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Genie TZ-50 Service Manual 84577 – PDF DOWNLOAD
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Description
Genie TZ-50 Service Manual 84577 – PDF DOWNLOAD
Language : English
Pages : 253
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie TZ-50 Service Manual 84577 – PDF DOWNLOAD
Front Cover.................................................................................... 1 Introduction................................................................................... 2 Revision History............................................................................... 3 Serial Number Legend........................................................................... 5 Safety Rules................................................................................... 6 Table of Contents ............................................................................. 8 Specifications ................................................................................ 17 Machine Specifications .................................................................... 17 Performance Specifications ................................................................ 18 Hydraulic Specifications .................................................................. 18 Manifold Component Specifications ......................................................... 19 Machine Torque Specifications ............................................................. 20 Honda GX160K1 Engine Specifications ....................................................... 21 Hydraulic Hose and Fitting Torque Specifications .......................................... 22 SAE and Metric Fastener Torque Chart....................................................... 24 Scheduled Maintenance Procedures .............................................................. 25 Pre-delivery Preparation................................................................... 27 Maintenance Inspection Report.............................................................. 29 Checklist A Procedures .................................................................... 30 A-1 Inspect the Manuals and Decals..................................................... 30 A-2 Perform Pre-operation Inspection................................................... 31 A-3 Perform Function Tests............................................................. 31 A-4 Perform Engine Maintenance (if equipped)........................................... 31 A-5 Torque the Lug Bolts .............................................................. 32 A-6 Perform Hitch Maintenance ......................................................... 32 A-7 Perform Engine Maintenance (if equipped) .......................................... 33 A-8 Perform Axle Maintenance .......................................................... 33 A-9 Perform 30 Day Service ............................................................ 34 A-10 Perform Engine Maintenance (if equipped) ......................................... 34 A-11 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 35 A-12 Perform Engine Maintenance (if equipped) ......................................... 35 Checklist B Procedures .................................................................... 36 B-1 Inspect the Batteries.............................................................. 36 B-2 Inspect the Electrical Wiring...................................................... 37 B-3 Inspect the Electrical Contactor .................................................. 38 B-4 Test the Emergency Stop........................................................... 38 B-5 Test the Key Switch............................................................... 39 B-6 Test the Manual Override.......................................................... 39 B-7 Perform Hydraulic Oil Analysis.................................................... 41 B-8 Perform Axle Maintenance ......................................................... 42 B-9 Service the Tongue Jack............................................................ 42 B-10 Inspect the Parking Brake......................................................... 43 B-11 Check the Wheel Bearings ......................................................... 48 B-12 Service the Hitch ................................................................ 49 B-13 Check the Brakes ................................................................. 50 B-14 Perform Engine Maintenance (if equipped).......................................... 50 Checklist C Procedures .................................................................... 51 C-1 Grease the Platform Overload Mechanism (if equipped) ............................. 51 C-2 Test the Platform Overload System (if equipped)................................... 51 C-3 Perform Axle Maintenance ......................................................... 52 C-4 Replace Hydraulic Tank Breather Cap ............................................. 53 C-5 Grease the Axle Wheel Bearings ................................................... 53 C-6 Adjust the Brakes................................................................ 54 Checklist D Procedures .................................................................... 56 D-1 Perform Axle Maintenance ......................................................... 56 D-2 Check the Boom Wear Pads.......................................................... 56 D-3 Replace the Hydraulic Tank Return Filter........................................... 57 D-4 Check the Turntable Rotation Bearing Bolts......................................... 58 D-5 Inspect for Turntable Bearing Wear .............................................. 59 Checklist E Procedures .................................................................... 60 E-1 Test or Replace the Hydraulic Oil................................................. 60 E-2 Perform Engine Maintenance (if equipped).......................................... 61 Repair Procedures ............................................................................. 63 Platform Components ....................................................................... 64 1-1 Platform........................................................................... 64 1-2 Platform Rotator................................................................... 64 Jib Boom Components ....................................................................... 66 2-1 Jib Boom........................................................................... 66 2-2 Jib Boom Lift Cylinder............................................................. 68 Primary Boom Components ................................................................... 70 3-1 Cable Track........................................................................ 71 3-2 Primary Boom....................................................................... 73 3-3 Primary Boom Lift Cylinder......................................................... 76 3-4 Platform Leveling Cylinders........................................................ 77 Secondary Boom Components ................................................................. 80 4-1 Secondary Boom..................................................................... 81 4-2 Secondary Boom Lift Cylinder....................................................... 83 Engine .................................................................................... 85 5-1 Fuse Replacement.................................................................. 85 Ground Controls ........................................................................... 86 6-1 Level Sensor....................................................................... 86 Hydraulic Pump ............................................................................ 90 7-1 Function Pump...................................................................... 90 Manifolds ................................................................................. 92 8-1 Function Manifold Components....................................................... 92 8-2 Jib Manifold Components............................................................ 94 8-3 Drive Manifold Components (if equipped)............................................ 96 8-4 Valve Adjustments - Function Manifold.............................................. 98 8-5 Valve Coils........................................................................100 Hydraulic Tank.............................................................................102 9-1 Hydraulic Tank.....................................................................102 Axle Components ...........................................................................103 10-1 Axle..............................................................................103 Trailer Components ........................................................................104 11-1 Hydraulic and Mechanical Brakes...................................................104 11-2 Parking Brake.....................................................................104 Outriggers.................................................................................105 12-1 Outrigger Components..............................................................105 12-2 Outrigger Cylinder................................................................106 Platform Overload Components...............................................................107 13-1 Platform Overload System..........................................................107 Drive Components ..........................................................................109 14-1 Drive Motor ......................................................................109 14-2 Drive Control Box ................................................................110 Schematics ....................................................................................113 Electrical Abbreviations Legend ..........................................................114 Wire Color Legend .........................................................................116 Limit Switch Legend .......................................................................117 Electrical Symbols Legend .................................................................118 Hydraulic Abbreviations Legend ...........................................................119 Hydraulic Symbols Legend .................................................................120 Honda GX160 Engine Wiring Diagram .........................................................121 Trailer Wiring Diagrams ...................................................................122 Trailer Lighting Wiring Diagram - ANSI / CSA ..........................................122 Trailer Lighting Wiring Diagram - Mechanical Axle, CE (to SN TZ5012-215) ..............123 Trailer Lighting Wiring Diagram - Mechanical Axle, CE (from SN TZ5012-216 )............124 Trailer Lighting Wiring Diagram - Electric Axle, AS (to SN TZ5012-252) ................125 Trailer Lighting Wiring Diagram - Electric Axle, AS (from SN TZ5012-253) ..............126 Trailer Lighting Wiring Diagram - Hydraulic Axle, AS (from SN TZ5012-216) .............127 Electrical Schematics - ANSI/CSA Markets ..................................................128 Ground Control Box Wiring Diagram - ANSI/CSA (to SN TZ5004-181) ......................128 Ground Control Box Wiring Diagram - ANSI/CSA (from SN TZ5004-182 to TZ5004-324) ......130 Ground Control Box Wiring Diagram - ANSI/CSA (from SN TZ5004-325 to TZ5005-284) ......132 Ground Control Box Wiring Diagram - ANSI/CSA (from SN TZ5005-285 to TZ5010-144) ......134 Ground Control Box Wiring Diagram - ANSI/CSA (from SN TZ5010-145 to TZ5011-131) ......136 Ground Control Box Wiring Diagram - ANSI/CSA (from SN TZ5011-132) ....................138 Platform Control Box Wiring Diagram - ANSI/CSA (to SN TZ5004-181) ....................140 Platform Control Box Wiring Diagram - ANSI/CSA (from SN TZ5004-182 to TZ5005-284) ....141 Platform Control Box Wiring Diagram - ANSI/CSA (from SN TZ5005-285 to TZ5010-144) ....142 Platform Control Box Wiring Diagram - ANSI/CSA (from SN TZ5010-145 to TZ5011-131) ....143 Platform Control Box Wiring Diagram - ANSI/CSA (from SN TZ5011-132) ..................144 Drive Control Box Wiring Diagram - ANSI/CSA (to SN TZ5004-284) .......................145 Electrical Schematic - ANSI/CSA (to SN TZ5004-181) ....................................166 Electrical Schematic - ANSI/CSA (from SN TZ5004-182 to TZ5005-210) ....................172 Electrical Schematic - ANSI/CSA (from SN TZ5005-211 to TZ5005-284) ....................178 Electrical Schematic - ANSI/CSA (from SN TZ5005-285 to TZ5010-144) ....................184 Electrical Schematic - ANSI/CSA (from SN TZ5010-145 to TZ5011-131) ....................190 Electrical Schematic - ANSI/CSA (from SN TZ5011-132 to TZ5011-310) ....................196 Electrical Schematic - ANSI/CSA (from SN TZ5011-311) ..................................202 Electrical Schematics - AS/CE Markets .....................................................146 Ground Control Box Wiring Diagram - AS/CE (to SN TZ5004-181) .........................146 Ground Control Box Wiring Diagram - AS/CE (from SN TZ5004-182 to TZ5004-324) .........148 Ground Control Box Wiring Diagram - AS/CE (from SN TZ5004-325 to TZ5005-284) .........150 Ground Control Box Wiring Diagram - AS/CE (from SN TZ5005-285 to TZ5010-144) .........152 Ground Control Box Wiring Diagram - AS/CE (from SN TZ5010-145 to TZ5011-131) .........154 Ground Control Box Wiring Diagram - AS/CE (from SN TZ5011-132) .......................156 Platform Control Box Wiring Diagram - AS/CE (to SN TZ5004-181) ........................158 Platform Control Box Wiring Diagram - AS/CE (from SN TZ5004-182 to TZ5005-284) ......159 Platform Control Box Wiring Diagram - AS/CE (from SN TZ5005-285 to TZ5010-144) ......160 Platform Control Box Wiring Diagram - AS/CE (from SN TZ5010-145 to TZ5011-131) ......161 Platform Control Box Wiring Diagram - AS/CE (from SN TZ5011-132) ....................162 Drive Control Box Wiring Diagram - AS/CE (to SN TZ5004-284) ...........................163 Electrical Schematic - AS/CE (to SN TZ5004-181) .......................................208 Electrical Schematic - AS/CE (from SN TZ5004-182 to TZ5005-210) ......................214 Electrical Schematic - AS/CE (from SN TZ5005-211 to TZ5005-284) ......................220 Electrical Schematic - AS/CE (from SN TZ5005-285 to TZ5010-144) ......................226 Electrical Schematic - AS/CE (from SN TZ5010-145 to TZ5011-131) ......................232 Electrical Schematic - AS/CE (from SN TZ5011-132 to TZ5011-310) ......................238 Electrical Schematic - AS/CE (from SN TZ5011-311) ....................................244 Hydraulic Schematic (to SN TZ5006-210) ....................................................250 Hydraulic Schematic (from SN TZ5006-211) ..................................................251 Back Cover.....................................................................................253
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