Terex Genie TZ-50 Service Manual
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Terex Genie TZ-50 Service Manual

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  • Page 2 824982 Rev B3 August 2016 future printings of this and all other manuals. Second Edition, Second Printing "Genie" and "TZ" are registered trademarks of Contact Us: Terex South Dakota, Inc. in the USA and many other countries. http://www.genielift.com Printed on recycled paper e-mail: awp.techpub@terex.com Printed in U.S.A.

  • Page 3: Revision History

    REFERENCE EXAMPLES: Honda Engine_Section 2_Specifi cations. 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 #. highlighted in blue to view the update. Part No. 824982 Genie TZ-50...
  • Page 4 REFERENCE EXAMPLES: Electronic Version Honda Engine_Section 2_Specifi cations. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. 5-35, 5-56, 5-104_Section 5_Schematic Page #. Genie TZ-50 Part No. 824982...

  • Page 5: Serial Number Legend

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

  • Page 6: Safety Rules

    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. Genie TZ-50 Part No. 824982...
  • Page 7 Be sure to properly dispose of old oil or other fl uids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Part No. 824982 Genie TZ-50...

  • Page 8: Table Of Contents

    Maintenance Inspection Report .................3 - 5 Checklist A Procedures Inspect the Manuals and Decals ...............3 - 6 Perform Pre-operation Inspection ..............3 - 7 Perform Function Tests ..................3 - 7 Perform Engine Maintenance (if equipped) ............3 - 7 Genie TZ-50 Part No. 824982 viii...
  • Page 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 Part No. 824982 Genie TZ-50...
  • Page 10 Check the Turntable Rotation Bearing Bolts ...........3 - 30 Inspect for Turntable Bearing Wear ..............3 - 31 Checklist E Procedures Test or Replace the Hydraulic Oil ..............3 - 32 Perform Engine Maintenance (if equipped) ............3 - 33 Genie TZ-50 Part No. 824982...
  • Page 11 Function Pump ....................4 - 28 Manifolds Function Manifold Components ..............4 - 30 Jib Manifold Components ................4 - 32 Drive Manifold Components (if equipped) ............4 - 34 Valve Adjustments - Function Manifold ............4 - 36 Valve Coils ......................4 - 38 Part No. 824982 Genie TZ-50...
  • Page 12 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 Genie TZ-50 Part No. 824982...
  • Page 13 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 Part No. 824982 Genie TZ-50 xiii...
  • Page 14 January 2016 This page intentionally left blank. Genie TZ-50 Part No. 824982...

  • Page 15: Specifi Cations

    8 gallons (including tank) 30 liters For operational specifi cations, refer to the Operator's Manual. Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 824982 Genie TZ-50 2 - 1...

  • Page 16: Performance Specifi Cations

    Aviation A hydraulic fl uid 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 specifi cations are subject to change without notice. 2 - 2 Genie TZ-50 Part No. 824982...

  • Page 17: Manifold Component Specifi Cations

    Flow rate 5.6 gpm 21.2 L/min Hydraulic tank return line fi lter 10 micron Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 824982 Genie TZ-50 2 - 3...

  • Page 18: Machine Torque Specifi Cations

    195 ft-lbs 264 Nm Hitch mounting bolts -11 bolts, dry 170 ft-lbs 230 Nm Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. 2 - 4 Genie TZ-50 Part No. 824982...
  • Page 19 Use oils meeting API classifi cation SJ as they offer improved wear protection. Units ship with 10W-30 SJ. Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 824982 Genie TZ-50 2 - 5...

  • Page 20: Hydraulic Hose And Fitting Torque Specifi Cations

    -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 2 - 6 Genie TZ-50 Part No. 824982...
  • Page 21 fi tting. 5 Operate all machine functions and inspect the hoses and fi ttings and related components to confi rm that there are no leaks. Part No. 824982 Genie TZ-50 2 - 7...
  • Page 22 Section 2 • Specifi cations January 2016 SPECIFICATIONS 10.9 12.9 2 - 8 Genie TZ-50 Part No. 824982...

  • Page 23: Scheduled Maintenance Procedures

    • Machine parked on a fi rm, 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 Part No. 824982 Genie TZ-50 3 - 1...

  • Page 24: Pre-Delivery Preparation Report

    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. 3 - 2 Genie TZ-50 Part No. 824982...
  • Page 25 Serial number Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Terex South Dakota, Inc USA Genie UK 500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England...
  • Page 26 Section 3 • Scheduled Maintenance Procedures January 2016 This page intentionally left blank. 3 - 4 Genie TZ-50 Part No. 824982...

  • Page 27: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 824982 Genie TZ-50 3 - 5...

  • Page 28: Checklist A Procedures

    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. 3 - 6 Genie TZ-50 Part No. 824982...

  • Page 29: Perform Pre-Operation Inspection

    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. 824982 Genie TZ-50 3 - 7...

  • Page 30: Torque The Lug Bolts - Electric And Hydraulic Axles

    KNOTT Axle (Dexter part number LIT-001-00). Service Manual (KNOTT part number P005). Dexter Axle Operation Maintenance Service Manual KNOTT Axle Service Manual Genie part number 84376 Genie part number 84443 3 - 8 Genie TZ-50 Part No. 824982...

  • Page 31: Perform Hitch Maintenance - Hydraulic Axle

    91 Brake Actuators Owner/Operator Manual GX160 Engine Owner Manual (Demco part number BH20023). (Honda part number 31ZH7630). Demco Model 91 Owner/Operator Manual Honda GX160 Owner's Manual Genie part number 84592 Genie part number 97228 Part No. 824982 Genie TZ-50 3 - 9...

  • Page 32: Perform 30 Day Service

    GX160 Engine Owner Manual (Honda part number 31ZH7630). • D-3 Replace the Hydraulic Tank Return Filter Honda GX160 Owner's Manual • D-4 Check the Turnable Rotation Genie part number 97228 Bearing Bolts 3 - 10 Genie TZ-50 Part No. 824982...

  • Page 33: Grease The Turntable Rotation Bearing And Rotate Gear

    4 to 5 inches / 10 to 13 cm at a time and repeat this step until the entire bearing has been greased. 4 Apply grease to each tooth of the drive gear located under the turntable. Grease type Multipurpose grease Part No. 824982 Genie TZ-50 3 - 11...

  • Page 34: Checklist B Procedures

    1 Put on protective clothing and eye wear. 2 Be sure that the battery cable connections are free of corrosion. 8 Inspect the battery charger plug and pigtail for damage or excessive insulation wear. Replace as required. 3 - 12 Genie TZ-50 Part No. 824982...

  • Page 35: Inspect The Electrical Wiring

    5 Lower the 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 Part No. 824982 Genie TZ-50 3 - 13...

  • Page 36: Test The Manual Override

    Remove all rings, watches and other jewelry. turntable rotate valve Note: Replace the contactor if any damage is secondary boom down valve primary boom down valve found. primary boom up valve boom extend/retract valve 3 - 14 Genie TZ-50 Part No. 824982...
  • Page 37 Note: The valve spool must be reset for the Note: The valve spool must be reset for the primary boom up function to operate from the secondary boom down function to operate from machine controls. the machine controls. Part No. 824982 Genie TZ-50 3 - 15...

  • Page 38: Perform Hydraulic Oil Analysis

    14 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. 3 - 16 Genie TZ-50 Part No. 824982...

  • Page 39: Perform Axle Maintenance - Electric And Hydraulic Axles

    Dexter Axle Operation Maintenance Service Manual grease the internal gears. Rotate the handle Genie part number 84376 to evenly distribute the lubricant to the internal gears. 2 Securely install the cap onto the jack. Part No. 824982 Genie TZ-50 3 - 17...

  • Page 40: Inspect The Parking Brake

    5 through 8 until the adjustment is brake cables are too loose, the brakes will not correct OR see B-8, Perform Axle Maintenance activate when the lever is set. - Electric and Hydraulic Axles 3 - 18 Genie TZ-50 Part No. 824982...
  • Page 41 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. Part No. 824982 Genie TZ-50 3 - 19...

  • Page 42: Check The Wheel Bearings - Mechanical Axle

    See C-5, Grease the Axle Wheel Bearings - Mechanical Axle. 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 3 - 20 Genie TZ-50 Part No. 824982...

  • Page 43: Perform Axle Maintenance - Mechanical Axle

    Service Manual (KNOTT part number P005). axle information is available in the KNOTT Axle Service Manual (KNOTT part number P005). KNOTT Axle Service Manual Genie part number 84443 KNOTT Axle Service Manual Genie part number 84443 Part No. 824982 Genie TZ-50 3 - 21...

  • Page 44: Perform Engine Maintenance (If Equipped)

    GX160 Engine Owner Manual (Honda part number 31ZH7630) and the Honda GX160 Engine Shop Manual (Honda part number 61ZH700). Honda GX160 Owner's Manual Genie part number 97228 Honda GX160 Shop Manual Genie part number 97229 3 - 22 Genie TZ-50 Part No. 824982...

  • Page 45: Checklist C Procedures

    fl oor. Result: The platform overload indicator light should be off at both the ground and platform controls. Part No. 824982 Genie TZ-50 3 - 23...

  • Page 46: Perform Axle Maintenance - Electric And Hydraulic Axles

    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, refer to Repair Procedure 13-1, Calibrate the Platform Overload System (if equipped). 3 - 24 Genie TZ-50 Part No. 824982...

  • Page 47: Replace The Hydraulic Tank Breather Cap - Models With Optional Hydraulic Oil

    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. Part No. 824982 Genie TZ-50 3 - 25...

  • Page 48: Adjust The Brakes - Mechanical Axle

    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. 3 - 26 Genie TZ-50 Part No. 824982...
  • Page 49 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. 824982 Genie TZ-50 3 - 27...

  • Page 50: Checklist D Procedures

    84376 may cause binding or scraping of the boom. Note: Always maintain squareness between the outer and inner boom tubes. Boom wear pad specifi cations Wear pad thickness, minimum inch 11 mm 3 - 28 Genie TZ-50 Part No. 824982...

  • Page 51: Replace The Hydraulic Tank Return Filter

    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. Part No. 824982 Genie TZ-50 3 - 29...

  • Page 52: Check The Turntable Rotation Bearing Bolts

    264 Nm Bearing to swing chassis 250 ft-lbs 195 ft-lbs 339 Nm 264 Nm *Not lubricated from serial number TZ5016-1430. **Lubricated to serial number TZ5016-1429. Illustration 1 Bearing-to-swing chassis bolt torque sequence 3 - 30 Genie TZ-50 Part No. 824982...

  • Page 53: Inspect For Turntable Bearing Wear

    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. Part No. 824982 Genie TZ-50 3 - 31...

  • Page 54: Checklist E Procedures

    Hydraulic tank drain plug, dry 150 in-lbs result in death or serious injury. 16.9 Nm Remove all rings, watches and Hydraulic tank drain plug, lubricated 112 in-lbs other jewelry. 12.6 Nm 3 - 32 Genie TZ-50 Part No. 824982...

  • Page 55: Perform Engine Maintenance (If Equipped)

    fi lling 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. 824982 Genie TZ-50 3 - 33...
  • Page 56 Section 3 • Scheduled Maintenance Procedures January 2016 This page intentionally left blank. 3 - 34 Genie TZ-50 Part No. 824982...
  • Page 57 Read, understand and obey the safety rules hazardous situation which, if not and operating instructions in the appropriate avoided, will result in death or Genie TZ-50 Operator's Manual on your serious injury. machine. Indicates a potentially hazardous Be sure that all necessary tools and parts are situation which, if not avoided, available and ready for use.

  • Page 58: Platform Components

    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 mount. Do not apply any lifting pressure. 4 - 2 Genie TZ-50 Part No. 824982...
  • Page 59 2 Activate the platform rotate left function and supported when the pivot pin is rotate the platform completely to the left. removed. Continue to activate the rotate left function for 3 seconds. Part No. 824982 Genie TZ-50 4 - 3...

  • Page 60: Jib Boom Components

    Bodily injury hazard. Spraying pinched. 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. 4 - 4 Genie TZ-50 Part No. 824982...
  • Page 61 24 Attach a lifting strap of suitable capacity from an overhead crane to the jib mount. Support Component damage hazard. the mount. Do not apply any lifting pressure. Cables and hoses can be damaged if they are kinked or pinched. Part No. 824982 Genie TZ-50 4 - 5...

  • Page 62: Jib Boom Lift Cylinder

    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. 4 - 6 Genie TZ-50 Part No. 824982...
  • Page 63 Remove the cylinder from the machine. Crushing hazard. The jib cylinder could fall if not properly supported when the pivot pin is removed. Part No. 824982 Genie TZ-50 4 - 7...

  • Page 64: Primary Boom Components

    (located behind ground control box) extension boom turntable platform level slave cylinder secondary boom pivot pin 4 - 8 Genie TZ-50 Part No. 824982...

  • Page 65: Cable Track

    Crushing hazard. If the cable bridge and the cable track are not properly secured together, the combination could become unbalanced and fall when removed from the machine. Part No. 824982 Genie TZ-50 4 - 9...
  • Page 66 Crushing hazard. The cable track through a full cycle to ensure smooth operation could become unbalanced and of the new section of cable track. fall if not properly attached to the overhead crane. 4 - 10 Genie TZ-50 Part No. 824982...

  • Page 67: Primary Boom

    Cables and hoses can be damaged if they are kinked or pinched. For ease of assembly, pay close attention to how the cables are routed when pulling the cables to the mid pivot. Part No. 824982 Genie TZ-50 4 - 11...
  • Page 68 Crushing hazard. The primary boom could become unbalanced 9 Remove the pin retaining fastener from the and fall if not properly supported primary lift cylinder rod end pivot pin. when removed from the machine. 4 - 12 Genie TZ-50 Part No. 824982...
  • Page 69 18 Using a soft metal drift, remove the primary the platform level slave cylinder hoses to the boom extension cylinder rod-end pivot pins. extension boom. 19 Remove the primary boom extension cylinder from the boom extension. Part No. 824982 Genie TZ-50 4 - 13...

  • Page 70: Primary Boom Lift Cylinder

    4 Using a soft metal drift, remove the lift cylinder rod end pivot pin. Crushing hazard. The cylinder will fall if not properly supported when the pivot pin is removed. 4 - 14 Genie TZ-50 Part No. 824982...

  • Page 71: Platform Leveling Cylinders

    Do not allow oil to machine squirt or spray. Part No. 824982 Genie TZ-50 4 - 15...
  • Page 72 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. 4 - 16 Genie TZ-50 Part No. 824982...
  • Page 73 January 2016 Section 4 • Repair Procedures This page intentionally left blank. Part No. 824982 Genie TZ-50 4 - 17...

  • Page 74: Secondary Boom Components

    (located behind ground control box) extension boom turntable platform level slave cylinder secondary boom pivot pin 4 - 18 Genie TZ-50 Part No. 824982...

  • Page 75: Secondary Boom

    Raise the cylinder to a if not properly supported when the horizontal position. pin is removed. Part No. 824982 Genie TZ-50 4 - 19...
  • Page 76 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. 4 - 20 Genie TZ-50 Part No. 824982...

  • Page 77: Secondary Boom Lift Cylinder

    90°. when the pivot pin is removed. 10 Raise the cylinder slightly, remove the block and lower the cylinder through the secondary link and onto the front bulkhead. Part No. 824982 Genie TZ-50 4 - 21...
  • Page 78 14 Carefully remove the cylinder from the machine. Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported when removed from the machine. 4 - 22 Genie TZ-50 Part No. 824982...

  • Page 79: Engine

    Genie part number 97228 Honda Engines Shop Manual Genie part number 97229 5 amp fuse - starter circuit (inside cover) 50 amp fuse - starter circuit 50 amp fuse - alternator circuit Part No. 824982 Genie TZ-50 4 - 23...

  • Page 80: Ground Controls

    Remove the level sensor from the 2 Turn the key switch to ground control and pull machine. out the red Emergency Stop buttons to the on position at both the ground and platform controls. 4 - 24 Genie TZ-50 Part No. 824982...
  • Page 81 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. Repeat this procedure beginning with step 6. Part No. 824982 Genie TZ-50 4 - 25...
  • Page 82 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. 4 - 26 Genie TZ-50 Part No. 824982...
  • Page 83 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 confi rm that the machine is level. Part No. 824982 Genie TZ-50 4 - 27...

  • Page 84: Hydraulic Pump

    3 Turn the key switch to ground control and pull gradually. Do not allow oil to squirt out the red Emergency Stop button to the or spray. on position at both the ground and platform controls. 4 - 28 Genie TZ-50 Part No. 824982...
  • Page 85 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. Part No. 824982 Genie TZ-50 4 - 29...

  • Page 86: Manifolds

    Orifi ce - plug, 0.080 inch / 2 mm .....Q ..Restricts platform down fl uid fl ow — Port plug ..........................97-117 in-lbs / 11-13 Nm Solenoid valve, 3 position 4 way with manual override .......R ..Turntable rotate left/right ...... 18-20 ft-lbs / 25-27 Nm Red Beaded Security Tie 4 - 30 Genie TZ-50 Part No. 824982...
  • Page 87 January 2016 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 Part No. 824982 Genie TZ-50 4 - 31...

  • Page 88: Jib Manifold Components

    Orifi ce - plug, 0.040 inch / 1 mm .... AJ ..Jib boom down circuit — Port plug ..........................97-117 in-lbs / 11-13 Nm Shuttle valve, 2 position 3 way ....AK ..Platform level circuit .........4-5 ft-lbs / 6 Nm 4 - 32 Genie TZ-50 Part No. 824982...
  • Page 89 Section 4 • Repair Procedures MANIFOLDS Models with Platform Rotate Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Models without Platform Rotate Part No. 824982 Genie TZ-50 4 - 33...

  • Page 90: Drive Manifold Components (If Equipped)

    Solenoid valve, 2 position 4 way ....BN..Drive circuit, left side ......18-20 ft-lbs / 25-27 Nm Proportional valve, 2 position 2 way ..BO ..Drive circuit, left side ......18-20 ft-lbs / 25-27 Nm 4 - 34 Genie TZ-50 Part No. 824982...
  • Page 91 MANIFOLDS Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Y50A After Before Serial Number Serial Number TZ5004-152 TZ5004-151 Part No. 824982 Genie TZ-50 4 - 35...

  • Page 92: Valve Adjustments - Function Manifold

    6 Repeat step 3 to confi rm the relief valve 7 Repeat step 4 to confi rm the relief valve pressure. pressure. 4 - 36 Genie TZ-50 Part No. 824982...
  • Page 93 Begin timing when the turntable begins to rotate. 9 Continue rotating the turntable and note the time when the machine stops rotating at 359°. Refer to Section 2, Specifi cations. Part No. 824982 Genie TZ-50 4 - 37...

  • Page 94: Valve Coils

    30%. 24V DC with diode Result: If the resistance is not within (schematic items CA, CB, CC and CD) specifi cation, plus or minus 30%, replace the coil. 4 - 38 Genie TZ-50 Part No. 824982...
  • Page 95 Genie part number 27287 COIL MULTI METER BATTERY RESISTOR multimeter 9V DC battery 10 resistor coil Note: Dotted lines in illustration indicate a reversed connection as specifi ed in step 6 Part No. 824982 Genie TZ-50 4 - 39...

  • Page 96: Hydraulic Tank

    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. 4 - 40 Genie TZ-50 Part No. 824982...

  • Page 97: Axle Components

    Note: When the axle is installed, the brakes should be bled. Refer to the appropriate brake manufacturer's manual that was shipped with your primary brake cable Genie TZ-50. tension equalizer secondary brake cables Part No. 824982 Genie TZ-50...

  • Page 98: Trailer Components

    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 4 - 42 Genie TZ-50 Part No. 824982...

  • Page 99: Outriggers

    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. 824982 Genie TZ-50 4 - 43...

  • Page 100: Outrigger Cylinder

    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. 4 - 44 Genie TZ-50 Part No. 824982...

  • Page 101: Platform Overload Components

    6 Using a suitable lifting device, place an switch wires. Securely install the wires onto the appropriate test weight equal to that of the limit switch. maximum platform capacity at the center of the platform fl oor. Part No. 824982 Genie TZ-50 4 - 45...
  • Page 102 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. Result: All ground control functions should not operate. 4 - 46 Genie TZ-50 Part No. 824982...

  • Page 103: Drive Components

    Returning the joystick to the neutral position will 4 Remove the drive motor mounting fasteners disable the drive and steer function, and set the and remove the drive motor from the machine. parking brake. Part No. 824982 Genie TZ-50 4 - 47...

  • Page 104: Drive Control Box

    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. 4 - 48 Genie TZ-50 Part No. 824982...

  • Page 105: Schematics

    January 2016 Section 5 • Schematics Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.

  • Page 106: Electrical Abbreviations Legend

    Section 5 • Schematics January 2016 Electrical Abbreviations Legend Item Description Item Description Battery Button Battery BN94 Function enable (boom down, boom retract, rotate left, outrigger extend) Button BN95 Function enable (boom up, boom extend, Engine start rotate right, outrigger retract) Choke BN96 Autolevel...
  • Page 107 January 2016 Section 5 • Schematics Electrical Abbreviations Legend Item Description Item Description Control Relay Light or LED CR71 Platform level Load sense at ground (load sense option) CR72 Outrigger Load sense at platform (load sense option) CR73 Function enable (ground controls) Left front outrigger CR74 Function enable (platform controls) Right front outrigger...
  • Page 108 Section 5 • Schematics January 2016 Electrical Abbreviations Legend Item Description Wire Color Legend Resistor Item ........Description Function speed, 0-10K ohms BL ........... Blue 1000 ohm BK ........... Black R22B 5600 ohm GN ..........Green OR ..........Orange Sensor RD ..........Red Level sensor WH ..........

  • Page 109: Limit Switch Legend

    January 2016 Section 5 • Schematics Limit Switch Legend Item Description Schematic Boom limit switches LS18 / LS18A Outrigger limit switch LS12/LS13/LS14/LS15 Part No. 824982 TZ-50 5 - 5...

  • Page 110: Electrical Symbols Legend

    Section 5 • Schematics January 2016 Electrical Symbols Legend Terminal 6V Battery Control relay Diode Resistor Fuse Power unit or motor KEY SWITCH Key switch Hour meter EMERGENCY STOP Emergency stop button, Motor controller normally closed Alarm Circuit breaker Battery charger Solenoid valve with diode N.C.H.O.
  • Page 111 January 2016 Section 5 • Schematics Hydraulic Abbreviations Legend Item Description Item Description Auxiliary pump Pilot operated directional valve - left Relief valve - turntable rotate Orifi ce - drive speed Pilot operated relief valve Pilot operated pressure compensator Shuttle valve - turntable rotate Orifi...

  • Page 112: Hydraulic Symbols Legend

    Section 5 • Schematics January 2016 Hydraulic Symbols Legend 0.090 inch 2.3 mm Orifi ce with size Check valve Shuttle valve Filter Check valve, Motor Fixed Variable speed motor pilot to open displacement pump Pilot operated Brake release Fixed Brake 2 position 2 way displacement directional valve...

  • Page 113: Honda Gx160 Engine Wiring Diagram

    January 2016 Section 5 • Schematics Honda GX160 Engine Wiring Diagram BATTERY STARTER SOLENOID BK/WH CONTROL BOX 5A FUSE ENGINE CIRCUIT BREAKER SWITCH RECTIFIER BK/RD OIL LEVEL TRANSISTORIZED SWITCH IGNITION UNIT SPARK PLUG CHARGING COIL Part No. 824982 TZ-50 5 - 9...

  • Page 114: Trailer Lighting Wiring Diagram - Ansi / Csa

    Section 5 • Schematics January 2016 Trailer Lighting Wiring Diagram - ANSI / CSA RIGHT SIDE MARKER QD12 TRAILER PLUG BN/YL RIGHT REAR TAIL LIGHT 1 GN 2 YL 3 BN/YL LEFT SIDE MARKER 3 BN LEFT REAR 4 WH TAIL LIGHT 5 - 10 TZ-50...

  • Page 115: Trailer Lighting Wiring Diagram - Mechanical Axle, Ce

    January 2016 Section 5 • Schematics Trailer Lighting Wiring Diagram - Mechanical Axle, CE RIGHT SIDE MARKER Trailer Chassis Wiring Harness 1 RD/BK RD/BK RD/BK 2 BL 1 RD/BK 3 WH WH/BK WH/BK 2 BL 4 GN 3 WH 5 OR 4 GN 6 RD 5 OR...

  • Page 116: Trailer Lighting Wiring Diagram - Electric Axle, As

    Section 5 • Schematics January 2016 Trailer Lighting Wiring Diagram - Electric Axle, AS BATTERY Trailer Chassis Wiring Harness BREAK AWAY ELECTRIC BRAKE BATTERY CHARGER RIGHT SIDE MARKER BK WH RD BK ELECTRIC BREAK AWAY KIT 7 PIN PLUG INSTALLED BY CUSTOMER LEFT TURN SIGNAL REVERSE LIGHT BREAK AWAY BATTERY CHARGER...

  • Page 117: Trailer Lighting Wiring Diagram - Hydraulic Axle, As

    January 2016 Section 5 • Schematics Trailer Lighting Wiring Diagram - Hydraulic Axle, AS RIGHT SIDE MARKER Trailer Chassis Wiring Harness 1 RD/BK RD/BK RD/BK 2 BL 1 RD/BK 3 WH WH/BK WH/BK 2 BL 4 GN 3 WH 5 OR 4 GN 6 RD 5 OR...

  • Page 118: Ground Control Box Wiring Diagram - Ansi/Csa

    Section 5 • Schematics January 2016 Ground Control Box Wiring Diagram - ANSI/CSA OR/BK TB33 BK/RD CR15 TERMINAL 86 CR1 TERMINAL 86 TURNTABLE HARNESS PIN E MODELS POWER CABLE PIN 1 WITH ENGINE CR6 TERMINAL 30 (OPTION) CR15 TERMINAL 30 BCI + EMERGENCY STOP TURNTABLE HARNESS...
  • Page 119 January 2016 Section 5 • Schematics Ground Control Box Wiring Diagram - ANSI/CSA TERMINAL BASE TB34A MANIFOLD HARNESS BN55 GN/BK GN/BK PIN P3-L TB22 DRIVE MANIFOLD HARNESS PIN 8 TB11 CR72 CR78A MANIFOLD HARNESS PLATFORM OUTRIGGERS LIFT CUT-OUT TB35 HARNESS AUTO TERMINAL PA LEVEL...

  • Page 120: Platform Control Box Wiring Diagram - Ansi/Csa

    Section 5 • Schematics January 2016 Platform Control Box Wiring Diagram - ANSI/CSA ZENER DIODE 5.1V DC R22B BN65 BN67 5.6K OHM BOOM BOOM PLATFORM R22C FUNCTION EXTEND/RETRACT LEVEL SPEED 5.6K OHM 10K OHM EMERGENCY STOP P1-8 POWER CABLE PIN 1 BK/WH OR/BK P2-4...
  • Page 121 January 2016 Section 5 • Schematics This page intentionally left blank. Part No. 824982 TZ-50 5 - 17...

  • Page 122: Ground Control Box Wiring Diagram - Ce

    Section 5 • Schematics January 2016 Ground Control Box Wiring Diagram - AS/CE OR/BK TB33 BK/RD CR15 TERMINAL 86 CR1 TERMINAL 86 TURNTABLE HARNESS PIN E MODELS POWER CABLE PIN 1 WITH ENGINE CR6 TERMINAL 30 (OPTION) CR15 TERMINAL 30 BCI + EMERGENCY STOP TURNTABLE HARNESS...
  • Page 123 January 2016 Section 5 • Schematics Ground Control Box Wiring Diagram - AS/CE TERMINAL BASE TB34A MANIFOLD HARNESS BN55 GN/BK GN/BK PIN P3-L TB22 TB11 DRIVE MANIFOLD HARNESS PIN 8 CR72 CR78A MANIFOLD HARNESS PLATFORM OUTRIGGERS LIFT CUT-OUT TB35 HARNESS AUTO TERMINAL PA LEVEL...

  • Page 124: Platform Control Box Wiring Diagram - Ce

    Section 5 • Schematics January 2016 Platform Control Box Wiring Diagram - CE ZENER DIODE 5.1V DC R22B BN65 BN67 5.6K OHM BOOM BOOM PLATFORM R22C FUNCTION EXTEND/RETRACT LEVEL SPEED 5.6K OHM 10K OHM EMERGENCY LIMIT SWITCH HARNESS STOP TERMINAL 3 P1-4 P1-8 POWER CABLE PIN 1...

  • Page 125: Platform Control Box Wiring Diagram - As

    January 2016 Section 5 • Schematics Platform Control Box Wiring Diagram - AS UPPER CONTROL BOX U35 LOAD SENSE OPT AUSTRALIAN LOAD SENSE BUMP LOAD RECOVERY R22B 5.1V ZENER 5.6K OHM BLK TB29 (-) BN65 BN67 BOOM PLATFORM EXTEND/ LEVEL RETRACT R22C 5.6K OHM...

  • Page 126: Electrical Schematic - Ansi/Csa

    Section 5 • Schematics January 2016 Electrical Schematic - ANSI/CSA 5 - 22 5 - 21...
  • Page 127 Section 5 • Schematics January 2016 Electrical Schematic - ANSI/CSA, 1 of 3 LOAD SENSE LS19 LIMIT SWITCH LOAD SENSE OPTION LS19A PLATFORM CONTROL BOX PLATFORM E-STOP POWER LOAD SENSE POWER LOAD SENSE POWER PLATFORM LS19A LS19 CHOKE START CONTROLS R101 FAULT ALARM...
  • Page 128 January 2016 Section 5 • Schematics Electrical Schematic - ANSI/CSA, 2 of 3 PLATFORM CONTROL BOX PLATFORM CONTROL BOX PLATFORM E-STOP POWER BN61 BN62 DOWN ENABLE ENABLE PLATFORM GROUND DOWN AUTOLEVEL MODULE ENABLE ENABLE DRIVE E-STOP POWER HALL EFFECT WITH ELECTRONIC DAMPING R22B 5.6K CR71...
  • Page 129 January 2016 Section 5 • Schematics Electrical Schematic - ANSI/CSA 5 - 23 5 - 24...
  • Page 130 January 2016 Section 5 • Schematics Electrical Schematic - ANSI/CSA, 3 of 3 PLATFORM CONTROL BOX BN67 BN98 BN66 PLAT PLAT ROTATE LEVEL ROTATE ENABLE ENABLE ENABLE CR78B CR78B BN64 BN63 BN65 BN97 ENABLE ENABLE ENABLE ENABLE CR71 CR87 PLATFORM GROUND GROUND CONTROL BOX BN57 BN58...
  • Page 131 January 2016 Section 5 • Schematics Electrical Schematic - ANSI/CSA 5 - 25 5 - 26...

  • Page 132: Electrical Schematic - Ce

    Section 5 • Schematics January 2016 Electrical Schematic - CE 5 - 28 5 - 27...
  • Page 133 Section 5 • Schematics January 2016 Electrical Schematic - CE, 1 of 3 LOAD SENSE LS19 LIMIT SWITCH LOAD SENSE OPTION LS19A PLATFORM CONTROL BOX PLATFORM E-STOP POWER LOAD SENSE POWER LOAD SENSE POWER PLATFORM LS19A LS19 CHOKE START CONTROLS R101 FAULT ALARM...
  • Page 134 January 2016 Section 5 • Schematics Electrical Schematic - CE, 2 of 3 PLATFORM CONTROL BOX PLATFORM CONTROL BOX PLATFORM E-STOP POWER BN61 BN62 LOAD SENSE POWER DOWN ENABLE ENABLE 4.7K LS19A LS19 PLATFORM GROUND 2 SEC DOWN AUTOLEVEL MODULE ENABLE ENABLE DRIVE E-STOP...

  • Page 135: Electrical Schematics - As

    January 2016 Section 5 • Schematics Electrical Schematic - CE 5 - 29 5 - 30...
  • Page 136 January 2016 Section 5 • Schematics Electrical Schematic - CE, 3 of 3 PLATFORM CONTROL BOX BN67 BN98 BN66 PLAT PLAT ROTATE LEVEL ROTATE ENABLE ENABLE ENABLE CR78B CR78B BN64 BN63 BN65 BN97 ENABLE ENABLE ENABLE ENABLE CR71 CR87 PLATFORM GROUND GROUND CONTROL BOX GROUND BN93...
  • Page 137 January 2016 Section 5 • Schematics Electrical Schematic - CE 5 - 31 5 - 32...

  • Page 138: Electrical Schematic - As

    Section 5 • Schematics January 2016 Electrical Schematic - AS 5 - 34 5 - 33...
  • Page 139 Section 5 • Schematics January 2016 Electrical Schematic - AS, 1 of 3 LOAD SENSE LS19 LIMIT SWITCH LOAD SENSE OPTION LS19A PLATFORM CONTROL BOX PLATFORM E-STOP POWER LOAD SENSE POWER LOAD SENSE POWER PLATFORM LS19A LS19 CHOKE START CONTROLS R101 FAULT ALARM...
  • Page 140 January 2016 Section 5 • Schematics Electrical Schematic - AS, 2 of 3 AUSTRALIAN LOAD SENSE SHOCK LOAD RECOVERY LOAD SENSE OPTION PLATFORM CONTROLS (BLT1) (BLT1) PLATFORM E-STOP POWER PLATFORM E-STOP POWER LOAD SENSE POWER LOAD SENSE POWER BN61 BN62 DOWN ENABLE ENABLE...
  • Page 141 January 2016 Section 5 • Schematics Electrical Schematic - AS 5 - 35 5 - 36...
  • Page 142 January 2016 Section 5 • Schematics Electrical Schematic - AS, 3 of 3 PLATFORM CONTROL BOX BN67 BN98 BN66 PLAT PLAT ROTATE LEVEL ROTATE ENABLE ENABLE ENABLE CR78B CR78B BN64 BN63 BN65 BN97 ENABLE ENABLE ENABLE ENABLE CR71 CR87 PLATFORM GROUND GROUND CONTROL BOX GROUND BN93...
  • Page 143 January 2016 Section 5 • Schematics Electrical Schematic - AS 5 - 37 5 - 38...

  • Page 144: Hydraulic Schematic

    Section 5 • Schematics January 2016 Hydraulic Schematic 5 - 40 5 - 39...
  • Page 145 Section 5 • Schematics January 2016 Hydraulic Schematic 5 - 40 TZ-50 Part No. 824982...

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