Manual Servicio Tz 50

Part No. 84577

Rev A1

April 2006

Service Manual

(from serial number TZ5004-1)

Genie TZ-50/30 Part No. 84577

November 2004

ii

Introduction

Important

Read, understand and obey the safety rules andoperating instructions in the Genie TZ-50/30Operator's Manual before attempting anymaintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified serviceprofessionals.

Basic mechanical, hydraulic and electricalskills are required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice center.

Technical Publications

Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specificationsare subject to change without notice.

Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.

Contact Us:

PO Box 97030Redmond, WA 98073-9730 USA

http://www.genieindustries.come-mail: [email protected]

Copyright © 2004 by Genie Industries

84577 Rev A November 2004First Edition, First Printing

"Genie" is a registered trademark of GenieIndustries in the USA and many other countries."TZ" is a trademark of Genie Industries.

Printed on recycled paper

Printed in U.S.A.

Part No. 84577 Genie TZ-50/30

November 2004

iii

Safety Rules

Section 1 • Safety Rules

DangerFailure to obey the instructions and safety rules inthis manual and the Genie TZ-50/30 Operator'sManual will result in death or serious injury.

Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.


November 2004

SAFETY RULES

iv

Section 1 • Safety Rules

Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.

Read each procedure thoroughly. Thismanual and the decals on the machineuse signal words to identify the following:

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.

Workplace SafetyBe sure to wear protective eye wear andother protective clothing if the situationwarrants it.

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

Be sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases

and engine fuels. Always have an approved fireextinguisher within easy reach.

Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of

debris that could get into machine components andcause damage.

Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the

weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.

Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.

Be sure that your workshop or work areais properly ventilated and well lit.


November 2004

Table of Contents

v

Introduction

Important Information ......................................................................................... ii

Section 1 Safety Rules

General Safety Rules ........................................................................................ iii

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

A Checklist 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


April 2006

TABLE OF CONTENTS

vi

Section 3 Rev Scheduled Maintenance Procedures, continued

A Checklist 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

B Checklist 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

B Checklist 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

A Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 34

E-2 Perform Engine Maintenance (if equipped) ....................................... 3 - 35


November 2004

TABLE OF CONTENTS

vii

Section 4 Rev Repair

Introduction .................................................................................................. 4 - 1

A Platform Components

1-1 Platform ............................................................................................. 4 - 2

1-2 Platform Rotator ................................................................................. 4 - 2

A Jib Boom Components

2-1 Jib Boom ............................................................................................ 4 - 4

2-2 Jib Boom Lift Cylinder ........................................................................ 4 - 6

A Primary 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

A Secondary Boom Components

4-1 Secondary Boom ............................................................................. 4 - 18

4-2 Secondary Boom Lift Cylinder .......................................................... 4 - 21

A Engine

5-1 RPM Adjustment .............................................................................. 4 - 23

5-2 Fuse Replacement ........................................................................... 4 - 23

A Ground Controls

6-1 Level Sensor .................................................................................... 4 - 24

A Hydraulic Pump

7-1 Function Pump ................................................................................. 4 - 28

A 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 - 39


April 2006

viii

TABLE OF CONTENTS

Section 4 Rev Repair, continued

A Hydraulic Tank

9-1 Hydraulic Tank ................................................................................. 4 - 41

A Axle Components

10-1 Axle .................................................................................................. 4 - 42

A Trailer Components

11-1 Hydraulic and Mechanical Brakes .................................................... 4 - 43

11-2 Parking Brake .................................................................................. 4 - 43

A Outriggers

12-1 Outrigger Components ..................................................................... 4 - 44

12-2 Outrigger Cylinder ............................................................................ 4 - 45

A Platform 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 1All Models (before serial number TZ5004-182) ............................................ 5 - 4

A Ground Control Box Wiring Diagram - View 2All Models (before serial number TZ5004-182) ............................................ 5 - 5

A Ground Control Box Wiring Diagram - View 1ANSI and CSA Models (from serial number TZ5004-182 to TZ5004-324) ... 5 - 6

A Ground Control Box Wiring Diagram - View 2ANSI and CSA Models (from serial number TZ5004-182 to TZ5004-324) ... 5 - 7

A Ground Control Box Wiring Diagram - View 1ANSI and CSA Models (after serial number TZ5004-324) ........................... 5 - 8

A Ground Control Box Wiring Diagram - View 2ANSI and CSA Models (after serial number TZ5004-324) ........................... 5 - 9


November 2004

ix

TABLE OF CONTENTS

Section 5 Rev Schematics, continued

A Ground Control Box Wiring Diagram - View 1CE Models (from serial number TZ5004-182 to TZ5004-324) .................... 5 - 10

A Ground Control Box Wiring Diagram - View 2CE Models (from serial number TZ5004-182 to TZ5004-324) .................... 5 - 11

A Ground Control Box Wiring Diagram - View 1CE Models (after serial number TZ5004-324) ............................................ 5 - 12

A Ground Control Box Wiring Diagram - View 2CE Models (after serial number TZ5004-324) ............................................ 5 - 13

A Platform Control Box Wiring DiagramAll Models (before serial number TZ5004-182) .......................................... 5 - 14

A Platform Control Box Wiring DiagramANSI and CSA Models (after serial number TZ5004-181) ......................... 5 - 15

A Platform Control Box Wiring DiagramCE 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


November 2004

x

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Part No. 84577 Genie TZ-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 gallons18 liters

Hydraulic system 8 gallons(including tank) 30 liters

For operational specifications, refer to theOperators 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 psi4.48 bar

Tires and wheels - CE models

Axle

Tire size 215/70R14104/102N

Load range C

Lug bolt torque, dry 192 ft-lbs 260 Nm

Tire pressure, maximum (cold) 66 psi4.55 bar

Tongue jack - all models

Tire size 12 x 3.25

Type Polyolefin with rubber tread

Continuous improvement of our products is a Geniepolicy. Product specifications are subject to changewithout notice.

2 - 2 Genie TZ-50/30 Part No. 84577


REV A

November 2004

Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 13 ft-lbs / 18 Nm





Valve Coil Resistance

Description Specification

Solenoid valve, 2 position 3 way 25 to 27Ω20V DC with diode(schematic items F, G, I, AA and AB)

Solenoid valve, 3 position 4 way 25 to 27Ω20V DC with diode(schematic items J, M, Q, AD and AE)

Solenoid valve, 2 position 4 way 25 to 27Ω20V DC with diode(schematic item Bl and BN)

Solenoid valve, 2 position 2 way N.C. 25 to 27Ω20V DC with diode (schematic item BI)

Proportional valve, 2 position 2 way N.C. 25 to 27Ω20V DC with diode (schematic item BK and BO)

Solenoid valve, 2 position 2 way N.C. 29 to 31Ω24V DC with diode(schematic items CA, CB, CC and CD)

Performance Specifications

Boom function speeds, maximumfrom 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 dBMaximum sound level at normal operation workstations(A-weighted)

For operational specifications, refer to theOperators Manual.

Continuous improvement of our products is a Geniepolicy. Product specifications are subject to changewithout notice.

SPECIFICATIONS

Part No. 84577 Genie TZ-50/30 2 - 3


REV A

November 2004

SPECIFICATIONS

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentApproximate SAE grade 5W-20Viscosity index rating 200

Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and have a minimum viscosity indexrating of 150. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Premium ECO 46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.

Function pump (models without drive option)

Type: single section gear pump

Displacement per revolution 0.244 cu in4 cc

Flow rate 2.8 gpm10.6 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 in8 cc

Flow rate 5.6 gpm21.2 L/min

Hydraulic tank return line filter 10 micron

Function manifold

System 3000 psirelief valve pressure 207 bar

Turntable rotate 600 psirelief valve pressure 41 bar

Primary boom down 1600 psirelief valve pressure 110 bar

2 - 4 Genie TZ-50/30 Part No. 84577


REV A

November 2004

SPECIFICATIONS

Machine Torque Specifications

Platform rotator

3/4 -13 center bolt, lubricated 200 ft-lbs271 Nm

3/8 -16 bolts, lubricated 32 ft-lbs43 Nm

Turntable rotate motor

1/2 -13 bolts, dry 60 ft-lbs81 Nm

Turntable rotate motor pinion

5/8 -18 bolt, dry 180 ft-lbs244 Nm

Turntable rotate bearing

all bolts, lubricated 195 ft-lbs264 Nm

Hitch mounting bolts

5/8 -11 bolts, dry 170 ft-lbs230 Nm

Part No. 84577 Genie TZ-50/30 2 - 5


REV A

November 2004

Honda GX160K1 Engine

Displacement 9.9 cu in163 cm2

Number of cylinders 1

Bore & stroke 2.7 x 1.8 inches68 x 45 mm

Horsepower 5.4 hp @ 3600 rpm4 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 quarts0.6 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 offerimproved 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 inches0.7 to 0.8 mm

Fuel unleaded gasoline86 octane minimum

Fuel tank capacity 0.95 gallons3.6 liters

SPECIFICATIONS

2 - 6 Genie TZ-50/30 Part No. 84577


REV A

November 2004

SPECIFICATIONS

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®

fittings and hose ends. Genie specificationsrequire that fittings and hose ends be torqued tospecification when they are removed and installedor 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)


-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)


-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 ProcedureSeal-Lok® fittings

1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.

The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield service kit.

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated andretained properly.

4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.

5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.

6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.

Part No. 84577 Genie TZ-50/30 3 - 1

November 2004 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly and semi-annually asspecified on the Maintenance InspectionReport.

Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating the machine.

Keep records on all inspections for three years.

Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.

Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:

· Machine disconnected from tow vehicle

· Machine parked on a firm, level surface

· Boom in the stowed position with bothlatches secured

· Key switch in the off position with thekey removed

· Wheels chocked

· Parking brake applied

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

Each procedure includes a description, safetywarnings and step-by-step instructions.

Symbols Legend

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.

Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

3 - 2 Genie TZ-50/30 Part No. 84577

November 2004Section 3 • Scheduled Maintenance Procedures

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appears at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

Indicates that a cold motor or pump willbe required to perform this procedure.

Indicates that dealer service will berequired to perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report containschecklists for each type of scheduled inspection.

Make copies of the Pre-delivery Preparation reportto use for each inspection. Store completed formsas required.

Maintenance Schedule

There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, semi-annually, annually, andtwo year. The Scheduled Maintenance ProceduresSection and the Maintenance Inspection Reporthave been divided into five subsections—A, B, C,D, and E. Use the following chart to determinewhich group(s) of procedures are required toperform a scheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours orevery 3000 miles / 4800 km A + B

Semi-annually or every 500 hours orevery 6000 miles / 9600 km A + B + C

Annually or every 1000 hours orevery 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 containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.

Part No. 84577 Genie TZ-50/30 3 - 3


Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of GenieIndustries. Rev A

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompleted

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 completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.

Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machinefrom service, repair and re-inspect it. After repair,place a check in the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior toeach delivery. The inspection is designed to discover ifanything is apparently wrong with a machine before itis put into service.

A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.

Scheduled maintenance inspections shall beperformed by qualified service technicians, accordingto the manufacturer's specifications and therequirements listed in the responsibilities manual.

3 - 4 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 3 - 5

April 2006 Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Checklist B - Rev A Y N R

B-1 Batteries

B-2 Electrical wiring

B-3 Emergency Stop

B-4 Key switch

B-5 Manual override

B-6 Hydraulic oil analysis

B-7 Turntable bearing bolts

B-8 Axle maintenance -ANSI models

B-9 Tongue jack

B-10 Parking brake

B-11 Wheel bearings -CE models

B-12 Hitch - CE models

B-13 Brakes - CE models

Perform every 300 hours:

B-14 Engine maintenance(if equipped)

Checklist C - Rev B Y N R

C-1 Grease platformoverload (if equipped)

C-2 Test platform overload(if equipped)

C-3 Axle maintenance -ANSI models

C-4 Axle wheel bearings -CE models

C-5 Brakes - CE models

Checklist D - Rev B Y N R

D-1 Axle maintenance -ANSI models

D-2 Boom wear pads

D-3 Hydraulic filter

Checklist E - Rev A Y N R

E-1 Hydraulic oil

E-2 Engine maintenance(if equipped)

Checklist A - Rev A Y N R

A-1 Pre-operation inspect

A-2 Function tests

A-3 Engine maintenance(if equipped)

A-4 Lug bolts - CE models

A-5 Hitch maintenance -ANSI models


A-7 Axle maintenance -ANSI models

Perform after 40 hours:

A-8 Perform 30 day service




A-10 Grease rotate bearing


Instructions· Make copies of this report to use for

each inspection.

· Select the appropriate checklist(s) forthe type of inspection to beperformed.

Daily or 8 hoursInspection: A

Quarterly or 250 hours or3000 mile / 4800 kmInspection: A+B

Semi-annually or 500 hoursor 6000 mile / 9600 kmInspection: A+B+C

Annually or 1000 hours or12,000 mile / 19,300 kmInspection: A+B+C+D

Two year or 2000 hoursInspection: A+B+C+D+E

· Place a check in the appropriate boxafter each inspection procedure iscompleted.

· Use the step-by-step procedures inthis section to learn how to performthese inspections.

· If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.

LegendY = yes, acceptableN = no, remove from service

R = repaired

Comments

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

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3 - 6 Genie TZ-50/30 Part No. 84577


A-1Perform Pre-operation InspectionCompleting a Pre-operation Inspection is essentialto safe machine operation. The Pre-operationInspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The Pre-operation Inspectionalso serves to determine if routine maintenanceprocedures are required.

Complete information to perform this procedure isavailable in the Genie TZ-50/30 Operator'sManual. Refer to the Operator's Manual on yourmachine.

Checklist A Procedures

A-2Perform Function TestsCompleting the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.

Complete information to perform this procedure isavailable in the Genie TZ-50/30 Operator'sManual. Refer to the Operator's Manual on yourmachine.

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Part No. 84577 Genie TZ-50/30 3 - 7


CHECKLIST A PROCEDURES

A-3Perform Engine Maintenance(if equipped)

Engine specifications require thatthis procedure be performed every8 hours or daily, whichever comesfirst.

Required maintenance procedures and additionalengine information is available in the HondaGX160 Engine Owner Manual(Honda part number 31ZH7630).

Honda GX160 Owner's ManualGenie part number 97228

A-4Torque the Lug Bolts -CE Models

Axle specifications require that thisprocedure be performed initiallyafter 50 km, or 50 km after awheel change.

Proper axle maintenance, following the axlemanufacturer's maintenance schedule, is essentialto good axle performance and service life. Failureto perform the maintenance procedures can lead topoor axle performance and component damage.

1 Check each lug bolt for proper torque. Refer toSection 2, Specifications.

Required maintenance procedures and additionalaxle information is available in the KNOTT AxleService Manual (KNOTT part number P005).

KNOTT Axle Service ManualGenie part number 84443

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3 - 8 Genie TZ-50/30 Part No. 84577



A-5Perform Hitch Maintenance -ANSI Models

Hitch specifications require thatthis procedure be performedweekly.

Required maintenance procedures and additionalhitch information is available in the Demco Model91 Brake Actuators Owner/Operator Manual(Demco part number BH20023).

Demco Model 91 Owner/Operator ManualGenie part number 84592


Engine specifications require thatthis procedure be performedinitially at 20 hours or 30 days,whichever comes first.



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Part No. 84577 Genie TZ-50/30 3 - 9


A-7Perform Axle Maintenance -ANSI Models

Axle specifications require that thisprocedure be performed initially at200 miles.

Required maintenance procedures and additionalaxle information is available in the Dexter AxleOperation Maintenance Service Manual(Dexter part number LIT-001-00).

Dexter Axle Operation Maintenance Service ManualGenie part number 84376

A-8Perform 30 Day Service

The 30 day maintenance procedure is a onetimeprocedure to be performed after the first 30 days or40 hours of usage. After this interval, refer to themaintenance tables for continued scheduledmaintenance.

1 Perform the following maintenance procedures:

· A-10 Grease the Turntable RotationBearing and Rotate Gear

· B-7 Check the Turnable RotationBearing Bolts

· B-10 Inspect the Parking Brake

· D-4 Replace the Hydraulic TankReturn Filter


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3 - 10 Genie TZ-50/30 Part No. 84577



Engine specifications require thatthis procedure be performed every50 hours or quarterly, whichevercomes first. Perform thisprocedure more often if dustyconditions exist.




A-10Grease the Turntable RotationBearing and Rotate Gear

Genie specifications require thatthis procedure be performed every100 hours of operation.

Regular application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an insufficiently greased bearing and gearwill result in component damage.

1 Raise the boom enough to access the turntablebearing.

2 Before serial number TZ5004-391: Locate thegrease fitting on the inside of the turntablerotation bearing.After serial number TZ5004-390: Locate thegrease fitting below the ground control box.

3 Pump multipurpose grease into the turntablerotation bearing. Rotate the turntable inincrements of 4 to 5 inches / 10 to 13 cm at atime and repeat this step until the entire bearinghas been greased.

4 Apply grease to each tooth of the drive gearlocated under the turntable.

Grease type Multipurpose grease

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Part No. 84577 Genie TZ-50/30 3 - 11



Engine specifications requirethat this procedure be performedevery 6 months or every 100hours, whichever comes first.Perform this procedure more oftenif dusty conditions exist.




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3 - 12 Genie TZ-50/30 Part No. 84577


B-1Inspect the Batteries

Proper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damage andhazardous conditions.

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

Perform this procedure after fullycharging the batteries.

For a more accurate determinationof battery condition, fully chargethe batteries and allow thebatteries to rest 24 hours beforeperforming this procedure to allowthe battery cells to equalize.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections arefree of corrosion.

3 Be sure that the battery retaining fasteners andcable connections are tight.

4 Remove the battery vent caps from all batteriesand check the specific gravity of each batterycell with a hydrometer.

Result: If any battery cell displays a specificgravity of less than 1.026, the battery must bereplaced.

5 Check the battery acid level of each battery. Ifneeded, replenish with distilled water to thebottom of the battery fill tube. Do not overfill.

Checklist B Procedures

6 Install the battery vent caps.

7 Check each battery pack and verify that thebatteries are wired correctly.

8 Inspect the battery charger plug and pigtail fordamage or excessive insulation wear. Replaceas required.

9 Connect the battery charger to a properlygrounded 115V/60Hz or 230V/60Hz singlephase AC power supply.

Result: The charger should operate and begincharging the batteries.

Result: Simultaneously, the charger alarmsounds and the LED's blink one time. Correctthe charger connections at the fuse and battery.The charger will then operate correctly andbegin charging the batteries.

Result: Simultaneously, the charger alarmsounds and the LED's blink two times. Theinput voltage is too low or too high. Correct thevoltage issue. The charger will then operatecorrectly and begin charging the batteries.

Result: Simultaneously, the charger alarmsounds and the LED's blink three times. Thecharger is overheated. Allow the charger tocool. The charger will then operate correctlyand begin charging the batteries.

If you have any further questionsregarding the battery chargeroperation, please contact theGenie Industries Scissor ServiceDepartment.

+ -

M-

A2

1

B-

B+

3+

+

-

+

-

+

-

+

-

Motor Controller

Battery Charger Side Ground Control Side

Pump

A1

D1

MotorCharger

275A Fuse

Black

Red

-

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Part No. 84577 Genie TZ-50/30 3 - 13


CHECKLIST B PROCEDURES

B-3Test the Emergency StopA properly functioning Emergency Stop is essentialfor safe machine operation. An improperlyoperating red Emergency Stop button will fail toshut off power and stop all machine functions,resulting in a hazardous situation.

1 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols. Pull out the red Emergency Stopbutton to the on position at the drive controls (ifequipped).

2 Push in the red Emergency Stop button at theground controls to the off position.

Result: No machine functions should operate.

The red Emergency Stop button atthe ground controls will stop allmachine operation without regardto the position of the key switch.

3 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at the ground controls.

4 Push down the red Emergency Stop button atthe platform controls to the off position.

Result: No machine functions should operate.

Models with drive (option):

5 Pull out the red Emergency Stop button to theon position at the platform controls.

6 Push down the red Emergency Stop button atthe drive controls to the off position.

Result: The drive function should not operate.

B-2Inspect the Electrical WiringMaintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.

Electrocution hazard. Contactwith hot or live circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

1 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Turntable area

· Ground controls

· Power unit wiring

2 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

3 Raise the secondary boom until the platform isapproximately 10 feet / 3 m off the ground.

4 Inspect the boom storage area for burnt, chafedand pinched cables.

5 Lower the boom to the stowed position and turnthe machine off.

6 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Boom to platform cable harness

· Primary and secondary booms

Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at the ground controls.

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3 - 14 Genie TZ-50/30 Part No. 84577


B-5Test the Manual OverrideTesting the manual override for malfunctions isessential for safe machine operation. An unsafeworking condition exists if the manual overridefunction does not operate in the event of a mainpower loss.

Turntable Rotate

1 Australia models: Locate the turntable rotatevalve coil on the function manifold. Push in andturn fully in a clockwise direction the redthumbscrew at the center of the valve stem.

Result: The head of the thumbscrew shouldrotate approximately one and one half turns in aclockwise direction.

All other models: Locate the turntable rotatevalve coils on the function manifold. Push inand hold the red thumbscrew at the center ofthe valve stem.

Result: The head of the thumbscrew shouldmove 1/4 inch / 6 mm inwards.

B-4Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.

Perform this procedure from theground using the platform controls.Do not stand in the platform.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols. Pull out the red Emergency Stopbutton to the on position at the drive controls (ifequipped).

2 Turn the key switch to platform control.

3 Check the machine functions from the groundcontrols.

Result: The machine functions should notoperate.

4 Check the machine functions from the drivecontrols.

Result: The drive functions should operate.

5 Turn the key switch to ground control.

6 Check the machine functions from the platformcontrols.

Result: The machine functions should notoperate.

7 Check the machine functions from the drivecontrols.

Result: The drive functions should operate.

8 Turn the key switch to the off position.

Result: No function should operate.


a

b

c

d

e

a turntable rotate valveb secondary boom down valvec primary boom down valved primary boom up valvee boom extend/retract valve

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Part No. 84577 Genie TZ-50/30 3 - 15


2 Australia models: Turn fully in a counterclockwise direction the red thumbscrew at thecenter of the valve stem, to reset the valve.

All other models: Release the red thumbscrewat the center of the valve stem, to reset thevalve.

The valve spool must be reset forthe turntable rotate function tooperate from the machinecontrols.

3 Australia models: Locate the turntable rotatevalve coil on the function manifold. Pull out andturn fully in a counter clockwise direction thered thumbscrew at the center of the valve stem.

Result: The head of the thumbscrew shouldrotate approximately one and one half turns in acounter clockwise direction.

All other models: Pull out and hold the redthumbscrew at the center of the valve stem.

Result: The head of the thumbscrew shouldmove 1/4 inch / 6 mm outwards.

4 Australia models: Turn fully in a clockwisedirection the red thumbscrew at the center ofthe valve stem, to reset the valve.



Secondary Boom Down

5 Locate the secondary boom down valve coil onthe function manifold. Push in and turn fully in acounter clockwise direction the red thumbscrewat the center of the valve stem.

Result: The head of the thumbscrew shouldrotate one-quarter turn in a counter clockwisedirection.


6 Push in and turn fully in a clockwise directionthe red thumbscrew at the center of the valvestem, to reset the valve.

The valve spool must be reset forthe secondary boom downfunction to operate from themachine controls.

Primary Boom Down

7 Locate the primary boom down valve coil on thefunction manifold. Push in and turn fully in acounter clockwise direction the red thumbscrewat the center of the valve stem.



The valve spool must be reset forthe primary boom down function tooperate from the machinecontrols.

Primary Boom Up

9 Locate the primary boom up valve coil on thefunction manifold. Push in and turn fully in acounter clockwise direction the red thumbscrewat the center of the valve stem.



The valve spool must be reset forthe primary boom up function tooperate from the machinecontrols.

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3 - 16 Genie TZ-50/30 Part No. 84577


Boom Extend/Retract

11 Australia models: Locate the boomextend/retract valve coils on the functionmanifold. Push in and turn fully in a clockwisedirection the red thumbscrew at the center ofthe valve stem.

Result: The head of the thumbscrew shouldrotate approximately one and one half turns in aclockwise direction.

All other models: Locate the boomextend/retract valve coils on the functionmanifold. Push in and hold the red thumbscrewat the center of the valve stem.

Result: The head of the thumbscrew shouldmove 1/4 inch / 6 mm inwards.

12 Australia models: Turn fully in a counterclockwise direction the red thumbscrew at thecenter of the valve stem, to reset the valve.



13 Australia models: Locate the boomextend/retract valve coils on the functionmanifold. Pull out and turn fully in a counterclockwise direction the red thumbscrew at thecenter of the valve stem.

Result: The head of the thumbscrew shouldrotate approximately one and one half turns in acounter clockwise direction.

All other models: Locate the boomextend/retract valve coils on the functionmanifold. Pull out and hold the red thumbscrewat the center of the valve stem.

Result: The head of the thumbscrew shouldmove 1/4 inch / 6 mm outwards.


14 Australia models: Turn fully in a clockwisedirection the red thumbscrew at the center ofthe valve stem, to reset the valve.



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Part No. 84577 Genie TZ-50/30 3 - 17


B-6Perform Hydraulic Oil Analysis

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test. See E-1,Test or Replace the Hydraulic Oil.


Tongue

9

11

1

10

5

3

8

12

2 6

4

7

B-7Check the Turntable RotationBearing Bolts

Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque or torque sequence couldresult in an unsafe operating condition andcomponent damage.

1 Be sure that each turntable rotation bearingmounting bolt above the turntable is torqued insequence to specification.Refer to Illustration 1.

Illustration 1

Bearing-to-swing chassis bolt torque sequence

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3 - 18 Genie TZ-50/30 Part No. 84577


2 Working from underneath the turntable, be surethat each turntable rotation bearing mountingbolt is torqued in sequence to specification.Refer to Illustration 2.

Illustration 2

Bearing-to-chassis bolt torque sequence

Turntable rotation bearing bolt torque specifications

Bearing to chassis, lubricated 195 ft-lbs264 Nm

Bearing to swing chassis, lubricated 195 ft-lbs264 Nm


B-8Perform Axle Maintenance -ANSI Models

Axle specifications require that thisprocedure be performed quarterlyor every 3000 miles, whichevercomes first.




Tongue

1

5

3

8 2

6

4

79

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Part No. 84577 Genie TZ-50/30 3 - 19


B-9Service the Tongue Jack

Maintaining the tongue jack in good condition isessential to safe operation and good machineperformance. Failure to lubricate the internal gearsand bearings of the jack and axle bolt could resultin unsafe operating conditions and may causecomponent damage.

Jack specifications require thatthis procedure be performedquarterly or every 3000 miles,whichever comes first.

1 Remove the cap from the top of the jackhousing and, using automotive grease, lightlygrease the internal gears. Rotate the handle toevenly distribute the lubricant to the internalgears.

2 Securely install the cap onto the jack.

B-10Inspect the Parking Brake

A properly functioning parking brake is essential tosafe machine operation. The parking brake ismanually activated. An improperly functioningparking brake will prevent the operator fromproperly securing the machine when not in use.

ANSI models without drive option:

1 Visually inspect the parking brake cables andcomponents for damage.

2 Visually inspect the parking brake cables toensure both are properly secured and installedinto the brake backing plate.

3 Set the parking brake.

If the brake cables are too tight theparking brake assembly will bedifficult to apply. If the brakecables are too loose, the brakeswill not activate when the lever isset.

4 Attempt to manually push the machine.

Result: The machine should not move.

Result: The machine moves. Proceed to step 5.

5 Chock the wheels

6 Release the parking brake.

7 Loosen the set screw at the side of the parkingbrake handle.


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3 - 20 Genie TZ-50/30 Part No. 84577


8 Adjust the handle just to the point where it isdifficult to apply the parking brake, then rotatethe top of the parking brake handlecounterclockwise one full turn.

9 Tighten the set screw. Do not overtighten.

10 Engage the parking brake. Attempt to move themachine in both directions.

Result: The parking brake should prevent themachine from moving. If the parking brake doesnot prevent the machine from moving, repeatsteps 5 through 8 until the adjustment is correctOR see B-9, Perform Axle Maintenance - ANSIModels.

CE models without drive option:


2 Visually inspect the parking brake cables toensure both are properly secured and installedinto the brake backing plate.







5 At the ground controls, extend the outriggersuntil the axle is off the ground and the machineis level.


7 Pull out the nose of the hitch as far as it will go.

8 Loosen the lock nuts at the tension equalizer.

9 Turn the wheel in a forward motion, adjustingthe wheel brakes until the wheel turns withdifficulty or not at all.

10 Adjust the wheel brakes until the wheel turnsfreely.

Slight rubbing noises, which donot affect the free turning of thewheel, are permitted.

11 Repeat steps 9 and 10 for the other wheel.

12 Engage and release the parking brake 4 times.

13 Tighten the nuts on the tension equalizerbracket until the bracket is balanced. Securelytighten the lock nuts.

14 Adjust the linkage until it is free of play andwithout initial tension.

15 Lower the machine and return the outriggers tothe stowed position.


Result: The parking brake should prevent themachine from moving. If the parking brake doesnot prevent the machine from moving, repeatsteps 5 through 16 until adjustment is correctOR see B-14, Check the Brakes - CE Models.

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Part No. 84577 Genie TZ-50/30 3 - 21


ANSI models with drive option:


2 Visually inspect the parking brake cables toensure all are properly secured and installedinto the brake backing plate and parking brakebalance bar.






5 Adjust the brakes. See B-9, Perform AxleMaintenance - ANSI Models.

6 Chock the wheels




10 Tighten the set screw. Do not overtighten.


12 Engage the parking brake.

13 Remove the parking brake cylinder inspectioncover.

14 Adjust the parking brake cylinder input cableuntil the cylinder flange just contacts thecylinder slider assembly.



a rear parking brake cableb cylinder output rodc tension equalizer bracketd parking brake cylindere cylinder flangef slider assemblyg drive motor brake cableh cylinder input cable

16 Adjust both rear parking brake cables at thetension equalizer bracket until, when turning thewheel in the direction of travel, a slight rubbingnoise can be heard from the brakes. Loosenthe cables just until no noise can be heardwhen turning the wheels.

Be sure a minimum of one fullthread of the cable end is showingthrough the adjustment nut at thetension equalizer bracket.


a d ecb g hf

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3 - 22 Genie TZ-50/30 Part No. 84577



19 Engage both drive motors.

20 Working from the front end of the parking brakecylinder, adjust the drive motor brake cables byhand until they have zero play and zeroresistance. Be sure the brake cylinder balancebar is square to the parking brake input cable.

21 Disengage both drive motors.


Result: The parking brake should prevent themachine from moving. If the parking brake doesnot prevent the machine from moving, repeatthis procedure beginning with step 5.

CE models with drive option:


2 Visually inspect the parking brake cables toensure all are properly secured and installedinto the brake backing plate and parking brakebalance bar.








7 Pull out the nose of the hitch as far as it will go.

8 Remove the parking brake cylinder inspectioncover.

9 Visually inspect the parking brake cables toensure all are properly secured and installedinto the brake backing plate and tensionequalizer bracket.

10 Loosen the lock nuts at the tension equalizerbracket.

11 Turn the wheel in a forward motion, adjustingthe wheel brakes until the wheel turns withdifficulty or not at all.

12 Adjust the wheel brakes until the wheel turnsfreely.

Slight rubbing noises, which donot affect the free turning of thewheel, are permitted.

13 Repeat steps 11 and 12 for the other wheel.


a rear parking brake cableb cylinder output rodc tension equalizer bracketd parking brake cylindere cylinder flangef slider assemblyg drive motor brake cableh cylinder input cable

a d ecb g hf

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Part No. 84577 Genie TZ-50/30 3 - 23


14 Engage and release the parking brake 4 times.


16 Adjust the parking brake cylinder input cableuntil the cylinder flange just contacts thecylinder slider assembly.


18 Adjust both rear parking brake cables at thetension equalizer bracket until, when turning thewheel in the direction of travel, a slight rubbingnoise can be heard from the brakes. Loosenthe cables just until no noise can be heardwhen turning the wheels.

Be sure a minimum of one fullthread of the cable end is showingthrough the adjustment nut at thetension equalizer bracket.



21 Engage both drive motors.

22 Working from the front end of the parking brakecylinder, adjust the drive motor brake cables byhand until they have zero play and zeroresistance. Be sure the brake cylinder balancebar is square to the parking brake input cable.

23 Disengage both drive motors.



B-11Check the Wheel Bearings -CE Models

Axle specifications require that thisprocedure be performed quarterlyor every 5000 km, whichevercomes first.



2 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Result: There is side to side or up and downmovement. See C-4, Grease the Axle WheelBearings - CE Models.




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3 - 24 Genie TZ-50/30 Part No. 84577


B-12Service the Hitch -CE Models

Axle specifications require that thisprocedure be performed quarterlyor every 5000 km, whichevercomes first.


1 Clean all visible surfaces of the ball coupler.

2 Lubricate the hitch at both grease fittings at thetop of the over-run hitch.

3 Lubricate all bolts and articulated points on thehand brake lever using commonly availablemachine oil or motor oil.

4 Lubricate all bolts and movable parts of thecoupler using commonly available machine oilor motor oil.

5 Lightly grease the ball mount.

6 Conform that the brake cable is securelyinstalled into the brake handle linkage.

7 Apply the hand brake.


Result: The machine does not move.

Result: The machine moves. Adjust the brakes.See Maintenance procedure C-5, Adjust theBrakes - CE Models.




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Part No. 84577 Genie TZ-50/30 3 - 25



B-13Check the Brakes -CE Models

Axle specifications require that thisprocedure be performed annuallyor every 5000 km, whichevercomes first.


1 Chock the wheels.

2 Release the hand brake.

3 Inspect the brakes shoes for wear.

Result: The lining of the brake shoes is thin.Replace the brake shoes. To adjust the brakes,see C-5, Adjust the Brakes - CE Models.

The lining of the brake shoes canbe inspected using the small viewholes on the back of the brakes.



B-14Perform Engine Maintenance(if equipped)

Engine specifications require thatthis procedure be performed every300 hours or annually, whichevercomes first.

Required maintenance procedures and additionalengine information is available in the HondaGX160 Engine Owner Manual (Honda part number31ZH7630) and the Honda GX160 Engine ShopManual (Honda part number 61ZH700).


Honda GX160 Shop ManualGenie part number 97229

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3 - 26 Genie TZ-50/30 Part No. 84577

April 2006Section 3 • Scheduled Maintenance Procedures

Checklist C Procedures

C-1Grease the Platform OverloadMechanism (if equipped)

Genie specifications requirethat this procedure be performedevery 500 hours or 6 months,whichever comes first. Performthis procedure more often if dustyconditions exist.

Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.

1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.

2 Thoroughly pump grease into each greasefitting.

Grease type Multipurpose grease

C-2Test the Platform OverloadSystem (if equipped)

Genie specifications require thatthis procedure be performed every500 hours or 6 months, whichevercomes first.

Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stabilitycould be compromised resulting in the machinetipping over.

Perform this procedure with themachine on a firm, level surface.


2 Release the boom hold down latch.


4 Level the platform.

5 Determine the maximum platform capacity.Refer to the machine serial plate.

6 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity in the center of theplatform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.

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Part No. 84577 Genie TZ-50/30 3 - 27


7 Add an additional 44 lbs / 20 kg of weight tooverload the platform.

Result: The platform overload indicator lightshould be flashing at both the ground andplatform controls.

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.


10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Lift the test weight off the platform floor using asuitable lifting device.

Result: The platform overload indicator lightshould turn off at both the ground and platformcontrols.


Result: All ground control functions shouldoperate normally.



Result: All platform control functions shouldoperate.

If the platform overload system isnot operating properly, refer toRepair Procedure 13-1, Calibratethe Platform Overload System (ifequipped).

C-3Perform Axle Maintenance -ANSI Models

Axle specifications require that thisprocedure be performed every 6months or 6000 miles, whichevercomes first.



CHECKLIST C PROCEDURES

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3 - 28 Genie TZ-50/30 Part No. 84577


C-4Grease the Axle Wheel Bearings -CE Models

Axle specifications require that thisprocedure be performed every 6months or 10,000 km, whichevercomes first.

Maintaining the axle wheel bearings is essential tosafe operation and good machine performance.Towing the machine with loose or worn wheelbearings may cause an unsafe towing conditionand continued use may result in component orproperty damage. Regular steam cleaning andpressure washing of the machine may require thatthis procedure be performed more often.

1 Loosen the wheel lug bolts. Do not removethem.


3 Remove the lug bolts and remove the tire andwheel assembly from the machine.

4 Remove, wash and inspect the axle wheelbearings and spacer ring.

5 Pack both bearings with clean, fresh grease.

6 Install the bearings and spacer ring onto theaxle and reassemble the axle.

7 Tighten the castle nut until the wheel runs with alittle bite.

8 Loosen the castle nut just until the cotter pin fitsinto the next hole. Install a new cotter pin andlock into position. Install the dust cap.

Always replace the cotter pin witha new one when removing thecastle nut or when checking thetorque of the castle nut.

9 Install the tire and wheel onto the axle. Installand torque the lug bolts to specification. Referto Section 2, Specifications.

10 Perform steps 3 through 9 for the other side ofthe machine.

11 Return the outriggers to the stowed position.




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Part No. 84577 Genie TZ-50/30 3 - 29


C-5Adjust the Brakes -CE Models

Axle specifications require that thisprocedure be performed every 6months or 10,000 km, whichevercomes first.

Maintaining the axle wheel bearings is essential tosafe operation and good machine performance.Towing the machine with loose or worn wheelbearings may cause an unsafe towing conditionand continued use may result in component orproperty damage. Regular steam cleaning andpressure washing of the machine may requiredthat this procedure be performed more often.



3 Working from the exposed inside face of thebrake plate, opposite the cable entry, tightenthe adjusting screw until the wheel can only beturned with difficulty or not at all.

When tighten the adjusting screw,turn the wheel only in the directionof travel.

4 Ease off the adjusting screw approximately one-half turn in a counterclockwise direction, untilthe wheel turns freely.

5 Repeat steps 3 through 4 for the other brake.

6 Inspect the balance plate at the control cables.

Result: The balance plate is at a right angle tothe direction of towing.

Result: The balance plate is not at a right angleto the direction of towing. Tighten or loosen thebrake cable ends coming from the axle until thebalance plate is at a right angle to the directionof towing.

The balance plate is locatedbeneath the diamond plate coverin front of the turntable.


8 Apply the parking brake.


Result: The machine does not move.

Result: The machine moves. Repeat thisprocedure beginning with step 1.

Result: One wheel rolls and the other onedoesn’t. Repeat step 6 and adjust the balanceplate to tighten the brake cable from the wheelwhich is rolling.




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3 - 30 Genie TZ-50/30 Part No. 84577


Checklist D Procedures

D-1Perform Axle Maintenance -ANSI Models

Axle specifications require that thisprocedure be performed every 12months or 12,000 miles,whichever comes first.



D-2Check the Boom Wear Pads

Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.

If the wear pads are withinspecification, refer to RepairProcedure 3-2, How to Shim theBoom.

1 Extend the boom until the wear pads areaccessible.

2 Measure the thickness of the top, side andbottom wear pads. If the wear pad is withinspecification, shim as necessary to obtain zeroclearance and zero drag.

3 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.

Always maintain squarenessbetween the outer and innerboom tubes.

Boom wear pad specifications

Wear pad thickness, minimum 7/16 inch11 mm

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D-3Replace the Hydraulic TankReturn Filter

Replacement of the hydraulic tank return filterelement is essential for good machine performanceand service life. A dirty or clogged filter elementmay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require that thefilter element be replaced more often.

Burn hazard. Beware of hot oil.Contact with hot oil may causesevere burns.

The hydraulic filter is mounted onthe bulkhead next to the hydraulictank.

1 Clean the area around the hydraulic oil filter.Remove the filter with an oil filter wrench.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.

CHECKLIST D PROCEDURES

2 Apply a thin layer of fresh oil onto the gasket ofthe new oil filter.

3 Install the filter and tighten it securely by hand.

4 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe new filter.

5 Clean up any oil that may have spilled duringthe replacement procedure. Properly discardthe used filter.

6 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

7 Raise the platform approximately 3 ft / 1 m.

8 Inspect the filter and related components tobe sure that there are no leaks.

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E-1Test or Replace the Hydraulic Oil

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer toSection 2, Hydraulic Hose andFitting Torque Specifications.

Perform this procedure with themachine in the stowed position.

1 Disconnect the battery pack from the machine.

Electrocution hazard. Contactwith hot or live circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

2 Remove the drain plug from the hydraulic tankand completely drain the tank into a suitablecontainer. Refer to Section 2, Specifications, forcapacity information.


3 Tag and disconnect the hydraulic return linefrom the filter head to tank.

4 Tag and disconnect the hydraulic inlet line tothe filter head. Cap the fitting on the line.

5 Remove the filter head from the machine.

6 Tag and disconnect the hydraulic line from thetank to the pump. Cap the fitting on the pump.

7 Remove the hydraulic tank mounting fasteners.Remove the hydraulic tank from the machine.

8 Clean the inside of the hydraulic tank using amild solvent.

9 Install and tighten the hydraulic tank drain plugusing thread sealer on the threads. Torque tospecification.

Torque specifications

Hydraulic tank drain plug, dry 150 in-lbs16.9 Nm

Hydraulic tank drain plug, lubricated 112 in-lbs12.6 Nm

Checklist E Procedures

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CHECKLIST E PROCEDURES

10 Install the hydraulic tank and install and tightenthe hydraulic tank mounting fasteners. Torqueto specification.


Hydraulic tank mounting fasteners, dry 35 in-lbs4 Nm

Hydraulic tank mounting fasteners, lubricated 26 in-lbs2.9 Nm

11 Install the hydraulic line onto the inlet side of thehydraulic pump.

12 Install the hydraulic filter head onto the machineand securely tighten the fasteners. Do not overtighten.

13 Install the hydraulic lines into the filter head.

14 Connect the battery pack to the machine.

15 Fill the hydraulic tank with hydraulic oil until thefluid is at the FULL mark on the tank. Do notoverfill. Refer to Section 2, Specifications.

16 Activate the pump to fill the hydraulic systemwith oil and bleed the system of air.

Component damage hazard. Thepump can be damaged if operatedwithout oil. Be careful not to emptythe hydraulic tank while in theprocess of filling the hydraulicsystem.

17 Repeat steps 15 through 16 until the hydraulicsystem and tank are both full. Inspect for leaks.

18 Clean up any oil that may have spilled.

E-2Perform Engine Maintenance(if equipped)

Engine specifications requirethat this procedure be performedevery two years.

Required maintenance procedures and additionalengine information is available in the HondaGX160 Engine Shop Manual(Honda part number 61ZH700)

Honda GX160 Shop ManualGenie part number 97229

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November 2004Section 4 • Repair Procedures

1-1Platform

How to Remove the Platform1 Tag and disconnect the taillight control cable at

the front of the platform.

2 Remove the platform control box retainingfasteners. Remove the platform control boxfrom the platform and set it to the side.

Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.

3 Support and secure the platform to anappropriate lifting device. Do not apply anylifting pressure.

4 Remove the fasteners securing the platform tothe lower side of the platform mount.

5 Remove the fasteners and pin securing theplatform to the platform mount.

Crushing hazard. The platformcould become unbalanced and fallif not properly supported when thepin is removed.

6 Remove the platform from the platform mount.

Platform Components

1-2Platform Rotator

The platform rotator is a hydraulically-operatedhelical gear assembly used to rotate the platform160°.

How to Remove thePlatform Rotator (if equipped)1 Remove the platform. See 1-1, How to Remove

the Platform.

2 Raise the jib boom 4 to 5 feet / 1.2 to 1.5 m.

3 Lower the jib boom until the platform mountrests on sawhorses or a work table of sufficientcapacity.

4 Remove the wire harness from the platformmount. Set the platform controls and wireharness cables to the side.

5 Tag, disconnect and plug the hydraulic hoses tothe platform rotator. Cap the fittings on therotator.


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November 2004 Section 4 • Repair Procedures

6 Attach a lifting strap of suitable capacity from anoverhead crane to the platform mount. Supportthe mount. Do not apply any lifting pressure.

7 Remove the pin retaining fasteners securing theplatform mount pivot pins.

8 Using a soft metal drift, remove the platformmount pivot pins. Remove the platform mountfrom the machine.

Crushing hazard. The platformmount could fall if not properlysupported when the pivot pin isremoved.

PLATFORM COMPONENTS

How toBleed the Platform Rotator1 Activate the platform rotate right function and

rotate the platform completely to the right.Continue to activate the rotate right function for3 seconds.

2 Activate the platform rotate left function androtate the platform completely to the left.Continue to activate the rotate left function for 3seconds.

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2-1Jib Boom

The jib boom lift cylinder raises and lowers the jibboom. The jib boom lift cylinder is equipped with acounterbalance valve to prevent movement in theevent of a hydraulic line failure.

How to Remove the Jib BoomWhen removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer to Section2, Hydraulic Hose and FittingTorque Specifications.

1 Remove the platform. See 1-1, How to Removethe Platform.



4 Tag and disconnect the wire harness from theplatform control box.

5 Tag and disconnect the wires from the jibmanifold.

6 Remove the wire harness from the platformmount and the jib boom.

7 Pull the all harness cables through the jib boomand lay them off to the side of the primaryboom.


a platform mountb jib boom cylinder barrel-end pivot pinc jib link pivot pind jib linke jib boom lift cylinderf jib boomg jib boom cylinder rod-end pivot pinh jib boom pivot pini jib mount pivot pinj platform level slave cylinder rod end pivot pin

ba fd e g h i jc

Jib Boom Components

8 Tag, disconnect and plug the hydraulic hoses tothe platform rotator. Cap the fittings on therotator.


9 Tag, disconnect and plug the hydraulic hoses tothe jib cylinder. Cap the fittings on the cylinder.


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11 Remove the pin retaining fasteners securing theplatform mount pivot pins.

12 Using a soft metal drift, remove the platformmount pivot pins. Remove the platform mountfrom the machine.


13 Remove the jib manifold retaining fasteners.


14 Attach a lifting strap of suitable capacity from anoverhead crane to the jib boom. Support the jibboom. Do not apply any lifting pressure.

15 Remove the pin retaining fasteners securing thejib boom pivot pins.

16 Using a soft metal drift, remove the jib boompivot pins. Remove the jib boom from themachine.


17 Lay the jib manifold and hoses off to the side ofthe primary boom.


18 Attach a lifting strap of suitable capacity from anoverhead crane to the jib link at the groundcontrol side of the machine. Support the jib link.Do not apply any lifting pressure.

19 Working from the ground control side of themachine, use a soft metal drift to tap the jib linkpivot pin halfway out. Remove the jib link fromthe machine.

Crushing hazard. The jib link couldfall if not properly supported whenthe pivot pin is removed.

20 Attach a lifting strap of suitable capacity from anoverhead crane to the remaining jib link. Supportthe jib link. Do not apply any lifting pressure.

21 Working from the side of the machine oppositethe ground controls, use a soft metal drift to tapthe jib link pivot pin halfway out. Remove the jiblink from the machine.


22 Attach a lifting strap of suitable capacity from anoverhead crane to the jib cylinder. Support thecylinder. Do not apply any lifting pressure.

23 Using a soft metal drift, remove the jib cylinderpivot pin. Remove the cylinder from themachine.

Crushing hazard. The cylindercould fall if not properly supportedwhen the pivot pin is removed.

24 Attach a lifting strap of suitable capacity from anoverhead crane to the jib mount. Support themount. Do not apply any lifting pressure.

JIB BOOM COMPONENTS

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25 Remove the pin retaining fasteners securing thejib mount pivot pin and the platform level slavecylinder rod end pivot pin.

26 Place a wooden block between the primaryboom and the platform level slave cylinder.

27 Using a soft metal drift, remove the platformlevel slave cylinder rod end pivot pin. Rest thecylinder on the block.


28 Using a soft metal drift, remove the jib mountpivot pin. Remove the jib mount from themachine.

Crushing hazard. The jib mountcould fall if not properly supportedwhen the pivot pin is removed.

2-2Jib Boom Lift Cylinder

How to Remove theJib Boom Lift Cylinder

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer to Section2, Hydraulic Hose and FittingTorque Specifications.



3 Tag, disconnect and plug the hydraulic hoses tothe jib cylinder. Cap the fittings on the cylinder.



5 Attach a lifting strap of suitable capacity from anoverhead crane to the jib boom. Support the jibboom. Do not apply any lifting pressure.

JIB BOOM COMPONENTS

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6 Place a wooden block between the jib cylinderand the jib links.

7 Remove the pin retaining fasteners securing thejib boom cylinder barrel end pivot pin.

8 Using a soft metal drift, remove the jib boomcylinder barrel end pivot pin. Lower the cylinderonto the wooden block.

Crushing hazard. The jib cylindercould fall if not properly supportedwhen the pivot pin is removed.

Crushing hazard. The jib boomcould fall if not properly supportedwhen the pivot pin is removed.

9 Install the jib boom onto the platform mount.Install the pivot pin securing the jib boom to theplatform mount.

10 Attach a lifting strap of suitable capacity from anoverhead crane to the jib link at the groundcontrol side of the machine. Support the jib link.Do not apply any lifting pressure.

11 Working from the ground control side of themachine, use a soft metal drift to tap the jib linkpivot pin halfway out. Lower the jib link.


12 Working from the ground control side of themachine, use a soft metal drift to tap the jib linkpivot pin out just enough to release the jibcylinder. Remove the cylinder from themachine.

Crushing hazard. The jib cylindercould fall if not properly supportedwhen the pivot pin is removed.

JIB BOOM COMPONENTS

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Primary Boom Components

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a mid-pivotb primary boom lift cylinder barrel-end pivot pinc platform level master cylinderd primary boom pivot pine platform level master cylinder rod-end pivot pinf extension cylinder barrel-end pivot ping primary boom lift cylinderh primary boom lift cylinder rod-end pivot pini primary boomj primary boom latchk extension booml platform level slave cylinder

m jib boomn secondary boom pivot pino secondary boom link pivot pinp secondary boom latchq secondary boomr secondary boom links secondary lift cylinder rod-end pivot pint secondary boom lift cylinderu secondary lift cylinder barrel-end pivot pin

(located behind ground control box)v turntablew secondary boom pivot pin

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5 Tag, disconnect and plug the hydraulic hoses atthe jib boom end of the cable bridge. Cap thefittings on the hydraulic hard lines. Refer to 'XX'in the illustration below.


3-1Cable Track

The boom cable track guides cables and hosesrunning up the boom. It can be repaired link by linkwithout removing the cables and hoses that runthrough it. Removing the entire boom cable trackmay be necessary when performing major repairsthat involve removing the boom.

How to Remove the Cable TrackWhen removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer to SectionTwo, Hydraulic Hose and FittingTorque Specifications.

1 Tag and disconnect the wire harness from theplatform control box.

2 Tag and disconnect the wires from the jibmanifold.

3 Remove the wire harness from the platformmount and the jib boom.

4 Pull the all harness cables through the jib boomand lay them off to the side of the primaryboom.


a extension boomb cable bridgec cable trackd track supporte platform level slave cylinderf jib boom

6 Tag, disconnect and plug the hydraulic hoses atthe lower end of the cable track. Cap the fittingson the hydraulic hard lines. Refer to 'YY' in theillustration above.

7 Place blocks between the cable bridge and thecable track and secure them together.

Crushing hazard. If the cablebridge and the cable track are notproperly secured together, thecombination could becomeunbalanced and fall when removedfrom the machine.

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PRIMARY BOOM COMPONENTS

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8 Attach a lifting strap of suitable capacity from anoverhead crane to the rod end of the primary liftcylinder. Support the cylinder. Do not apply anylifting pressure.

9 Remove the pin retaining fastener from theprimary lift cylinder rod end pivot pin.

10 Using a soft metal drift, remove the primary liftcylinder rod end pivot pin.

Crushing hazard. The cylinder willfall if not properly supported whenthe pivot pin is removed.

11 Lower the cylinder onto the secondary boom.

12 Remove the wire harness cables from thebottom of the primary boom. Secure thehydraulic hard lines to the boom.

13 Place blocks between the cable bridge and thecable track. Secure the cable bridge and thecable track together.

Crushing hazard. If the cablebridge and the cable track are notproperly secured together, thecombination could becomeunbalanced and fall when removedfrom the machine.

14 Attach a lifting strap from an overhead crane tothe cable track.

15 Remove the mounting fasteners that attach thelower cable track to the boom.

16 Remove the cable track from the machine andplace it on a structure capable of supporting it.

Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.

How to Repair the Cable TrackComponent damage hazard. Thecable track can be damaged if it istwisted.

1 Visually inspect the cable track and determinewhich 7 link section needs to be replaced.

2 Using a flat blade screwdriver, pry open thehinge bar on each link of the 7 link section, plusone more on each end making a total of 9.

3 Using a flat blade screwdriver at one side of thelink to be replaced, separate the connection andopen the joint slightly by sliding the link over thelink pivot. Repeat for the other side of the link toseparate the link sections.

4 Repeat step 3 for the other end of the section tobe replaced.

5 Lift up the hoses and cables and carefullyremove the damaged section of cable track.

Component damage hazard. Hosesand cables can be damaged if theyare kinked or pinched.

6 Lift up the hoses and cables and carefully insertthe new section of cable track.

7 Install the new section of cable track onto theexisting track. Be sure the link pivot on bothsides of the link are in place and that the trackhinges correctly

8 Securely lock the hinge bar for each link.

9 Operate the boom extend/retract functionthrough a full cycle to ensure smooth operationof the new section of cable track.


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3-2Primary Boom

How toShim the Primary Boom1 Extend the boom until the wear pads are

accessible.

2 Loosen the wear pad mounting fasteners.

3 Install the new shims under the wear pad toobtain zero clearance and zero drag.

4 Securely tighten the mounting fasteners. Do notover tighten.

5 Extend and retract the boom through an entirecycle. Check for tight spots that could causebinding or scraping.

Always maintain squarenessbetween the outer and innerboom tubes.

How toRemove the Primary Boom

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools could result in death orserious injury and significantcomponent damage. Dealerservice is required.

Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.


1 Remove the platform. See 1-1, How toRemove the Platform.

2 Remove the jib boom. See 2-1, How to Removethe Jib Boom.

3 Remove the wire harness cables from thebottom of the secondary boom. Secure thehydraulic hard lines to the boom.

4 Tag and disconnect the wire harness cablesfrom the ground controls. Pull the cables to themid pivot.


For ease of assembly, pay closeattention to how the cables arerouted when pulling the cables tothe mid pivot.


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5 Remove the harness clamps inside the midpivot. Pull the wire harness cables through themid pivot and lay them off to the side of theprimary boom.


6 Tag, disconnect and plug the hoses from theplatform level master cylinder. Cap the fittingson the cylinder.


7 Tag, disconnect and plug the hoses from theprimary boom extension cylinder. Cap thefittings on the cylinder.


8 Attach a lifting strap of suitable capacity from anoverhead crane to the rod end of the primary liftcylinder. Support the cylinder. Do not apply anylifting pressure.

9 Remove the pin retaining fastener from theprimary lift cylinder rod end pivot pin.

10 Using a soft metal drift, remove the primary liftcylinder rod end pivot pin.



12 Remove the pin retaining fastener from theplatform level master cylinder rod end pivot pin.

13 Using a soft metal drift, remove the platformlevel master cylinder rod end pivot pin.

14 Attach a lifting strap of suitable capacity from anoverhead crane to the primary boom. Supportthe boom. Do not apply any lifting pressure.

Component damage hazard. Thecable track can be damaged if notprotected when lifting the boom.

15 Remove the pin retaining fasteners securing theprimary boom pivot pin.

16 Using a soft metal drift, remove the primaryboom pivot pin.

Crushing hazard. The primaryboom could become unbalancedand fall if not properly supportedwhen the pin is removed.

17 Release the latch at the turntable end of themachine.

18 Remove the primary boom from the machine.

Crushing hazard. The primaryboom could become unbalancedand fall if not properly supportedwhen removed from the machine.


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How toRemove the Boom Extension

This procedure in this sectionrequires specific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.



1 Remove the platform. See 1-1, How to Removethe Platform.

2 Remove the jib boom. See 2-1, How to Removethe Jib Boom.

3 Remove the primary boom. See 3-2, How toRemove the Boom.

4 Set the primary boom assembly on a suitablestructure capable of supporting it.

5 Place a block between the platform level slavecylinder and the extension boom.

6 Remove the fasteners and hose clamp securingthe platform level slave cylinder hoses to theextension boom.

7 Remove the pin retaining fastener from theplatform level slave cylinder barrel-end pivot pin.

8 Using a soft metal drift, remove the platformlevel slave cylinder barrel-end pivot pin.

9 Tag, disconnect and plug the hoses from theplatform level slave cylinder. Cap the fittings onthe cylinder.

10 Remove the platform level slave cylinder fromthe boom.

11 Remove the primary boom upper wear padretaining fasteners. Remove the upper wearpads from the primary boom.

12 Remove the primary boom side wear padretaining fasteners. Remove the side wear padsand shims from the primary boom.

For ease of assembly, note thequantity and location of shimsduring disassembly.

13 Remove the primary boom lower wear padretaining fasteners. Remove the lower wearpads from the primary boom.

14 Remove the pin retaining fastener from theprimary boom extension cylinder barrel-endpivot pin.

15 Using a soft metal drift, remove the primaryboom extension cylinder barrel-end pivot pin.

16 Remove the boom extension from the primaryboom.

17 Remove the pin retaining fasteners from theprimary boom extension cylinder rod-end pivotpins.

18 Using a soft metal drift, remove the primaryboom extension cylinder rod-end pivot pins.

19 Remove the primary boom extension cylinderfrom the boom extension.


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3-3Primary Boom Lift Cylinder

How to Remove thePrimary Boom Lift CylinderThe primary boom lift cylinder raises and lowers theprimary boom. The primary boom lift cylinder isequipped with a counterbalance valve to preventmovement in the event of a hydraulic line failure.


1 Tag, disconnect and plug the hydraulic hoses onthe lift cylinder. Cap the fittings on the cylinder.


2 Attach a lifting strap of suitable capacity from anoverhead crane to the lift cylinder.

3 Remove the pin retaining fastener from the liftcylinder rod end pivot pin.

4 Using a soft metal drift, remove the lift cylinderrod end pivot pin.



6 Remove the pin retaining fastener from the liftcylinder barrel end pivot pin.

7 Using a soft metal drift, remove the lift cylinderbarrel end pivot pin.


8 Carefully remove the cylinder from the machine.

Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported whenremoved from the machine.


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a platform level master cylinderb platform level slave cylinder

2 Remove the pin retaining fastener from themaster cylinder barrel end pivot pin.

3 Using a soft metal drift, remove the mastercylinder barrel end pivot pin.

4 Attach a lifting strap from an overhead crane tothe lug on the rod end of the master cylinder.

5 Remove the pin retaining fastener from the rodend pivot pin.

6 Using a soft metal drift, remove the mastercylinder rod end pivot pin. Remove the mastercylinder from the machine.

Crushing hazard. The mastercylinder could become unbalancedand fall if not properly supportedwhen removed from the machine.

3-4Platform Leveling Cylinders

How toRemove the Master CylinderThe master cylinder, located inside the mid pivot,acts as a pump for the slave cylinder, which islocated at the platform end of the extension boom.The master cylinder operates in a closed-circuithydraulic loop with the slave cylinder, keeping theplatform level through the entire range of boommotion.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation.Refer to Section Two, HydraulicHose and Fitting TorqueSpecifications.

1 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on the cylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.


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How toRemove the Slave CylinderThe slave cylinder, via a closed-circuit hydraulicloop, works in tandem with the master cylinder tomaintain the platform in a level condition throughthe entire range of boom motion. The slavecylinder, located at the platform end of theextension boom, is equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure.

Before cylinder removal isconsidered to correct amalfunction, bleed the slavecylinder to be sure there is no air inthe closed loop hydraulic circuit.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer to SectionTwo, Hydraulic Hose and FittingTorque Specifications.

1 Extend the boom approximately12 inches / 30 cm.

2 Tag, disconnect and plug the slave cylinderhydraulic hoses from the tee fittings on the jibmanifold, and connect them together using aconnector. Cap the fittings on the manifold.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

a platform level master cylinderb platform level slave cylinder

3 Remove the pin retaining fastener fromthe slave cylinder rod end pivot pin. Do notremove the pin.

4 Remove the external retaining rings from thebarrel end pivot pin.

5 Using a soft metal drift, remove the rod endpivot pin.

6 Carefully pull the cylinder out of the boom.

Component damage hazard. Hosescan be damaged if they are kinkedor pinched.

How to Bleed the Slave Cylinder1 Raise the boom to a horizontal position.

2 Activate the platform level function in both upand down directions through two completeplatform leveling cycles to remove any air thatmight be in the system.

The master cylinder acts as a pump for the slavecylinder. It is part of the closed loop hydrauliccircuit that keeps the platform level through theentire range of boom motion. The master cylinder islocated inside the mid pivot.


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Secondary Boom Components

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a mid-pivotb primary boom lift cylinder barrel-end pivot pinc platform level master cylinderd primary boom pivot pine platform level master cylinder rod-end pivot pinf extension cylinder barrel-end pivot ping primary boom lift cylinderh primary boom lift cylinder rod-end pivot pini primary boomj primary boom latchk extension booml platform level slave cylinder

m jib boomn secondary boom pivot pino secondary boom link pivot pinp secondary boom latchq secondary boomr secondary boom links secondary lift cylinder rod-end pivot pint secondary boom lift cylinderu secondary lift cylinder barrel-end pivot pin

(located behind ground control box)v turntablew secondary boom pivot pin

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4-1Secondary Boom

How toRemove the Secondary Boom

This procedure requires specificrepair skills, lifting equipment anda suitable workshop. Attemptingthis procedure without these skillsand tools could result in death orserious injury and significantcomponent damage. Dealerservice is required.



1 Remove the platform. See 1-1, How toRemove the Platform.

2 Remove the jib boom. See 2-1, How toRemove the Jib Boom.

3 Remove the primary boom. See 3-2, How toRemove the Primary Boom.

Remove the mid-pivot

4 Attach a lifting strap of suitable capacity from anoverhead crane to the rod end of the primary liftcylinder. Raise the cylinder to a horizontalposition.

5 Remove the pin retaining fasteners securing theprimary lift cylinder barrel end pivot pin.

6 Using a soft metal drift, remove the primary liftcylinder barrel end pivot pin. Remove thecylinder from the machine.


7 Attach a lifting strap of suitable capacity from anoverhead crane to the mid-pivot. Support themid pivot. Do not apply any lifting pressure.

8 Remove the pin retaining fasteners securing thesecondary boom pivot pin at the mid-pivot.

9 Remove the pin retaining fasteners securing thesecondary link pivot pin at the mid-pivot.

10 Tag, disconnect and plug the hydraulic hoses tothe hydraulic hard lines at the mid-pivot end ofthe secondary boom. Cap the fittings.



11 Using a soft metal drift, remove the secondaryboom pivot pin at the mid-pivot.

Crushing hazard. The mid-pivotcould become unbalanced and fallif not properly supported when thepin is removed.

SECONDARY BOOM COMPONENTS

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12 Using a soft metal drift, remove the secondarylink pivot pin at the mid-pivot.

Crushing hazard. The secondarylink could become unbalanced andfall if not properly supported whenthe pin is removed.

13 Remove the mid-pivot from the machine.

Crushing hazard. The mid-pivotcould become unbalanced and fallif not properly supported whenremoved from the machine.

Remove the secondary boom

14 Attach a lifting strap of suitable capacity from anoverhead crane to the secondary boom. Supportthe secondary boom. Do not apply any liftingpressure.

15 Remove the pin retaining fasteners securing thelift cylinder pivot pin to the secondary boom.

16 Place a wooden block between the secondarylink and the secondary lift cylinder.

17 Using a soft metal drift, remove the lift cylinderpivot pin from the secondary boom.


18 Lower the cylinder onto the wooden block.

19 Raise the secondary boom to a horizontalposition.

20 Tag, disconnect and plug the hydraulic hoses tothe hydraulic hard lines at the turntable end ofthe secondary boom. Cap the fittings.



36 Remove the pin retaining fasteners securing thesecondary boom pivot pin to the turntable.

37 Using a soft metal drift, remove the secondaryboom pivot pin.

Crushing hazard. The secondaryboom could become unbalancedand fall if not properly supportedwhen the pin is removed.

38 Remove the secondary boom from the machine.

Remove the secondary link

39 Working at the ground controls, remove thepower to platform wiring from the ground controlbox.

40 Remove the ground controls from the machine.

41 Rotate the rod end of the secondary boom liftcylinder approximately 90°.

42 Attach a lifting strap of suitable capacity from anoverhead crane to the rod end of the liftcylinder. Raise the cylinder slightly, remove theblock and lower the cylinder through thesecondary link and onto the front bulkhead.


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Part No. 84577 Genie TZ-50/30 4 - 21


43 Remove the pin retaining fasteners securing thesecondary link pivot pin to the turntable.

44 Using a soft metal drift, remove the secondarylink pivot pin.

Crushing hazard. The secondarylink could become unbalanced andfall if not properly supported whenthe pin is removed.

45 Release the latch at the tongue end of themachine.

46 Remove the secondary link from the machine.

Crushing hazard. The secondarylink could become unbalanced andfall if not properly supported whenremoved from the machine.

47 Tag, disconnect and plug the hoses from thesecondary lift cylinder. Cap the fittings on thecylinder.

48 Attach a lifting strap of suitable capacity from anoverhead crane to the secondary lift cylinder.Raise the cylinder to a horizontal position.

49 Remove the pin retaining fasteners securing thesecondary lift cylinder pivot pin to the mid-pivot.

50 Using a soft metal drift, remove the secondarylift cylinder pivot pin. Remove the cylinder fromthe machine.


4-2Secondary Boom Lift Cylinder

The secondary boom lift cylinder raises and lowersthe secondary boom. The secondary boom liftcylinder is equipped with a counterbalance valve toprevent movement in the event of a hydraulic linefailure.

1 Release the boom latch at both the tongue endand turntable end of the boom.

2 Raise the secondary boom to a horizontalposition.

3 Attach a lifting strap of suitable capacity from anoverhead crane to the mid-pivot. Support themid-pivot. Do not apply any lifting pressure.

4 Attach a lifting strap of suitable capacity from anoverhead crane to the lift cylinder. Support thecylinder. Do not apply any lifting pressure.

5 Remove the pin retaining fasteners securing thelift cylinder rod end pivot pin.

6 Place a wooden block between the secondarylink and the lift cylinder.

7 Using a soft metal drift, remove the lift cylinderpivot pin.


8 Lower the cylinder onto the wooden block.

9 Rotate the rod end of the secondary boom liftcylinder approximately 90°.

10 Raise the cylinder slightly, remove the block andlower the cylinder through the secondary linkand onto the front bulkhead.


REV A

4 - 22 Genie TZ-50/30 Part No. 84577


11 Tag, disconnect and plug the hydraulic hoses onthe lift cylinder. Cap the fittings on the cylinder.


Place rags beneath the barrel endof the lift cylinder before looseningthe hydraulic lines.

It may be helpful to remove theturntable rotate motor.

12 Remove the pin retaining fasteners securing thelift cylinder barrel end pivot pin.

13 Using a soft metal drift, remove the lift cylinderbarrel end pivot pin.


14 Carefully remove the cylinder from the machine.

Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported whenremoved from the machine.


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Part No. 84577 Genie TZ-50/30 4 - 23


Engine

5-1RPM Adjustment

Refer to Maintenance Procedure B-6,Check and Adjust the Engine RPM.

5-2Fuse Replacement

The electric engine starter circuit is protected byboth a 5 amp and 50 amp fuse. If either fuse burnsout, the electric starter will not operate. The enginecan, however, still be manually started.

Additional engine information is available in theHonda GX160 Engine Owner Manual(Honda part number 31ZH7630) OR theHonda Engines Shop Manual(Honda part number 61ZH700).


Honda Engines Shop ManualGenie part number 97229

a

bc

a 5 amp fuse - starter circuit (inside cover)b 50 amp fuse - starter circuitc 50 amp fuse - alternator circuit

REV A

4 - 24 Genie TZ-50/30 Part No. 84577


Ground Controls

6-1Level Sensor

Each machine is equipped with two types of levelsensors:

Tilt level sensorOne level sensor monitors the incline of theturntable after the outriggers are deployed and themachine is level. When this level sensor activates,an alarm will sound, making the operator aware of apotentially hazardous situation.

The tilt alarm sounds when the incline of thechassis exceeds 2.5° in any direction.

Outrigger auto level systemWhen deploying the outriggers using the autolevelfunction, outrigger level sensors are used tomonitor the incline of the turntable and assist inleveling the machine.

In early production, two level sensors arecomponents of the outrigger auto level circuit. Laterin production, a single autolevel module was used.

How to Install and Calibrate theTilt Level Level Sensor

Tip-over hazard. Failure to installor calibrate the level sensor asinstructed could result in themachine tipping over causingdeath or serious injury. Do notinstall or calibrate the level sensorother than specified in thisprocedure.

1 Perform this procedure with the machine on afirm, level surface that is free of obstructions.

2 Turn the key switch to ground control and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.

CR66AUTO

LEVEL

RELAY

c

Y

X

Y

X

Y

X

a b

ddd e

b

3 Push and hold the yellow function enable button.Push and hold the auto level button.

Result: The outriggers will lower and adjust tolevel the machine and raise the wheels off theground. Use the bubble level located below theground controls to confirm that the machine islevel.


5 Locate the tilt level sensor beneath the groundcontrol panel. Refer to the following illustrations.

a tilt level sensorb outrigger level sensorc autolevel relay (early production)d "X" indicatore adjusting fastener

If you are not installing a new level sensor,proceed to step 10.

Install the level sensor:

6 Tag and disconnect the wire harness from thetilt level sensor.

7 Remove the three level sensor retainingfasteners. Remove the level sensor from themachine.

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Part No. 84577 Genie TZ-50/30 4 - 25


8 Install the new level sensor onto the machinewith the "X" on the level sensor housing locatedas shown in the illustrations. Install and tightenthe level sensor retaining fasteners.

9 Connect the wire harness to the level sensor.

10 Tighten the level sensor adjusting fasteners untilthe bubble in the top of the level sensor iscentered in the circles.

Be sure there are threads showingthrough the top of the adjustingfasteners.


12 Raise the secondary boom approximately12 inches / 30 cm.

Result: The tilt sensor alarm should not sound.

13 Using a digital level, lower the tank side of themachine until the turntable is 2.4° out of level.


Result: The tilt alarm will sound at 180 beepsper minute. The level sensor is faulty and mustbe replaced. Repeat this procedure beginningwith step 6.

14 Continue to lower the tank side of the machineuntil the turntable is 2.7° out of level.

Result: The tilt alarm will sound at 180 beepsper minute.

Result: The tilt alarm does not sound. The levelsensor is faulty and must be replaced. Repeatthis procedure beginning with step 6.



16 Using a digital level, lower the ground controlside of the machine until the turntable is 2.4°out of level.



17 Continue to lower the ground control side of themachine until the turntable is 2.7° out of level.





19 Using a digital level, lower the platform end ofthe machine until the turntable is 2.4° out oflevel.



GROUND CONTROLS

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4 - 26 Genie TZ-50/30 Part No. 84577


20 Continue to lower the platform end of themachine until the turntable is 2.7° out of level.





22 Using a digital level, lower the tongue end of themachine until the turntable is 2.4° out of level.



23 Continue to lower the tongue end of the machineuntil the turntable is 2.7° out of level.




GROUND CONTROLS

How to Install and Calibrate theOutrigger Level Sensor

Tip-over hazard. Failure to installor calibrate the level sensor asinstructed could result in themachine tipping over causingdeath or serious injury. Do notinstall or calibrate the level sensorother than specified in thisprocedure.

1 Perform this procedure with the machine on afirm, level surface that is free of obstructions.


3 Lower all four outriggers and raise the machineoff the ground. Level the machine. Use thebubble level located below the ground controlsto confirm that the machine is level.


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Part No. 84577 Genie TZ-50/30 4 - 27


5 Locate the outrigger level sensors located belowthe ground control panel. Refer to the followingiIllustrations.

If you are not installing a new level sensor,proceed to step 10.

6 Tag and disconnect the wire harness from theoutrigger level sensor.

7 Remove the three level sensor retainingfasteners. Remove the level sensor from themachine.

8 Install the new level sensor onto the machinewith the "X" on the level sensor housing locatedas shown in the illustrations. Install and tightenthe level sensor retaining fasteners.

9 Connect the wire harness to the level sensor.

10 Tighten the level sensor adjusting fasteners untilthe bubble in the top of the level sensor iscentered in the circles.

Be sure there are threads showingthrough the top of the adjustingfasteners.


12 Raise the outriggers until all of the outriggers areoff the ground.



a tilt level sensorb outrigger level sensorc autolevel relay (early production)d "X" indicatore adjusting fastener

CR66AUTO

LEVEL

RELAY

c

Y

X

Y

X

Y

X

a b

ddd e

b

d

b

Y

X

Y

X

a

d e

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4 - 28 Genie TZ-50/30 Part No. 84577


Hydraulic Pump

7-1Function Pump

The hydraulic pumps are attached to the motorwhich makes up the hydraulic power unit.

How to Test the Hydraulic PumpWhen removing a hose assemblyor fitting, the fitting and/or hoseend must be torqued tospecification during installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.

1 Tag, disconnect and plug the high pressurehydraulic hose from the hydraulic pump.


2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the high pressure port on the pump.


4 Activate the platform up function from theground controls.

Result: If the pressure gauge reads3200 psi / 221 bar, immediately stop. The pumpis good.

Result: If pressure fails to reach3200 psi / 221 bar, the pump is bad and willneed to be serviced or replaced.

Component damage hazard. Thereis no relief valve in the hydraulicpump and the pump can bedamaged if the pressure is allowedto exceed 3200 psi / 221 bar.When testing the pump, activatethe pump in one second intervalsuntil 3200 psi / 221 bar isconfirmed. Do not over-pressurizethe pump.

5 Remove the pressure gauge and reconnect thehydraulic hose. Torque to specification.


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Part No. 84577 Genie TZ-50/30 4 - 29


HYDRAULIC PUMP

How to Remove theHydraulic Pump

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer to SectionTwo, Hydraulic Hose and FittingTorque Specifications.



2 Tag and disconnect the hydraulic power unitcables at the motor controller.

3 Remove the hydraulic power unit retainingfasteners.

5 Tag, disconnect and plug the hydraulic hard lineat the pump. Cap the fitting on the pump.

6 Tag, disconnect and plug the high pressure hoseat the pump. Cap the fitting on the pump.


7 Remove the pump mounting bolts. Carefullyremove the pump.

Tip-over hazard. After replacing thehydraulic pump, it is critical toreturn the function speed settingsto original factory specifications.Failure to restore the machine tooriginal factory specifications couldcause the machine to tip overresulting in death or serious injury.

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4 - 30 Genie TZ-50/30 Part No. 84577


Manifolds

8-1Function Manifold ComponentsThe function manifold is located under the turntable cover at the ground controls side of the machine.

Index SchematicNo. Description Item Function Torque

— Coil nut (items F, H, J, K, N, P and R) ....................................................................................... 4-5 ft-lbs / 7-9 Nm

1 Hand pump ............................................A ........ Auxiliary down ..................................... 25-27 ft-lbs / 34-36 Nm

2 Relief valve, 600 psi / 41 bar .................B ........ Turntable rotate circuit ........................ 18-20 ft-lbs / 25-27 Nm

3 Differential sensing valve ..................... C ........ Returns extra hydraulic fluid totank when operating turntablerotate function ...................................... 25-27 ft-lbs / 34-36 Nm

4 Shuttle valve, 2 position 3 way ............. D ........ Turntable rotate circuit ................................... 4-5 ft-lbs / 6 Nm

5 Orifice - plug, 0.040 inch / 1 mm ............E ........ Restricts turntable rotate fluid flow— Port plug ....................................................................................................................... 97-117 in-lbs / 11-13 Nm

6 Solenoid valve, 2 position 3 waywith manual override ............................. F ........ Secondary boom down ....................... 18-20 ft-lbs / 25-27 Nm

7 Diagnostic nipple .................................. G ........ Testing

8 Solenoid valve, 2 position 3 waywith manual override ............................ H ........ Primary boom down ............................ 18-20 ft-lbs / 25-27 Nm

9 Relief valve, 1600 psi / 110 bar ............. I ......... Primary boom circuit ........................... 18-20 ft-lbs / 25-27 Nm

10 Solenoid valve, 2 position 3 waywith manual override ............................. J ......... Primary boom up ................................. 18-20 ft-lbs / 25-27 Nm

11 Solenoid valve, 3 position 4 waywith manual override .............................K ........ Boom extend/retract ............................ 18-20 ft-lbs / 25-27 Nm

12 Relief valve, 3000 psi / 207 bar ............. L ........ System relief ........................................ 18-20 ft-lbs / 25-27 Nm

13 Counterbalance valve .......................... M ........ Outrigger retract circuit ........................ 30-35 ft-lbs / 41-47 Nm

14 Solenoid valve, 3 position 4 way .......... N ........ Outrigger extend/retract ...................... 18-20 ft-lbs / 25-27 Nm

15 Check valve .......................................... O ........ Outrigger retract circuit ........................ 25-30 ft-lbs / 34-41 Nm

16 Solenoid valve, 2 position 3 way ...........P ........ Secondary boom up ............................ 18-20 ft-lbs / 25-27 Nm

17 Orifice - plug, 0.080 inch / 2 mm ........... Q ........ Restricts platform down fluid flow— Port plug ....................................................................................................................... 97-117 in-lbs / 11-13 Nm

18 Solenoid valve, 3 position 4 waywith manual override ............................ R ........ Turntable rotate left/right ..................... 18-20 ft-lbs / 25-27 Nm

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Part No. 84577 Genie TZ-50/30 4 - 31


MANIFOLDS

B

A

C

D

E

F

H

I

J

K

L

M

O

P

R

QG

N

1

3

2

4

5

6

8

9

11

12

13

14

15

18

16

177

Y22Y23

Y52

Y53

Y21

Y22

Y26

10

Y25

Y40

Y39

Note: 'alpha' callouts referto corresponding notes onthe hydraulic schematic

Note: 'alpha-numeric' calloutsrefer to corresponding noteson the electrical schematic

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4 - 32 Genie TZ-50/30 Part No. 84577


8-2Jib Manifold ComponentsThe jib manifold is located on the jib boom.


— Coil nut (items AA, AB, AD and AE) ......................................................................................... 4-5 ft-lbs / 7-9 Nm

1 Solenoid valve, 2 position 3 way ......... AA ....... Jib boom up ......................................... 18-20 ft-lbs / 25-27 Nm

2 Solenoid valve, 2 position 3 way ......... AB ....... Jib boom down .................................... 18-20 ft-lbs / 25-27 Nm

3 Relief valve, 3000 psi / 207 bar ........... AC ....... Platform level circuit ............................ 18-20 ft-lbs / 25-27 Nm

4 Solenoid valve, 3 position 4 way ......... AD ....... Platform rotate left/right ....................... 18-20 ft-lbs / 25-27 Nm

5 Solenoid valve, 3 position 4 way ......... AE ....... Platform up/down ................................ 18-20 ft-lbs / 25-27 Nm

6 Counterbalance valve ......................... AF ....... Platform level circuit ............................ 25-30 ft-lbs / 34-41 Nm

7 Differential sensing valve .................... AG ....... Maintains fluid flow tojib boom, platform level andplatform rotate functions ...................... 25-27 ft-lbs / 34-36 Nm

8 Orifice - plug, 0.055 inch / 1.4 mm ....... AH ....... Platform rotate circuit— Port plug ....................................................................................................................... 97-117 in-lbs / 11-13 Nm

9 Orifice - plug, 0.055 inch / 1.4 mm ........ AI ........ Jib boom up circuit— Port plug ....................................................................................................................... 97-117 in-lbs / 11-13 Nm

10 Orifice - plug, 0.040 inch / 1 mm ...........AJ ....... Jib boom down circuit— Port plug ....................................................................................................................... 97-117 in-lbs / 11-13 Nm

11 Shuttle valve, 2 position 3 way ............ AK ....... Platform level circuit ....................................... 4-5 ft-lbs / 6 Nm

MANIFOLDS

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Part No. 84577 Genie TZ-50/30 4 - 33


MANIFOLDS

AA

AB

AC

AE

AG

AH

A I

AK

AD

AF

AJ

AA

AB

AC

AE

A I

AK

AF

AJ

31 2 4 5

6

3

7

8

9

10

11

5

AG

6

7

11

10

9

1

2

Models with Platform Rotate

Models without Platform Rotate

Y19

Y61

Y20

Y60

Y19

Y20

Y62

Y63



Y61

Y60

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4 - 34 Genie TZ-50/30 Part No. 84577


8-3Drive Manifold Components (if equipped)The drive manifold is located next to the function manifold.


— Coil nut (items BI, BK, BL, BN and BO) .................................................................................... 4-5 ft-lbs / 7-9 Nm

1 Differential sensing valve .................... BA ....... Maintains traction equal to BJ ............. 25-27 ft-lbs / 34-36 Nm

2 Orifice - plug, 0.090 inch / 2.3 mm ....... BB ....... Drive circuit

3 Differential sensing valve .................... BC ....... Maintains torque while driving ............ 25-27 ft-lbs / 34-36 Nm

4 Orifice - plug, 0.090 inch / 2.3 mm ....... BD ....... Pump 2 circuit— Port plug ....................................................................................................................... 97-117 in-lbs / 11-13 Nm

5 Counterbalance valve ......................... BE ....... Drive circuit, left side ........................... 30-35 ft-lbs / 41-47 Nm

6 Differential sensing valve .................... BF ....... Returns pump 2 hydraulic fluidto tank when not driving ...................... 25-27 ft-lbs / 34-36 Nm

7 Counterbalance valve ......................... BG ....... Drive circuit, right side ......................... 25-30 ft-lbs / 34-41 Nm

8 Shuttle valve, 2 position 3 way ............ BH ....... Drive circuit ..................................................... 4-5 ft-lbs / 6 Nm

9 Solenoid valve, 2 position 2 way .......... BI ........ Brake release ...................................... 18-20 ft-lbs / 25-27 Nm

10 Differential sensing valve .....................BJ ....... Maintains traction equal to BA ............ 25-27 ft-lbs / 34-36 Nm

11 Proportional valve, 2 position 2 way ... BK ....... Drive circuit, right side ......................... 18-20 ft-lbs / 25-27 Nm

12 Solenoid valve, 2 position 4 way ......... BL ....... Drive circuit, right side ......................... 18-20 ft-lbs / 25-27 Nm

13 Check valve, 10 psi / 0.7 bar ............... BM ....... Pump 2 circuit ...................................... 18-20 ft-lbs / 25-27 Nm

14 Solenoid valve, 2 position 4 way ......... BN ....... Drive circuit, left side ........................... 18-20 ft-lbs / 25-27 Nm

15 Proportional valve, 2 position 2 way ... BO ....... Drive circuit, left side ........................... 18-20 ft-lbs / 25-27 Nm

MANIFOLDS

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Part No. 84577 Genie TZ-50/30 4 - 35


MANIFOLDS

4

3

5

6

7

10

13

1 2

15

14

11

9

9

812

BA BB BC

BE

BD

BF

BG

BJ

BK

BL

BN

BO

B I

BM

BH

B I

BeforeSerial Number TZ5004-152

AfterSerial Number

TZ5004-151

Y11

Y11

Y58

Y50A

Y50

Y59



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4 - 36 Genie TZ-50/30 Part No. 84577


8-4Valve Adjustments -Function Manifold

How to Adjust theSystem Relief Valve

Perform this procedure with theoutriggers in the stowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port (item G) on the functionmanifold.


3 Push and hold the yellow function enable downbutton. Observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.

MANIFOLDS

STOP

a

b

c

d

e

a test port (schematic item G)b system relief valve (schematic item L)

L

Ga

b

a blue function enable button BN60b yellow function enable button BN59c outrigger auto level button BN49d primary boom up/down button BN54e turntable rotate button BN57

4 Release the button. Use a wrench to hold therelief valve and remove the cap (item L).

5 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.

Tip-over hazard. Do not adjustthe relief valve higher thanspecified.

6 Repeat step 3 to confirm the relief valvepressure.

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Part No. 84577 Genie TZ-50/30 4 - 37


How to Adjust thePrimary Boom Down Relief Valve1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port (item G) on the functionmanifold.

MANIFOLDS


Result: The outriggers will lower and adjust tolevel the machine and raise the wheels off theground.

a test port (schematic item G)b primary boom down relief valve

(schematic item I)

I

Ga

b


4 Push and hold the yellow function enable button.Push and hold the primary boom down button.Fully lower the primary boom and continue tohold the buttons while observing the pressurereading on the pressure gauge. Refer to Section2, Specifications.

5 Release the buttons. Use a wrench to hold therelief valve and remove the cap (item I).



7 Repeat step 4 to confirm the relief valvepressure.

STOP

a

b

c

d

e


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4 - 38 Genie TZ-50/30 Part No. 84577


How to Adjust theTurntable Rotate Relief Valve1 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port (item G) on the functionmanifold.

MANIFOLDS

B

G

a

b

STOP

a

b

c

d

e

a turntable rotate relief valve (schematic item B)b test port (schematic item G)



Result: The outriggers will lower and adjust tolevel the machine and raise the wheels off theground.

4 Raise the secondary boom approximately12 inches / 30 cm.

5 Push and hold the blue function enable button.Push and hold the primary boom up/downbutton. Fully rotate the turntable and continue tohold the buttons while observing the pressurereading on the pressure gauge. Refer to Section2, Specifications.


6 Release the buttons. Use a wrench to hold therelief valve and remove the cap (item B).



8 Push and hold the yellow function enable button.Push and hold the primary boom up/down buttonand fully rotate the turntable in the oppositedirection. Begin timing when the turntablebegins to rotate.

9 Continue rotating the turntable and note the timewhen the machine stops rotating at 359°. Referto Section 2, Specifications.

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Part No. 84577 Genie TZ-50/30 4 - 39


8-5Valve Coils

How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.


1 Tag and disconnect the wire harness from thecoil to be tested.

2 Test the coil resistance.

Result: The resistance should be withinspecification, plus or minus 30%.

Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.

Valve Coil Resistance

Description Specification

Solenoid valve, 2 position 3 way 25 to 27Ω20V DC with diode(schematic items F, G, I, AA and AB)

Solenoid valve, 3 position 4 way 25 to 27Ω20V DC with diode(schematic items J, M, Q, AD and AE)

Solenoid valve, 2 position 4 way 25 to 27Ω20V DC with diode(schematic item Bl and BN)

Solenoid valve, 2 position 2 way N.C. 25 to 27Ω20V DC with diode (schematic item BI)

Proportional valve, 2 position 2 way N.C. 25 to 27Ω20V DC with diode (schematic item BK and BO)

Solenoid valve, 2 position 2 way N.C.29 to 31W24V DC with diode(schematic items CA, CB, CC and CD)

MANIFOLDS

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4 - 40 Genie TZ-50/30 Part No. 84577


How to Test a Coil DiodeGenie incorporates spike-suppressing diodes in allof its coils. Properly functioning coil diodes protectthe electrical circuit by suppressing voltage spikes.Voltage spikes naturally occur within a functioncircuit following the interruption of electrical currentto a coil. Faulty diodes can fail to protect theelectrical system, resulting in a tripped circuitbreaker or component damage.


1 Test the coil for resistance. See 4-3, How toTest a Coil.

2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.

The battery should read 9V DC ormore when measured across theterminals.

Resistor, 10ΩΩΩΩΩGenie part number 27287

3 Set a multimeter to read DC amperage.

The multimeter, when set to readDC amperage, should be capableof reading up to 800 mA.

4 Connect the negative lead to the other terminalon the coil.

If testing a single-terminal coil,connect the negative lead to theinternal metallic ring at either endof the coil.

5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9Vbattery. Note and record the current reading.

6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.

Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.

Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.

a multimeterb 9V DC batteryc 10Ω resistord coil

Note: Dotted lines in illustration indicate areversed connection as specified in step 6

9V

BATTERY

10

RESISTOR

MULTI

METER

COIL

+

-

+

-

d

b

b

a

c

c

MANIFOLDS

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Part No. 84577 Genie TZ-50/30 4 - 41


Hydraulic Tank

9-1Hydraulic Tank

The primary functions of the hydraulic tank are tocool and deaerate the hydraulic fluid duringoperation. It has an external return line filter.

How to Remove theHydraulic Tank

Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulicsystem.

When removing a hose assemblyor fitting, the fitting and/or hoseend must be torqued tospecification during installation.Refer to Section 2, Hydraulic Hoseand Fitting Torque Specifications.

Perform this procedure with theplatform in the stowed position.



2 Remove the drain plug from the hydraulic tankand allow all of the oil from the tank to drain intoa suitable container. Refer to Section 2,Specifications.


3 Tag and disconnect the return hard line from thefilter head. Remove the hard line from themachine. Cap the fitting on the filter head.

4 Tag and disconnect the supply hard line fromthe pump. Cap the fitting on the pump.

5 Remove the hydraulic tank retaining fastenersand remove the hydraulic tank and supply hardline from the machine.

a hydraulic filterb supply hard line (to pump)c hydraulic tankd return hard line (from filter)


Hydraulic tank retaining fasteners, dry 35 in-lbs4 Nm

Hydraulic tank retaining fasteners, lubricated 26 in-lbs2.9 Nm

c

a

b

d

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4 - 42 Genie TZ-50/30 Part No. 84577


Axle Components

10-1Axle

How to Remove the AxleANSI models:

1 Lower the outriggers and adjust to level themachine and raise the wheels off the ground.

2 Disconnect the secondary brake cables at thetension equalizer.

3 Pull the cables free of the trailer.

4 Tag, disconnect and plug the brake line from theback of the hub. Cap the fitting.

5 Clean up any brake fluid that may have spilled.

6 Repeat steps 4 through 5 for the other side.

7 Support and secure the axle assembly to anappropriate lifting device.

8 Remove the axle mounting fasteners andremove the axle from the machine.

Crushing hazard. The axle couldbecome unbalanced and fall if notproperly supported and securedwhen removed from the machine.

When the axle is installed, thebrakes should be bled. Refer to theappropriate brake manufacturer'smanual that was shipped with yourGenie TZ.

CE models:

1 Lower the outriggers and adjust to level themachine and raise the wheels off the ground.

2 Disconnect the secondary brake cables at thetension equalizer.

3 Support and secure the axle assembly to anappropriate lifting device.

4 Remove the axle mounting fasteners andremove the axle from the machine.

Crushing hazard. The axle couldbecome unbalanced and fall if notproperly supported and securedwhen removed from the machine.

b c

d

c

a

a

d

Models with Drive(option)

Models without Drive

a primary brake cableb parking brake cylinder

(models with drive option)c tension equalizerd secondary brake cables

REV A

Part No. 84577 Genie TZ-50/30 4 - 43


11-1Hydraulic and MechanicalBrakes

Hydraulic Brake System -ANSI ModelsRepair procedures and additional axle information isavailable in the Dexter Axle Operation MaintenanceService Manual(Dexter part number LIT-001-00).


Mechanical Brake System -CE ModelsRepair procedures and additional axle information isavailable in the KNOTT Axle Service Manual(KNOTT part number P005).


11-2Parking Brake

How to Adjust the Parking BrakeANSI models:

1 Adjust the brakes. Refer to the Dexter AxleOperation Maintenance Service Manual(Dexter part number LIT-001-00).


2 Chock the wheels.




6 Tighten the set screw. Do not over tighten.

7 Engage the parking brake. Attempt to move themachine.


CE models:



Trailer Components

REV A

4 - 44 Genie TZ-50/30 Part No. 84577


12-1Outrigger Components

How to Remove an OutriggerOutriggers are essential to safe machine operationand machine stability. Operating a machine with adamaged or improperly operating outrigger willresult in death or serious injury.

Perform this procedure with themachine disconnected from thetow vehicle and the parking brakeapplied.

Perform this procedure with theoutriggers in the stowed position.

1 Attach a lifting strap of suitable capacity from anoverhead crane to the pad end of the outrigger.Do not apply any lifting pressure.

2 Tag and disconnect the wire harness from theoutrigger valve coil.

3 Tag, disconnect and plug the hydraulic hoses atthe outrigger cylinder. Cap the fittings.

4 Remove the pin retaining fasteners from theoutrigger pivot pin. Do not remove the pin.

5 Remove the pin retaining fasteners from theoutrigger cylinder rod end pivot pin.

6 Attach a lifting strap of suitable capacity from anoverhead crane to the rod end of the outriggercylinder. Support the cylinder. Do not apply anylifting pressure.

7 Place a wooden block under the cylinder.

8 Lower the outrigger enough to remove theoutrigger cylinder rod end pivot pin.

9 Using a soft metal drift, remove the outriggercylinder rod end pivot pin.

Crushing hazard. The cylindercould fall if not properly supportedwhen the pivot pin is removed fromthe machine.

10 Using a soft metal drift, remove the outriggerpivot pin. Remove the outrigger from themachine.

Crushing hazard. The outrigger willfall if not properly supported whenthe pivot pin is removed from themachine.

Outriggers

REV A

Part No. 84577 Genie TZ-50/30 4 - 45


12-2Outrigger Cylinder

How to Remove an OutriggerCylinder


1 Extend the outrigger until the pad just touchesthe ground. Do not rest the weight of themachine on the outrigger.

2 Remove the hose guard mounting fastenersfrom the rod end of the outrigger cylinder andremove the hose guard from the machine.

3 Remove the cover above the barrel end of theoutrigger cylinder.

4 Tag and disconnect the wire harness from theoutrigger cylinder valve coil.

5 Tag, disconnect and plug the hydraulic hosesfrom the outrigger cylinder. Cap the fittings onthe cylinder.


6 Attach a lifting strap from an overhead crane tothe lug on the rod end of the cylinder.

7 Remove the pin retaining fasteners from theoutrigger cylinder rod-end pivot pin.

8 Using a soft metal drift, remove the outriggercylinder rod-end pivot pin.

9 Raise the cylinder to a vertical position.

10 Remove the pin retaining fasteners from theoutrigger cylinder barrel-end pivot pin.

11 Using a soft metal drift, remove the outriggercylinder barrel-end pivot pin.

Crushing hazard. The outriggercylinder could fall if not properlysupported when the pivot pin isremoved from the machine.

Component damage hazard. Thesolenoid valve can be damaged.Use caution when removing thecylinder from the machine.

OUTRIGGERS

REV A

4 - 46 Genie TZ-50/30 Part No. 84577

April 2006Section 4 • Repair Procedures

13-1Platform Overload System

Calibrate the Platform OverloadSystem (if equipped)

Perform this procedure with themachine on a firm, level surface.


2 Release the boom hold down latch and raise theplatform approximately 2 feet / 60 cm. Level theplatform.

3 Tag and disconnect the wire harness from theload sense limit switch.

The load sense limit switch islocated near the platform support.

4 Set a multi-meter to measure continuity.Connect the leads from the multi-meter to theblack and red wires disconnected from the limitswitch in step 3.

5 Determine the maximum platform capacity.Refer to the machine serial plate.

6 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity at the center of theplatform floor.

Platform Overload Components

Determine the limit switch trigger point:

7 Gently move the platform up and down by hand,so it bounces 1 to 2 inches / 2.5 to 5 cm.

8 Check the continuity between the black and redwires originating from the limit switch of theplatform overload assembly.

Result: There is no continuity. Slowly tightenthe load spring adjustment nut by turning itclockwise just until the limit switch closes andshows continuity.

Result: There is continuity. Slowly loosen theload spring adjustment nut by turning itcounterclockwise just until the limit switchopens and shows no continuity.

The platform will need to becontinuously moved up and downwhile making adjustments.

Fine adjustment of the switch trigger point:

9 Continue moving the platform up and down andadjust the load spring adjustment nut clockwiseor counterclockwise just until the limit switch isalternately opening and closing.

When the limit switch is adjustedcorrectly, there will be continuityslightly longer than no continuity.

10 Remove the continuity tester from the limitswitch wires. Securely install the wires onto thelimit switch.

REV A

Part No. 84577 Genie TZ-50/30 4 - 47

April 2006 Section 4 • Repair Procedures

Confirm the setting:


12 Lift the test weight off the platform floor using asuitable lifting device.

13 Place the test weight back onto the platformfloor using a suitable lifting device.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.

14 Add an additional 44 lbs / 20 kg of weight tooverload the platform.

Result: The platform overload indicator lightshould be flashing at both the ground andplatform controls.


Result: All platform control functions should notoperate.



Result: All ground control functions should notoperate.

PLATFORM OVERLOAD COMPONENTS

4 - 48 Genie TZ-50/30 Part No. 84577

April 2006Section 4 • Repair Procedures


Section 5 • SchematicsNovember 2004

Part No. 84577 Genie TZ-50/30 5 - 1

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating the machine.

Before Troubleshooting:

Read, understand and obey the safety rulesand operating instructions printed in theGenie TZ-50/30 Operator's Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

REV A

Section 5 • Schematics November 2004

5 - 2 Genie TZ-50/30 Part No. 84577

Abbreviation LegendElectrical Schematics

ABBREVIATION LEGEND Item Description B5 Battery

Button BN BN2 = Engine start BN3 = Choke BN36 = Jib boom up/down BN49 = Outrigger auto level BN50 = Left rear outrigger BN51 = Right rear outrigger BN52 = Left front outrigger BN53 = Right front outrigger BN54 = Primary boom up/down BN55 = Secondary boom up/down BN56 = Boom extend/retract BN57 = Turntable rotate BN58 = Platform level up/down BN59 = Function enable (boom down, boom retract, rotate left, outrigger extend) BN60 = Function enable (boom up, boom extend, rotate right, outrigger retract) BN61 = Function enable (boom down, boom retract, turntable/platform rotate left) BN62 = Function enable (boom up, boom extend, turntable/platform rotate right) BN63 = Primary boom up/down BN64 = Secondary boom up/down BN65 = Boom extend/retract BN66 = Turntable rotate BN67 = Platform level up/down BN68 = Engine start BN90 = Choke BN93 = Platform rotate BN94 = Function enable (boom down, boom retract, rotate left, outrigger extend) BN95 = Function enable (boom up, boom extend, rotate right, outrigger retract) BN96 = Autolevel BN97 = Jib boom up/down BN98 = Platform rotate Capacitor C C4 = Zener diode, 5.1V DC C4A = Zener diode, 3.3V DC C4B = Zener diode, 5.1V DC C5 = 4700uF Circuit breaker CB CB1 = 15A, Engine CB2 = 15A, Controls Control relay CR CR1 = Engine start CR8 = Ignition CR9 = Jib boom up/down CR15 = Choke CR28 = Power supply CR61 = Auto level system CR64 = Fault ground CR65 = Motor controller cutout CR66 = Level sensor (auto level) CR67 = Primary boom CR68 = Secondary boom CR69 = Boom extend/retract CR70 = Turntable rotate CR71 = Platform level CR72 = Outrigger CR73 = Function enable (ground controls) CR74 = Function enable (platform controls) CR75 = Level sensor CR76 = Limit switch fault CR77 = Down enable CR78 = Lift cut-out CR86 = Sequencing CR87 = Platform rotate

D1 Alternator Fuse F F6 = 275A, Function F9 = 50A, Alternator F9A = 50A, Engine starter

FB1 Flashing beacons (option) GND Ground

ABBREVIATION LEGEND Item Description

Gauge G G6 = Hour meter G7 = Battery charge indicator (option) Horn or alarm H H1 = Horn H5 = Multifunction alarm

JC5 Drive joystick KS1 Key switch

Light or LED L L4 = Load sense at ground (load sense option) L4A = Load sense at platform (load sense option) L12 = Left front outrigger L13 = Right front outrigger L14 = Left rear outrigger L15 = Right rear outrigger L33 = Right rear tail light L34 = Left rear tail light L35 = Right side marker L36 = Left side marker Limit switch LS LS12 = Left front outrigger LS13 = Right front outrigger LS14 = Left rear outrigger LS15 = Right rear outrigger LS18 = Boom down LS19 = Load sense Motor M M3 = Engine starter M5 = Hydraulic power unit

N.C. Normally closed N.C.H.O. Normally closed held open N.O. Normally open N.O.H.C. Normally open held closed

Power switch P P1 = Emergency Stop button at ground controls P2 = Emergency Stop button at platform controls P3 = Emergency Stop button at drive controls

Q7 Choke solenoid Resistor R R14 = Function speed, 0-10K ohms R22 = 1000 ohm R22B = 5600 ohm Sensor S S7 = Level sensor S9 = Level sensor, front/rear axis (auto level) S10 = Level sensor, left/right axis (auto level) Electronic component U U6 = Motor controller U9 = Battery charger U16 = Time delay U24 = Drive controls printed circuit board U26 = Ignition module Valve coil Y Y11 = Brake release Y19 = Platform down Y20 = Platform up Y21 = Primary down Y22 = Primary up Y23 = Turntable rotate left Y24 = Turntable rotate right Y25 = Boom retract Y26 = Boom extend Y33 = Left rear outrigger Y34 = Right rear outrigger Y35 = Left front outrigger Y36 = Right front outrigger Y39 = Outrigger retract Y40 = Outrigger extend Y50 = Drive forward/reverse left Y50A = Drive forward/reverse right Y52 = Secondary down Y53 = Secondary up Y58 = Proportional drive right Y59 = Proportional drive left Y60 = Jib boom retract Y61 = Jib boom extend Y62 = Platform rotate left Y63 = Platform rotate right

REV A


Part No. 84577 Genie TZ-50/30 5 - 3

Abbreviation LegendWire Colors

WIRE COLOR LEGEND

Color Description BL Blue BK Black GN Green OR Orange RD Red WH White

BL/BK Blue / Black BL/WH Blue / White BK/RD Black / Red BK/WH Black / White GN/BK Green / Black GN/WH Green / White OR/BK Orange / Black OR/RD Orange / Red OR/WH Orange / White RD/BK Red / Black RD/WH Red / White WH/BK White / Black WH/RD White / Red

REV A


5 - 4 Genie TZ-50/30 Part No. 84577

Ground Control Box Wiring Diagram - View 1All Models (before serial number TZ5004-182)

H5 ALARM G6 HOUR METER

++

--

TB3

TB32

TB35

PA3

WH

RD

WH

BK

BL/WH

BL/WH

WH

RD

RD

RD

RD

RD

RD

GN/WH

GN/WH

WH

OR/BK

BK/RD

CB115 AMP

CB215 AMP

RD/WH

RD/WH

OR/WH

OR/WH

RD

WH/BK

GN/WH

BL/BK

RD/BK

GN

RD

BK/WH

TB9

TB17

TB18

TB35

TB23

CC7

TB10

TURNTABLE HARNESS

PIN B

CR8 TERMINAL 87

POWER CABLE PIN 1

CR1 TERMINAL 30

CR15 TERMINAL 30

TURNTABLE HARNESS

PIN E

TB3

CC9

TB24

TB4A

TB33

CR15 TERMINAL 86

TB20

CC3

TB21

CC5

CR78A TERMINAL 30CR73 TERMINAL 87

TB31

TB30

TB25

TB26

TB29

CR78A TERMINAL 87

TB27

CR1 TERMINAL 86

P1 EMERGENCY STOPKS1KEY SWITCH

BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE

(BOOM UP, EXTEND, ROTATE

RIGHT AND OUTRIGGER RETRACT)

BN36JIB

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN58PLATFORM

LEVEL

UP/DOWN

BN49AUTO LEVEL

BN50LEFT REAR OUTRIGGER

BN52LEFT FRONT OUTRIGGER

BN51RIGHT REAR OUTRIGGER

BN53RIGHT FRONT

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

BN57TURNTABLE

ROTATE

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN93PLATFORM

ROTATE

RD

WH

RD

BK

MODELS

WITH

ENGINE

(OPTION)

BN90CHOKE

BN68ENGINE

START

RDTB3

TB7

L4LED

(CE MODELS)

REV A


Part No. 84577 Genie TZ-50/30 5 - 5

Ground Control Box Wiring Diagram - View 2All Models (before serial number TZ5004-182)

RD

RD

WH

BL

WH

TB3

TB7

TB6

BN58

TB3

TB16

TB8

TURNTABLE

HARNESS

PIN H

CR78ALIFT CUT-OUT

CR76LIMIT SWITCH FAULT

CR75LEVEL SENSOR

30

86

85

87A87

CR73FUNCTION ENABLE

TURNTABLE

HARNESS

PIN C

WH

9

8

7

6

5

4

3

2

1

TB34AWH

TB35BK

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

TB11WH

TB22WH

WH

TB12WH

WHTB32

WH

TB2WH

CD10WH/BK

TB4AWH

RDBN55

WH

CR28POWER SUPPLY

CR65BU6 CUT-OUT

CR64FAULT GROUND

CR65AU6 CUT-OUT

CR77DOWN ENABLE

TB35WH

C4ZENER

5.1V DC

C4AZENER DIODE

3.3V DC

BK/WH

GN/BK

WH/BK

BL/BK

RD/BK

BK/WH

WH/BK

BK

PB8

TB22

TB31

TB25

TB26

TB27

TB16

CR70PLATFORM ROTATE

CR67PRIMARY BOOM

CR86SEQUENCING

CR69BOOM EXTEND

CR72OUTRIGGERS

TURNTABLE HARNESS

PIN J

MANIFOLD HARNESS

PIN L

MANIFOLD HARNESS

PIN K

MANIFOLD HARNESS

PIN P

MANIFOLD HARNESS

PIN N

MANIFOLD HARNESS

PIN S

MANIFOLD HARNESS

PIN R

MANIFOLD HARNESS

PIN U

MANIFOLD HARNESS

PIN T

MANIFOLD HARNESS

PIN W

MANIFOLD HARNESS

PIN V

PD9

CR68SECONDARY BOOM

GN

GN/BK

BK/WH

BK

BL/BK

BL

WH/BK

WH

WH/BK

RD/BK

RD

10

11

12

13

14

15

16

17

18

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

CR8IGNITION

CR1ENGINE START

CR15STARTING AID

TB12RD

TB35

RDTB2

BK

BK

PA1

BN68

BK

BK/RDPA2

BN90BK/RD

BK/RDPD10

TB15BL

MODELS

WITH

ENGINE

(OPTION)

RDP1

TERMINALBASE

34A

3

4A

13

23

14

16

22

22

21

20

19

18

17

8

9

10

11

11

12

12

35

35

35

35

35

34

33

32

32

31

30

29

28

28

27

26

25

24

7

6

5

4

3

3

2

2

1

R221000 OHM

15

C54700uF

REV A


5 - 6 Genie TZ-50/30 Part No. 84577

Ground Control Box Wiring Diagram - View 1ANSI and CSA Models(from serial number TZ5004-182 to TZ5004-324)


++

--

TB3

TB32

TB35

PA3

WH

RD

WH

BK

BL/WH

BL/WH

WH

RD

RD

RD

RD

RD

GN/WH

GN/WH

WH

OR/BK

BK/RD

CB115 AMP

CB215 AMP

RD/WH

RD/WH

OR/WH

OR/WH

RD

WH/BK

GN/WH

BL/BK

RD/BK

GN

RD

BK/WH

TB9

TB17

TB18

TB35

TB23

CC7

TB10

TURNTABLE HARNESS

PIN B

CR6 TERMINAL 30

POWER CABLE PIN 1

CR15 TERMINAL 30

TURNTABLE HARNESS

PIN E

TB3

CC9

TB24

TB4A

TB33

CR15 TERMINAL 86

TB20

CC3

TB21

CC5

TB31

TB30

TB25

TB26

TB29

CR78A TERMINAL 87A

TB27


BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE



BN36JIB

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN58PLATFORM

LEVEL

UP/DOWN

BN49AUTO LEVEL




BN53RIGHT FRONT

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

BN57TURNTABLE

ROTATE

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN93PLATFORM

ROTATE

(OPTION)

RD

WH

RD

BK

MODELS

WITH

ENGINE

(OPTION)

BN90CHOKE

BN68ENGINE

START

RDCR1 TERMINAL 86

TB11

REV A


Part No. 84577 Genie TZ-50/30 5 - 7

Ground Control Box Wiring Diagram - View 2ANSI and CSA Models

(from serial number TZ5004-182 to TZ5004-324)

TERMINAL BASE

BK/WH

GN/BK

WH/BK

BL/BK

RD/BK

BK/WH

WH/BK

BK

PB8

TB22

TB31

TB25

TB26

TB27

TB16

CR70PLATFORM ROTATE

CR67PRIMARY BOOM

CR86SEQUENCING

CR69BOOM EXTEND

CR72OUTRIGGERS

TURNTABLE HARNESS

PIN J

MANIFOLD HARNESS

PIN L

MANIFOLD HARNESS

PIN K

MANIFOLD HARNESS

PIN P

MANIFOLD HARNESS

PIN N

MANIFOLD HARNESS

PIN S

MANIFOLD HARNESS

PIN R

MANIFOLD HARNESS

PIN U

MANIFOLD HARNESS

PIN T

MANIFOLD HARNESS

PIN W

MANIFOLD HARNESS

PIN V

PD9

CR68SECONDARY BOOM

GN

GN/BK

BK/WH

BK

BL/BK

BL

WH/BK

WH

WH/BK

RD/BK

RD

10

11

12

13

14

15

16

17

18

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

CR8IGNITION

CR1ENGINE START

CR15STARTING AID

TB12RD

TB35

RDTB2

BK

BK

PA1

BN68

BK

BK/RDPA2

BN90BK/RD

BK/RDPB10

TB15BL

MODELS

WITH

ENGINE

(OPTION)

RDP1

RD

RD

BL

WH

PA3

TB7

TB6

TB14

TB8

TURNTABLE

HARNESS

PIN H

CR78ALIFT CUT-OUT


CR75LEVEL SENSOR

30

86

85

87A87

TURNTABLE

HARNESS

PIN C

WH

9

7

6

5

4

3

2

1

TB34AWH

TB35BK

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

TB22WH

WH

TB12WH

WHTB32

WH

TB2WH

CD10WH/BK

TB4AWH

RDBN55

WH

CR28POWER SUPPLY

CR65BU6 CUT-OUT

CR64FAULT GROUND

CR65AU6 CUT-OUT

CR77DOWN ENABLE

C4ZENER

5.1V DC

C4AZENER DIODE

3.3V DC

TB11

BLTB15

NOTE: DIODES ARE 2 AMP

UNLESS OTHERWISE MARKED

34A

3

4A

13

23

14

16

22

22

21

20

19

18

17

8

9

10

11

11

12

12

35

35

35

35

35

34

33

32

32

31

30

29

28

28

27

26

25

24

7

6

5

4

3

3

2

2

1

R221000 OHM

15

C54700uF

PA5

PLATFORM

HARNESS

TERMINAL PA

DRIVE MANIFOLD HARNESS PIN 8

DC

6A6A

DE

6A

6A

REV A


5 - 8 Genie TZ-50/30 Part No. 84577

Ground Control Box Wiring Diagram - View 1ANSI and CSA Models(after serial number TZ5004-324)


++

--

TB3

TB32

TB35

PA3

RD

WH

BK

BL/WH

BL/WH

GN/WH

GN/WH

WH

RD/WH

RD/WH

OR/WH

OR/WH

RD

WH/BK

GN/WH

BL/BK

RD/BK

GN

RD

BK/WH

TB17

TB18

TB35

TB23

CC7

CC9

TB24

TB4A

TB20

CC3

TB21

CC5

TB31

TB30

TB25

TB26

TB29

CR78A TERMINAL 87A

TB27

BN36JIB

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN58PLATFORM

LEVEL

UP/DOWN

BN49AUTO LEVEL




BN53RIGHT FRONT

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

BN57TURNTABLE

ROTATE

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN93PLATFORM

ROTATE

(OPTION)

RD

WH

RD

BK

TB11

WH

WH

RD

RD

RD

OR/BK

BK/RD

CB115 AMP

CB215 AMP

TB9

TB10

CR6 TERMINAL 30

POWER CABLE PIN 1

CR15 TERMINAL 30

TURNTABLE HARNESS

PIN E

TB33

CR15 TERMINAL 86

P1 EMERGENCY STOP

BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE



MODELS

WITH

ENGINE

(OPTION)

BN90CHOKE

BN68ENGINE

START

TB3

RDCR1 TERMINAL 86

RD

RDTURNTABLE HARNESS

PIN B

KS1KEY SWITCH

REV A


Part No. 84577 Genie TZ-50/30 5 - 9

Ground Control Box Wiring Diagram - View 2ANSI and CSA Models

(after serial number TZ5004-324)

TERMINAL BASE

BK/WH

GN/BK

WH/BK

BL/BK

RD/BK

BK/WH

WH/BK

BK

PB8

TB22

TB31

TB25

TB26

TB27

TB16

CR70PLATFORM ROTATE

CR67PRIMARY BOOM

CR86SEQUENCING

CR69BOOM EXTEND

CR72OUTRIGGERS

TURNTABLE HARNESS

PIN J

MANIFOLD HARNESS

PIN L

MANIFOLD HARNESS

PIN K

MANIFOLD HARNESS

PIN P

MANIFOLD HARNESS

PIN N

MANIFOLD HARNESS

PIN S

MANIFOLD HARNESS

PIN R

MANIFOLD HARNESS

PIN U

MANIFOLD HARNESS

PIN T

MANIFOLD HARNESS

PIN W

MANIFOLD HARNESS

PIN V

PD9

CR68SECONDARY BOOM

GN

GN/BK

BK/WH

BK

BL/BK

BL

WH/BK

WH

WH/BK

RD/BK

RD

10

11

12

13

14

15

16

17

18

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

CR8IGNITION

CR1ENGINE START

CR15STARTING AID

TB12RD

TB35

RDTB2

BK

BK

PA1

BN68

BK

BK/RDPA2

BN90BK/RD

BK/RDPB10

TB15BL

MODELS

WITH

ENGINE

(OPTION)

RDP1

RD

RD

BL

WH

PA3

TB7

TB6

TB14

TB8

TURNTABLE

HARNESS

PIN H

CR78ALIFT CUT-OUT


CR75LEVEL SENSOR

30

86

85

87A87

TURNTABLE

HARNESS

PIN C

WH

9

7

6

5

4

3

2

1

TB34AWH

TB35BK

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

TB22WH

WH

TB12WH

WHTB32

WH

TB2WH

CD10WH/BK

TB4AWH

RDBN55

WH

CR28POWER SUPPLY

CR65BU6 CUT-OUT

CR64FAULT GROUND

CR65AU6 CUT-OUT

CR77DOWN ENABLE

C4ZENER

5.1V DC

C4AZENER DIODE

3.3V DC

TB11

BLTB15



34A

3

4A

13

23

14

16

22

22

21

20

19

18

17

8

9

10

11

11

12

12

35

35

35

35

35

34

33

32

32

31

30

29

28

28

27

26

25

24

7

6

5

4

3

3

2

2

1

R221000 OHM

15

C54700uF

PA5

PLATFORM

HARNESS

TERMINAL PA


DC

6A6A

DE

6A

6A

REV A


5 - 10 Genie TZ-50/30 Part No. 84577

Ground Control Box Wiring Diagram - View 1CE Models(from serial number TZ5004-182 to GS5004-324)


++

--

TB3

TB32

TB35

PA3

WH

RD

WH

BK

BL/WH

BL/WH

WH

RD

RD

RD

RD

GN/WH

GN/WH

WH

OR/BK

BK/RD

CB115 AMP

CB215 AMP

RD/WH

RD/WH

OR/WH

OR/WH

RD

WH/BK

GN/WH

BL/BK

RD/BK

GN

RD

BK/WH

TB9

TB17

TB18

TB35

TB23

CC7

TB10

TURNTABLE HARNESS

PIN B

CR6 TERMINAL 30

POWER CABLE PIN 1

CR15 TERMINAL 30

TURNTABLE HARNESS

PIN E

CC9

TB24

TB4A

TB33

CR15 TERMINAL 86

TB20

CC3

TB21

CC5

TB31

TB30

TB25

TB26

TB29

CR78A TERMINAL 87A

TB27


BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE



BN36JIB

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN58PLATFORM

LEVEL

UP/DOWN

BN49AUTO LEVEL




BN53RIGHT FRONT

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

BN57TURNTABLE

ROTATE

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN93PLATFORM

ROTATE

(OPTION)

RD

WH

RD

BK

MODELS

WITH

ENGINE

(OPTION)

BN90CHOKE

BN68ENGINE

START

TB3

L4LED

RDCR1 TERMINAL 86

TB11

RD

TB7OR

ORPA4

REV A


Part No. 84577 Genie TZ-50/30 5 - 11

Ground Control Box Wiring Diagram - View 2CE Models

(from serial number TZ5004-182 to GS5004-324)

TERMINAL BASE

BK/WH

GN/BK

WH/BK

BL/BK

RD/BK

BK/WH

WH/BK

BK

PB8

TB22

TB31

TB25

TB26

TB27

TB16

CR70PLATFORM ROTATE

CR67PRIMARY BOOM

CR86SEQUENCING

CR69BOOM EXTEND

CR72OUTRIGGERS

TURNTABLE HARNESS

PIN J

MANIFOLD HARNESS

PIN L

MANIFOLD HARNESS

PIN K

MANIFOLD HARNESS

PIN P

MANIFOLD HARNESS

PIN N

MANIFOLD HARNESS

PIN S

MANIFOLD HARNESS

PIN R

MANIFOLD HARNESS

PIN U

MANIFOLD HARNESS

PIN T

MANIFOLD HARNESS

PIN W

MANIFOLD HARNESS

PIN V

PD9

CR68SECONDARY BOOM

GN

GN/BK

BK/WH

BK

BL/BK

BL

WH/BK

WH

WH/BK

RD/BK

RD

10

11

12

13

14

15

16

17

18

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

CR8IGNITION

CR1ENGINE START

CR15STARTING AID

TB12RD

TB35

RDTB2

BK

BK

PA1

BN68

BK

BK/RDPA2

BN90BK/RD

BK/RDPB10

TB15BL

MODELS

WITH

ENGINE

(OPTION)

RDP1

RD

RD

BL

WH

PA3

TB7

TB6

TB14

TB8

TURNTABLE

HARNESS

PIN H

CR78ALIFT CUT-OUT


CR75LEVEL SENSOR

30

86

85

87A87

TURNTABLE

HARNESS

PIN C

WH

9

7

6

5

4

3

2

1

TB34AWH

TB35BK

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

TB22WH

WH

TB12WH

WHTB32

WH

TB2WH

CD10WH/BK

TB4AWH

RDBN55

WH

CR28POWER SUPPLY

CR65BU6 CUT-OUT

CR64FAULT GROUND

CR65AU6 CUT-OUT

CR77DOWN ENABLE

C4ZENER

5.1V DC

C4AZENER DIODE

3.3V DC

TB11

BLTB15

34A

3

4A

13

23

14

16

22

22

21

20

19

18

17

8

9

10

11

11

12

12

35

35

35

35

35

34

33

32

32

31

30

29

28

28

27

26

25

24

7

6

5

4

3

3

2

2

1

R221000 OHM

15

C54700uF

PA5

PLATFORM

HARNESS

TERMINAL PA


DC

6A6A

DE

6A

6A



REV A


5 - 12 Genie TZ-50/30 Part No. 84577

Ground Control Box Wiring Diagram - View 1CE Models(after serial number TZ5004-324)


++

--

TB3

TB32

TB35

PA3

RD

WH

BK

BL/WH

BL/WH

GN/WH

GN/WH

WH

RD/WH

RD/WH

OR/WH

OR/WH

RD

WH/BK

GN/WH

BL/BK

RD/BK

GN

RD

BK/WH

TB17

TB18

TB35

TB23

CC7

CC9

TB24

TB4A

TB20

CC3

TB21

CC5

TB31

TB30

TB25

TB26

TB29

CR78A TERMINAL 87A

TB27

BN36JIB

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN58PLATFORM

LEVEL

UP/DOWN

BN49AUTO LEVEL




BN53RIGHT FRONT

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

BN57TURNTABLE

ROTATE

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN93PLATFORM

ROTATE

(OPTION)

RD

WH

RD

BK

TB11

WH

WH

RD

RD

RD

OR/BK

BK/RD

CB115 AMP

CB215 AMP

TB9

TB10

CR6 TERMINAL 30

POWER CABLE PIN 1

CR15 TERMINAL 30

TURNTABLE HARNESS

PIN E

TB33

CR15 TERMINAL 86

P1 EMERGENCY STOP

BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE



MODELS

WITH

ENGINE

(OPTION)

BN90CHOKE

BN68ENGINE

START

TB3

L4LED

RDCR1 TERMINAL 86

RD

TB7OR

ORPA4

RDTURNTABLE HARNESS

PIN B

KS1KEY SWITCH

REV A


Part No. 84577 Genie TZ-50/30 5 - 13

Ground Control Box Wiring Diagram - View 2CE Models


TERMINAL BASE

BK/WH

GN/BK

WH/BK

BL/BK

RD/BK

BK/WH

WH/BK

BK

PB8

TB22

TB31

TB25

TB26

TB27

TB16

CR70PLATFORM ROTATE

CR67PRIMARY BOOM

CR86SEQUENCING

CR69BOOM EXTEND

CR72OUTRIGGERS

TURNTABLE HARNESS

PIN J

MANIFOLD HARNESS

PIN L

MANIFOLD HARNESS

PIN K

MANIFOLD HARNESS

PIN P

MANIFOLD HARNESS

PIN N

MANIFOLD HARNESS

PIN S

MANIFOLD HARNESS

PIN R

MANIFOLD HARNESS

PIN U

MANIFOLD HARNESS

PIN T

MANIFOLD HARNESS

PIN W

MANIFOLD HARNESS

PIN V

PD9

CR68SECONDARY BOOM

GN

GN/BK

BK/WH

BK

BL/BK

BL

WH/BK

WH

WH/BK

RD/BK

RD

10

11

12

13

14

15

16

17

18

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

CR8IGNITION

CR1ENGINE START

CR15STARTING AID

TB12RD

TB35

RDTB2

BK

BK

PA1

BN68

BK

BK/RDPA2

BN90BK/RD

BK/RDPB10

TB15BL

MODELS

WITH

ENGINE

(OPTION)

RDP1

RD

RD

BL

WH

PA3

TB7

TB6

TB14

TB8

TURNTABLE

HARNESS

PIN H

CR78ALIFT CUT-OUT


CR75LEVEL SENSOR

30

86

85

87A87

TURNTABLE

HARNESS

PIN C

WH

9

7

6

5

4

3

2

1

TB34AWH

TB35BK

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

TB22WH

WH

TB12WH

WHTB32

WH

TB2WH

CD10WH/BK

TB4AWH

RDBN55

WH

CR28POWER SUPPLY

CR65BU6 CUT-OUT

CR64FAULT GROUND

CR65AU6 CUT-OUT

CR77DOWN ENABLE

C4ZENER

5.1V DC

C4AZENER DIODE

3.3V DC

TB11

BLTB15



34A

3

4A

13

23

14

16

22

22

21

20

19

18

17

8

9

10

11

11

12

12

35

35

35

35

35

34

33

32

32

31

30

29

28

28

27

26

25

24

7

6

5

4

3

3

2

2

1

R221000 OHM

15

C54700uF

PA5

PLATFORM

HARNESS

TERMINAL PA


DC

6A6A

DE

6A

6A

REV A


5 - 14 Genie TZ-50/30 Part No. 84577

Platform Control Box Wiring DiagramAll Models(before serial number TZ5004-182)

+ -

CR78B TERMINAL 30 AND

CR74 TERMINAL 87

POWER CABLE

TB2

CR87 TERMINAL 86 AND PA7

OR/BK

RD

BK/WHPB4

WHPA8

RD

BLPA1

RD/WH

BL/BK

RD

BK

BK/RDPA2

PB2

CR 78B TERMINAL 87A

GNCR 9 TERMINAL 30 AND PB6

GNPOWER CABLE

POWER CABLEBK

RD

WH

BK

CR74 TERMINAL 86

PA6

CR78B TERMINAL 86 AND

PB1

WH/BK

GN/WHCR87 TERMINAL 30 AND

PB7

RD/BKPB3

BN61FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE

LEFT)

TURNTABLE AND

PLATFORM

BN62FUNCTION ENABLE

(BOOM UP, EXTEND,

TURNTABLE AND

PLATFORM ROTATE

RIGHT)

L4A LED

(CE MODELS)

BN2ENGINE

START

BN3ENGINE CHOKE

BN97JIB BOOM

UP/DOWN

BN63PRIMARY BOOM

UP/DOWN

BN98PLATFORM

ROTATE

G7BATTERY CHARGE

INDICATOR

BN64SECONDARY BOOM

UP/DOWN

BN66TURNTABLE

ROTATE

P2EMERGENCY

STOP

BN67PLATFORM

LEVEL

R14BOOM

FUNCTION

SPEED

10K OHM

BN65BOOM

EXTEND/RETRACT

R22B5.6K OHM

C4A ZENER DIODE 5.1V DC

MODELS

WITH

ENGINE

(OPTION)

CR78BLIFT CUT-OUT

CR9JIB BOOM UP/DOWN

CR87PLATFORM ROTATE

CR74FUNCTION ENABLE

CR71PLATFORM LEVEL

BN64

JIB HARNESS PIN 2

BL/BK

BL

OR/BK

OR

RD

GN/BK

GN

1

2

3

4

5

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

RDBN66

BL

JIB HARNESS PIN 3

JIB HARNESS PIN 4

JIB HARNESS PIN 5

JIB HARNESS PIN 6

JIB HARNESS PIN 7

TB1

PA7

PA6

BN61

TB3

PB5

TB2

BN97

PB6

WH

RD

BL

RD/WH

RD/WH

BK

OR/BK

GN

GN

TB2

BN67

BLBN62

PB7GN/WH

TB2

BN98

REV A


Part No. 84577 Genie TZ-50/30 5 - 15

Platform Control Box Wiring DiagramANSI and CSA Models


+ -

POWER CABLE PIN 1

TB6

TB4

OR/BK

RD

BK/WHPB4

WHPA8

RD

BLPA1

RD/WH

BL/BK

RD

BK

BK/RDPA2

PB2

CR 78B TERMINAL 87A


RDPOWER CABLE PIN 2

TB9BK

RD

WH

BK

TB2

TB5WH/BK

GN/WHTB8

RD/BKPB3

BN61FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE

LEFT)

TURNTABLE AND

PLATFORM

BN62FUNCTION ENABLE

(BOOM UP, EXTEND,

TURNTABLE AND

PLATFORM ROTATE

RIGHT)

BN2ENGINE

START

BN3ENGINE CHOKE

BN97JIB BOOM

UP/DOWN

BN63PRIMARY BOOM

UP/DOWN

BN98PLATFORM

ROTATE (OPTION)

G7BATTERY CHARGE

INDICATOR

BN64SECONDARY BOOM

UP/DOWN

BN66TURNTABLE

ROTATE

P2EMERGENCY

STOP

BN67PLATFORM

LEVEL

R14BOOM

FUNCTION

SPEED

10K OHM

BN65BOOM

EXTEND/RETRACT

R22B5.6K OHM

C4B ZENER DIODE 5.1V DC

MODELS

WITH

ENGINE

(OPTION)

3 2 16 5 49 8 7

PA6

G7 “+”

CR78BLIFT CUT-OUT

CR9JIB BOOM UP/DOWN

CR87PLATFORM ROTATE

CR71PLATFORM LEVEL

BN64

JIB HARNESS PIN 2

BL/BK

BL

OR/BK

OR

RD

GN/BK

GN

2

3

4

5

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

BL

JIB HARNESS PIN 3

JIB HARNESS PIN 4

JIB HARNESS PIN 5

JIB HARNESS PIN 6

JIB HARNESS PIN 7

TB9

TB6

TB7

BN97

PB6

RD

BK

OR/BK

GN

GN

TB8GN/WH

TB3

TB4

TB1RD

TB3

RDTB1

RDTB1

R22C5.6K OHM

REV A


5 - 16 Genie TZ-50/30 Part No. 84577

Platform Control Box Wiring DiagramCE Models(after serial number TZ5004-181)

+ -

TB6

TB4

OR/BK

RD

BK/WHPB4

WHPA8

BLPA1

BL/BK

RD

BK

BK/RDPA2

PB2

CR 78B TERMINAL 87A


RD

WH

BK

GN/WHTB8

RD/BKPB3

BN61FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE

LEFT)

TURNTABLE AND

PLATFORM

BN62FUNCTION ENABLE

(BOOM UP, EXTEND,

TURNTABLE AND

PLATFORM ROTATE

RIGHT)

L4ALED

BN2ENGINE

START

BN3ENGINE CHOKE

BN97JIB BOOM

UP/DOWN

BN63PRIMARY BOOM

UP/DOWN

G7BATTERY CHARGE

INDICATOR

BN64SECONDARY BOOM

UP/DOWN

BN66TURNTABLE

ROTATE

P2EMERGENCY

STOP

BN67PLATFORM

LEVEL

R14BOOM

FUNCTION

SPEED

10K OHM

BN65BOOM

EXTEND/RETRACT

R22B5.6K OHM

C4A ZENER DIODE 5.1V DC

MODELS

WITH

ENGINE

(OPTION)

3 2 16 5 49 8 7

PA6

G7 “+”

CR78BLIFT CUT-OUT

CR9JIB BOOM UP/DOWN

CR87PLATFORM ROTATE (OPTION)

CR71PLATFORM LEVEL

BN64

JIB HARNESS PIN 2

BL/BK

BL

OR/BK

OR

RD

GN/BK

GN

2

3

4

5

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

30

86

85

87A87

BL

JIB HARNESS PIN 3

JIB HARNESS PIN 4

JIB HARNESS PIN 5

JIB HARNESS PIN 6

JIB HARNESS PIN 7

TB9

TB6

TB7

BN97

PB6

RD

BK

OR/BK

GN

GN

TB8GN/WH

TB3

TB4

TB1RD

POWER CABLE PIN 1

PA4

OR

OR

LIMIT SWITCH HARNESS

TERMINAL 3

TB9BK

RDPOWER CABLE PIN 2

RDTB1

PA12RD

BN98PLATFORM

ROTATE (OPTION)

RDTB3

TB5WH/BK

RD/WHTB2

R22C5.6K OHM

REV A


Part No. 84577 Genie TZ-50/30 5 - 17

Drive Control Box Wiring Diagram

DKGN/BK

DDRD/WH

DH

DJ

DG

RD

WH

BL

P3EMERGENCY

STOP

GY

GN

OR

PP

GY

GN

OR

PP

WH

/BL

GN

OR

PP

WH

/BL

GN

OR

PP

WH

/BK

GN

OR

PP

RD

GN

OR

PP

RD/BKDE

BK/WHDF

DAGN

CE MODELS

GN/WHDL

BK

JC5JOYSTICK

CONTROLLER

BK

RD

DM

DN

DC

OR/BK

OR

WH/BK

DP

DB

BL/BK

BK

U24DRIVE CONTROLS

PRINTED CIRCUIT BOARD

1

2

3

4

5

6

RD

OR/BK

OR

WH/BK

BL/BK

BK

RD

YL/BK

YL

WH/BK

WH/RD

BK

BN94FUNCTION ENABLE

(BOOM DOWN, RETRACT,

ROTATE LEFT AND

OUTRIGGER EXTEND)

BN95FUNCTION ENABLE



P3EMERGENCY

STOP

BN96AUTO LEVEL

GY

GN

OR

PP

GY

GN

OR

PP

WH

/BL

GN

OR

PP

WH

/BL

GN

OR

PP

WH

/BK

GN

OR

PP

RD

GN

OR

PP

RD/BKDE

BK/WHDF

DAGN

DKGN/BK

DDRD/WH

DH

DJ

DG

RD

WH

BL

ANSI MODELS

GN/WHDL

BK

JC5JOYSTICK

CONTROLLER

1

2

3

4

5

6

RD

OR/BK

OR

WH/BK

BL/BK

BK

RD

YL/BK

YL

WH/BK

WH/RD

BK

BK

RD

DM

DN

DC

OR/BK

OR

WH/BK

DP

DB

BL/BK

BK

U24DRIVE CONTROLS

PRINTED CIRCUIT BOARD

REV A


5 - 18 Genie TZ-50/30 Part No. 84577

Trailer Lighting Wiring Diagram

CE Models

RD

RD

BK

YL

BNRUN

STOP

TURN

GND

GND

TURN

STOP

RUN

GN

WH

WH

RD

BL

YL

BK

BN

GN

WH

2 BL

3 WH

1 YL

4 GN

5 BN

6 RD

7 BK 4

5

6

7

1

2

3

QD12TRAILER PLUG

L33RIGHT REAR

TAIL LIGHT

GYFOG

GYFOG

L34LEFT REAR

TAIL LIGHT

L36ALEFT SIDE MARKER

L35ARIGHT SIDE MARKER

L36CLEFT SIDE MARKER

L35CRIGHT SIDE MARKER

L36BLEFT SIDE MARKER

L35BRIGHT SIDE MARKER

ANSI, CSA Models

3

1

2

4

QD12TRAILER PLUG

GN

WH

YL

BN/YL BN

RD

RD

BN

BN

WH

GN

YL

BN

BK

BN BK

WH

2 YL

3 BN/YL

3 BN

1 GN

4 WH

L35RIGHT SIDE MARKER

L36LEFT SIDE MARKER

L33RIGHT REAR

TAIL LIGHT

L34LEFT REAR

TAIL LIGHT

REV A


Part No. 84577 Genie TZ-50/30 5 - 19

Honda GX160 Engine Wiring Diagram

ENGINE

KEY

SWITCH

5A FUSE

RECTIFIER

CIRCUIT

BREAKER

STARTER

SOLENOID

BATTERY

(+)

WHBK/WH

WH WH

CHARGING COIL

WH

GN

BK/RD

YL

OIL LEVEL

SWITCH

SPARK PLUG

TRANSISTORIZED

IGNITION UNIT

BK

CONTROL BOX


5 - 20 Genie TZ-50/30 Part No. 84577


REV A


Part No. 84577 Genie TZ-50/30 5 - 21

Electrical Symbols Legend

B+

1

T2

B- 3

S2

A1

M5

TB1

KS1KEY SWITCH

PL

AT

FO

RM

GR

OU

ND

CB215A

P1EMERGENCY

STOP

N.C.N.O.H.C.N.C.H.O.

+

-

87A 87 85

30 86

+

G6

Terminal

Diode

Key switch

Emergency stop button,normally closed

Circuit breaker

Limit switch

Toggle switch

Control relay

Resistor

LED

Alarm

Solenoid valve with diode

Quick disconnect

6V Battery

Fuse

Power unit or motor

Motor controller

Hour meter

Battery charger

Level sensor

REV A


5 - 22 Genie TZ-50/30 Part No. 84577

Electrical SchematicANSI and CSA Models(before serial number TZ5004-182) Part 1 of 6

WH

WH

BK

WH

/RD

GN

OR

BK

/RD

BK

WH

WH

/BK

PL

AT

FO

RM

GR

OU

ND

PA33 PA51 2 PA4DA DCDB

TB3

TB2

TB1

TB7

TB5

TB6

PA2PA11PA10

PB11

RD

PB12

RD

/WH

FB

8587

8630 4

87A

8587

8630 5

87A8587

8630 3

87A

8587

8630 2

87A

8587

8630 1

87A8587

8630 17

87A8587

8630 15

87A

PB10

BK

/RD

+

8587

8630 16

87A

TB35

H5ALARM

U6MOTOR

CONTROLLER

B+

3

T2

B- 1

A1

S2

M5

0-5V DC

KEY

M5MOTOR

F6275A

FUSE

A

N.O.

S7LEVEL

SENSOR

C F

C A

RD

WH

GN/WH

BK

B

GN

BK

BK

PA1

TO

+ - LOAD

A

TO B(DRIVE CONTROLS)

(PLATFORM CONTROLS)

FB1FLASHING BEACON

(OPTION)

U16BTIME DELAY

L4LED

BN90CHOKE

BN68ENGINE

START

CR64FAULT

GROUND

CR65AU6 CUTOUT

CR65BU6 CUTOUT

CR76LIMIT SWITCH

FAULT

CR75LEVEL SENSOR

D1ALTERNATOR

Q7CHOKE

SOLENOID

F950 AMP

PR5POWER

RELAY

CR15STARTING AID

CR1ENGINE START

CR8IGNITION

KS1KEY

SWITCH

P1EMERGENCY

STOP

CB215 AMP

GROUNDCONTROLBOX

- NOTE -MACHINE SHOWN IN

STOWED POSITION WITH

THE POWER OFF

E

RD

CB115 AMP

MODELSWITH

ENGINE(OPTION)

RD

B D PB8

WH

BK

+

-

-

+

+

-

-

+

BK

PB9

M3

G

U26IGNITION

M3STARTER

MOTOR

F9A50 AMP

B54-6V

BATTERY

U9BATTERY CHARGER

AC

INPUT

(10 TO 30 SECONDS)

ES-TZ50A

REV A


Part No. 84577 Genie TZ-50/30 5 - 23

Electrical SchematicANSI and CSA Models

(before serial number TZ5004-182) Part 2 of 6

GN

/BK

BL

GN

/WH

BL

/WH

OR

/WH

RD

/WH

GN

/WH

WH

/BK

OR

/RD

BL

/WH

OR

/WH

RD

/WH

RD

WH

GN

/BK

RD

/BK

PA7 PA8

5 6 7 8J

PA9PA6 DJDH DKDEDD

TB4

TB8

TB9

TB10

TB11

TB13

TB

12

TB20 TB21 TB23 TB24

TB28

CD1 CD2CC1 CC2 CD3 CD4CC3 CC4 CD5 CD6CC5 CC6 CD7 CD8CC7 CC8 CC9 CC10

BL

DG

BK

/WH

DF

TB32

TB16

TB14

RD

WH

2 4

TB17

TB18

8587

8630 6

87A

8587

8630 7

87A8587

8630 18

87A

WH

/BK

3

+

-

LO

AD

TB35

BL

H

RD

/WH

LS18BOOM DOWN

N.C.H.O.

N.C.H.O.

N.O.H.C.

N.O.H.C.

CD11CD9CD10

LS18ABOOM DOWN

A

B

TO A

TO B

TO C(AUTO-LEVEL)

(DRIVE CONTROLS)

(PLATFORM CONTROLS)

BN52LEFT

FRONT

OUTRIGGER

BN53RIGHT

FRONT

OUTRIGGER

BN50LEFT

REAR

OUTRIGGER

BN51RIGHT

REAR

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

CR77DOWN

ENABLE

CR86SEQUENCING

TB22

CR28POWER SUPPLY

U16ATIME DELAY

BK

1

BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE

(BOOM UP, EXTEND,

ROTATE RIGHT

AND OUTRIGGER

RETRACT)

BN49AUTO LEVEL

R221000 OHM

C4ZENER

DIODE

5.1V DC

C4AZENER

DIODE

3.3V DC

N.C.H.O. N.C.H.O. N.C.H.O.

Y36RIGHT FRONT

OUTRIGGER

Y35LEFT FRONT

OUTRIGGER

Y33LEFT REAR

OUTRIGGER

Y34RIGHT REAR

OUTRIGGER

N.C.H.O.

LS13RIGHT FRONT

OUTRIGGER

LS12LEFT FRONT

OUTRIGGER

LS14LEFT REAR

OUTRIGGER

LS15RIGHT REAR

OUTRIGGER

OUTRIGGERS SHOWN IN

STOWED POSITION

GROUNDCONTROL

BOX



THE POWER OFFRD

/WH

(AUTO-LEVEL)

C54700uF

TB15

RD

WH

/BK

WH

(0.1 TO 10 SECONDS)

ES-TZ50A


5 - 24 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 25


REV A


5 - 26 Genie TZ-50/30 Part No. 84577


Y23ROTATE

LEFT

Y21PRIMARY

DOWN

Y52SECONDARY

DOWN

Y25BOOM

RETRACT

Y24ROTATE

RIGHT

Y22PRIMARY

UP

Y53SECONDARY

UP

Y26BOOM

EXTEND

Y40OUTRIGGER

EXTEND

Y39OUTRIGGER

RETRACT

TO A


(PLATFORM CONTROLS)

TO C(AUTO-LEVEL)

A

B

C

RD

/BK

BL

/BK

WH

/BK

OR

/BK

BK

/WH

GN

/WH

PB1 PB2 PB3 PB4PB5 PB7

TB25 TB26 TB27 TB29

TB28

TB33TB31

TB34

8587

8630 8

87A 8587

8630 9

87A

8587

8630 14

87A8587

8630 13

87A8587

8630 12

87A8587

8630 11

87A8587

8630 10

87A

WH

/BK

BL

/BK

RD

/BK

BK

/WH

WH

BL

RD

BK

GN

GN

/BK

BRN

OR

/BK

OR

WH

WH

K L M N P R S T U V W 531 72

TB35

Y50DRIVE

FWD/REV

LEFT

Y50ADRIVE

FWD/REV

RIGHT

Y58PROPORTIONAL

DRIVE

RIGHT

Y59

LEFT

PROPORTIONAL

DRIVE



THE POWER OFF

TB34A

CR72OUTRIGGER

CR70TURNTABLE

ROTATE

CR68SECONDARY

BOOM

CR67PRIMARY

BOOM

CR69BOOM

EXTEND

BN57TURNTABLE

ROTATE

CR78ALIFT CUT-OUT

CR73FUNCTION

ENABLE

BN58PLATFORM

LEVEL

UP/DOWN

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN36JIB

BOOM

UP/DOWN

G6HOUR

METER+

GN

PB6 DL DNDM

BK

GN

/WH

OR

OR

/BK

BL

/BK

DP

TB32

BL

8

Y11BRAKE

RELEASE

(DRIVE)

TB30

BN93PLATFORM

ROTATE

(OPTION)

GROUNDCONTROL

BOX

ES-TZ50A

REV A


Part No. 84577 Genie TZ-50/30 5 - 27



C

4

WH

2

RD

1

BK

3

WH

/BK

5

RD

/WH

8

GN

/WH

6

OR

/WH

7

BL

/WH

S10LEFT/RIGHT AXIS

LEVEL SENSOR

S9FRONT/REAR AXIS

LEVEL SENSOR

CR61AUTO LEVEL

SYSTEM RELAY

CR66LEVEL SENSOR RELAY

AUTO LEVEL

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

YLGN GN

RD

87A 87 85

30 86

YL

RD

4 42 23 31 1

TO A


(PLATFORM CONTROLS)

A

B

ES-TZ50A


5 - 28 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 29


REV A


5 - 30 Genie TZ-50/30 Part No. 84577


A

B

TO A(PLATFORM CONTROLS)

DRIVECONTROLBOX

BN95FUNCTION ENABLE

(BOOM UP, EXTEND,

ROTATE RIGHT

AND OUTRIGGER

RETRACT)

DG

BL

DK

GN

/BK

DD

RD

/WH

WH

DJ

JC5JOYSTICK

CONTROLLER

BN94FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

1

2

DN

OR

/BK

4

DC

WH

/BK

3

DM

OR

5

DL

GN

/WH

6

DB

BK

7

DPB

L/B

KDA DE

P3EMERGENCY

STOP

GN

RD

/BK

DF

BK

/WH

BN96AUTOLEVEL

DH

RD

ES-TZ50A

REV A


Part No. 84577 Genie TZ-50/30 5 - 31



A

PLATFORMCONTROLBOX

1 2

P2EMERGENCY

STOP

WH

GN

G7BATTERY

CHARGE

INDICATOR

F

E

3

BK

BN2ENGINE

START

BN3CHOKE

PA2

BK

/RD

PA1

BK

H1ALARM

PA3

WH

4 1 2 3

PA5

WH

/RD

PA9

OR

/RD

PA6

RD

/WH

BN61FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

TURNTABLE AND

PLATFORM ROTATE

LEFT)

PA7

BL

BN62FUNCTION ENABLE

(BOOM UP,

BOOM EXTEND

TURNTABLE AND

PLATFORM ROTATE

RIGHT)

8587

8630 1

87A

CR74FUNCTION

ENABLE

R22B5.6K OHM

C4BZENER

DIODE

5.1V DC

R14RESISTOR

0-10K OHM

BN66TURNTABLE

ROTATE

PA4

OR

PA8

GN

/BK

PB5

OR

/BK

CR78BLIFT CUT-OUT

8587

8630 2

87A

8587

8630 3

87A

CR71PLATFORM

LEVEL

Y19PLATFORM

LEVEL

DOWN

Y20PLATFORM

LEVEL

UP

1

8587

8630 4

87A

CR9JIB BOOM

UP/DOWN

Y60JIB

BOOM

RETRACT

Y61JIB

BOOM

EXTEND

GN

/BK

GN

4 5

BN97JIB

BOOM

UP/DOWN

BN63PRIMARY

BOOM

UP/DOWN

BN64SECONDARY

BOOM

UP/DOWN

BN65BOOM

EXTEND/

RETRACT

8587

8630 5

87A

CR87PLATFORM

ROTATE

Y62PLATFORM

ROTATE

LEFT

Y63PLATFORM

ROTATE

RIGHT

GN

/BK

GN

6 7

PB6

GN

PB7

GN

/WH

PB4

BK

/WH

PB2

BL

/BK

PB3

RD

/BK

OR

/BK

OR

2 3

BK

RD

WH

MODELS

WITH

ENGINE

(OPTION)

PB1

WH

/BK

BN98PLATFORM

ROTATE

BN67PLATFORM

LEVEL

PLATFORM

ROTATE(OPTION)

ES-TZ50A

REV A


5 - 32 Genie TZ-50/30 Part No. 84577

Electrical SchematicANSI and CSA Models(after serial number TZ5004-181) Part 1 of 6

WH

WH

BK

WH

/RD

GN

OR

LE

VE

LS

EN

SO

RR

EL

AY

BK

/RD

BK

WH

WH

/BK

PL

AT

FO

RM

GR

OU

ND


TB3

TB2

TB1

TB7

TB5

PA2PA11PA10

PB11

RD

PB12

RD

/WH

FB

8587

8630 4

87A

8587

8630 5

87A8587

8630 3

87A

8587

8630 2

87A

8587

8630 1

87A8587

8630 17

87A8587

8630 15

87A

PB10

BK

/RD

+

8587

8630 16

87A

TB35

H5ALARM

U6MOTOR

CONTROLLER

B+

3

T2

B-

1

A1

S2

M5

0-5V DC

KEY

M5MOTOR

F6275A

FUSE

A

N.O.

S7LEVEL

SENSOR

C F

C A

RD

WH

GN/WH

BK

B

GN

BK

BK

PA1

TO

+- LOAD

A


(PLATFORM CONTROLS)

FB1FLASHING BEACON

(OPTION)

U16BTIME DELAY

(10 TO 30 SECONDS)

L4LED

BN90CHOKE

BN68ENGINE

START

CR64FAULT

GROUND

CR65AU6 CUTOUT

CR65BU6 CUTOUT

CR76LIMIT SWITCH

FAULT

CR75LEVEL SENSOR

D1ALTERNATOR

Q7CHOKE

SOLENOID

F950 AMP

PR5POWER

RELAY

CR15STARTING AID

CR1ENGINE START

CR8IGNITION

KS1KEY

SWITCH

P1EMERGENCY

STOP

CB215 AMP

GROUNDCONTROLBOX



THE POWER OFF

E

RD

CB115 AMP

MODELSWITH

ENGINE(OPTION)

RD

B D PB8

WH

BK

+

-

-

+

+

-

-

+

BK

PB9

M3

G

U26IGNITION

M3STARTER

MOTOR

F9A50 AMP

B54-6V

BATTERY

U9BATTERY CHARGER

AC

INPUT

ES-TZ50D

REV A


Part No. 84577 Genie TZ-50/30 5 - 33


(after serial number TZ5004-181) Part 2 of 6

GN

/BK

BL

GN

/WH

BL

/WH

OR

/WH

RD

/WH

GN

/WH

WH

/BK

OR

/RD

BL

/WH

OR

/WH

RD

/WH

RD

WH

GN

/BK

RD

/BK

PA7 PA8

5 6 7 8J

PA9PA6 DJDH DKDEDD

TB4

TB8

TB9 TB10

TB11

TB13

TB12

TB20 TB21 TB23 TB24

TB28


BL

DG

BK

/WH

DF

TB32

TB16

TB14

RD

WH

2 4

TB17

TB18

8587

8630 6

87A

8587

8630 7

87A8587

8630 18

87A

WH

/BK

3

+

-

LO

AD

TB35

BL

H

RD

/WH

LS18BOOM DOWN

N.C.H.O.

N.C.H.O.

N.O.H.C.

N.O.H.C.

CD11CD9CD10

LS18ABOOM DOWN

A

B

TO A

TO B

TO C(AUTO-LEVEL)

(DRIVE CONTROLS)

(PLATFORM CONTROLS)

BN52LEFT

FRONT

OUTRIGGER

BN53RIGHT

FRONT

OUTRIGGER

BN50LEFT

REAR

OUTRIGGER

BN51RIGHT

REAR

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

CR77DOWN

ENABLE

CR86SEQUENCING

TB22

CR28POWER SUPPLY

BK

1

BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE

(BOOM UP, EXTEND,

ROTATE RIGHT

AND OUTRIGGER

RETRACT)

BN49AUTO LEVEL

R221000 OHM

C4ZENER

DIODE

5.1V DC

C4AZENER

DIODE

3.3V DC


Y36RIGHT FRONT

OUTRIGGER

Y35LEFT FRONT

OUTRIGGER

Y33LEFT REAR

OUTRIGGER

Y34RIGHT REAR

OUTRIGGER

N.C.H.O.

LS13RIGHT FRONT

OUTRIGGER

LS12LEFT FRONT

OUTRIGGER

LS14LEFT REAR

OUTRIGGER

LS15RIGHT REAR

OUTRIGGER

OUTRIGGERS SHOWN IN

STOWED POSITION

GROUNDCONTROL

BOX



THE POWER OFFRD

/WH

(AUTO-LEVEL)

C54700uF

TB15

RD

WH

/BK

WH

6A6A

6A6A

U16ATIME DELAY(0.1 TO 10 SECONDS)

TB4A

ES-TZ50D


5 - 34 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 35


REV A


5 - 36 Genie TZ-50/30 Part No. 84577


Y23ROTATE

LEFT

Y21PRIMARY

DOWN

Y52SECONDARY

DOWN

Y25BOOM

RETRACT

Y24ROTATE

RIGHT

Y22PRIMARY

UP

Y53SECONDARY

UP

Y26BOOM

EXTEND

Y40OUTRIGGER

EXTEND

Y39OUTRIGGER

RETRACT

TO A


(PLATFORM CONTROLS)

TO C(AUTO-LEVEL)

A

B

C

RD

/BK

BL

/BK

WH

/BK

OR

/BK

BK

/WH

GN

/WH


TB25 TB26 TB27 TB29

TB28

TB33TB31

TB34

8587

8630 9

87A

8587

8630 13

87A8587

8630 12

87A8587

8630 11

87A8587

8630 10

87A

WH

/BK

BL

/BK

RD

/BK

BK

/WH

WH

BL

RD

BK

GN

GN

/BK

BRN

OR

/BK

OR

WH

WH

K L M N P R S T U V W 531 72

Y50DRIVE

FWD/REV

LEFT

Y50ADRIVE

FWD/REV

RIGHT

Y58PROPORTIONAL

DRIVE

RIGHT

Y59

LEFT

PROPORTIONAL

DRIVE



THE POWER OFF

TB34A

CR72OUTRIGGER

CR70TURNTABLE

ROTATE

CR68SECONDARY

BOOM

CR67PRIMARY

BOOM

BN57TURNTABLE

ROTATE

CR78ALIFT CUT-OUT

BN58PLATFORM

LEVEL

UP/DOWN

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN36JIB

BOOM

UP/DOWN

G6HOUR

METER+

GN

PB6 DL DNDM

BK

GN

/WH

OR

OR

/BK

BL

/BK

DP

TB32

BL

8

Y11BRAKE

RELEASE

(DRIVE)

8587

8630 14

87A

TB35

CR69BOOM

EXTEND

TB30

BN93PLATFORM

ROTATE

(OPTION)

GROUNDCONTROL

BOX

RD

PA12

ES-TZ50D

REV A


Part No. 84577 Genie TZ-50/30 5 - 37



C

4

WH

2

RD

1

BK

3

WH

/BK

5

RD

/WH

8

GN

/WH

6

OR

/WH

7

BL

/WH

S10LEFT/RIGHT AXIS

LEVEL SENSOR

S9FRONT/REAR AXIS

LEVEL SENSOR

CR61AUTO LEVEL

SYSTEM RELAY


AUTO LEVEL

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

YLGN GN

RD

87A 87 85

30 86

YL

RD

4 42 23 31 1

TO A


(PLATFORM CONTROLS)

A

B

ES-TZ50D


5 - 38 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 39


REV A


5 - 40 Genie TZ-50/30 Part No. 84577


A

B


DRIVECONTROLBOX

DG

BL

DK

GN

/BK

DD

RD

/WH

WH

DJ

JC5JOYSTICK

CONTROLLER1

2

DN

OR

/BK

4

DC

WH

/BK

3

DM

OR

5

DLG

N/W

H

6

DB

BK

7

DP

BL

/BK

DA DE

P3EMERGENCY

STOP

GN

RD

/BK

DF

BK

/WH

DH

RD

BN95FUNCTION ENABLE

(BOOM UP, EXTEND,

ROTATE RIGHT

AND OUTRIGGER

RETRACT)

BN94FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN96AUTOLEVEL

ES-TZ50D

REV A


Part No. 84577 Genie TZ-50/30 5 - 41



A

PLATFORMCONTROLBOX

1 2

P2EMERGENCY

STOP

WH

GN

G7BATTERY

CHARGE

INDICATOR

F

E

3

BK

BN2ENGINE

START

BN3CHOKE

PA2

BK

/RD

PA1

BK

H1ALARM

PA3

WH

4 1 2 3

PA5

WH

/RD

PA9

OR

/RD

PA6

RD

/WH

BN61FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

TURNTABLE AND

PLATFORM ROTATE

LEFT)

PA7

BL

BN62FUNCTION ENABLE

(BOOM UP,

BOOM EXTEND

TURNTABLE AND

PLATFORM ROTATE

RIGHT)

R22B5.6K OHM

C4BZENER

DIODE

5.1V DC

R14RESISTOR

0-10K OHM

BN66TURNTABLE

ROTATE

PA4

OR

PA8

GN

/BK

PB5

OR

/BK

CR78BLIFT CUT-OUT

8587

8630 2

87A

8587

8630 3

87A

CR71PLATFORM

LEVEL

Y19PLATFORM

LEVEL

DOWN

Y20PLATFORM

LEVEL

UP

1

8587

8630 4

87A

CR9JIB BOOM

UP/DOWN

Y60JIB

BOOM

RETRACT

Y61JIB

BOOM

EXTEND

GN

/BK

GN

4 5

BN97JIB

BOOM

UP/DOWN

BN63PRIMARY

BOOM

UP/DOWN

BN64SECONDARY

BOOM

UP/DOWN

BN65BOOM

EXTEND/

RETRACT

8587

8630 5

87A

CR87PLATFORM

ROTATE

Y62PLATFORM

ROTATE

LEFT

Y63PLATFORM

ROTATE

RIGHT

GN

/BK

GN

6 7

PB6

GN

PB7

GN

/WH

PB4

BK

/WH

PB2

BL

/BK

PB3

RD

/BK

OR

/BK

OR

2 3

BK

RD

WH

MODELS

WITH

ENGINE

(OPTION)

PB1

WH

/BK

BN98PLATFORM

ROTATE

BN67PLATFORM

LEVEL

LS19LOAD

SENSE

N.C.

N.O.

(SWITCH SHOWN INUNLOADED POSITION)

L4ALED

PA12

RD

TB1

TB2

TB4

6A

6A

TB3

TB5TB6

TB7

TB8

BN97JIB

BOOM

UP/DOWN

PLATFORM

ROTATE

(OPTION)

TB9

R22C5.6K OHM

ES-TZ50D

REV A


5 - 42 Genie TZ-50/30 Part No. 84577

Electrical SchematicCE Models(before serial number TZ5004-182) Part 1 of 6

WH

WH

BK

WH

/RD

GN

OR

BK

/RD

BK

WH

WH

/BK

PL

AT

FO

RM

GR

OU

ND


TB3

TB2

TB1

TB7

TB5

TB6

PA2PA11PA10

PB11

RD

PB12

RD

/WH

FB

8587

8630 4

87A

8587

8630 5

87A8587

8630 3

87A

8587

8630 2

87A

8587

8630 1

87A8587

8630 17

87A8587

8630 15

87A

PB10

BK

/RD

+

8587

8630 16

87A

TB35

H5ALARM

U6MOTOR

CONTROLLER

B+

3

T2

B- 1

A1

S2

M5

0-5V DC

KEY

M5MOTOR

F6275A

FUSE

A

N.O.

S7LEVEL

SENSOR

C F

C A

RD

WH

GN/WH

BK

B

GN

BK

BK

PA1

TO

+ - LOAD

A


(PLATFORM CONTROLS)

FB1FLASHING BEACON

(OPTION)

U16BTIME DELAY

L4LED

BN90CHOKE

BN68ENGINE

START

CR64FAULT

GROUND

CR65AU6 CUTOUT

CR65BU6 CUTOUT

CR76LIMIT SWITCH

FAULT

CR75LEVEL SENSOR

D1ALTERNATOR

Q7CHOKE

SOLENOID

F950 AMP

PR5POWER

RELAY

CR15STARTING AID

CR1ENGINE START

CR8IGNITION

KS1KEY

SWITCH

P1EMERGENCY

STOP

CB215 AMP

GROUNDCONTROLBOX



THE POWER OFF

E

RD

CB115 AMP

MODELSWITH

ENGINE(OPTION)

RD

B D PB8

WH

BK

+

-

-

+

+

-

-

+

BK

PB9

M3

G

U26IGNITION

M3STARTER

MOTOR

F9A50 AMP

B54-6V

BATTERY

U9BATTERY CHARGER

AC

INPUT

(10 TO 30 SECONDS)

ES-TZ50A

REV A


Part No. 84577 Genie TZ-50/30 5 - 43

Electrical SchematicCE Models


GN

/BK

BL

GN

/WH

BL

/WH

OR

/WH

RD

/WH

GN

/WH

WH

/BK

OR

/RD

BL

/WH

OR

/WH

RD

/WH

RD

WH

GN

/BK

RD

/BK

PA7 PA8

5 6 7 8J

PA9PA6 DJDH DKDEDD

TB4

TB8

TB9

TB10

TB11

TB13

TB

12

TB20 TB21 TB23 TB24

TB28


BL

DG

BK

/WH

DF

TB32

TB16

TB14

RD

WH

2 4

TB17

TB18

8587

8630 6

87A

8587

8630 7

87A8587

8630 18

87A

WH

/BK

3

+

-

LO

AD

TB35

BL

H

RD

/WH

LS18BOOM DOWN

N.C.H.O.

N.C.H.O.

N.O.H.C.

N.O.H.C.

CD11CD9CD10

LS18ABOOM DOWN

A

B

TO A

TO B

TO C(AUTO-LEVEL)

(DRIVE CONTROLS)

(PLATFORM CONTROLS)

BN52LEFT

FRONT

OUTRIGGER

BN53RIGHT

FRONT

OUTRIGGER

BN50LEFT

REAR

OUTRIGGER

BN51RIGHT

REAR

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

CR77DOWN

ENABLE

CR86SEQUENCING

TB22

CR28POWER SUPPLY

U16ATIME DELAY

BK

1

BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE

(BOOM UP, EXTEND,

ROTATE RIGHT

AND OUTRIGGER

RETRACT)

BN49AUTO LEVEL

R221000 OHM

C4ZENER

DIODE

5.1V DC

C4AZENER

DIODE

3.3V DC


Y36RIGHT FRONT

OUTRIGGER

Y35LEFT FRONT

OUTRIGGER

Y33LEFT REAR

OUTRIGGER

Y34RIGHT REAR

OUTRIGGER

N.C.H.O.

LS13RIGHT FRONT

OUTRIGGER

LS12LEFT FRONT

OUTRIGGER

LS14LEFT REAR

OUTRIGGER

LS15RIGHT REAR

OUTRIGGER

OUTRIGGERS SHOWN IN

STOWED POSITION

GROUNDCONTROL

BOX



THE POWER OFFRD

/WH

(AUTO-LEVEL)

C54700uF

TB15

RD

WH

/BK

WH

(0.1 TO 10 SECONDS)

ES-TZ50A


5 - 44 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 45


REV A


5 - 46 Genie TZ-50/30 Part No. 84577


Y23ROTATE

LEFT

Y21PRIMARY

DOWN

Y52SECONDARY

DOWN

Y25BOOM

RETRACT

Y24ROTATE

RIGHT

Y22PRIMARY

UP

Y53SECONDARY

UP

Y26BOOM

EXTEND

Y40OUTRIGGER

EXTEND

Y39OUTRIGGER

RETRACT

TO A


(PLATFORM CONTROLS)

TO C(AUTO-LEVEL)

A

B

C

RD

/BK

BL

/BK

WH

/BK

OR

/BK

BK

/WH

GN

/WH


TB25 TB26 TB27 TB29

TB28

TB33TB31

TB34

8587

8630 8

87A 8587

8630 9

87A

8587

8630 14

87A8587

8630 13

87A8587

8630 12

87A8587

8630 11

87A8587

8630 10

87A

WH

/BK

BL

/BK

RD

/BK

BK

/WH

WH

BL

RD

BK

GN

GN

/BK

BRN

OR

/BK

OR

WH

WH

K L M N P R S T U V W 531 72

TB35

Y50DRIVE

FWD/REV

LEFT

Y50ADRIVE

FWD/REV

RIGHT

Y58PROPORTIONAL

DRIVE

RIGHT

Y59

LEFT

PROPORTIONAL

DRIVE



THE POWER OFF

TB34A

CR72OUTRIGGER

CR70TURNTABLE

ROTATE

CR68SECONDARY

BOOM

CR67PRIMARY

BOOM

CR69BOOM

EXTEND

BN57TURNTABLE

ROTATE

CR78ALIFT CUT-OUT

CR73FUNCTION

ENABLE

BN58PLATFORM

LEVEL

UP/DOWN

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN36JIB

BOOM

UP/DOWN

G6HOUR

METER+

GN

PB6 DL DNDM

BK

GN

/WH

OR

OR

/BK

BL

/BK

DP

TB32

BL

8

Y11BRAKE

RELEASE

(DRIVE)

TB30

BN93PLATFORM

ROTATE

(OPTION)

GROUNDCONTROL

BOX

ES-TZ50A

REV A


Part No. 84577 Genie TZ-50/30 5 - 47



C

4

WH

2

RD

1

BK

3

WH

/BK

5

RD

/WH

8

GN

/WH

6

OR

/WH

7

BL

/WH

S10LEFT/RIGHT AXIS

LEVEL SENSOR

S9FRONT/REAR AXIS

LEVEL SENSOR

CR61AUTO LEVEL

SYSTEM RELAY


AUTO LEVEL

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

YLGN GN

RD

87A 87 85

30 86

YL

RD

4 42 23 31 1

TO A


(PLATFORM CONTROLS)

A

B

ES-TZ50A


5 - 48 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 49


REV A


5 - 50 Genie TZ-50/30 Part No. 84577


A

B


DRIVECONTROLBOX

DG

BL

DK

GN

/BK

DD

RD

/WH

WH

DJ

JC5JOYSTICK

CONTROLLER1

2

DN

OR

/BK

4

DC

WH

/BK

3

DM

OR

5

DL

GN

/WH

6

DB

BK

7

DPB

L/B

KDA DE

P3EMERGENCY

STOP

GN

RD

/BK

DF

BK

/WH

DH

RD

ES-TZ50A

REV A


Part No. 84577 Genie TZ-50/30 5 - 51



A

PLATFORMCONTROLBOX

1 2

P2EMERGENCY

STOP

WH

GN

G7BATTERY

CHARGE

INDICATOR

F

E

3

BK

BN2ENGINE

START

BN3CHOKE

PA2

BK

/RD

PA1

BK

H1ALARM

PA3

WH

4 1 2 3

LS19LOAD

SENSE

N.C.

N.O.


PA5

WH

/RD

PA9

OR

/RD

PA6

RD

/WH

BN61FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

TURNTABLE AND

PLATFORM ROTATE

LEFT)

PA7

BL

BN62FUNCTION ENABLE

(BOOM UP,

BOOM EXTEND

TURNTABLE AND

PLATFORM ROTATE

RIGHT)

8587

8630 1

87A

CR74FUNCTION

ENABLE

R22B5.6K OHM

C4BZENER

DIODE

5.1V DC

R14RESISTOR

0-10K OHM

BN66TURNTABLE

ROTATE

PA4

OR

PA8

GN

/BK

PB5

OR

/BK

CR78BLIFT CUT-OUT

8587

8630 2

87A

8587

8630 3

87A

CR71PLATFORM

LEVEL

Y19PLATFORM

LEVEL

DOWN

Y20PLATFORM

LEVEL

UP

1

8587

8630 4

87A

CR9JIB BOOM

UP/DOWN

Y60JIB

BOOM

RETRACT

Y61JIB

BOOM

EXTEND

GN

/BK

GN

4 5

BN97JIB

BOOM

UP/DOWN

BN63PRIMARY

BOOM

UP/DOWN

BN64SECONDARY

BOOM

UP/DOWN

BN65BOOM

EXTEND/

RETRACT

8587

8630 5

87A

CR87PLATFORM

ROTATE

Y62PLATFORM

ROTATE

LEFT

Y63PLATFORM

ROTATE

RIGHT

GN

/BK

GN

6 7

PB6

GN

PB7

GN

/WH

PB4

BK

/WH

PB2

BL

/BK

PB3

RD

/BK

OR

/BK

OR

2 3

BK

RD

WH

L4ALED

MODELS

WITH

ENGINE

(OPTION)

PB1

WH

/BK

BN98PLATFORM

ROTATE

PLATFORM

ROTATE(OPTION)

ES-TZ50A

REV A


5 - 52 Genie TZ-50/30 Part No. 84577

Electrical SchematicCE Models(after serial number TZ5004-181) Part 1 of 6

WH

WH

BK

WH

/RD

GN

OR

LE

VE

LS

EN

SO

RR

EL

AY

BK

/RD

BK

WH

WH

/BK

PL

AT

FO

RM

GR

OU

ND


TB3

TB2

TB1

TB7

TB5

PA2PA11PA10

PB11

RD

PB12

RD

/WH

FB

8587

8630 4

87A

8587

8630 5

87A8587

8630 3

87A

8587

8630 2

87A

8587

8630 1

87A8587

8630 17

87A8587

8630 15

87A

PB10

BK

/RD

+

8587

8630 16

87A

TB35

H5ALARM

U6MOTOR

CONTROLLER

B+

3

T2

B-

1

A1

S2

M5

0-5V DC

KEY

M5MOTOR

F6275A

FUSE

A

N.O.

S7LEVEL

SENSOR

C F

C A

RD

WH

GN/WH

BK

B

GN

BK

BK

PA1

TO

+- LOAD

A


(PLATFORM CONTROLS)

FB1FLASHING BEACON

(OPTION)

U16BTIME DELAY

(10 TO 30 SECONDS)

L4LED

BN90CHOKE

BN68ENGINE

START

CR64FAULT

GROUND

CR65AU6 CUTOUT

CR65BU6 CUTOUT

CR76LIMIT SWITCH

FAULT

CR75LEVEL SENSOR

D1ALTERNATOR

Q7CHOKE

SOLENOID

F950 AMP

PR5POWER

RELAY

CR15STARTING AID

CR1ENGINE START

CR8IGNITION

KS1KEY

SWITCH

P1EMERGENCY

STOP

CB215 AMP

GROUNDCONTROLBOX



THE POWER OFF

E

RD

CB115 AMP

MODELSWITH

ENGINE(OPTION)

RD

B D PB8

WH

BK

+

-

-

+

+

-

-

+

BK

PB9

M3

G

U26IGNITION

M3STARTER

MOTOR

F9A50 AMP

B54-6V

BATTERY

U9BATTERY CHARGER

AC

INPUT

ES-TZ50D

REV A


Part No. 84577 Genie TZ-50/30 5 - 53



GN

/BK

BL

GN

/WH

BL

/WH

OR

/WH

RD

/WH

GN

/WH

WH

/BK

OR

/RD

BL

/WH

OR

/WH

RD

/WH

RD

WH

GN

/BK

RD

/BK

PA7 PA8

5 6 7 8J

PA9PA6 DJDH DKDEDD

TB4

TB8

TB9 TB10

TB11

TB13

TB12

TB20 TB21 TB23 TB24

TB28


BL

DG

BK

/WH

DF

TB32

TB16

TB14

RD

WH

2 4

TB17

TB18

8587

8630 6

87A

8587

8630 7

87A8587

8630 18

87A

WH

/BK

3

+

-

LO

AD

TB35

BL

H

RD

/WH

LS18BOOM DOWN

N.C.H.O.

N.C.H.O.

N.O.H.C.

N.O.H.C.

CD11CD9CD10

LS18ABOOM DOWN

A

B

TO A

TO B

TO C(AUTO-LEVEL)

(DRIVE CONTROLS)

(PLATFORM CONTROLS)

BN52LEFT

FRONT

OUTRIGGER

BN53RIGHT

FRONT

OUTRIGGER

BN50LEFT

REAR

OUTRIGGER

BN51RIGHT

REAR

OUTRIGGER

L15RR LED

L14LR LED

L13RF LED

L12LF LED

CR77DOWN

ENABLE

CR86SEQUENCING

TB22

CR28POWER SUPPLY

BK

1

BN59FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

ROTATE LEFT

AND OUTRIGGER

EXTEND)

BN60FUNCTION ENABLE

(BOOM UP, EXTEND,

ROTATE RIGHT

AND OUTRIGGER

RETRACT)

BN49AUTO LEVEL

R221000 OHM

C4ZENER

DIODE

5.1V DC

C4AZENER

DIODE

3.3V DC


Y36RIGHT FRONT

OUTRIGGER

Y35LEFT FRONT

OUTRIGGER

Y33LEFT REAR

OUTRIGGER

Y34RIGHT REAR

OUTRIGGER

N.C.H.O.

LS13RIGHT FRONT

OUTRIGGER

LS12LEFT FRONT

OUTRIGGER

LS14LEFT REAR

OUTRIGGER

LS15RIGHT REAR

OUTRIGGER

OUTRIGGERS SHOWN IN

STOWED POSITION

GROUNDCONTROL

BOX



THE POWER OFFRD

/WH

(AUTO-LEVEL)

C54700uF

TB15

RD

WH

/BK

WH

6A6A

6A6A

U16ATIME DELAY(0.1 TO 10 SECONDS)

TB4A

ES-TZ50D


5 - 54 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 55


REV A


5 - 56 Genie TZ-50/30 Part No. 84577


Y23ROTATE

LEFT

Y21PRIMARY

DOWN

Y52SECONDARY

DOWN

Y25BOOM

RETRACT

Y24ROTATE

RIGHT

Y22PRIMARY

UP

Y53SECONDARY

UP

Y26BOOM

EXTEND

Y40OUTRIGGER

EXTEND

Y39OUTRIGGER

RETRACT

TO A


(PLATFORM CONTROLS)

TO C(AUTO-LEVEL)

A

B

C

RD

/BK

BL

/BK

WH

/BK

OR

/BK

BK

/WH

GN

/WH


TB25 TB26 TB27 TB29

TB28

TB33TB31

TB34

8587

8630 9

87A

8587

8630 13

87A8587

8630 12

87A8587

8630 11

87A8587

8630 10

87A

WH

/BK

BL

/BK

RD

/BK

BK

/WH

WH

BL

RD

BK

GN

GN

/BK

BRN

OR

/BK

OR

WH

WH

K L M N P R S T U V W 531 72

Y50DRIVE

FWD/REV

LEFT

Y50ADRIVE

FWD/REV

RIGHT

Y58PROPORTIONAL

DRIVE

RIGHT

Y59

LEFT

PROPORTIONAL

DRIVE



THE POWER OFF

TB34A

CR72OUTRIGGER

CR70TURNTABLE

ROTATE

CR68SECONDARY

BOOM

CR67PRIMARY

BOOM

BN57TURNTABLE

ROTATE

CR78ALIFT CUT-OUT

BN58PLATFORM

LEVEL

UP/DOWN

BN55SECONDARY

BOOM

UP/DOWN

BN54PRIMARY

BOOM

UP/DOWN

BN56BOOM

EXTEND/RETRACT

BN36JIB

BOOM

UP/DOWN

G6HOUR

METER+

GN

PB6 DL DNDM

BK

GN

/WH

OR

OR

/BK

BL

/BK

DP

TB32

BL

8

Y11BRAKE

RELEASE

(DRIVE)

8587

8630 14

87A

TB35

CR69BOOM

EXTEND

TB30

BN93PLATFORM

ROTATE

(OPTION)

GROUNDCONTROL

BOX

RD

PA12

ES-TZ50D

REV A


Part No. 84577 Genie TZ-50/30 5 - 57



C

4

WH

2

RD

1

BK

3

WH

/BK

5

RD

/WH

8

GN

/WH

6

OR

/WH

7

BL

/WH

S10LEFT/RIGHT AXIS

LEVEL SENSOR

S9FRONT/REAR AXIS

LEVEL SENSOR

CR61AUTO LEVEL

SYSTEM RELAY


AUTO LEVEL

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

87A 87 85

30 86

YLGN GN

RD

87A 87 85

30 86

YL

RD

4 42 23 31 1

TO A


(PLATFORM CONTROLS)

A

B

ES-TZ50D


5 - 58 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 59


REV A


5 - 60 Genie TZ-50/30 Part No. 84577


A

B


DRIVECONTROLBOX

DG

BL

DK

GN

/BK

DD

RD

/WH

WH

DJ

JC5JOYSTICK

CONTROLLER1

2

DN

OR

/BK

4

DC

WH

/BK

3

DM

OR

5

DLG

N/W

H

6

DB

BK

7

DP

BL

/BK

DA DE

P3EMERGENCY

STOP

GN

RD

/BK

DF

BK

/WH

DH

RD

ES-TZ50D

REV A


Part No. 84577 Genie TZ-50/30 5 - 61



A

PLATFORMCONTROLBOX

1 2

P2EMERGENCY

STOP

WH

GN

G7BATTERY

CHARGE

INDICATOR

F

E

3

BK

BN2ENGINE

START

BN3CHOKE

PA2

BK

/RD

PA1

BK

H1ALARM

PA3

WH

4 1 2 3

PA5

WH

/RD

PA9

OR

/RD

PA6

RD

/WH

BN61FUNCTION ENABLE

(BOOM DOWN,

BOOM RETRACT,

TURNTABLE AND

PLATFORM ROTATE

LEFT)

PA7

BL

BN62FUNCTION ENABLE

(BOOM UP,

BOOM EXTEND

TURNTABLE AND

PLATFORM ROTATE

RIGHT)

R22B5.6K OHM

C4BZENER

DIODE

5.1V DC

R14RESISTOR

0-10K OHM

BN66TURNTABLE

ROTATE

PA4

OR

PA8

GN

/BK

PB5

OR

/BK

CR78BLIFT CUT-OUT

8587

8630 2

87A

8587

8630 3

87A

CR71PLATFORM

LEVEL

Y19PLATFORM

LEVEL

DOWN

Y20PLATFORM

LEVEL

UP

1

8587

8630 4

87A

CR9JIB BOOM

UP/DOWN

Y60JIB

BOOM

RETRACT

Y61JIB

BOOM

EXTEND

GN

/BK

GN

4 5

BN97JIB

BOOM

UP/DOWN

BN63PRIMARY

BOOM

UP/DOWN

BN64SECONDARY

BOOM

UP/DOWN

BN65BOOM

EXTEND/

RETRACT

8587

8630 5

87A

CR87PLATFORM

ROTATE

Y62PLATFORM

ROTATE

LEFT

Y63PLATFORM

ROTATE

RIGHT

GN

/BK

GN

6 7

PB6

GN

PB7

GN

/WH

PB4

BK

/WH

PB2

BL

/BK

PB3

RD

/BK

OR

/BK

OR

2 3

BK

RD

WH

MODELS

WITH

ENGINE

(OPTION)

PB1

WH

/BK

BN98PLATFORM

ROTATE

BN67PLATFORM

LEVEL

LS19LOAD

SENSE

N.C.

N.O.


L4ALED

PA12

RD

TB1

TB2

TB4

6A

6A

TB3

TB5TB6

TB7

TB8

BN97JIB

BOOM

UP/DOWN

PLATFORM

ROTATE

(OPTION)

TB9

R22C5.6K OHM

ES-TZ50D

REV A


5 - 62 Genie TZ-50/30 Part No. 84577

Hydraulic Component Reference

Jib Manifold(models with platform rotate)

AA

AB

AC

AE

AG

AHA I

AK

AD

AF

AJ

AA

AB

AC

AE

AH

A I

AKAF

AJ

Jib Manifold(models without platform rotate)

Function Manifold

Drive Manifold

BA

C

D

E

F

H

I

J

K

L

M

O

P

R

Q

G

N

Brake Release Manifold

BA

BB

BC

BE

BD

BF

BG

BJ

BK

BL

BN

BO

B I

BM

BH

B I

Before Serial Number TZ5004-152

AfterSerial Number

TZ5004-151

REV A


Part No. 84577 Genie TZ-50/30 5 - 63

Hydraulic Symbols and Abbreviation Legend

0.090 inch2.3 mm

M

Y52Y53Y39Y40

Y26

Filter

Check valve

Motor

Brake release

Pilot operated2 position 2 waydirectional valvenormally open

Solenoid operated2 position 4 waydirectional valve

Double actingcylinder

Shuttlevalve

Adjustablerelief valve

Orifice with size

Fixed displacementpump

Fixed displacementhand pump

Pilot operated2 position 2 way

pressure compensatornormally closed

Solenoid operated2 position 2 waydirectional valvenormally closed

Counterbalance valve


Check valve,pilot to open

Variable speed motor

Brake


Solenoid operated2 position 3 way

directional valve withmanual override


proportional valvenormally closed


directional valve withmanual override

ABBREVIATION LEGEND Item Description

A Auxiliary pump B Relief valve – turntable rotate C Pilot operated relief valve D Shuttle valve – turntable rotate E Orifice – turntable speed F Secondary boom down (with override) G Primary boom down (with override) H Relief valve – primary boom I Primary boom up (with override) J Boom extend/retract (with override) K System relief L Outrigger counterbalance M Outrigger extend/retract N Check valve – outrigger circuit O Secondary boom up P Orifice –

primary/secondary boom down speed Q Turntable rotate left/right (with override)

AA Jib boom extend AB Jib boom retract AC Relief valve – platform level circuit AD Platform rotate left/right (option) AE Platform level up/down AF Platform level counterbalance AG Pilot operated relief valve AH Orifice – platform rotate speed AI Orifice – jib boom up speed AJ Orifice –

jib boom down and platform level speed AK Shuttle valve – platform level circuit

BA Pilot operated directional valve – left BB Orifice – drive speed BC Pilot operated pressure compensator BD Orifice – drive speed BE Counterbalance valve BF Pilot operated pressure compensator BG Counterbalance valve BH Shuttle valve BI Brake Dump BJ Pilot operated directional valve – right BK Proportional valve – right BL Drive forward/reverse – right BM Check valve – drive circuit BN Drive forward/reverse – left BO Proportional valve – left

CA Outrigger – left rear CB Outrigger – right rear CC Outrigger – left front CD Outrigger – right front CE Parking brake release (drive option)

REV A


5 - 64 Genie TZ-50/30 Part No. 84577

Hydraulic SchematicPart 1 of 4

DRIVE

MANIFOLD

CE

B

BC

D1 D2 D3 D4

M2.8 gpm

10.6 L/min

0.090 inch2.3 mm

BRAKE

RELEASE

RIGHT

DRIVE MOTOR

HYDRAULIC

POWER UNIT

LEFT

DRIVE MOTOR

HYDRAULIC TANK

MODELS

WITHOUT

DRIVE

(OPTION)

MODELS WITH DRIVE (OPTION)

BD

BM

BB

BF

BN

BE

BHBL

3000 psi

207 bar

10:1

3000 psi

207 bar

10:1

0.090 inch2.3 mm

80 psi

5.5 bar

Y50

BI

Y11

Y50A

BA10 psi

0.7 bar

BOY59

10 psi

0.7 bar

BKY58

80 psi

5.5 bar

BJ

BG

2.8 gpm

10.6 L/min

HSTZ50DCC

REV A


Part No. 84577 Genie TZ-50/30 5 - 65


0.037 inch

0.94 mm

RR

RR

EE

EE

G1

RIGHT FRONTOUTRIGGER

CYLINDER

LEFT FRONTOUTRIGGERCYLINDER

RIGHTOUTRIGGER

CYLINDER

REARLEFT REAROUTRIGGERCYLINDER

Y33

Y35

Y34

Y36

A2A1 B1

Y39Y40

B2

3000 psi

207 bar

FUNCTION

MANIFOLD

EXTENSION

CYLINDER

1000 psi

69 bar

3:1

Y25Y26

0.090 inch

2.3 mm

PE PR

T1

P1

HYDRAULIC TANK

MODELS

WITHOUT

DRIVE

(OPTION)

K

L A

N

O

M

3000 psi

207 bar

3:1

CC CD

CA CB

0.037 inch

0.94 mm

0.037 inch

0.94 mm

0.037 inch

0.94 mm

G

HSTZ50DCC


5 - 66 Genie TZ-50/30 Part No. 84577



Part No. 84577 Genie TZ-50/30 5 - 67


REV A


5 - 68 Genie TZ-50/30 Part No. 84577


FUNCTION

MANIFOLD

SECONDARY BOOM

LIFT CYLINDER

3000 psi

207 bar

1.5:1

Y53

Y52

PRIMARY BOOM

LIFT CYLINDER

3000 psi

207 bar

1.5:1

Y21

1600 psi

110 bar

Y22

600 psi

41 bar

Y23Y24

TURNTABLE

ROTATE

PJ

TJ

PU RL RRPD LSSU SD

DBI

J

F

H

P

C

R

80 psi

5.5 bar

0.040 inch

1 mmE0.080 inch

2 mmQ

HSTZ50DCC

REV A


Part No. 84577 Genie TZ-50/30 5 - 69


JIB

MANIFOLD

P

T

Y61

Y60

JIB

BOOM

3000 psi

207 bar

3:1

3000 psi / 207 bar

4.5:1

(before serial number TZ5004-219)

3000 psi / 207 bar

3:1


PLATFORM

LEVEL

MASTER

CYLINDER

SLAVE

CYLINDER

Y19Y20

3000 psi

207 bar

4.5:1

PLATFORM

ROTATE

(OPTION)

Y62Y63

JU JD PLU PLD PRL PRR

3000 psi

207 bar

MODELS WITH

PLATFORM ROTATE

(OPTION)

MODELS WITHOUT

PLATFORM ROTATE

MODELS WITH

PLATFORM ROTATE

AB

AC

ADAE

AF

80 psi

5.5 bar

AG

AH0.055 inch

1.4 mm

AI

0.040 inch

1 mm

AJ

AK

AA

0.040 inch

1 mm

135 psi / 9.3 bar

3:1

HSTZ50DCC

AUSTRALIAMODELS

ONLY


5 - 70 Genie TZ-50/30 Part No. 84577


Dis

trib

ute

d B

y:

California Proposition 65

WARNINGThe exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Genie North America

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Brasil

Genie Holland

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Phone +86 21 53852570

Fax +86 21 53852569

Phone +65 98 480 775

Fax +65 67 533 544

Phone +81 3 3453 6082

Fax +81 3 3453 6083

Phone +82 25 587 267

Fax +82 25 583 910

Phone +55 11 41 665 755

Fax +55 11 41 665 754

Phone +31 183 581 102

Fax +31 183 581 566

Genie Scandinavia

Genie France

Genie Iberica

Genie Germany

Genie U.K.

Genie Mexico City

Phone +46 31 575100

Fax +

Phone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Phone +34 93 579 5042

Fax +34 93 579 5059

Phone 0800 180 9017

Fax +49 422 149 1820

Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Phone +52 55 5666 5242

Fax +52 55 5666 3241

46 31 579020

Phone +49 422 149 1818

Documents

Manual Servicio Tz 50