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