Genie TZ-50 Bedienungsanleitung

Service Manual

TZ-50

Part No. 824982

Rev A1

September 2014

Serial Number Range

from TZ5012-254

Genie TZ-50 Part No. 824982

September 2014

Introduction

824982 Rev A June 2013

Second Edition, First Printing

"Genie" and "TZ" are registered trademarks of

Terex South Dakota, Inc. in the USA and many

other countries.

Printed on recycled paper

Printed in U.S.A.

INTRODUCTION

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate operator's

manual on your machine before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting fault

codes and repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer service

center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

http://www.genielift.com

e-mail: [email protected]

Part No. 824982 Genie TZ-50

September 2014

Revision History

iii

Revision Date Section Procedure / Schematic Page / Description

A 6/2013 New release

A1 9/2014 5 - Schem 5-34

REFERENCE EXAMPLES:

Honda Engine_Section 2_Specifications.

A-6,B-3,C-7_Section 3_Maintenance Procedure.

3-2, 6-4, 9-1_Section 4_Repair Procedure.

5-35, 5-56, 5-104_Section 5_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

Genie TZ-50 Part No. 824982

September 2014

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

Honda Engine_Section 2_Specifications.

A-6,B-3,C-7_Section 3_Maintenance Procedure.

3-2, 6-4, 9-1_Section 4_Repair Procedure.

5-35, 5-56, 5-104_Section 5_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

Part No. 824982 Genie TZ-50

September 2014

Serial Number Legend

INTRODUCTION

Genie TZ-50 Part No. 824982

September 2014

Safety Rules

Section 1 • Safety Rules

Danger

Failure to obey the instructions and safety rules in

this manual and the appropriate Operator's Manual

on your machine will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates an imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

Part No. 824982 Genie TZ-50

September 2014

SAFETY RULES

vii

Section 1 • Safety Rules

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an approved fire

extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

Genie TZ-50 Part No. 824982

September 2014

Table of Contents

viii

Introduction

Important Information......................................................................................................

Revision History.............................................................................................................

iii

Serial Number Legend ...................................................................................................

Section 1 Safety Rules

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

Section 2 Specifications

Machine Specifications ............................................................................................. 2 - 1

Performance Specifications ...................................................................................... 2 - 2

Hydraulic Specifications............................................................................................ 2 - 2

Manifold Component Specifications .......................................................................... 2 - 3

Machine Torque Specifications ................................................................................. 2 - 4

Honda GX160K1 Engine Specifications ................................................................... 2 - 5

Hydraulic Hose and Fitting Torque Specifications ..................................................... 2 - 6

SAE and Metric Fastener Torque Chart .................................................................... 2 - 8

Section 3 Scheduled Maintenance Procedures

Introduction ............................................................................................................... 3 - 1

Pre-delivery Preparation Report ............................................................................... 3 - 3

Maintenance Inspection Report ................................................................................ 3 - 5

Checklist A Procedures

A-1 Inspect the Manuals and Decals ..................................................................... 3 - 6

A-2 Perform Pre-operation Inspection ................................................................... 3 - 7

A-3 Perform Function Tests ................................................................................... 3 - 7

A-4 Perform Engine Maintenance (if equipped) ..................................................... 3 - 7

Part No. 824982 Genie TZ-50

September 2014

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

A-5 Torque the Lug Bolts - Electric and Hydraulic Axles ....................................... 3 - 8

A-6 Torque the Lug Bolts - Mechanical Axle .......................................................... 3 - 8

A-7 Perform Hitch Maintenance - Hydraulic Axle ................................................... 3 - 9

A-8 Perform Engine Maintenance (if equipped) ..................................................... 3 - 9

A-9 Perform 30 Day Service ................................................................................ 3 - 10

A-10 Perform Engine Maintenance (if equipped) ................................................... 3 - 10

A-11 Grease the Turntable Rotation Bearing and Rotate Gear.............................. 3 - 11

A-12 Perform Engine Maintenance (if equipped) ................................................... 3 - 11

Checklist B Procedures

B-1 Inspect the Batteries ..................................................................................... 3 - 12

B-2 Inspect the Electrical Wiring .......................................................................... 3 - 13

B-3 Test the Electrical Contactor ......................................................................... 3 - 14

B-4 Test the Manual Override.............................................................................. 3 - 14

B-5 Perform Hydraulic Oil Analysis...................................................................... 3 - 16

B-6 Perform Axle Maintenance - Electric and Hydraulic Axles............................. 3 - 17

B-7 Service the Tongue Jack .............................................................................. 3 - 17

B-8 Inspect the Parking Brake ............................................................................. 3 - 18

B-9 Check the Wheel Bearings - Mechanical Axle............................................... 3 - 20

B-10 Service the Hitch - Mechanical Axle .............................................................. 3 - 20

B-11 Perform Axle Maintenance - Mechanical Axle ............................................... 3 - 21

B-12 Perform Engine Maintenance (if equipped) ................................................... 3 - 22

Genie TZ-50 Part No. 824982

September 2014

TABLE OF CONTENTS

Section 3 Scheduled Maintenance Procedures, continued

Checklist C Procedures

C-1 Grease the Platform Overload Mechanism (if equipped) ............................... 3 - 23

C-2 Test the Platform Overload System (if equipped) .......................................... 3 - 23

C-3 Perform Axle Maintenance - Electric and Hydraulic Axles............................. 3 - 24

C-4 Replace the Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil ................................................................ 3 - 25

C-5 Grease the Axle Wheel Bearings - Mechanical Axle ..................................... 3 - 25

C-6 Adjust the Brakes - Mechanical Axle ............................................................. 3 - 26

Checklist D Procedures

D-1 Perform Axle Maintenance - Electric and Hydraulic Axles............................. 3 - 28

D-2 Check the Boom Wear Pads ......................................................................... 3 - 28

D-3 Replace the Hydraulic Tank Return Filter...................................................... 3 - 29

D-4 Check the Turntable Rotation Bearing Bolts ................................................. 3 - 30

D-5 Inspect for Turntable Bearing Wear .............................................................. 3 - 31

Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil.................................................................. 3 - 32

E-2 Perform Engine Maintenance (if equipped) ................................................... 3 - 33

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