: Use Chevron Aviation A hydraulic fluid when
ambient temperatures are consistently below
0°F / -17°C.
Note: Use Shell Tellus S2 V 46 hydraulic oil when
oil temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Service Department before use.
Function pump (models without drive option)
Type: single section gear pump
Displacement per revolution 0.244 cu in
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 3000psi
relief valve pressure 207 bar
Turntable rotate 600 psi
relief valve pressure 41 bar
Primary boom down 1600 psi
relief valve pressure 110 bar
Manifold Component Specifications
Plug torque
SAE No. 2 36 in-lbs / 4 Nm
SAE No. 4 10 ft-lbs / 13 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
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.

Section 2 • Specifications January 2016
2 - 4 Genie TZ-50 Part No. 824982
SPECIFICATIONS
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.
Machine Torque Specifications
Platform rotator
3/4-10 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

Section 2 • SpecificationsJanuary 2016
Part No. 824982 Genie TZ-50 2 - 5
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
Continuous improvement of our products
is a Genie policy. Product specifications are
subject to change without notice.

Section 2 • Specifications January 2016
2 - 6 Genie TZ-50 Part No. 824982
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC 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.
Seal-Lok™Fittings
(hose end - ORFS)
SAE Dash size Torque
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1
1/4
-8 3/4-16 1
-10 7/8-14 1
-12 1
1/16-12 1
-16 1
5/16-12 1
-20 1
5/8-12 1
-24 1
7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
(all types)
SAE Dash size Torque
-4 14 ft-lbs / 19 Nm
-6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
-16 125 ft-lbs / 169.5 Nm
-20 151 ft-lbs / 204.7 Nm
-24 184 ft-lbs / 249.5 Nm
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash size Torque
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
Adjustable
fitting (Adj)
Non-adjustable
fitting (Non-adj)
Jamb nut
SPECIFICATIONS