Genie TZ-34-20 Trailer Boom Lift Instruction Manual

TZ-34-20 Trailer Boom Lift

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the following is the text from the user manual / instructions:
Serial Number Range from TZ3403-001 to TZ3413-595
Part No. 84382 Rev D1 August 2022
Introduction
Introduction
August 2022
Important
Read, understand and obey the safety rules and operating instructions in the appropriate operator’s manual on your machine before attempting any maintenance or repair procedure.
This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center.
Compliance
Machine Classification Group B/Type 3 as defined by ISO 16368
Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice.
Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.
Contact Us:
http://www.genielift.com e-mail: awp.techpub@terex.com
84382 Rev D June 2013 First Edition, Fourth Printing
Genie is a registered trademarks of Terex South Dakota, Inc. in the USA and many other countries.
TZ is a trademark of Terex South Dakota, INC.
Printed on recycled paper
Printed in U.S.A.
ii
Genie TZ-34/20
Part No. 84382
August 2022
Revision History
Revision
A D
D1
Date
11/2004 6/2013
8/2022
Section
Introduction 2 – Spec.
3 – Maint.
4 – Repair 5 – Schem. 4 – Repair
Procedure / Schematic Page / Description
New release Revision History Added Hydraulic Specifications SAE and Metric Fastener Torque Chart Added specific maintenance to all axle procedures. Revised procedures. Revised procedures. Revised all schematics and grouped by market 6-2
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 #.
Part No. 84382
Genie TZ-34/20
iii
August 2022 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.
iv
Genie TZ-34/20
Part No. 84382
August 2022
Introduction
Serial Number Legend
TZ-34 11 – 299
Model: TZ-34
Serial number: TZ3411-299
Model year: 2011
Manufacture date: 03/14/11
Electrical schematic number: Position 3
Machine unladen weight: 99.999 lbs / 99.999 kg
Rated work load (including occupants): Position 4
Maximum number of platform occupants: Pos 5

Serial Number Range from TZ3403-001 to TZ3413-595
Part No. 84382 Rev D1 August 2022

Introduction
Introduction

August 2022

Important
Read, understand and obey the safety rules and operating instructions in the appropriate operator’s manual on your machine before attempting any maintenance or repair procedure.
This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes and repair procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center.
Compliance
Machine Classification Group B/Type 3 as defined by ISO 16368
Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice.
Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.
Contact Us:
http://www.genielift.com e-mail: awp.techpub@terex.com

Copyright © 2011 Terex Corporation
84382 Rev D June 2013 First Edition, Fourth Printing
Genie is a registered trademarks of Terex South Dakota, Inc. in the USA and many other countries.
“TZ” is a trademark of Terex South Dakota, INC.
Printed on recycled paper
Printed in U.S.A.

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Genie TZ-34/20

Part No. 84382

August 2022

Revision History

Revision
A D
D1

Date
11/2004 6/2013
8/2022

Section
Introduction 2 – Spec.
3 – Maint.
4 – Repair 5 – Schem. 4 – Repair

Procedure / Schematic Page / Description
New release Revision History Added Hydraulic Specifications SAE and Metric Fastener Torque Chart Added specific maintenance to all axle procedures. Revised procedures. Revised procedures. Revised all schematics and grouped by market 6-2

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 #.

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August 2022 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.

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Introduction
Serial Number Legend

TZ-34 11 – 299

Model: TZ-34

Serial number: TZ3411-299

Model year: 2011

Manufacture date: 03/14/11

Electrical schematic number: Position 3

Machine unladen weight: 99.999 lbs / 99.999 kg

Rated work load (including occupants): Position 4
Maximum number of platform occupants: Pos 5

Maximum allowable side force: Position 6

Maximum allowable inclination of the chassis: Position 7
Maximum wind speed: Position 8 Maximum platform height: Position 9 Maximum platform reach: Position 10 Power supply voltage: Position 12

Gradeability:Position 11

Control system voltage: Position 13 Nominal battery/design voltage power: Position 14 Nominal Power: Position 40

Maximum hydraulic pressure: Position 27 Country of manufacture:

Manufacturer:

Terex USA, LLC. 590 Huey Road
Rock Hill, SC 29732 USA

European Representative: Genie UK LTD The Maltings Wharf Road, Grantham, Lin NG31 6BH United Kingdom

This machine complies with: Compliance STD #1 Compliance STD #2
Compliance STD #3

Model

Sequence number

Model year

DATE: GVWR / PNBV: GAWR / PNBE: TIRES / PNEU: RIMS / JANTE: COLD TIRE INFLATION/

99.999 lbs/ 99.99 kg 99.999 lbs/ 99.99 kg Position 25 Position 24 Position 26

PRESS.DE GONFL. A FROID `SINGLE’ THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.

THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE OF MANUFACTURE/ CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLAMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN VIGUER A LA DATE DE SA FABRICATION V.I.N/N.I.V.:

TYPE OF VEHICLE/TYPE DE VEHICULE:TRAILER/REMORQUE MODEL: TZ-34 SERIAL NUMBER: TZ3411-299

MODEL YEAR: 2011

ELECTRICAL SCHEMATIC: ES0441

NOMINAL POWER:

Position 40

PN – 77172

PN – 77055

Serial label

Serial number (stamped on chassis)

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Section 1 · Safety Rules
Safety Rules

August 2022

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 modify or alter a MEWP without prior written permission from the manufacture.
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.

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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.

Section 1 · Safety Rules SAFETY RULES

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Table of Contents

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Introduction

Important Information ………………………………………………………………………………………… ii Revision History ………………………………………………………………………………………………. iii Serial Number Legend ………………………………………………………………………………………. v

Section 1

Safety Rules General Safety Rules ……………………………………………………………………………………….. iv

Section 2

Specifications Machine Specifications ………………………………………………………………………………… 2 – 1 Performance Specifications ………………………………………………………………………….. 2 – 2 Hydraulic Specifications ……………………………………………………………………………….. 2 – 2 Manifold Component Specifications ……………………………………………………………….. 2 – 3 Hydraulic Hose and Fitting Torque Specifications …………………………………………….. 2 – 4 SAE and Metric Fastener Torque Chart …………………………………………………………… 2 – 6

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 Torque the Lug Bolts – ANSI/CSA/AS ……………………………………………………. 3 – 7 A-5 Torque the Lug Bolts – CE ……………………………………………………………………. 3 – 8

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Section 3

Scheduled Maintenance Procedures, continued A-6 Perform Hitch Maintenance – ANSI/CSA/AS ……………………………………………. 3 – 8 A-7 Perform 30 Day Service ………………………………………………………………………. 3 – 9 A-8 Grease the Turntable Rotation Bearing and Rotate Gear ……………………………. 3 – 9 Checklist B Procedures B-1 Inspect the Batteries …………………………………………………………………………. 3 – 10 B-2 Inspect the Electrical Wiring ……………………………………………………………….. 3 – 11 B-3 Inspect the Electrical Contactor …………………………………………………………… 3 – 11 B-4 Test the Emergency Stop …………………………………………………………………… 3 – 12 B-5 Test the Key Switch ………………………………………………………………………….. 3 – 12 B-6 Test the Manual Override …………………………………………………………………… 3 – 13 B-7 Test the Platform Rotation (if equipped) ……………………………………………….. 3 – 17 B-8 Perform Hydraulic Oil Analysis ……………………………………………………………. 3 – 17 B-9 Perform Axle Maintenance – ANSI/CSA/AS …………………………………………… 3 – 18 B-10 Check the Wheel Bearings – CE ………………………………………………………….. 3 – 18 B-11 Service the Hitch – CE ……………………………………………………………………….. 3 – 19 B-12 Perform Axle Maintenance – CE ………………………………………………………….. 3 – 19 B-13 Inspect the Parking Brake ………………………………………………………………….. 3 – 20 B-14 Service the Tongue Jack ……………………………………………………………………. 3 – 20 Checklist C Procedures C-1 Grease the Platform Overload Mechanism (if equipped) ………………………….. 3 – 21 C-2 Test the Platform Overload System (if equipped) …………………………………… 3 – 21 C-3 Perform Axle Maintenance – ANSI/CSA/AS …………………………………………… 3 – 23

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Section 3 Section 4

Scheduled Maintenance Procedures, continued C-4 Replace the Hydraulic Tank Breather Cap
Models with Optional Hydraulic Oil ………………………………………………………. 3 – 23 C-5 Grease the Axle Wheel Bearings – CE ………………………………………………….. 3 – 24 C-6 Adjust the Brakes – CE ………………………………………………………………………. 3 – 25 Checklist D Procedures D-1 Perform Axle Maintenance – ANSI/CSA/AS …………………………………………… 3 – 26 D-2 Check the Boom Wear Pads ………………………………………………………………. 3 – 26 D-3 Replace the Hydraulic Tank Return Filter ………………………………………………. 3 – 27 D-4 Check the Turntable Rotation Bearing Bolts ………………………………………….. 3 – 28 D-5 Inspect for Turntable Bearing Wear ……………………………………………………… 3 – 29 Checklist E Procedure E-1 Test or Replace the Hydraulic Oil ………………………………………………………… 3 – 31
Repair Introduction ………………………………………………………………………………………………… 4 – 1 Platform Components 1-1 Platform ……………………………………………………………………………………………. 4 – 2 1-2 Platform Rotator (if equipped) ……………………………………………………………….. 4 – 2 Primary Boom Components 2-1 Cable Track ……………………………………………………………………………………….. 4 – 7 2-2 Primary Boom ……………………………………………………………………………………. 4 – 9 2-3 Primary Boom Lift Cylinder …………………………………………………………………. 4 – 13 2-4 Platform Leveling Cylinders ………………………………………………………………… 4 – 14 Secondary Boom Components 3-1 Secondary Boom ………………………………………………………………………………. 4 – 17 3-2 Secondary Boom Lift Cylinder …………………………………………………………….. 4 – 19 Ground Controls 4-1 Level Sensor ……………………………………………………………………………………. 4 – 20

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Section 4

Repair, continued Hydraulic Power Unit 5-1 Hydraulic Power Unit Components (to serial number TZ3412-298) …………….. 4 – 24 5-2 Hydraulic Power Unit Components (from serial number TZ3412-299) …………. 4 – 26 5-3 Valve Adjustments – Hydraulic Power Unit ……………………………………………. 4 – 28 5-4 Hydraulic Pump ………………………………………………………………………………… 4 – 29 Manifolds 6-1 Function Manifold Components
(to serial number TZ3403-248) …………………………………………………………….. 4 – 30 6-2 Function Manifold Components
(from serial number TZ3403-249 to TZ3405-171) ……………………………………. 4 – 32 6-3 Function Manifold Components
(from serial number TZ3405-172) …………………………………………………………. 4 – 34 6-4 Outrigger Counterbalance Valve Manifold Components
(from serial number TZ3412-299) …………………………………………………………. 4 – 36 6-5 Valve Coils ………………………………………………………………………………………. 4 – 37 Turntable Rotation Components 7-1 Turntable Rotation Motor ……………………………………………………………………. 4 – 39 Axle Components 8-1 Axle ………………………………………………………………………………………………… 4 – 40 Trailer Components 9-1 Hydraulic and Mechanical Brakes ………………………………………………………… 4 – 41 9-2 Parking Brake …………………………………………………………………………………… 4 – 41 Outriggers 10-1 Outrigger Components ……………………………………………………………………….. 4 – 42 10-2 Outrigger Cylinder ……………………………………………………………………………… 4 – 43 Platform Overload Components 11-1 Platform Overload System …………………………………………………………………. 4 – 44

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Section 5

Schematics Introduction ………………………………………………………………………………………………… 5 – 1 Electrical Abbreviations Legend …………………………………………………………………….. 5 – 2 Wire Color Legend ……………………………………………………………………………………….. 5 – 4 Limit Switch Legend …………………………………………………………………………………….. 5 – 5 Electrical Symbols Legend ……………………………………………………………………………. 5 – 6 Hydraulic Abbreviations Legend …………………………………………………………………….. 5 – 7 Hydraulic Symbols Legend ……………………………………………………………………………. 5 – 8 Trailer Lighting Wiring Diagram – ANSI/CSA …………………………………………………….. 5 – 9 Trailer Lighting Wiring Diagram – Mechanical Axle, CE
(to serial number TZ3412-193) …………………………………………………………….. 5 – 10 Trailer Lighting Wiring Diagram – Mechanical Axle, CE
(from serial number TZ3412-194) …………………………………………………………. 5 – 11 Trailer Lighting Wiring Diagram – Hydraulic Axle, AS
(from serial number TZ3412-193) …………………………………………………………. 5 – 12

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Section 5

Schematics, continued
Control Box Wiring Diagrams – ANSI/CSA
Ground Control Box Wiring Diagram – ANSI/CSA (to serial number TZ3403-185) …………………………………………………………….. 5 – 14
Ground Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3403-186 to TZ3403-248) ……………………………………. 5 – 16
Ground Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3403-249 to TZ3404-303) ……………………………………. 5 – 18
Ground Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3404-304 to TZ3404-505) ……………………………………. 5 – 20
Ground Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3404-506 to TZ3405-189) ……………………………………. 5 – 22
Ground Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3405-190 to TZ3406-204) …………………………………… 5 – 24
Ground Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3406-205) …………………………………………………………. 5 – 26
Platform Control Box Wiring Diagram – ANSI/CSA (to serial number TZ3403-185) …………………………………………………………….. 5 – 28
Platform Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3403-186 to TZ3403-248) ……………………………………. 5 – 29
Platform Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3403-249 to TZ3404-303) ……………………………………. 5 – 30
Platform Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3404-304 to TZ3406-204) ……………………………………. 5 – 31
Platform Control Box Wiring Diagram – ANSI/CSA (from serial number TZ3406-205) …………………………………………………………. 5 – 32

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Section 5

Schematics, continued
Control Box Wiring Diagrams – AS/CE
Ground Control Box Wiring Diagram – AS/CE (to serial number TZ3404-303) …………………………………………………………….. 5 – 34
Ground Control Box Wiring Diagram – AS/CE (from serial number TZ3404-304 to TZ3404-505) ……………………………………. 5 – 36
Ground Control Box Wiring Diagram – AS/CE (from serial number TZ3404-506 to TZ3405-189) ……………………………………. 5 – 38
Ground Control Box Wiring Diagram – AS/CE (from serial number TZ3405-190 to TZ3406-204) ……………………………………. 5 – 40
Ground Control Box Wiring Diagram – AS/CE (from serial number TZ3406-205) …………………………………………………………. 5 – 42
Platform Control Box Wiring Diagrams – AS/CE (to serial number TZ3404-303) …………………………………………………………….. 5 – 44
Platform Control Box Wiring Diagrams – AS/CE (from serial number TZ3404-304 to TZ3406-204) ……………………………………. 5 – 45
Platform Control Box Wiring Diagrams – AS/CE (from serial number TZ3406-205 to TZ3410-144) ……………………………………. 5 – 46
Platform Control Box Wiring Diagrams – AS/CE (from serial number TZ3410-145) …………………………………………………………. 5 – 47

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Section 5

Schematics, continued
Electrical Schematics – ANSI/CSA
Electrical Schematic – ANSI/CSA (to serial number TZ3403-185) …………………………………………………………….. 5 – 50
Electrical Schematic – ANSI/CSA (from serial number TZ3403-186 to TZ3403-248) ……………………………………. 5 – 54
Electrical Schematic – ANSI/CSA (from serial number TZ3403-249 to TZ3404-303) ……………………………………. 5 – 58
Electrical Schematic – ANSI/CSA (from serial number TZ3404-304 to TZ3405-189) ……………………………………. 5 – 62
Electrical Schematic – ANSI/CSA (from serial number TZ3405-190 to TZ3406-204) ……………………………………. 5 – 66
Electrical Schematic – ANSI/CSA (from serial number TZ3406-205 to TZ3411-358) ……………………………………. 5 – 70
Electrical Schematic – ANSI/CSA (from serial number TZ3411-359 to TZ3412-344) ……………………………………. 5 – 74
Electrical Schematic – ANSI/CSA (from serial number TZ3413-345) …………………………………………………………. 5 – 78

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Section 5

Schematics, continued
Electrical Schematics – AS/CE
Electrical Schematic – AS/CE (to serial number TZ3404-303) …………………………………………………………….. 5 – 82
Electrical Schematic – AS/CE (from serial number TZ3404-304 to TZ3405-189) ……………………………………. 5 – 86
Electrical Schematic – AS/CE (from serial number TZ3405-190 to TZ3406-204) ……………………………………. 5 – 90
Electrical Schematic – AS/CE (from serial number TZ3406-205 to TZ3411-358) ……………………………………. 5 – 94
Electrical Schematic – AS/CE (from serial number TZ3411-359 to TZ3413-344) ……………………………………. 5 – 98
Electrical Schematic – AS/CE (from serial number TZ3413-345) ………………………………………………………… 5 – 102
Hydraulic Schematics
Hydraulic Schematic (to serial number TZ3403-248) ………………………………………. 5 – 106
Hydraulic Schematic (from serial number TZ3403-249 to TZ3405-171) ………………. 5 – 107
Hydraulic Schematic (from serial number TZ3405-172 to TZ3412-298) ………………. 5 – 110
Hydraulic Schematic (from serial number TZ3412-299) …………………………………… 5 – 111

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Section 2 · Specifications
Specifications

Machine Specifications

Batteries Type Group Quantity Battery capacity Reserve capacity @ 25A rate Fluid capacities To TZ3407-483 Hydraulic tank
Hydraulic system (including tank) From TZ3407-484 Hydraulic tank
Hydraulic system (including tank)

6V DC T-105
4 225AH 447 minutes
2.2 gallons 8.4 liters
3.9 gallons 14.8 liters
2.8 gallons 10.6 liters
4.5 gallons 17 liters

Tires and wheels – ANSI/CSA/AS Axle Tire size Load range Lug nut torque, dry
Tire pressure, maximum (cold)
Tongue jack Tire size Tire pressure, maximum (cold)
Tires and wheels – CE Axle Tire size
Lug bolt torque, dry

Tire pressure, maximum (cold)

Tongue jack Tire size

ST205/75 R14 C
100 ft-lbs 135 Nm 50 psi 3.4 bar
4.10 / 3.50-4 50 psi 3.4 bar
185 R14C 104/102N
66 ft-lbs 90 Nm 65 psi 4.5 bar
8 x 2

For operational specifications, refer to the Operator’s Manual.
Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

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Section 2 · Specifications

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SPECIFICATIONS

Performance Specifications

Boom function speeds, maximum from platform controls (no weight in platform)

Primary boom up

14 to 22 seconds

Primary boom down

24 to 32 seconds

Primary boom extend

18 to 28 seconds

Primary boom retract

18 to 28 seconds

Secondary boom up

14 to 24 seconds

Secondary boom down

14 to 24 seconds

Turntable rotate – 359°

80 to 115 seconds

Airborne noise emissions

80 dB

Maximum sound level at normal operation workstations

(A-weighted)

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Viscosity grade Viscosity index

Chevron Rando HD equivalent Multi-viscosity 200

Cleanliness level, minimum

15/13

Water content, maximum

200 ppm

Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils. Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.

Optional fluids Biodegradable
Fire resistant Mineral based

Petro Canada Environ MV 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE-S
UCON Hydrolube HP-5046 Quintolubric 822
Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron Aviation A
Arnica 32

Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32°F / 0°C may result in component damage.
Note: Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below 0°F / -17°C.
Note: Use Shell Tellus S2 V 46 hydraulic oil when oil temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Service Department before use.

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

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Section 2 · Specifications

SPECIFICATIONS

Function pump – To TZ3407-483

Displacement per revolution

0.122 cu in 2.0 cc

Flow rate @ 3500 rpm

1.65 gallons per minute 6.25 liters per minute

Function pump – From TZ3407-484

Displacement per revolution

0.101 cu in 1.66 cc

Flow rate @ 3500 rpm

1.3 gallons per minute 4.9 liters per minute

Relief Valve Pressures

System relief valve pressure

3500 psi 241.3 bar

Outrigger relief valve pressure

4000 psi 275.8 bar

Turntable rotate relief valve pressure

1200 psi 82.7 bar

Boom extend relief valve pressure

1800 psi 124.1 bar

Primary boom lift cylinder relief valve pressure

1600 psi 110.3 bar

Secondary boom lift cylinder relief valve pressure

1100 psi 75.8 bar

Manifold Component Specifications

Plug torque SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 SAE No. 12

50 in-lbs / 6 Nm 13 ft-lbs / 18 Nm 18 ft-lbs / 24 Nm 50 ft-lbs / 68 Nm 55 ft- lbs / 75 Nm 75 ft-lbs / 102 Nm

Valve Coil Resistance

Description

Specification

Solenoid valve, 3 position 4 way

29 to 31

24V DC with diode

(schematic item B, AA, AB, AC, AD and AE)

Solenoid valve, 3 position 4 way

20 to 22

24V DC with diode (schematic items K, M, Q and T)

Solenoid valve, 2 position 3 way

29 to 31

24V DC with diode (schematic items O and V)

Solenoid valve, 2 position 2 way, N.C.

29 to 31

24V DC with diode (schematic items W, X, Y and Z)

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

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Section 2 · Specifications

August 2022

SPECIFICATIONS

Hydraulic Hose and Fitting Torque Specifications
Your machine is equipped with Parker Seal-LokTM ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.

Seal-LokTM Fittings
(hose end – ORFS)

SAE Dash size

Torque

-4

10 ft-lbs / 13.6 Nm

-6

30 ft-lbs / 40.7 Nm

-8

40 ft-lbs / 54.2 Nm

-10

60 ft-lbs / 81.3 Nm

-12

85 ft-lbs / 115 Nm

-16

110 ft-lbs / 150 Nm

-20

140 ft-lbs / 190 Nm

-24

180 ft-lbs / 245 Nm

JIC 37° Fittings (swivel nut or hose connection)

SAE Dash size

Thread Size

-4

7/16-20

-6

9/16-18

-8

3/4-16

-10

7/8-14

-12

1 1/16-12

-16

1 5/16-12

-20

1 5/8-12

-24

1 7/8-12

Flats 2
1 1/4 1 1 1 1 1 1

SAE O-ring Boss Port
(tube fitting – installed into Aluminum) (all types)

SAE Dash size

Torque

-4

14 ft-lbs / 19 Nm

-6

23 ft-lbs / 31.2 Nm

-8

36 ft-lbs / 54.2 Nm

-10

62 ft-lbs / 84 Nm

-12

84 ft-lbs / 114 Nm

-16

125 ft-lbs / 169.5 Nm

-20

151 ft-lbs / 204.7 Nm

-24

184 ft-lbs / 249.5 Nm

Jamb nut
Adjustable fitting (Adj)

Non-adjustable fitting (Non-adj)

SAE O-ring Boss Port
(tube fitting – installed into Steel)

SAE Dash size

Torque

-4 ORFS / 37° (Adj) ORFS (Non-adj) 37° (Non-adj)

15 ft-lbs / 20.3 Nm 26 ft-lbs / 35.3 Nm
22 ft-lbs / 30 Nm

-6 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)

35 ft-lbs / 47.5 Nm 29 ft-lbs / 39.3 Nm

-8 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)
-10 ORFS (Adj / Non-adj) 37° (Adj / Non-adj)

60 ft-lbs / 81.3 Nm 52 ft-lbs / 70.5 Nm
100 ft-lbs / 135.6 Nm 85 ft-lbs / 115.3 Nm

-12 (All types)

135 ft-lbs / 183 Nm

-16 (All types) -20 (All types) -24 (All types)

200 ft-lbs / 271.2 Nm 250 ft-lbs / 339 Nm
305 ft-lbs / 413.5 Nm

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Genie TZ-34/20

Part No. 84382

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Section 2 · Specifications

SPECIFICATIONS

Torque Procedure
Seal-LokTM fittings
1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.
Note: The O-rings used in the Parker Seal LokTM fittings and hose ends are custom-size O-rings. They are not standard SAE size O-rings. They are available in the O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated and retained properly.
4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight.
5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table.
6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks.
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand-tight, approximately 30 in-lbs / 3.4 Nm.
2 Make a reference mark on one of the flats of the hex nut, and continue it on to the body hex fitting with a permanent ink marker. Refer to Figure 1.

a

c

b

Figure 1
a hex nut b reference mark c body hex fitting
3 Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Figure 2.
Note: Use the JIC 37° Fittings table on the previous page to determine the correct number of flats for the proper tightening position.
Note: The marks indicate that the correct tightening positions have been determined. Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened.

b a
c b
Figure 2
a body hex fitting b reference mark c second mark
4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting.
5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks.

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Section 2 · Specifications SPECIFICATIONS

August 2022

4.6

8.8

10.9

12.9

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Section 3 · Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:
Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine.
Scheduled maintenance inspections shall be completed daily, quarterly and semi-annually as specified on the Maintenance Inspection Report. The frequency and extent of periodical examinations and tests may also depend on national regulations.
Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage.
Immediately tag and remove from service a damaged or malfunctioning machine.
Repair any machine damage or malfunction before operating the machine.
Use only Genie approved replacement parts.
Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.
Unless otherwise specified, perform each maintenance procedure with the machine in the following configuration:
· Machine disconnected from tow vehicle
· Machine parked on a firm, level surface
· Boom in the stowed position with both latches secured
· Key switch in the off position with the key removed
· Wheels chocked
· Parking brake applied

About This Section
This section contains detailed procedures for each scheduled maintenance inspection.
Each procedure includes a description, safety warnings and step-by-step instructions.
Symbols Legend
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.
Indicates that a specific result is expected after performing a series of steps.
Indicates that an incorrect result has occurred after performing a series of steps.

Part No. 84382

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Section 3 · Scheduled Maintenance Procedures

August 2022

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend
The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appears at the beginning of a maintenance procedure, it conveys the meaning below.
Indicates that tools will be required to perform this procedure.
Indicates that new parts will be required to perform this procedure.
Indicates that a cold motor or pump will be required to perform this procedure.
Indicates that dealer service will be required to perform this procedure.

Pre-delivery Preparation Report
The pre-delivery preparation report contains checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation report to use for each inspection. Store completed forms as required.
Maintenance Schedule
There are five types of maintenance inspections that must be performed according to a schedule– daily, quarterly, semi-annually, annually, and two year. The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections–A, B, C, D, and E. Use the following chart to determine which group(s) of procedures are required to perform a scheduled inspection.

Inspection

Checklist

Daily or every 8 hours

A

Quarterly or every 250 hours or every 3000 miles / 5000 km

A + B

Semi-annually or every 500 hours or every 6000 miles / 10,000 km

A + B + C

Annually or every 1000 hours or every 12,000 miles

A + B + C + D

Two year or every 2000 hours

A + B + C + D + E

Maintenance Inspection Report
The maintenance inspection report contains checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements.

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Part No. 84382

Pre-Delivery Preparation

August 2022
Fundamentals
It is the responsibility of the dealer to perform the Pre-delivery Preparation.
The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service.
A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.
Repairs to the machine may only be made by a qualified service technician, according to the manufacturer’s specifications.
Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer’s specifications and the requirements listed in the responsibilities manual.

Section 3 · Scheduled Maintenance Procedures
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completing the Pre-operation Inspection, the Maintenance items and the Function Tests.
Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box.
Legend Y = yes, completed N = no, unable to complete R = repaired
Comments

Pre-Delivery Preparation Pre-operation inspection completed
Maintenance items completed
Function tests completed

Y NR

Terex South Dakota, Inc USA 500 Oak Wood Road PO Box 1150 Watertown, SD 57201-6150 605-882-4000
Part No. 84382

Genie UK The Maltings, Wharf Road
Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333

Model Serial number Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company

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Section 3 · Scheduled Maintenance Procedures

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Part No. 84382

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Section 3 · Scheduled Maintenance Procedures
Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions · Make copies of this report to use for
each inspection.
· Select the appropriate checklist(s) for the type of inspection to be performed.

Daily or 8 hours

Inspection:

A

Quarterly or 250 hours or

3000 mile / 5000 km

Inspection:

A+B

Semi-annually or

500 hours or

6000 mile / 10,000 km

Inspection:

A+B+C

Annually or 1000 hours or

12,000 mile

Inspection:

A+B+C+D

Two year or 2000 hours Inspection: A+B+C+D+E

· Place a check in the appropriate box after each inspection procedure is completed.
· Use the step-by-step procedures in this section to learn how to perform these inspections.

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

Legend Y = yes, acceptable N = no, remove from service R = repaired

Checklist A

YNR

A-1 Manuals and Decals

A-2 Pre-operation inspect

A-3 Function tests

A-4 Lug Bolts ANSI/CSA/AS

A-5 Lug Bolts – CE

A-6 Hitch maintenance ANSI/CSA/AS

Perform after 40 hours:

A-7 Perform 30 day service

Perform every 100 hours:

A-8 Grease rotate bearing

Checklist B

YNR

B-1 Batteries

B-2 Electrical wiring

B-3 Electrical Contactor

B-4 Emergency Stop

B-5 Key switch

B-6 Manual override

B-7 Platform rotation

B-8 Hydraulic Oil Analysis

B-9 Axle maintenance ANSI/CSA/AS

B-10 Wheel bearings – CE

B-11 Hitch – CE

B-12 Axle maintenance – CE

B-13 Parking brake

B-14 Tongue jack

Comments

Checklist C

YNR

C-1 Grease platform overload (if equipped)

C-2 Test platform overload (if equipped)

C-3 Axle maintenance ANSI/CSA/AS

C-4 Breather Cap

C-5 Wheel Bearings – CE

C-6 Brakes – CE

Checklist D

YNR

D-1 Axle maintenance ANSI/CSA/AS

D-2 Boom wear pads

D-3 Hydraulic filter

D-4 Turntable bearing bolts

D-5 Turntable bearing wear

Checklist E E-1 Hydraulic oil

YNR

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Section 3 · Scheduled Maintenance Procedures
Checklist A Procedures

August 2022

A-1 Inspect the Manuals and Decals
Genie specifications require that this procedure be performed daily or every 8 hours, whichever comes first.
Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition.
In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions.
1 Check to make sure that the operator’s and safety manuals are present and complete in the storage container on the platform.
2 Examine the pages of each manual to be sure that they are legible and in good condition.
Result: The operator’s manual is appropriate for the machine and all manuals are legible and in good condition.
Result: The operator’s manual is not appropriate for the machine or all manuals are not in good condition or are illegible. Remove the machine from service until the manual is replaced.

3 Open the operator’s manual to the decals inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage.
Result: The machine is equipped with all required decals, and all decals are legible and in good condition.
Result: The machine is not equipped with all required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced.
4 Always return the manuals to the storage container after use.
Note: Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed.

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Section 3 · Scheduled Maintenance Procedures

CHECKLIST A PROCEDURES

A-2 Perform Pre-operation Inspection
Completing a Pre-operation Inspection is essential to safe machine operation. The Pre-operation Inspection is a visual inspection performed by the operator prior to each work shift. The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests. The Pre-operation Inspection also serves to determine if routine maintenance procedures are required.
Complete information to perform this procedure is available in the appropriate operator’s manual. Refer to the Operator’s Manual on your machine.
A-3 Perform Function Tests
Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before the machine is put into service. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service.
Complete information to perform this procedure is available in the appropriate operator’s manual. Refer to the Operator’s Manual on your machine.

A-4 Torque the Lug Bolts ANSI/CSA/AS

Axle specifications require that this procedure be performed initially after 10, 25 and 50 miles.
Proper axle maintenance, following the axle manufacturer’s maintenance schedule, is essential to good axle performance and service life. Failure to perform the maintenance procedures can lead to poor axle performance and component damage.
1 Check each lug bolt for proper torque. Refer to Section 2, Specifications.
Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual (Dexter part number LIT-001-00).

Dexter Axle Operation Maintenance Service Manual

Genie part number

84376

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Section 3 · Scheduled Maintenance Procedures

August 2022

CHECKLIST A PROCEDURES
A-5 Torque the Lug Bolts – CE

A-6 Perform Hitch Maintenance ANSI/CSA/AS

Axle specifications require that this procedure be performed initially after 50 km, or 50 km after a wheel change.
Proper axle maintenance, following the axle manufacturer’s maintenance schedule, is essential to good axle performance and service life. Failure to perform the maintenance procedures can lead to poor axle performance and component damage.
1 Check each lug bolt for proper torque. Refer to Section 2, Specifications.
Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual (KNOTT part number P005).

Hitch specifications require that this procedure be performed weekly.
· Brake fluid level · Inspect actuator
Required maintenance procedures and additional hitch information is available in the Demco Model 91 Brake Actuators Owner/Operator Manual (Demco part number BH20023).

Demco Model 91 Owner/Operator Manual Genie part number

84592

KNOTT Axle Service Manual Genie part number

84443

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Section 3 · Scheduled Maintenance Procedures

A-7 Perform 30 Day Service

CHECKLIST A PROCEDURES
A-8 Grease the Turntable Rotation Bearing and Rotate Gear

The 30 day maintenance procedure is a onetime procedure to be performed after the first 30 days or 40 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance.

1 Perform the following maintenance procedures:

· A-8
· B-13 · D-3
· D-4

Grease the Turntable Rotation Bearing and Rotate Gear
Inspect the Parking Brake
Replace the Hydraulic Tank Return Filter
Check the Turnable Rotation Bearing Bolts

Genie specifications require that this procedure be performed every 100 hours of operation.
Regular application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life. Continued use of an insufficiently greased bearing and gear will result in component damage.
1 Raise the boom enough to access the turntable bearing.
2 Locate the grease fitting on the platform end of the turntable, next to the boom hold-down latch.
3 Pump multipurpose grease into the turntable rotation bearing. Rotate the turntable in increments of 4 to 5 inches / 10 to 13 cm at a time and repeat this step until the entire bearing has been greased.
4 Apply grease to each tooth of the drive gear located under the turntable.

Grease type

Multipurpose grease

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Section 3 · Scheduled Maintenance Procedures
Checklist B Procedures

August 2022

B-1 Inspect the Batteries
Proper battery condition is essential to good machine performance and operational safety. A faulty battery cell can result in poor machine performance and improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions.
Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Perform this test after fully charging the battery.
For a more accurate determination of battery condition, fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are free of corrosion.

3 Be sure that the battery retaining fasteners and cable connections are tight.
4 Remove the battery vent caps from all batteries and check the specific gravity of each battery cell with a hydrometer.
Result: If any battery cell displays a specific gravity of less than 1.026, the battery must be replaced.
5 Check the battery acid level of each battery. If needed, replenish with distilled water to the bottom of each battery fill tube. Do not overfill.
6 Install the battery vent caps.
7 Check each battery pack and verify that the batteries are wired correctly.
– + Tongue

Battery Battery

Battery Battery

–

–

–

–

-+
Battery Charger

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Section 3 · Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-2 Inspect the Electrical Wiring
Maintaining electrical wiring in good condition is essential to safe operation and good machine performance. Failure to find and replace burnt, chafed, corroded or pinched wires could result in unsafe operating conditions and may cause component damage.
Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other 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 pull out the red Emergency Stop button to the on position at both the ground and platform controls.
3 Raise the secondary boom until the platform is approximately 10 feet / 3 m off the ground.
4 Inspect the boom storage area for burnt, chafed and pinched cables.
5 Lower the boom to the stowed position and turn the machine off.
6 Inspect the following areas for burnt, chafed, corroded, pinched and loose wires:
· Boom to platform cable harness
· Primary and secondary booms

B-3 Inspect the Electrical Contactor
Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.
Maintaining the electrical contactor in good condition is essential to safe machine operation. Failure to locate a worn or damaged contactor could result in an unsafe working condition and component damage.
1 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position.
2 Disconnect the batteries.
3 Remove the hydraulic power unit cover.
4 Locate the electrical contactor mounted by the hydraulic power unit.
5 Visually inspect the contact points of the contactor for the following items:
· Excessive burns · Excessive arcs · Excessive pitting
Electrocution/burn hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Note: Replace the contactor if any damage is found.

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Section 3 · Scheduled Maintenance Procedures

August 2022

CHECKLIST B PROCEDURES

B-4 Test the Emergency Stop
A properly functioning Emergency Stop is essential for safe machine operation. An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions, resulting in a hazardous situation.
Note: As a safety feature, selecting and operating the ground controls will override the platform controls.
1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls.
2 Push in the red Emergency Stop button at the ground controls to the off position.
Result: No machine functions should operate.
3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls.
4 Push in the red Emergency Stop button at the platform controls to the off position.
Result: No machine functions should operate.
Note: The red Emergency Stop button at the ground controls will stop all machine operation without regard to the position of the key switch.

B-5 Test the Key Switch
Proper key switch action and response is essential to safe machine operation. The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch. Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation.
Note: Perform this procedure from the ground using the platform controls. Do not stand in the platform.
1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.
2 Turn the key switch to platform control.
3 Check the platform up/down function from the ground controls.
Result: The machine functions should not operate.
4 Turn the key switch to ground control.
5 Check the machine functions from the platform controls.
Result: The machine functions should not operate.
6 Turn the key switch to the off position.
Result: No function should operate.

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Section 3 · Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-6 Test the Manual Override
Testing the manual override for malfunctions is essential for safe machine operation. An unsafe working condition exists if the manual override function does not operate in the event of a main power loss.
Before serial number TZ3405-172:
1 Locate the primary boom up valve at the side of the manifold opposite the ground controls. Fully loosen the thumbscrew locknut and turn the thumbscrew fully in a clockwise direction to open the valve. Result: The locknut should loosen and the thumbscrew should screw all the way in.
Turntable rotate
Primary boom extend Primary boom up Secondary boom up
Turntable rotate side
2 To close the valve, turn the thumbscrew fully in a counterclockwise direction. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.

3 Locate the secondary boom up valve at the side of the manifold opposite the ground controls. Fully loosen the thumbscrew locknut and turn the thumbscrew fully in a clockwise direction to open the valve.
Result: The locknut should loosen and the thumbscrew should screw all the way in.
4 To close the valve, turn the thumbscrew fully in a counterclockwise direction. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.
5 Locate the primary boom extend valve at the side of the manifold opposite the ground controls. Fully loosen the thumbscrew locknut and turn the thumbscrew fully in a clockwise direction to open the valve.
Result: The locknut should loosen and the thumbscrew should screw all the way in.
6 To close the valve, turn the thumbscrew fully in a counterclockwise direction. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.
7 Locate the primary boom down valve on the manifold at the ground controls side of the machine. Fully loosen the thumbscrew locknut and turn the thumbscrew fully in a clockwise direction to open the valve.
Result: The locknut should loosen and the thumbscrew should screw all the way in.

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CHECKLIST B PROCEDURES

8 Turn the thumbscrew fully in a counterclockwise direction to close the valve. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.
Turntable rotate
Primary boom retract Primary boom down Secondary boom down
Ground controls side
9 Locate the secondary boom down valve on the manifold at the ground controls side of the machine. Fully loosen the thumbscrew locknut and turn the thumbscrew fully in a clockwise direction to open the valve. Result: The locknut should loosen and the thumbscrew should screw all the way in.
10 Turn the thumbscrew fully in a counterclockwise direction to close the valve. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.

11 Locate the primary boom retract valve on the manifold at the ground controls side of the machine. Loosen the thumbscrew locknut and turn the thumbscrew fully in a counterclockwise direction to open the valve.
Result: The locknut should loosen and the thumbscrew should screw all the way in.
12 Turn the thumbscrew fully in a counterclockwise direction to close the valve. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.
13 Locate the turntable rotate valve on the manifold at the ground controls side of the machine. Fully loosen the thumbscrew locknut and turn the thumbscrew fully in a clockwise direction to open the valve. Push the turntable in either direction.
Result: The locknut should loosen, the thumbscrew should screw all the way in and the turntable should rotate.
14 Turn the thumbscrew fully in a counterclockwise direction to close the valve. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.

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Section 3 · Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

From serial number TZ3403-249 to TZ3405-171:
15 Locate the turntable rotate valve at the side of the manifold opposite the ground controls. Fully loosen the thumbscrew locknut and turn the thumbscrew fully in a clockwise direction to open the valve.
Result: The locknut should loosen and the thumbscrew should screw all the way in.
16 Turn the thumbscrew fully in a counterclockwise direction to close the valve. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.
17 Locate the turntable rotate function valve coil on the manifold at the ground controls side of the machine. Loosen the thumbscrew locknut and turn the thumbscrew fully in a clockwise direction to open the valve.
Result: The locknut should loosen and the thumbscrew should screw all the way in.
18 Turn the thumbscrew fully in a counterclockwise direction to close the valve. Tighten the locknut.
Note: The machine functions will not operate unless the valves are closed.

After serial number TZ3405-171: 1 Locate the primary boom up/down valve at the
manifold on the ground controls side of the machine. Push the thumbscrew in and turn fully in a clockwise direction to open the valve. Result: The thumbscrew should move easily.
Turntable rotate
Primary boom extend/retract Primary boom up/down Secondary boom up/down
Ground controls side
2 To close the valve, push the thumbscrew in and turn fully in a counterclockwise direction and release.
3 Pull the thumbscrew out and turn fully in a clockwise direction to open the valve. Result: The thumbscrew should move easily.
4 To close the valve, pull the thumbscrew out and turn fully in a clockwise direction and release.
Note: The machine functions will not operate unless the valves are closed.

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CHECKLIST B PROCEDURES

5 Locate the secondary boom up/down valve at the manifold. Push the thumbscrew in and turn fully in a clockwise direction to open the valve.
Result: The thumbscrew should move easily.
6 To close the valve, push the thumbscrew in and turn fully in a counterclockwise direction and release.
7 Pull the thumbscrew out and turn fully in a clockwise direction to open the valve.
Result: The thumbscrew should move easily.
8 To close the valve, pull the thumbscrew out and turn fully in a counterclockwise direction and release.
Note: The machine functions will not operate unless the valves are closed.
9 Locate the primary boom extend/retract valve at the manifold. Push the thumbscrew in and turn fully in a clockwise direction to open the valve.
Result: The thumbscrew should move easily.
10 To close the valve, push the thumbscrew in and turn fully in a counterclockwise direction and release.

11 Pull the thumbscrew out and turn fully in a clockwise direction to open the valve.
Result: The thumbscrew should move easily.
12 To close the valve, pull the thumbscrew out and turn fully in a counterclockwise direction and release.
Note: The machine functions will not operate unless the valves are closed.
13 Locate the turntable rotate valve at the manifold. Push the thumbscrew in and turn fully in a clockwise direction to open the valve.
Result: The thumbscrew should move easily.
14 To close the valve, push the thumbscrew in and turn fully in a counterclockwise direction and release.
15 Pull the thumbscrew out and turn fully in a clockwise direction to open the valve.
Result: The thumbscrew should move easily.
16 To close the valve, pull the thumbscrew out and turn fully in a counterclockwise direction and release.
Note: The machine functions will not operate unless the valves are closed.

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Section 3 · Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-7 Test the Platform Rotation (if equipped)
Testing the platform rotation for malfunctions is essential for safe machine operation. The platform rotator is operated by manually turning the hand crank in either a clockwise or counterclockwise direction.
1 Turn the hand crank at the platform in the clockwise direction.
Result: The platform should rotate to the right and operate smoothly without any hesitation or binding.
2 Turn the hand crank at the platform in the counterclockwise direction.
Result: The platform should rotate to the left and operate smoothly without any hesitation or binding.

B-8 Perform Hydraulic Oil Analysis
Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often.
Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil.

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CHECKLIST B PROCEDURES
B-9 Perform Axle Maintenance ANSI/CSA/AS

B-10 Check the Wheel Bearings – CE

Axle specifications require that this procedure be performed quarterly or every 3000 miles, whichever comes first.
· Brake Adjustment
Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual (Dexter part number LIT-001-00).

Dexter Axle Operation Maintenance Service Manual

Genie part number

84376

Axle specifications require that this procedure be performed quarterly or every 5000 km, whichever comes first.
Proper axle maintenance, following the axle manufacturer’s maintenance schedule, is essential to good axle performance and service life. Failure to perform the maintenance procedures can lead to poor axle performance and component damage.
1 At the ground controls, extend the outriggers until the axle is off the ground and the machine is level.
2 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up and down.
Result: There should be no side to side or up and down movement.
Result: There is side to side or up and down movement. See C-5, Grease the Axle Wheel Bearings – CE.
Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual (KNOTT part number P005).

KNOTT Axle Service Manual Genie part number

84443

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Section 3 · Scheduled Maintenance Procedures

CHECKLIST B PROCEDURES

B-11 Service the Hitch – CE
Axle specifications require that this procedure be performed quarterly or every 5000 km, whichever comes first.
Proper axle maintenance, following the axle manufacturer’s maintenance schedule, is essential to good axle performance and service life. Failure to perform the maintenance procedures can lead to poor axle performance and component damage.
1 Clean all visible surfaces of the ball coupler.
2 Lubricate the hitch at both grease fittings at the top of the over-run hitch.
3 Lubricate all bolts and articulated points on the hand brake lever using commonly available machine oil or motor oil.
4 Lubricate all bolts and movable parts of the coupler using commonly available machine oil or motor oil.
5 Lightly grease the ball mount.
6 Confirm that the brake cable is securely installed into the brake handle linkage.
7 Apply the hand brake.

8 Attempt to manually push the machine.
Result: The machine does not move.
Result: The machine moves. Adjust the brakes. See Maintenance procedure C-6, Adjust the Brakes – CE.
Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual (KNOTT part number P005).

KNOTT Axle Service Manual Genie part number

84443

B-12 Perform Axle Maintenance – CE
Axle specifications require that this procedure be performed annually or every 5000 km, whichever comes first. · Brake Inspection · Axle Inspection Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual (KNOTT part number P005).

KNOTT Axle Service Manual Genie part number

84443

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CHECKLIST B PROCEDURES
B-13 Inspect the Parking Brake

B-14 Service the Tongue Jack

A properly functioning parking brake is essential to safe machine operation. The parking brake is manually activated. An improperly functioning parking brake will prevent the operator from properly securing the machine when not in use.
1 Visually inspect the parking brake cables and components for damage.
2 Visually inspect the parking brake cables to ensure both are properly secured and installed into the brake backing plate.
3 Set the parking brake.
Note: If the brake cables are too tight the parking brake will be difficult to set. If the brake cables are too loose, the brakes will not activate when the lever is set.
4 Attempt to manually push the machine.
Result: The machine should not move.
Result: The machine moves. Refer to Repair procedure 9-2, How To Adjust the Parking Brake.

Maintaining the tongue jack in good condition is essential to safe operation and good machine performance. Failure to lubricate the internal gears and bearings of the jack and axle bolt could result in unsafe operating conditions and may cause component damage.
1 Using a needle nose applicator, pump a small amount of automotive grease through the lubrication opening. Rotate the handle to evenly distribute the lubricant to the internal gears.
Note: The lubrication opening is located on the side of the jack, above the support plate.
2 Lightly grease the inner tube of the jack with the same type of grease.
3 Lubricate the handle at both sides of the tube with a lightweight oil.
4 Lubricate the axle bolt and nut assembly with a lightweight oil.
ANSI models:
5 Check each tire with an air pressure gauge and add air as needed. Refer to Section 2, Specifications.
An over-inflated tire can explode and could result in death or serious injury.

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Section 3 · Scheduled Maintenance Procedures
Checklist C Procedures

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

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

Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first. Perform this procedure more often if dusty conditions exist.
Application of lubrication to the platform overload mechanism is essential to safe machine operation. Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage.
1 Locate the grease fittings on each pivot pin of the platform overload assembly.
2 Thoroughly pump grease into each grease fitting using a multi-purpose grease.

Genie specifications require that this procedure be performed every 500 hours or 6 months, whichever comes first.
Testing the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition. Machine stability could be compromised resulting in the machine tipping over.
Note: Perform this procedure with the machine on a firm, level surface.
1 At the ground controls, extend the outriggers until the tires are off the ground and the machine is level.
2 Release the boom hold down latch.
3 Turn the key switch to platform control.
4 Level the platform.
5 Determine the maximum platform capacity. Refer to the machine serial plate.
6 Using a suitable lifting device, place an appropriate test weight equal to the maximum platform capacity in the center of the platform floor.
Result: The platform overload indicator light should be off at both the ground and platform controls.

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CHECKLIST C PROCEDURES

7 Add an additional 44 lbs / 20 kg of weight to overload the platform.
Result: The platform overload indicator light should be flashing at both the ground and platform controls.
8 Test all machine functions from the platform controls.
Result: All platform control functions should not operate.
9 Turn the key switch to ground control.
10 Test all machine functions from the ground controls.
Result: All ground control functions should not operate.
11 Lift the test weight off the platform floor using a suitable lifting device.
Result: The platform overload indicator light should turn off at both the ground and platform controls.

12 Test all machine functions from the ground controls.
Result: All ground control functions should operate normally.
13 Turn the key switch to platform control.
14 Test all machine functions from the platform controls.
Result: All platform control functions should operate.
Note: If the platform overload system is not operating properly, refer to Repair Procedure 11-1, Calibrate the Platform Overload System (if equipped).

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Section 3 · Scheduled Maintenance Procedures

C-3 Perform Axle Maintenance ANSI/CSA/AS

CHECKLIST C PROCEDURES
C-4 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil

Axle specifications require that this procedure be performed every 6 months or 6000 miles, whichever comes first.
· Brake Magnets · Brake Controller · Suspension Components
Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual (Dexter part number LIT-001-00).

Dexter Axle Operation Maintenance Service Manual

Genie part number

84376

The hydraulic tank is a vented-type tank. The breather cap has an internal air filter that can become clogged or, over time, can deteriorate. If the breather cap is faulty or improperly installed, impurities can enter the hydraulic system which may cause component damage. Extremely dirty conditions may require that the cap be inspected more often.
1 Remove and discard the hydraulic tank breather cap.
2 Install a new cap onto the tank.

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Section 3 · Scheduled Maintenance Procedures

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CHECKLIST C PROCEDURES

C-5 Grease the Axle Wheel Bearings CE
Axle specifications require that this procedure be performed every 6 months or 10,000 km, whichever comes first.
Maintaining the axle wheel bearings is essential to safe operation and good machine performance. Towing the machine with loose or worn wheel bearings may cause an unsafe towing condition and continued use may result in component or property damage. Regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often.
1 Loosen the wheel lug bolts. Do not remove them.
2 At the ground controls, extend the outriggers until the axle is off the ground and the machine is level.
3 Remove the lug bolts and remove the tire and wheel assembly from the machine.
4 Remove, wash and inspect the axle wheel bearings and spacer ring.
5 Pack both bearings with clean, fresh grease.
6 Install the bearings and spacer ring onto the axle and reassemble the axle.
7 Tighten the castle nut until the wheel runs with a little bite.

8 Loosen the castle nut just until the cotter pin fits into the next hole. Install a new cotter pin and lock into position. Install the dust cap.
Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut.
9 Install the tire and wheel onto the axle. Install and torque the lug bolts to specification. Refer to Section 2, Specifications.
10 Perform steps 3 through 9 for the other side of the machine.
11 Return the outriggers to the stowed position.
Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual (KNOTT part number P005).

KNOTT Axle Service Manual Genie part number

84443

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Section 3 · Scheduled Maintenance Procedures

CHECKLIST C PROCEDURES

C-6 Adjust the Brakes – CE
Axle specifications require that this procedure be performed every 6 months or 10,000 km, whichever comes first.
Proper axle maintenance, following the axle manufacturer’s maintenance schedule, is essential to good axle performance and service life. Failure to perform the maintenance procedures can lead to poor axle performance and component damage.
1 At the ground controls, extend the outriggers until the axle is off the ground and the machine is level.
2 Release the parking brake.
3 Working from the exposed inside face of the brake plate, opposite the cable entry, tighten the adjusting screw until the wheel can only be turned with difficulty or not at all.
When tighten the adjusting screw, turn the wheel only in the direction of travel.
4 Ease off the adjusting screw approximately onehalf turn in a counterclockwise direction, until the 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 to the direction of towing.
Result: The balance plate is not at a right angle to the direction of towing. Tighten or loosen the brake cable ends coming from the axle until the balance plate is at a right angle to the direction of towing.
7 Return the outriggers to the stowed position.
8 Apply the parking brake.
9 Attempt to manually push the machine.
Result: The machine does not move.
Result: The machine moves. Repeat this procedure beginning with step 1.
Result: One wheel rolls and the other one doesn’t. Repeat step 6 and adjust the balance plate to tighten the brake cable from the wheel which is rolling.
Required maintenance procedures and additional axle information is available in the KNOTT Axle Service Manual (KNOTT part number P005).

KNOTT Axle Service Manual Genie part number

84443

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Section 3 · Scheduled Maintenance Procedures
Checklist D Procedures

August 2022

D-1 Perform Axle Maintenance ANSI/CSA/AS

D-2 Check the Boom Wear Pads

Axle specifications require that this procedure be performed every 12 months or 12,000 miles, whichever comes first.
· Brake lining · Brake cylinders · Brake lines · Trailer brake wiring · Hub/Drum · Wheel bearings · Seals · Springs · Hangers
Required maintenance procedures and additional axle information is available in the Dexter Axle Operation Maintenance Service Manual (Dexter part number LIT-001-00).

Dexter Axle Operation Maintenance Service Manual

Genie part number

84376

Maintaining the boom wear pads in good condition is essential to safe machine operation. Wear pads are placed on boom tube surfaces to provide a low friction, replaceable wear pad between moving parts. Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions.
Note: If the wear pads are within specification, refer to Repair Procedure 3-2, How to Shim the Boom.
1 Extend the boom until the wear pads are accessible.
2 Measure the thickness of the top, side and bottom wear pads. If the wear pad is within specification, shim as necessary to obtain zero clearance and zero drag.
3 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom.
Note: Always maintain squareness between the outer and inner boom tubes.

Boom wear pad specifications Wear pad thickness, minimum

7/16 inch 11 mm

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D-3 Replace the Hydraulic Tank Return Filter

Section 3 · Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES 4 Install the filter and tighten it securely by hand.

a

b

c

Replacement of the hydraulic tank return filter element is essential for good machine performance and service life. A dirty or clogged filter element may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter element be replaced more often.
Burn hazard. Beware of hot oil. Contact with hot oil may cause severe burns.
1 Clean the area around the hydraulic oil filter. Remove the filter with an oil filter wrench.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
2 Use a permanent ink marker to write the date and number of hours from the hour meter on the new filter.
3 Apply a thin layer of fresh oil onto the gasket of the new oil filter.

d
e
f
g
h
i
Power unit components a breather cap b hydraulic tank c filler cap d hand pump e sight gauge (hidden from view) f hydraulic pump g motor h drain plug i hydraulic filter
5 Clean up any oil that may have spilled during the replacement procedure. Properly discard the used filter.

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Section 3 · Scheduled Maintenance Procedures

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CHECKLIST D PROCEDURES

6 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls.
7 Press and hold the yellow function enable button and activate the outrigger autolevel function.
Result: The motor should activate and the outriggers should lower.
8 Inspect the filter and related components to be sure that there are no leaks.

D-4 Check the Turntable Rotation Bearing Bolts
Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation. Improper bolt torque or torque sequence could result in an unsafe operating condition and component damage.
1 Be sure that each turntable rotation bearing mounting bolt above the turntable is torqued in sequence to specification. See below.

Tongue

13 5 11

3

1

9

15

6

12

8

2

4

10 7 14

Bearing-to-turntable bolt torque sequence

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Section 3 · Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES

2 Working through the bearing bolt access, be sure that each turntable rotation bearing mounting bolt is torqued in sequence to specification. See below.
Note: The rotate bearing bolt access is located next to the turntable rotate motor.

D-5 Inspect for Turntable Bearing Wear

Tongue

9 1 11

6

7

16

13

3

4

14

15

8

5

12 2 10

Bearing-to-chassis bolt torque sequence

Turntable rotation bearing bolt torque specifications

Bearing to chassis, lubricated

95 ft-lbs 129 Nm

Bearing to turntable, lubricated

200 ft-lbs 271 Nm

Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life. Continued use of a worn turntable bearing could create an unsafe operating condition, resulting in death or serious injury and component damage.
Perform this procedure with the machine on a firm, level surface and the boom in the stowed position.
1 Grease the turntable bearing. See A-8, Grease the Turntable Rotation Bearing and Rotate Gear.
2 Torque the turntable bearing bolts to specification. See D-4, Check the Turntable Rotation Bearing Bolts.
3 Start the machine from the ground controls and raise the primary and secondary booms to full height. Do not extend the primary boom.
4 Place a dial indicator between the drive chassis and the turntable at a point that is directly under, or inline with, the boom and no more than 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing.

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CHECKLIST D PROCEDURES

5 At the dial indicator, adjust it to “zero” the indicator.
a
b c d

8 Fully retract the primary boom. Raise the primary and secondary booms to full height. Visually inspect the dial indicator to be sure the needle returns to the “zero” position.
9 Remove the dial indicator and rotate the turntable 90°.
10 Repeat steps 4 through 9 until the rotation bearing has been checked in at least four equally spaced areas 90° apart.
11 Lower the primary and secondary booms to the stowed position and turn the machine off.
12 Remove the dial indicator from the machine.

a turntable b dial indicator c drive chassis d turntable rotation bearing
6 Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position. Fully extend the primary boom.
7 Note the reading on the dial indicator.
Result: The measurement is less than 0.025 inch / 0.635 mm. The bearing is good.
Result: The measurement is more than 0.025 inch / 0.635 mm. The bearing is worn and needs to be replaced.

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Section 3 · Scheduled Maintenance Procedures
Checklist E Procedure

E-1 Test or Replace the Hydraulic Oil
Replacement or testing of the hydraulic oil is essential for good machine performance and service life. Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require oil changes to be performed more often.
Note: Before replacing the hydraulic oil, the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary. If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test.
Note: Perform this procedure with the boom in the stowed position.
1 Open the power unit module tray.
2 Disconnect the battery pack from the machine.
Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

3 Remove the drain plug from the power unit valve body and completely drain the tank into a suitable container. Refer to Section 2, Specifications, for capacity information.

a

b

c

d
e
f
g
h
i
Power unit components a breather cap b hydraulic tank c filler cap d hand pump e sight gauge (hidden from view) f hydraulic pump g motor h drain plug i hydraulic filter
4 Tag and disconnect the wire harness from the valve coils on the power unit.
5 Tag and disconnect the wire harness from the motor controller and 275A fuse.
6 Pull the trailer wiring harness through the power unit module bulkhead.

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CHECKLIST E PROCEDURE

7 Tag, disconnect and plug the hydraulic hoses from the power unit. Cap the fittings.
Note: Do not disconnect the hydraulic filter lines from the power unit.
8 Tag and disconnect the brake line at the fitting under the motor controller.
9 Remove the hydraulic filter from the filter head.
10 Remove the power unit module retaining fasteners and remove the power unit module from the machine.
11 Remove the mounting fasteners that attach the hydraulic tank to the power unit. Remove the tank from the power unit.
12 Remove the pick-up filter. Clean the filter and tank using a mild solvent.
13 Install the pick-up filter onto the oil pick-up.
14 Apply thread sealant to the threads of the drain plug. Install the drain plug into the pump and tighten. Do not overtighten.
15 Install the hydraulic tank onto the power unit.
Component damage hazard. The O-ring can be damaged if the hydraulic tank is not installed correctly. Use caution when installing the hydraulic tank onto the power unit.
16 Install the power unit onto the machine, and install and tighten the power unit retaining fasteners. Do not overtighten.
17 Apply a thin layer of fresh oil to the gasket of the new oil filter.

18 Install the hydraulic hoses onto the power unit. Torque to specification.
19 Install the brake line to the brake fitting under the motor controller and tighten the fitting. Do not overtighten.
20 Install the wire harness onto the motor controller and 275A fuse.
21 Route the trailer wiring harness through the module bulkhead and to the front of the trailer. Secure the wiring.
22 Install the wiring harness onto the valve coils at the power unit.
23 Fill the tank with hydraulic oil until the oil is visible in the sight gauge. Do not overfill. Refer to Section 2, Specifications.
24 Activate the pump to fill the hydraulic system with oil and bleed the system of air.
Component damage hazard. The pump can be damaged if operated without oil. Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system.
25 Repeat steps 23 through 24 until the hydraulic system and tank are both full.
26 Retract the outriggers and return the boom to the stowed position.
27 Clean up any oil that may have spilled. Properly discard the used oil and filter.

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Section 4 · Repair Procedures
Repair Procedures

Observe and Obey:
Repair procedures shall be completed by a person trained and qualified on the repair of this machine.
Immediately tag and remove from service a damaged or malfunctioning machine.
Repair any machine damage or malfunction before operating the machine.
Before Repairs Start:
Read, understand and obey the safety rules and operating instructions in the appropriate Operator’s Manual on your machine.
Be sure that all necessary tools and parts are available and ready for use.
Use only Genie approved replacement parts.
Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.
Unless otherwise specified, perform each repair procedure with the machine in the following configuration: · Machine disconnected from tow vehicle · Machine parked on a firm, level surface · Boom in the stowed position with both
latches secured · Key switch in the off position with the
key removed · Wheels chocked · Parking brake applied

About This Section
Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point where repairs can be completed. Then to re-assemble, perform the disassembly steps in reverse order.
Symbols Legend
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.
Indicates that a specific result is expected after performing a series of steps.
Indicates that an incorrect result has occurred after performing a series of steps.

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Section 4 · Repair Procedures
Platform Components

August 2022

1-1 Platform
How to Remove the Platform
1 Tag and disconnect the taillight control cable at the front of the platform.
2 Remove the platform rotate handle (if equipped).
3 Support and secure the platform to an appropriate lifting device. Do not apply any lifting pressure.
4 Remove the fasteners securing the platform to the platform mount bracket.
5 Remove the pin securing the platform to the platform rotator assembly.
Crushing hazard. The platform could become unbalanced and fall if not properly supported when the pin is removed.
6 Remove the platform from the platform rotator assembly.

1-2 Platform Rotator (if equipped)
The platform rotator is a manually-operated gear assembly used to rotate the platform.
How to Remove the Platform Rotator
1 Remove the platform. See 1-1, How to Remove the Platform.
2 Tag and disconnect the platform control cable(s) from the platform controls.
3 Tag and disconnect the wiring at the power-toplatform junction box on the platform rotator assembly.
4 Completely loosen the shaft retaining fasteners at the bottom of the platform pivot shaft. Remove the platform rotate assembly from the machine.

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Section 4 · Repair Procedures

PLATFORM COMPONENTS

How to Adjust the Platform Rotator
The platform rotator is designed to allow the platform to slip in the event of striking an object to help prevent damage to the platform. If the platform rotator is too tight or seized, damage to the platform may occur. If the platform rotator is too loose, the platform may rotate side to side unexpectedly, resulting in a unsafe operating condition.
1 Remove the platform. See 1-1, How to Remove the Platform.

2 Remove the platform rotate mount, platform mount and platform rotate gear assembly from the machine.
3 Remove the four bolts securing the cover over the rotate handle shaft. Remove the cover.
4 Remove the rotate handle shaft and pinion from the rotate gear case.
5 Remove the fasteners securing the rotate gear case to the gear shaft seal plate. Remove the case from the rotate gear assembly.
6 Remove the gear assembly retaining nut from the top of the shaft.

e
f a
g

h b

a rotate gear assembly

b rotate gear shaft

c oil seal

c

d gear shaft seal plate

e rotate handle shaft cover

f pinion

d

g rotate shaft

h handle

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Section 4 · Repair Procedures

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PLATFORM COMPONENTS

7 Disassemble the gear assembly.

Note: For ease of assembly, note the order of disassembly of the gear assembly.

8 Visually inspect the inside of the platform rotator for the following items:

· Excessive wear · Broken or damaged parts · Rust or corrosion

· Binding

If any parts are lightly rusted or corroded, remove them and clean rust or corrosion off with a wire brush. If parts are worn, heavily rusted or corroded, replace them.

9 Remove the gear shaft from the shaft retainer bracket.

10 Thoroughly degrease and dry the case, covers and gear components.

11 Install the gear shaft fully into the shaft retainer bracket. Torque to specification.

12 Assemble the gear assembly in the reverse order of disassembly in step 7.
13 Install the gear assembly retaining nut onto the top of the shaft. Torque to specification.
14 Install the case over the gear assembly and onto the shaft seal plate. Install and securely tighten the retaining fasteners. Do not over tighten.

15 Thoroughly and heavily lubricate each tooth of the gear using multipurpose grease. Rotate the gear case as required.
When lubricating the gear, do not apply any grease to the remainder of the gear assembly components. Grease on the balance of the gear components may result in slippage and poor rotator performance.
16 Install the rotate handle shaft and pinion into the rotate gear case.
17 Thoroughly and heavily lubricate each tooth of the pinion using multipurpose grease.
18 Install the rotate handle shaft cover. Install and securely tighten the cover fasteners. Do not over tighten.

Torque specification Rotate gear shaft retainer bracket, dry
Rotate gear nut, dry

50 lbs-ft 68 Nm
200 lbs-ft 271 Nm

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Section 4 · Repair Procedures
Primary Boom Components

abcde f g

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m
l k
j

a primary boom pivot pin b primary boom c primary boom lift cylinder d cable tray e cable track f primary boom lift cylinder rod-end pivot pin g cable bridge h platform level slave cylinder i platform mount j battery charger k primary boom lift cylinder barrel-end AND
secondary boom pivot pin l platform level master cylinder

m mid-pivot n latch o ground controls p secondary boom lift cylinder barrel- end pivot pin q turntable r secondary boom pivot pin s secondary boom link pivot pin t secondary boom link u secondary boom v secondary boom lift cylinder w secondary lift cylinder rod-end pivot pin x secondary boom link pivot pin

nopq r s t

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PRIMARY BOOM COMPONENTS

2-1 Cable Track
The boom cable track guides cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire boom cable track may be necessary when performing major repairs that involve removing the boom.
How to Remove the Cable Track

Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications.

1 Working at the turntable, locate the three wire cables which are routed to the platform through the inside of the secondary boom.

ab c d

e

f

g

XX

YY
a mid pivot b cable tray c cable track d cable bridge e secondary boom f turntable g platform mount

2 Tag and disconnect two of these wire cables from their source at the ground control box.
3 At the rear of the chassis, open the AC plug. Tag and disconnect the wiring from the plug. Remove the wiring from the clamp behind the battery charger cover.
4 Working from the mid pivot, pull the three wire cables through the turntable, secondary boom and mid pivot. Set the cables off to the side of the primary boom.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
5 Tag and disconnect the wire harness from the platform control box.
6 Tag and disconnect the trailer lighting wire harness at the platform. Remove the wiring from the clamp.
7 Remove the cover from the AC outlet. Tag and disconnect the wiring from the outlet.
8 Pull the three harness cables through the platform mount and lay them off to the side of the primary boom.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
9 Tag, disconnect and plug the hydraulic hoses at the platform end of the cable bridge. Cap the fittings on the hydraulic hard lines. Refer to ‘XX’ in the illustration.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

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PRIMARY BOOM COMPONENTS

10 Tag, disconnect and plug the hydraulic hoses at the mid pivot end of the cable tray. Cap the fittings on the hydraulic hard lines. Refer to ‘YY’ in the illustration.
11 Place blocks between the cable bridge, cable track and cable tray. Secure them together.
Crushing hazard. If the cable bridge, cable track and cable tray are not properly secured together, the combination could become unbalanced and fall when removed from the machine.
12 Remove the fasteners securing the cable tray to the primary boom.
Crushing hazard. The cable track assembly could fall if not properly supported when the fasteners are removed.
13 Remove the fasteners securing the cable bridge to the extension boom.
14 Remove the cable track from the machine and place it on a structure capable of supporting it.
Crushing hazard. The cable track assembly could fall if not properly supported when removed from the machine.

How to Repair the Cable Track
Component damage hazard. The cable track can be damaged if it is twisted.
1 Visually inspect the cable track and determine which 7 link section needs to be replaced.
2 Using a flat blade screwdriver, pry open the hinge bar on each link of the 7 link section, plus one more on each end making a total of 9.
3 Using a flat blade screwdriver at one side of the link to be replaced, separate the connection and open the joint slightly by sliding the link over the link pivot. Repeat for the other side of the link to separate the link sections.
4 Repeat step 3 for the other end of the section to be replaced.
5 Lift up the hoses and cables and carefully remove the damaged section of cable track.
Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched.
6 Lift up the hoses and cables and carefully insert the new section of cable track.
7 Install the new section of cable track onto the existing track. Be sure the link pivot on both sides of the link are in place and that the track hinges correctly
8 Securely lock the hinge bar for each link.
9 Operate the boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track.

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PRIMARY BOOM COMPONENTS

2-2 Primary Boom
How to Shim the Primary Boom
1 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 to obtain zero clearance and zero drag.
4 Securely tighten the mounting fasteners. Do not overtighten.
5 Extend and retract the boom through an entire cycle. Check for tight spots that could cause binding or scraping.
Always maintain squareness between the outer and inner boom tubes.

How to Remove the Primary Boom
This procedure in this section requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required.
Note: Perform this procedure on a firm, level surface, with the boom in the stowed position.
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications.
1 Remove the platform. See 1-1, How to Remove the Platform.
2 Remove the cover under the ground controls.
3 Tag and disconnect the platform to ground control cable from the underside of the ground controls.
Note: Looking at the ground control box, the cable is at the far right and directly under the secondary boom up/down button.
4 Tag and disconnect the 8-pin wire harness connector behind the ground control box.

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PRIMARY BOOM COMPONENTS

5 Remove the battery charger cover at the rear of the machine and remove the cable clamp securing the power-to-platform plug to the chassis near the battery charger.
6 Pull the cables from steps 3, 4 and 5 fully through the secondary boom and mid-pivot until they are clear of the mid-pivot. Carefully lay the cables over the primary boom.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
Note: For ease of assembly, pay close attention to how the cables are routed when pulling the cables through the boom and mid-pivot.
7 Tag, disconnect and plug the hydraulic hoses to the primary boom lift cylinder. Cap the fittings.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
8 Attach a lifting strap of suitable capacity from an overhead crane to the primary boom lift cylinder.
9 Remove the pin retaining fasteners securing the primary boom lift cylinder pivot pin to the primary boom.
10 Using a soft metal drift, remove the primary boom lift cylinder pivot pin at the primary boom. Lower the cylinder onto the chassis.
Crushing hazard. The cylinder could fall if not properly supported when the pivot pin is removed.

11 Tag, disconnect and plug the hydraulic hoses to the platform level master cylinder. Cap the fittings.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
12 Attach a lifting strap of suitable capacity from an overhead crane to the platform level master cylinder.
13 Remove the pin retaining fasteners securing the platform level master cylinder pivot pin to the primary boom. Lower the cylinder
14 Using a soft metal drift, remove the platform level master cylinder pivot pin at the primary boom.
Crushing hazard. The cylinder could fall if not properly supported when the pivot pin is removed.
15 Tag, disconnect and plug the hydraulic hoses at the top of the primary boom near the mid-pivot. Cap the fittings.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

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PRIMARY BOOM COMPONENTS

16 Tag, disconnect and plug the hydraulic hoses to the primary boom extension cylinder at the mid pivot end of the primary boom. Cap the fittings.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
17 Attach a lifting strap of suitable capacity from an overhead crane to the primary boom. Raise the boom to a horizontal position.
18 Remove the pin retaining fasteners securing the primary boom pivot pin to the mid-pivot.
19 Using a soft metal drift, remove the primary boom pivot pin at the mid- pivot.
Crushing hazard. The primary boom could become unbalanced and fall if not properly supported when the pin is removed.
20 Remove the primary boom from the machine.
Crushing hazard. The primary boom could become unbalanced and fall if not properly supported when removed from the machine.

How to Remove the Boom Extension
This procedure in this section requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required.
Note: Perform this procedure on a firm level surface, boom in the stowed position.
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications.
1 Remove the primary boom. See 2-2, How to Remove the Boom.
2 Tag and disconnect the wiring at the power-toplatform junction box.
3 Tag and disconnect the cables from the platform control box.
4 Remove the platform controls and controls mounting bracket from the boom extension.

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PRIMARY BOOM COMPONENTS

5 Attach a lifting strap of suitable capacity from an overhead crane to the platform mount. Do not apply any lifting pressure.
6 Remove the pin retaining fasteners securing the platform mount pivot pin to the boom extension cylinder.
7 Using a soft metal drift, remove the platform mount pivot pin at the boom extension cylinder.
Crushing hazard. The platform mount could become unbalanced and fall if not properly supported when the pin is removed.
8 Remove the pin retaining fasteners securing the platform mount pivot pin to the platform level slave cylinder.
9 Using a soft metal drift, remove the platform mount pivot pin at the platform level slave cylinder.
Crushing hazard. The platform mount could become unbalanced and fall if not properly supported when the pin is removed.
10 Remove the wear pad retaining fasteners from the primary boom. Remove the wear pads from the boom.
Note: For ease of assembly, note the quantity and location of shims during disassembly.
11 Tag, disconnect and plug the hydraulic hoses from the platform level slave cylinder at the cable track. Cap the fittings.

12 Pull the boom extension out of the primary boom approximately 18 inches / 50 cm.
13 Remove the pin retaining fasteners securing the barrel end of the extension cylinder to the extension boom at the platform end.
14 Remove the retainer securing the hydraulic hoses at the platform end of the boom.
15 Remove the pin retaining fasteners securing the platform level slave cylinder pivot pin to the boom extension.
16 Using a soft metal drift, remove the platform level slave cylinder pivot pin.
17 Remove the pin retaining fasteners securing the boom extension cylinder pivot pin to the primary boom.
18 Using a soft metal drift, remove the boom extension cylinder pivot pin.
19 Remove the boom extension and cylinder from the boom.

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PRIMARY BOOM COMPONENTS

2-3 Primary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with a bi-directional solenoid valve to prevent movement in the event of a hydraulic line failure.
How to Remove the Primary Boom Lift Cylinder
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications.
Note: Perform this procedure on a firm, level surface, with the boom in the stowed position and latched.
1 Tag, disconnect and plug the hydraulic hoses on the lift cylinder. Cap the fittings on the cylinder.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

2 Attach a lifting strap of suitable capacity from an overhead crane to the lift cylinder.
3 Remove the pin retaining fastener from the lift cylinder rod-end pivot pin.
4 Place a rod through the hole in the outrigger pivot pin and twist to remove the pin.
Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed.
5 Lower the cylinder to a horizontal position.
6 Remove the pin retaining fastener from the lift cylinder barrel-end pivot pin.
7 Place a rod through the hole in the outrigger pivot pin and twist to remove the pin.
Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed.
8 Carefully remove the cylinder from the machine.
Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported when removed from the machine.
Component damage hazard. The solenoid valve can be damaged. Use caution when removing the cylinder from the machine.

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PRIMARY BOOM COMPONENTS

2-4

a

b

Platform Leveling Cylinders

How to Remove the Master Cylinder
The master cylinder, located inside the mid pivot, acts as a pump for the slave cylinder, which is located at the platform end of the extension boom. The master cylinder operates in a closed-circuit hydraulic loop with the slave cylinder, keeping the platform level through the entire range of boom motion.
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications.
1 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

a platform level slave cylinder b platform level master cylinder
2 Remove the pin retaining fastener from the master cylinder barrel end pivot pin.
3 Using a soft metal drift, remove the master cylinder barrel end pivot pin.
4 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder.
5 Remove the pin retaining fastener from the rod end pivot pin.
6 Using a soft metal drift, remove the master cylinder rod end pivot pin. Remove the master cylinder from the machine.
Crushing hazard. The master cylinder could become unbalanced and fall if not properly supported when removed from the machine.

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PRIMARY BOOM COMPONENTS

How to Remove the Slave Cylinder
The slave cylinder, via a closed-circuit hydraulic loop, works in tandem with the master cylinder to maintain the platform in a level condition through the entire range of boom motion. The slave cylinder, located at the platform end of the extension boom, is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.
Note: Before cylinder removal is considered to correct a malfunction, bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit.
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications.
1 Extend the boom approximately 12 inches / 30 cm.
2 Tag, disconnect and plug the slave cylinder hydraulic hoses from the tee fittings on the jib manifold, and connect them together using a connector. Cap the fittings on the manifold.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

a

b

a platform level slave cylinder b platform level master cylinder
3 Remove the pin retaining fastener from the slave cylinder rod end pivot pin. Do not remove the pin.
4 Remove the external retaining rings from the barrel end pivot pin.
5 Using a soft metal drift, remove the rod end pivot pin.
6 Carefully pull the cylinder out of the boom.
Component damage hazard. Hoses can be damaged if they are kinked or pinched.
How to Bleed the Slave Cylinder
1 Raise the boom to a horizontal position.
2 Activate the platform level function in both up and down directions through two complete platform leveling cycles to remove any air that might be in the system.
The master cylinder acts as a pump for the slave cylinder. It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of boom motion. The master cylinder is located inside the mid pivot.

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Section 4 · Repair Procedures
Secondary Boom Components

abcde f g

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m
l k
j

a primary boom pivot pin b primary boom c primary boom lift cylinder d cable tray e cable track f primary boom lift cylinder rod-end pivot pin g cable bridge h platform level slave cylinder i platform mount j battery charger k primary boom lift cylinder barrel-end AND
secondary boom pivot pin l platform level master cylinder

m mid-pivot n latch o ground controls p secondary boom lift cylinder barrel- end pivot pin q turntable r secondary boom pivot pin s secondary boom link pivot pin t secondary boom link u secondary boom v secondary boom lift cylinder w secondary lift cylinder rod-end pivot pin x secondary boom link pivot pin

nl o p q r s t

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SECONDARY BOOM COMPONENTS

3-1 Secondary Boom
How to Remove the Secondary Boom
This procedure in this section requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is required.
Note: Perform this procedure on a firm, level surface, with the boom in the stowed position.
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications.
1 Remove the primary boom. See 2-2, How to Remove the Primary Boom.

Remove the mid-pivot
2 Attach a lifting strap of suitable capacity from an overhead crane to the primary lift cylinder. Raise the cylinder to a horizontal position.
3 Remove the pin retaining fasteners securing the primary lift cylinder pivot pin to the mid-pivot.
4 Using a soft metal drift, remove the primary lift cylinder pivot pin at the mid-pivot.
Crushing hazard. The cylinder could fall if not properly supported when the pivot pin is removed.
5 Attach a lifting strap of suitable capacity from an overhead crane to the mid-pivot. Do not apply any lifting pressure.
6 Remove the pin retaining fasteners securing the secondary boom pivot pin to the mid-pivot.
7 Remove the pin retaining fasteners securing the secondary link pivot pin to the mid-pivot.
8 Remove the hose clamps securing the hydraulic hoses to the mid-pivot.
9 Tag, disconnect and plug the hydraulic hoses to the hydraulic hard lines at the mid-pivot end of the secondary boom. Cap the fittings.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

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SECONDARY BOOM COMPONENTS

10 Attach a lifting strap of suitable capacity from an overhead crane to the secondary link. Do not apply any lifting pressure.
11 Using a soft metal drift, remove the secondary boom pivot pin at the mid- pivot.
Crushing hazard. The mid-pivot could become unbalanced and fall if not properly supported when the pin is removed.
12 Using a soft metal drift, remove the secondary link pivot pin at the mid- pivot.
Crushing hazard. The secondary link could become unbalanced and fall if not properly supported when the pin is removed.
13 Remove the mid-pivot from the machine.
Crushing hazard. The mid-pivot could become unbalanced and fall if not properly supported when removed from the machine.
Remove the secondary boom
14 Remove the pin retaining fasteners securing the secondary link pivot pin to the turntable.
15 Using a soft metal drift, remove the secondary link pivot pin.
Crushing hazard. The secondary link could become unbalanced and fall if not properly supported when the pin is removed.
16 Remove the secondary link from the machine.
17 Attach a lifting strap of suitable capacity from an overhead crane to the lift cylinder. Do not apply any lifting pressure.

18 Remove the pin retaining fasteners securing the lift cylinder pivot pin to the secondary boom.
19 Using a soft metal drift, remove the lift cylinder pivot pin from the secondary boom. Lower the cylinder.
Crushing hazard. The cylinder could fall if not properly supported when the pivot pin is removed.
20 Tag, disconnect and plug the hydraulic hoses to the hydraulic hard lines at the turntable end of the secondary boom. Cap the fittings.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.
Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.
21 Attach a lifting strap of suitable capacity from an overhead crane to the secondary boom. Raise the boom to a horizontal position.
22 Remove the pin retaining fasteners securing the secondary boom pivot pin to the turntable.
23 Using a soft metal drift, remove the secondary boom pivot pin.
Crushing hazard. The secondary boom could become unbalanced and fall if not properly supported when the pin is removed.
24 Remove the secondary boom from the machine.

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SECONDARY BOOM COMPONENTS

3-2 Secondary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers the primary boom. The primary boom lift cylinder is equipped with a bi-directional solenoid valve to prevent movement in the event of a hydraulic line failure.
How to Remove the Secondary Boom Lift Cylinder
Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation. Refer to Section 2, Hydraulic Hose and Fitting Torque Specifications.
Note: Perform this procedure on a firm, level surface, with the boom in the stowed position.
1 Tag, disconnect and plug the hydraulic hoses on the lift cylinder. Cap the fittings on the cylinder.
Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

2 Attach a lifting strap of suitable capacity from an overhead crane to the lift cylinder.
3 Remove the pin retaining fastener from the lift cylinder rod-end pivot pin.
4 Place a rod through the hole in the outrigger pivot pin and twist to remove the pin.
Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed.
5 Lower the cylinder to a horizontal position.
6 Remove the pin retaining fastener from the lift cylinder barrel-end pivot pin.
7 Place a rod through the hole in the outrigger pivot pin and twist to remove the pin.
Crushing hazard. The lift cylinder will fall if not properly supported when the pivot pin is removed.
8 Carefully remove the cylinder from the machine.
Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported when removed from the machine.
Component damage hazard. The solenoid valve can be damaged. Use caution when removing the cylinder from the machine.

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Section 4 · Repair Procedures
Ground Controls

August 2022

4-1 Level Sensor
Each machine is equipped with two types of level sensors:
Tilt level sensor One level sensor monitors the incline of the turntable after the outriggers are deployed and the machine is level. When this level sensor activates, an alarm will sound, making the operator aware of a potentially hazardous situation.
The tilt alarm sounds when the incline of the chassis exceeds 2.5° in any direction. The tilt level sensor is located on the side of the machine opposite the ground controls.
Outrigger auto level system When deploying the outriggers using the autolevel function, outrigger level sensors are used to monitor the incline of the turntable and assist in leveling the machine.
In early production, two level sensors are components of the outrigger auto level circuit. Later in production, a single autolevel module was used. The outrigger level sensor(s) are located on the ground controls side of the machine.
How to Install and Calibrate the Tilt Level Sensor
Tip-over hazard. Failure to install or calibrate the level sensor as instructed could result in the machine tipping over causing death or serious injury. Do not install or calibrate the level sensor other than specified in this procedure.
1 Perform this procedure with the machine on a firm, level surface that is free of obstructions.

2 Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls.

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

Result: The outriggers will lower and adjust to level the machine and raise the wheels off the ground. Use the bubble levels located on the chassis to confirm that the machine is level.

4 Turn the key switch to the off position.

5 Locate the tilt level sensor behind the inspection door on the side of the machine opposite the ground controls.

a

b

c

d

e

FUNCTION MANIFOLD

Y X

TURNTABLE ROTATE MOTOR

TONGUE

PLATFORM

a function manifold b turntable rotate motor c tilt level sensor d adjusting fastener e “X” indicator

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Section 4 · Repair Procedures

GROUND CONTROLS

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 the tilt level sensor.
7 Remove the three level sensor retaining fasteners. Remove the level sensor from the machine.
8 Install the new level sensor onto the machine with the “X” on the level sensor housing located as shown in the illustration. Install and tighten the level sensor retaining fasteners.
9 Connect the wire harness to the level sensor.
10 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles.
Note: Be sure there are threads showing through the top of the adjusting fasteners.
11 Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls.
12 Raise the secondary boom approximately 12 inches / 30 cm.
Result: The tilt sensor alarm should not sound.
13 Using a digital level, lower the tank side of the machine until the turntable is 2.4° out of level.
Result: The tilt sensor alarm should not sound.
Result: The tilt alarm will sound at 180 beeps per minute. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 6.

14 Continue to lower the tank side of the machine until the turntable is 2.7° out of level.
Result: The tilt alarm will sound at 180 beeps per minute.
Result: The tilt alarm does not sound. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 6.
15 Push and hold the yellow function enable button. Push and hold the auto level button.
Result: The outriggers will lower and adjust to level the machine and raise the wheels off the ground. Use the bubble level located below the ground controls to confirm that the machine is level.
16 Using a digital level, lower the ground control side of the machine until the turntable is 2.4° out of level.
Result: The tilt sensor alarm should not sound.
Result: The tilt alarm will sound at 180 beeps per minute. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 6.
17 Continue to lower the ground control side of the machine until the turntable is 2.7° out of level.
Result: The tilt alarm will sound at 180 beeps per minute.
Result: The tilt alarm does not sound. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 6.
18 Push and hold the yellow function enable button. Push and hold the auto level button.
Result: The outriggers will lower and adjust to level the machine and raise the wheels off the ground. Use the bubble level located below the ground controls to confirm that the machine is level.

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GROUND CONTROLS

19 Using a digital level, lower the platform end of the machine until the turntable is 2.4° out of level.
Result: The tilt sensor alarm should not sound.
Result: The tilt alarm will sound at 180 beeps per minute. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 6.
20 Continue to lower the platform end of the machine until the turntable is 2.7° out of level.
Result: The tilt alarm will sound at 180 beeps per minute.
Result: The tilt alarm does not sound. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 6.
21 Push and hold the yellow function enable button. Push and hold the auto level button.
Result: The outriggers will lower and adjust to level the machine and raise the wheels off the ground. Use the bubble level located below the ground controls to confirm that the machine is level.
22 Using a digital level, lower the tongue end of the machine until the turntable is 2.4° out of level.
Result: The tilt sensor alarm should not sound.
Result: The tilt alarm will sound at 180 beeps per minute. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 6.
23 Continue to lower the tongue end of the machine until the turntable is 2.7° out of level.
Result: The tilt alarm will sound at 180 beeps per minute.
Result: The tilt alarm does not sound. The level sensor is faulty and must be replaced. Repeat this procedure beginning with step 6.
24 Return the outriggers to the stowed position.

How to Install and Calibrate the Outrigger Level Sensor
Tip-over hazard. Failure to install or calibrate the level sensor as instructed could result in the machine tipping over causing death or serious injury. Do not install or calibrate the level sensor other than specified in this procedure.
1 Perform this procedure with the machine on a firm, level surface that is free of obstructions.
2 Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls.
3 Lower all four outriggers and raise the machine off the ground. Level the machine. Use the bubble level located below the ground controls to confirm that the machine is level.
4 Turn the key switch to the off position.

4 – 22

Genie TZ-34/20

Part No. 84382

August 2022

Section 4 · Repair Procedures

GROUND CONTROLS

5 Locate the outrigger level sensor(s) behind the inspection door on the ground control side of the machine.

a

b

c

CR66
AUTOLEVEL RELAY

FUNCTION MANIFOLD

Y X

Y X

d

a

e

d

PLATFORM

TONGUE

a outrigger level sensor b autolevel relay (early production) c function manifold d “X” indicator e adjusting fastener

a

e

d

c

FUNCTION MANIFOLD

If you are not installing a new level sensor, proceed to step 10.
6 Tag and disconnect the wire harness from the outrigger level sensor.
7 Remove the three level sensor retaining fasteners. Remove the level sensor from the machine.
8 Install the new level sensor onto the machine with the “X” on the level sensor housing located as shown in the illustrations. Install and tighten the level sensor retaining fasteners.
9 Connect the wire harness to the level sensor.
10 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles.
Note: e sure there are threads showing through the top of the adjusting fasteners.
11 Turn the key switch to ground control.
12 Raise the outriggers until all of the outriggers are off the ground.
13 Push and hold the yellow function enable button. Push and hold the auto level button.
Result: The outriggers will lower and adjust to level the machine and raise the wheels off the ground. Use the bubble level located below the ground controls to confirm that the machine is level.

Y

X
PLATFORM

TONGUE

Part No. 84382

Genie TZ-34/20

4 – 23

Section 4 · Repair Procedures
Hydraulic Power Unit

August 2022

5-1 Hydraulic Power Unit Components
To Serial Number TZ3412-298
The power unit is located under the side cover on the side of the machine opposite of the ground controls.

Index No. 1 2 3 4 5 6 7
— 8 9 10 11 12 13
13
14 15 16
17 18 19 20 21 22 23 24

Description

Schematic Item Function

Torque

Hand pump ……………………………………………… Auxiliary functions

Dipstick/breather ………………………………………. Fluid level

Hose fitting ………………………………………………. To outrigger extend front circuit …….. 10-12 ft-lbs / 14-16 Nm

Hose fitting ………………………………………………. To outrigger extend rear circuit …….. 1

References

• press.de
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