115370 11 1 a - geniemanuals.gogenielift.com/parts and service manuals/data/service/material... ·...

Service Manual

Part No. 115370

Rev A1

January 2011

GRC -12

Serial Number Range

from GRC08-000101

January 2011

GRC-12 Part No. 115370ii

Important

Read, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anymaintenance procedure.

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

Compliance

Machine ClassificationGroup A/Type 2,3 as defined by ISO 16368

Machine Design LifeUnrestricted with proper opeation, inspection andscheduled maintenance.

Technical Publications

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

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

Contact Us:

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

Copyright © 2008 by Genie Industries

115370 Rev A September 2008First Edition, First Printing

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

Printed on recycled paper

Printed in U.S.A.

Introduction

September 2008

Part No. 115370 GRC-12

Serial Number Legend

iii

INTRODUCTION

September 2008

GRC-12 Part No. 115370

This page intentionally left blank.

iv

September 2008

Part No. 115370 GRC-12 v

DangerFailure to obey the instructions and safety rulesin this manual and the appropriate Operator'sManual on your machine will result in death orserious injury.

Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.

Do Not Perform MaintenanceUnless:

You are trained and qualified to performmaintenance on this machine.

You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksite

regulations- applicable governmental regulations

You have the appropriate tools, liftingequipment and a suitable workshop.

Safety Rules

September 2008


SAFETY RULES

vi

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

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

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

debris that could get into machine components andcause damage.

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

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

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

may fail if they are used a second time.

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

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

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

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

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

Indicates an imminently hazardoussituation which, if not avoided, willresult in death or serious injury.

Indicates a potentially hazardoussituation which, if not avoided,could result in death or seriousinjury.

Indicates a potentially hazardoussituation which, if not avoided,may cause minor or moderateinjury.

Indicates a potentially hazardoussituation which, if not avoided,may result in property damage.

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

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

placing loads. Always wear approved steel-toedshoes.

September 2008


Table of Contents

Introduction

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

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

Section 1 Safety Rules

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

Section 2 Rev Specifications

A 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 Fasteners Torque Charts ................................................... 2 - 6

Section 3 Rev Scheduled Maintenance Procedures

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

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

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

A Checklist A Procedures

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

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

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

A-4 Perform 30 Day Service ..................................................................... 3 - 8

A-5 Grease the Steer Yokes ..................................................................... 3 - 8

vii

September 2008


TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

A Checklist B Procedures

B-1 Inspect the Batteries ........................................................................... 3 - 9

B-2 Inspect the Electrical Wiring ............................................................. 3 - 11

B-3 Inspect the Tires and Wheels (including castle nut torque) ............... 3 - 12

B-4 Test the Emergency Stop ................................................................. 3 - 12

B-5 Test the Key Switch .......................................................................... 3 - 13

B-6 Test the Automotive-style Horn (if equipped) .................................... 3 - 13

B-7 Inspect the Voltage Inverter (if equipped) ......................................... 3 - 14

B-8 Test the Drive Brakes ....................................................................... 3 - 15

B-9 Test the Drive Speed - Stowed Position ........................................... 3 - 16

B-10 Test the Drive Speed - Raised Position ............................................ 3 - 17

B-11 Test the Slow Drive Speed ............................................................... 3 - 18

B-12 Test the Flashing Beacons ............................................................... 3 - 19

B-13 Test the Motion Alarm (if equipped) .................................................. 3 - 19

B-14 Perform Hydraulic Oil Analysis ......................................................... 3 - 20

B-15 Inspect the Breather Cap .................................................................. 3 - 21

A Checklist C Procedure

C-1 Replace the Hydraulic Tank Breather Cap -Models with Optional Hydraulic Oil ................................................... 3 - 22

A Checklist D Procedure

D-1 Replace the Hydraulic Tank Return Filter ......................................... 3 - 23

A Checklist E Procedure

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 24

viii

September 2008


TABLE OF CONTENTS

Section 4 Rev Repair Procedures

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

A Platform Controls

1-1 Circuit Boards .................................................................................... 4 - 2

1-2 Controller Adjustments ....................................................................... 4 - 3

1-3 Software Configuration ....................................................................... 4 - 8

A Platform Components

2-1 Platform ........................................................................................... 4 - 12

2-2 Platform Extension ........................................................................... 4 - 12

A Mast Components

3-1 Mast ................................................................................................. 4 - 14

3-2 Wear Pads ....................................................................................... 4 - 25

3-3 Lift Cylinder ...................................................................................... 4 - 26

3-4 Lift Cylinder Wear Block ................................................................... 4 - 28

3-5 Mast Coil Cord ................................................................................. 4 - 28

A Ground Controls

4-1 Level Sensor .................................................................................... 4 - 29

A Hydraulic Pump

5-1 Function Pump ................................................................................. 4 - 32

A Function Manifold

6-1 Function Manifold Components ........................................................ 4 - 34

6-2 Valve Adjustments - Function Manifold ............................................ 4 - 36

6-3 Valve Coils ....................................................................................... 4 - 40

A Hydraulic Tank

7-1 Hydraulic Tank ................................................................................. 4 - 42

ix

September 2008


TABLE OF CONTENTS

x

Section 4 Rev Repair Procedures, continued

A Steer Axle Components

8-1 Yoke and Drive Motor ...................................................................... 4 - 43

8-2 Steer Cylinder .................................................................................. 4 - 45

8-3 Steer Bellcrank ................................................................................. 4 - 45

A Non-steer Axle Components

9-1 Drive Brake ...................................................................................... 4 - 46

A Brake Release Hand Pump Components

10-1 Brake Release Hand Pump Components ......................................... 4 - 47

Section 5 Rev Fault Codes

Introduction .................................................................................................. 5 - 1

A Fault Code Chart ......................................................................................... 5 - 3

Section 6 Rev Schematics

A Introduction .................................................................................................. 6 - 1

A Electrical Component and Wire Color Legends ........................................... 6 - 2

A Relay Layout and ECM Pin-out Legend ....................................................... 6 - 3

A Wiring Diagram - Ground and Platform Controls .......................................... 6 - 4

A Electrical Symbols Legend........................................................................... 6 - 5

A Electrical Schematic .................................................................................... 6 - 6

A Hydraulic Component Reference and Symbol Legend ................................ 6 - 9

A Hydraulic Schematic .................................................................................. 6 - 10

Section 2 • Specifications

REV A

September 2008

Part No. 115370 GRC-12 2 - 1

Machine Specifications

Batteries, Standard

Voltage 6V DC

Group GC2

Type T-105

Quantity 4

Battery capacity, maximum 225AH

Reserve capacity @ 25A rate 447 minutes

Batteries, Maintenance-free (option)

Voltage 6V DC

Group GC2

Type 6V-AGM

Quantity 4

Battery capacity, maximum 200AH

Reserve capacity @ 25A rate 380 minutes

Fluid capacities

Hydraulic tank 1.5 gallons5.7 liters

Hydraulic system 2.2 gallons(including tank) 8.3 liters

Height, stowed maximum

GRC-12 66.8 in1.69 m

For operational specifications, refer to theOperator's Manual.

Tires and wheels

Tire size (solid rubber) 10 x 3 in25.4 x 2.5 cm

Tire contact area 6.5 sq in 41.9 cm2

Castle nut torque, dry 225 ft-lbs305 Nm

Castle nut torque, lubricated 175 ft-lbs237 Nm

Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.

Specifications


REV A

September 2008

2 - 2 GRC-12 Part No. 115370

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type Chevron Rykon MV equivalentViscosity grade Multi-viscosityViscosity index 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Environ MV 46Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046Quintolubric 822

Mineral based Shell Tellus T32Shell Tellus T46

Chevron Aviation A

Continued use of ChevronAviation A hydraulic fluid whenambient temperatures areconsistently above 32°F / 0°C mayresult in component damage.

Note: Use Chevron Aviation A hydraulic fluidwhen ambient temperatures are consistentlybelow 0°F / -17°C.

Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.

Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.

SPECIFICATIONS

Performance Specifications

Drive speed, maximum

Platform stowed, fast 2.5 mph40 ft / 10.9 sec

4 km/h12.2 m / 10.9 sec

Platform stowed, slow 1.1 mph40 ft / 24.8 sec

1.8 km/h12.2 m / 24.8 sec

Platform raised 0.5 mph40 ft / 55 sec

0.8 km/h12.2 m / 55 sec

Braking distance, maximum

High range on paved surface 19 in ± 6 in48 cm ± 15 cm

Gradeability 30%

Airborne noise emissions 70 dBMaximum sound level at normal operation workstations(A-weighted)

Function speed, maximum, from platform controls(with 1 person in platform)

Platform up 10 to 14 secondsPlatform down 14 to 18 seconds

Rated work load at full height, maximum

Platform 500 lbs227 kg



REV A

September 2008

Part No. 115370 GRC-12 2 - 3

SPECIFICATIONS

Manifold ComponentSpecifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 13 ft-lbs / 18 Nm





Valve Coil Resistance

Note: The following coil resistance specifications are atan ambient temperature of 68°F / 20°C. As valve coilresistance is sensitive to changes in air temperature,the coil resistance will typically increase or decrease by4% for each 18°F / -7.7°C that your air temperatureincreases or decreases from 68°F / 20°C.

Description Specification

Solenoid valve, 3 position 4 way 18 to 21Ω20V DC with diode (schematic item E)

Solenoid valve, 3 position 4 way 25 to 28Ω20V DC with diode (schematic item F)

Solenoid valve, 2 position 4 way 18 to 21Ω20V DC with diode (schematic item H)

Solenoid valve, 2 position 2 way N.C. 7.5 to 10.5Ωwith manual override12V DC with diode (schematic item N)


Function pump

Type Gear

Displacement per revolution 0.244 cu in 4 cc

Flow rate @ 2500 psi / 172 bar 4 gpm15 L/min

Hydraulic tank return filter 10 micron with25 psi / 1.7 bar bypass

Function manifold

System relief valve pressure, maximum 3500 psi241 bar

Lift relief valve pressure 1800 to 3500 psi124 to 241 bar

Steer relief valve pressure 1500 psi103 bar


REV A

September 2008

2 - 4 GRC-12 Part No. 115370

Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with JIC 37° flaredfittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.

JIC 37° Fittings(swivel nut or hose connection)

SAE Dash size Thread Size Flats

-4 7/16-20 2

-6 9/16-18 1 1/4

-8 3/4-16 1

-10 7/8-14 1

-12 1 1/16-12 1

-16 1 5/16-12 1

-20 1 5/8-12 1

-24 1 7/8-12 1

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

SAE Dash size Torque

-4 11 ft-lbs / 14.9 Nm

-6 23 ft-lbs / 31.2 Nm

-8 40 ft-lbs / 54.2 Nm

-10 69 ft-lbs / 93.6 Nm

-12 93 ft-lbs / 126.1 Nm

-16 139 ft-lbs / 188.5 Nm

-20 172 ft-lbs / 233.2 Nm

-24 208 ft-lbs / 282 Nm

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

SAE Dash size Torque

-4 16 ft-lbs / 21.7 Nm

-6 35 ft-lbs / 47.5 Nm

-8 60 ft-lbs / 81.3 Nm

-10 105 ft-lbs / 142.4 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 284.7 Nm

-20 260 ft-lbs / 352.5 Nm

-24 315 ft-lbs / 427.1 Nm

SPECIFICATIONS


REV A

September 2008

Part No. 115370 GRC-12 2 - 5

a

b

c

b

3 Working clockwise on the body hex fitting, makea second mark with a permanent ink marker toindicate the proper tightening position. Refer toFigure 2.

Use the JIC 37° Fittings table onthe previous page to determinethe correct number of flats for theproper tightening position.

The marks indicate that the correcttightening positions have beendetermined. Use the second markon the body hex fitting to properlytighten the joint after it has beenloosened.

Figure 1

a hydraulic hoseb hex nutc reference markd body hex fitting

b

c

a

d

Torque ProcedureJIC 37° fittings

1 Align the tube flare (hex nut) against the nose ofthe fitting body (body hex fitting) and tighten thehex 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 thehex nut, and continue it on to the body hexfitting with a permanent ink marker. Refer toFigure 1.

Figure 2

a body hex fittingb reference markc second mark

4 Tighten the hex nut until the mark on the hexnut is aligned with the second mark on the bodyhex fitting.

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

SPECIFICATIONS


REV A

September 2008

2 - 6 GRC-12 Part No. 115370

SPECIFICATIONS

Size

(mm)in- lbs N m in- lbs N m in-lbs N m in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m

5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

f t- lbs N m ft- lbs N m ft-lbs N m ft-lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m

8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.610 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

LUBEDDRYLUBED

Class 12.9Class 4.6

DRYLUBED

METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •

LUBED DRY

Class 10.9Class 8.8

DRY

SIZE THREAD

in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft - lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

5/16

3/8

7/16

1/2

10.9 12.98.84.6

Section 3 • Scheduled Maintenance ProceduresSeptember 2008

Part No. 115370 GRC-12 3 - 1

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completedby a person trained and qualified on themaintenance of this machine.

Scheduled maintenance inspections shall becompleted daily, quarterly, semi-annually,annually and every 2 years as specified on theMaintenance Inspection Report.

Failure to properly complete eachinspection when required maycause death, serious injury orsubstantial machine damage.

Immediately tag and remove from service adamaged or malfunctioning machine.

Repair any machine damage or malfunctionbefore operating the machine.

Use only Genie approved replacement parts.

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

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

· Machine parked on a firm, level surface

· Platform in the stowed position

· Key switch in the off position with the keyremoved

· The red Emergency Stop button in the offposition at both ground and platform controls

· Wheels chocked

· All external AC power supply disconnectedfrom the machine

About This Section

This section contains detailed procedures for eachscheduled maintenance inspection.

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

Symbols Legend






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

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

Section 3 • Scheduled Maintenance Procedures September 2008

3 - 2 GRC-12 Part No. 115370

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend

Note: The following symbols have been used inthis manual to help communicate the intent of theinstructions. When one or more of the symbolsappears at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will be requiredto perform this procedure.

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

Indicates that dealer service will berequired to perform this procedure.

Pre-delivery Preparation Report

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

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

Maintenance Schedule

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

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours A + B

Semi-annually or every 500 hours A + B + C

Annually or every 1000 hours A + B + C + D

Two year or every 2000 hours A + B + C + D + E

Maintenance Inspection Report

The maintenance inspection report containschecklists for each type of scheduled inspection.

Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of 4 years or in compliancewith employer, jobsite and governmentalregulations and requirements.


Part No. 115370 GRC-12 3 - 3

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

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

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

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

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompleted

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.

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

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

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

Comments

Fundamentals

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

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

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

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

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


3 - 4 GRC-12 Part No. 115370



Part No. 115370 GRC-12 3 - 5

Maintenance Inspection Report

Checklist B - Rev A Y N R

B-1 Batteries

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Emergency stop

B-5 Key switch

B-6 Horn (if equipped)

B-7 Inverter (if equipped)

B-8 Drive brakes

B-9 Drive speed - stowed

B-10 Drive speed - raised

B-11 Drive speed - slow

B-12 Flashing beacons

B-13 Alarm (if equipped)

B-14 Hydraulic oil analysis

B-15 Breather cap

Checklist C - Rev A Y N R

C-1 Breather cap - modelswith optional oil

Checklist D - Rev A Y N R

D-1 Tank return filter

Checklist E - Rev A Y N R

E-1 Hydraulic oil

Checklist A - Rev A Y N R

A-1 Inspect the manualsand decals

A-2 Pre-operationinspection

A-3 Function tests

Perform after 40 hours:

A-4 30 day service

Perform every 100 hours:

A-5 Grease steer yokes

Instructions· Make copies of this report to use for

each inspection.

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

Daily or 8 hoursInspection: A

Quarterly or 250 hoursInspection: A+B

Semi-annually or500 hoursInspection: A+B+C

Annually or1000 hoursInspection: A+B+C+D

Two year or2000 hoursInspection: A+B+C+D+E

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

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

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

LegendY = yes, acceptableN = no, remove from service

R = repaired

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Comments

Section 3 • Scheduled Maintenance Procedures

REV A

September 2008

3 - 6 GRC-12 Part No. 115370

A-1Inspect the Manuals and DecalsGenie specifications require that this procedure beperformed every 8 hours or daily, whichevercomes first.

Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.

In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and couldresult in unsafe operating conditions.

1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.

2 Examine the pages of each manual to be surethat they are legible and in good condition.

Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.

Result: The operator's manual is notappropriate for the machine or all manuals arenot in good condition or is illegible. Remove themachine from service until the manual isreplaced.

Checklist A Procedures

3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.

Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.

Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.

4 Always return the manuals to the storagecontainer after use.

Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.


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CHECKLIST A PROCEDURES

A-2Perform Pre-operation InspectionGenie specifications require that this procedure beperformed every 8 hours or daily, whichevercomes first.

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

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.

A-3Perform Function TestsGenie specifications require that this procedure beperformed every 8 hours or daily, whichevercomes first.

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

Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.


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A-4Perform 30 Day Service

The 30 day maintenance procedure is a one-timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage. After thisinterval, refer to the maintenance checklists forcontinued scheduled maintenance.

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

1 Perform the following maintenance procedures:

· B-3 Inspect the Tires and Wheels(including castle nut torque)

· D-1 Replace the Hydraulic TankReturn Filter

A-5Grease the Steer Yokes

Genie specifications require that this procedure beperformed every 100 hours of operation.

Regular application of lubrication to the steer yokesis essential to good machine performance andservice life. Continued use of an insufficientlygreased steer yoke will result in componentdamage.

1 Locate the grease fitting on the top of the steeryoke.

2 Pump multipurpose grease into the steer yokeuntil the steer yoke is full and grease is beingforced past the bearings. Repeat this step forthe other steer yoke.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 1 (lithium based)or equivalent

CHECKLIST A PROCEDURES


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Checklist B Procedures

B-1Inspect the Batteries

Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

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

Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.

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

1 Put on protective clothing and eye wear.

2 Raise the platform approximately 3 feet / 1 m.

3 Open the battery cover. Rest the cover againstthe chassis.

4 Lower the platform until the mast just contactsthe battery cover.

Crushing hazard. Keep handsclear of the battery cover whenlowering the platform.

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

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.

6 Be sure that the battery hold downs and cableconnections are tight.

-

+

-

+

-

+

-

+

275A FuseF6

-

+

QD1

a

b

c

Battery Charger

U9

RDBK

d

a batteries B5b 275A fuse F6c quick disconnect QD1d battery charger U9

7 Be sure that the battery separator wireconnections are tight (if equipped).

8 Fully charge the batteries. Allow the batteries torest 24 hours before performing this procedureto allow the battery cells to equalize.

9 Put on protective clothing and eye wear.

Models without maintenance-free or sealedbatteries:

10 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.


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CHECKLIST B PROCEDURES

11 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 15.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 12.

12 Perform an equalizing charge OR fully chargethe batteries and allow the batteries to rest atleast 6 hours.

13 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

14 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:

• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specific gravityof 1.277 or greater. The battery is fully charged.Proceed to step 15.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.177. Replace the battery.

15 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.

16 Install the vent caps and neutralize anyelectrolyte that may have spilled.

All models:

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

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

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

Result: The charger should operate and begincharging the batteries.

If, simultaneously, the charger alarm soundsand the LEDs blink one time, correct thecharger connections at the fuse and battery.The charger will then operate correctly andbegin charging the batteries.

If, simultaneously, the charger alarm soundsand the LEDs blink two times, the input voltageis too low or too high. Correct the voltage issue.The charger will then operate correctly andbegin charging the batteries.

If, simultaneously, the charger alarm soundsand the LEDs blink three times, the charger isoverheated. Allow the charger to cool. Thecharger will then operate correctly and begincharging the batteries.

Note: For best results, use an extension ofadequate size with a length no longer than50 feet / 15 m.

Note: If you have any further questions regardingthe battery charger operation, please contact theGenie Industries Scissor Service Department.


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B-2Inspect the Electrical Wiring


Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.


1 Inspect the underside of the chassis fordamaged or missing ground straps.

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

· Mast cable

· Platform controls

· Power to platform wiring

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

· Ground control panel

· Hydraulic power unit

4 Inspect for a liberal coating of dielectric greasein all wiring connections between the ECM andthe platform controls, and level sensor wiring.

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

6 Raise the platform approximately 8 feet / 2.4 mfrom the ground.

7 Place a lifting strap from an overhead craneunder the platform. Support the platform. Do notapply any lifting pressure.

Component damage hazard. Theplatform railings can be damagedif they are used to lift the platform.Do not attach the lifting strap tothe platform railings.

8 Inspect the center chassis area for burnt,chafed and pinched cables.

9 Open the battery tray cover.

10 Inspect the battery tray for burnt, chafed andpinched cables.

11 Close the battery tray cover.

12 Remove the strap from the platform.

13 Lower the platform to the stowed position andturn the machine off.


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B-3Inspect the Tires and Wheels(including castle nut torque)


Maintaining the tires and wheels in good condition,including proper castle nut torque, is essential tosafe operation and good performance. Tire and/orwheel failure could result in a machine tip-over.Component damage may also result if problemsare not discovered and repaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts,cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracks.

3 Remove the cotter pin and check each castlenut for proper torque. Refer to Section 2,Specifications.

Note: Always replace the cotter pin with a new onewhen removing the castle nut or when checkingthe torque of the castle nut.

4 Install a new cotter pin. Bend the cotter pin tolock it in place.

B-4Test the Emergency StopGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

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

Note: As a safety feature, selecting and operatingthe ground controls will override the platformcontrols, except the platform red Emergency Stopbutton.


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

Result: No machine functions should operate.

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

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


Note: The red Emergency Stop button at theground controls will stop all machine operation,even if the key switch is switched to platformcontrol.


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B-5Test the Key SwitchGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

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

Note: Perform this procedure from the groundusing the platform controls. Do not stand in theplatform.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Turn the key switch to platform control.

3 Check the platform up/down function from theground controls.

Result: The machine functions should notoperate.

4 Turn the key switch to ground control.

5 Check the machine functions from the platformcontrols.

Result: The machine functions should notoperate.

6 Turn the key switch to the off position.

7 Test the machine functions from the ground andplatform controls.


B-6Test the Automotive-style Horn(if equipped)Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

The horn is activated at the platform controls andsounds at the ground as a warning to groundpersonnel. An improperly functioning horn willprevent the operator from alerting groundpersonnel of hazards or unsafe conditions.

1 Turn the key switch to platform control andpull out the red Emergency Stop button to theon position at both the ground andplatform controls.

2 Push down the horn button at the platformcontrols.

Result: The horn should sound.


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B-7Inspect the Voltage Inverter(if equipped)Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

The inverter is activated whenever the power is on,and an electrical tool is connected to the inverterand turned on.

1 Inspect the inverter plug and pigtail for damageor excessive insulation wear. Replace asrequired.

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

FAULTFAULT

PART NUMBER XXX

PART NUMBER XXX

OUTPUTOUTPUT

POWER INVERTER

POWER INVERTER25V

24V-22V24V-22V21V

b

c

d

a

a right fault LEDb left fault LEDc 25V LEDd 21V LED

3 Connect an appropriate power tool to theinverter. Activate the tool.

Result: The power tool should operate. Theremay be a brief (0.5 second) delay if the powertool has not been used in the previous 10minutes.

If the left fault LED (REV_POL) is illuminated,the inverter is connected to batteries with theincorrect polarity. Correct the polarity issue withthe red wire to battery positive and the blackwire to battery negative. The inverter will thenoperate correctly and begin supplying ACpower.

If the right fault LED (123) blinks one time, thepower draw is too high. The tool being usedrequires too much power to operate or is beingused at or near the limit of the inverter for anextended period of time. Reduce the powerdraw. The inverter will then operate correctlyand begin supplying AC power.

If the right fault LED (123) blinks two times, theGround Fault Interrupt (GFI) has beenactivated. A short circuit or partial short existsbetween the AC hot and ground in the tool oroutlet. Check the tool for burnt, chafed,corroded and loose wires, and inspect the toolfor internal moisture. Correct the short circuit ormoisture issue OR inspect the wiring in thepower-to-platform box. The inverter will thenoperate correctly and begin supplying ACpower.

If right fault LED (123) blinks three times, theinverter is overheated. Allow the inverter tocool. The inverter will then operate correctlyand begin supplying AC power.

If the battery 25 volt fault LED (25V) blinks onetime, the battery voltage is over 30V. Operatethe machine to lower the voltage level. Theinverter will then operate correctly and beginsupplying AC power.

If the battery 21 volt fault LED (21V) blinks onetime, the battery voltage is less than 20V DC.The inverter will continue to operate until thebattery voltage falls to 17.8V DC.


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B-8Test the Drive Brakes


Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when notfully operational.

Note: Perform this procedure with the machine ona firm, level surface that is free of obstructions.

Note: Be sure the platform extension deck is fullyretracted and the platform is in the stowed position.

1 Mark a test line on the ground for reference.


3 Lower the platform to the stowed position.

4 Press the drive function select button.

5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

a

a drive function select button BN8

6 Bring the machine to top drive speed beforereaching the test line. Release the functionenable switch or the joystick when yourreference point on the machine crosses the testline.

7 Measure the distance between the test line andyour machine reference point. Refer to Section2, Specifications.

Note: The brakes must be able to hold the machineon any slope it is able to climb.


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B-9Test the Drive Speed -Stowed Position


Proper drive functions are essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.


1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.




5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

a

a drive function select button BN8

6 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.

7 Continue at full speed and note the time whenyour reference point on the machine passesover the finish line. Refer to Section 2,Specifications.


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B-10Test the Drive Speed -Raised Position






3 Press the lift function select button.

4 Press and hold the function enable switch onthe joystick.

5 Raise the platform approximately 4 feet / 1.2 mfrom the ground.


a lift function select button BN9b drive function select button BN8




ba


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B-11Test the Slow Drive Speed







4 Press the slow speed select button.


a

a slow speed select button BN6




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B-12Test the Flashing BeaconsGenie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Flashing beacons are used to alert operators andground personnel of machine proximity andmotion. The flashing beacons are located on bothsides of the mast.


Result: The beacons should flash.

2 Turn the key switch to platform controls.

Result: The beacons should flash.

B-13Test the Motion Alarm(if equipped)Genie specifications require that this procedure beperformed every 250 hours or quarterly, whichevercomes first.

Alarms are used to alert operators and groundpersonnel of machine proximity and motion. Themotion alarm is located in the ground control boxand, when activated, will sound at 60 beeps perminute.


2 Raise the platform approximately 1 foot / 0.3 m.

Result: When raising the platform, the motionalarm should sound.


Result: When lowering the platform, the motionalarm should sound.

4 Turn the key switch to platform controls.


6 Press and hold the function enable switch onthe joystick. Move the joystick off center, holdfor a moment and then release it. Move thejoystick off center in the opposite direction, holdfor a moment and then release it.

Result: The motion alarm should sound whenthe joystick is moved off center in eitherdirection.



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8 Press and hold the function enable switch onthe joystick. Move the joystick off center, holdfor a moment and then release it. Move thejoystick off center in the opposite direction, holdfor a moment and then release it.

Result: The motion alarm should sound whenthe joystick is moved off center in eitherdirection.

9 Press and hold the function enable switch onthe joystick. Press and hold the thumb rockerswitch for a moment to the left position and thenrelease it. Press and hold the thumb rockerswitch for a moment to the right position andthen release it.

Result: The motion alarm should sound whenthe rocker switch is moved off center in eitherdirection.

B-14Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften. Refer to Section 2, Specifications.

Before replacing the hydraulic oil, the oil may betested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary.If the hydraulic oil is not replaced at the twoyear inspection, test the oil quarterly. Replacethe oil when it fails the test. See E-1, Test orReplace the Hydraulic Oil.


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B-15Inspect the Breather CapGenie specifications require that this procedure beperformed quarterly or every 250 hours, whichevercomes first. Perform this procedure more often ifdusty conditions exist.

A free-breathing hydraulic tank cap is essential forgood machine performance and service life. A dirtyor clogged cap may cause the machine to performpoorly. Extremely dirty conditions may require thatthe cap be inspected more often.

1 Remove the breather cap from the hydraulictank.

2 Check for proper venting.

Result: Air passes through the breather cap.

Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.

Note: When checking for positive tank cap venting,air should pass freely through the cap.

3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat step 2.

4 Install the breather cap onto the hydraulic tank.


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C-1Replace theHydraulic Tank Breather Cap -Models with Optional Hydraulic Oil

Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first OR when the machine failsto lift the maximum rated load.

The hydraulic tank is a vented-type tank. Thebreather cap has an internal air filter that canbecome clogged or, over time, can deteriorate. Ifthe breather cap is faulty or improperly installed,impurities can enter the hydraulic system whichmay cause component damage. Extremely dirtyconditions may require that the cap be inspectedmore often.

1 Remove and discard the hydraulic tank breathercap.

2 Install and new cap onto the tank.

Checklist C Procedure


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Checklist D Procedure

D-1Replace theHydraulic Tank Return Filter

Genie specifications require that this procedure beperformed every 1000 hours or annually,whichever comes first.

Replacement of the hydraulic tank return filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Beware of hot oil. Contact with hotoil may cause severe burns.

Note: The hydraulic tank return filter is mounted onthe function manifold next to the hydraulic powerunit.

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

2 Apply a thin layer of oil to the new oil filtergasket.

3 Install the new filter and tighten it securely byhand.

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


6 Activate and hold the platform up toggle switch.

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

8 Clean up any oil that may have spilled.

Torque specifications

Hydraulic tank drain plug, dry 40 in-lbs4.5 Nm

Hydraulic tank drain plug, lubricated 30 in-lbs3.4 Nm


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Checklist E Procedure

E-1Test or Replace the Hydraulic Oil

Genie specifications require that this procedure beperformed every 2000 hours or every two years,whichever comes first.

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

Before replacing the hydraulic oil, the oil may betested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.

Note: Perform this procedure with the platform inthe stowed position.

1 Disconnect the battery pack from the machine.


2 Open the power unit module tray.

3 Tag and disconnect the hydraulic tank returnhard line from the hydraulic filter head andremove the hard line from the tank. Cap thefitting on the filter head.

4 Tag and disconnect the hydraulic pump inlethard line and remove the hard line from thetank. Cap the fitting on the pump.

5 Remove the hydraulic tank retaining fastenersand remove the hydraulic tank from themachine.

6 Drain all of the oil into a suitable container.Refer to Section 2, Specifications, for capacityinformation.

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

7 Clean up any oil that may have spilled. Properlydiscard the used oil.

8 Clean the inside of the hydraulic tank using amild solvent. Allow the tank to dry completely.

9 Install the hydraulic tank and install and tightenthe hydraulic tank retaining fasteners. Torque tospecification.


Hydraulic tank retaining fasteners, dry 35 in-lbs4 Nm

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


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CHECKLIST E PROCEDURE

10 Install the hydraulic pump inlet hard line into thetank. Install the fitting onto the pump and torqueto specification. Refer to Section 2,Specifications.

11 Install the hydraulic pump return hard line intothe tank. Install the fitting onto the hydraulicfilter head and torque to specification. Refer toSection 2, Specifications.

12 Fill the tank with hydraulic oil until the fluid is atthe FULL indicator on the hydraulic tank. Do notoverfill.

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

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

14 Repeat steps 12 through 13 until the hydraulicsystem and tank are both full.


3 - 26 GRC-12 Part No. 115370


Section 4 • Repair ProceduresSeptember 2008

Part No. 115370 GRC-12 4 - 1

Repair Procedures

Observe and Obey:

Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.



Before Repairs Start:

Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.

Be sure that all necessary tools and parts areavailable and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhere tothe instructions. Attempting shortcuts mayproduce hazardous conditions.

Unless otherwise specified, perform each repairprocedure with the machine in the followingconfiguration:





· Wheels chocked


About This Section

Most of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.

Perform disassembly procedures to the pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.

Symbols Legend






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

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

Section 4 • Repair Procedures

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The platform controls, used to operate the machinefrom the platform or while standing on the ground,can also be used to tune the performance of themachine.

Moving the joystick or activating a button sends asignal to the Electronic Control Module (ECM).When the ECM is in the function mode, theplatform controls are used to operate the variousmachine functions. When the ECM is in the speedtuning mode (PS is shown in the diagnostic displaywindow) or software configuration mode (SC isshown in the diagnostic display window), theplatform controls are used to adjust the functionspeed parameters or the machine configuration.

The platform controls consist of an electroniccircuit board, joystick, alarm, buttons and LEDs.

For further information or assistance, consult theGenie Industries Service Department.

1-1Circuit Boards

How to Remove the PlatformControls Circuit Board1 Push in the red Emergency Stop button to the

off position at both the ground and platformcontrols.

2 Remove the retaining fasteners securing thebottom to the platform control box. Open thecontrol box.

3 Remove the ties securing the wire harness.

4 Remove the alarm and red Emergency Stopbutton from the platform control box.

5 Carefully disconnect the three wire harnessconnectors from the platform controls circuitboard.


Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.

6 Carefully remove the platform controls circuitboard retaining fasteners.

7 Carefully remove the platform controls circuitboard from the platform control box lid.

Platform Controls

a joystick controller JC1b alarm H1c platform controls circuit board U3d red Emergency Stop button P2

d

b

a

c


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1-2Controller Adjustments

Platform lift speed, stowed drive speed, raiseddrive speed and slow drive speed are adjustable tocompensate for wear in the hydraulic pump anddrive motors.

The function speeds are determined by thepercentage of total controller output.

For further information or assistance, consult theGenie Industries Service Department.

Tip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingthe function speeds greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.

Tip-over hazard. This proceduremust only be performed by atrained service professional.Attempting this procedure withoutthe necessary skills could result indeath or serious injury.

Note: Select a test area that is firm, level and freeof obstructions.

How to Determine theSoftware Revision Level1 Remove the platform controls from the platform.

2 Place the platform controls close to thediagnostic display on the power unit side of themachine.

PLATFORM CONTROLS

a joystick controller JC1b lift function select button BN9c diagnostic display windowd red Emergency Stop button P2e yellow arrow


Result: The diagnostic display at the platformcontrols will show the battery condition. See1-3, How to Determine the Battery Voltage.


5 Slowly move the joystick in the directionindicated by the yellow arrow.

Result: The software revision level will appearin the diagnostic display.

6 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols and turn the key switch to the offposition.

a

e

d

c

b


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PLATFORM CONTROLS

How to Adjust the Lift SpeedTip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingthe function speeds greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.

Tip-over hazard. This proceduremust only be performed by atrained service professional.Attempting this procedure withoutthe necessary skills will result indeath or serious injury.

1 Pull out the red Emergency Stop button to theon position at the ground controls.

2 Push in the red Emergency Stop button to theoff position at the platform controls.


4 At the platform controls, press and hold the liftfunction select and horn buttons and pull outthe red Emergency Stop button to the onposition.

Result: The diagnostic display will show "PS."

5 Release the lift function select and hornbuttons.

Result: The diagnostic display will show themaximum lift speed percentage.


a joystick controller JC1 with thumbsteering rocker SW6

b horn button BN5c lift function select button BN9d red Emergency Stop button P2

7 Use the steering thumb rocker switch on thejoystick to increase or decrease the maximumlift speed percentage. Refer to Section 2,Specifications, for function speeds.


Note: Any change in software settings will not takeeffect until the key switch is turned to the offposition.

b

c

d

a


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PLATFORM CONTROLS

How to Adjust the Stowed DriveSpeed











b horn button BN5c lift function select button BN9d red Emergency Stop button P2e drive function select button BN8


Result: The diagnostic display will show thestowed drive speed percentage.

7 Use the steering thumb rocker switch on thejoystick to increase or decrease the stoweddrive speed percentage. Refer to Section 2,Specifications, for function speeds.



a

b

ec

d


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PLATFORM CONTROLS

How to Adjust the Raised DriveSpeed











b horn button BN5c lift function select button BN9d red Emergency Stop button P2


7 Press and hold the horn button.

Result: The diagnostic display will show theraised drive speed percentage.

8 Use the steering thumb rocker switch on thejoystick to increase or decrease the maximumlift speed percentage. Refer to Section 2,Specifications, for function speeds.



a

b

c

d


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How to Adjust the Slow DriveSpeed











b horn button BN5c lift function select button BN9d red Emergency Stop button P2e slow speed select button BN6

6 Press and hold the slow speed select button.

Result: The diagnostic display will show theslow drive speed percentage.

7 Use the steering thumb rocker switch on thejoystick to increase or decrease the stowedhigh torque drive speed percentage. Refer toSection 2, Specifications, for function speeds.



PLATFORM CONTROLS

a

b

c

e

d


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1-3Software Configuration

The Electronic Control Module (ECM) containsprogramming for all configurations of the GenieGRC. The machine can be adjusted to a differentconfiguration using the buttons at the platformcontrols.

How to Determine theSoftware Configuration1 Remove the platform controls from the platform.

2 Place the platform controls close to thediagnostic display on the power unit side of themachine.



5 At the platform controls, press and hold the liftfunction select and speed select buttons, andpull out the red Emergency Stop button to theon position.

Result: The diagnostic display, at the platformcontrols and the ECM, will show "SC."

PLATFORM CONTROLS

a lift function select button BN9b diagnostic displayc red Emergency Stop button P2d drive function select button BN8

6 Release the lift function select and speed selectbuttons.

Result: The diagnostic display will show thecurrent configuration.

7 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols and turn the key switch to the offposition.

a

c

b

d


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How to Change theSoftware Configuration1 Pull out the red Emergency Stop button to the

on position at the ground controls.





5 Release the lift function select and drivefunction select buttons.

Result: The diagnostic display will show thecurrent software configuration.


Result: The 'tens' digit setting will be activatedand the current 'tens' setting will flash in thediagnostic display. Use the steering thumbrocker switch on the joystick to increase ordecrease the value. See 1-3, MachineConfiguration Code Chart for configurationsettings.

7 Press and hold the lift function select button fora minimum of 3 seconds to set the 'tens' value.

PLATFORM CONTROLS


b lift function select button BN9c diagnostic displayd red Emergency Stop button P2e slow speed select button BN6f blue arrow


Result: The 'ones' digit setting will be activatedand the current 'ones' setting will flash in thediagnostic display. Use the steering thumbrocker switch on the joystick to increase ordecrease the value. See 1-3, MachineConfiguration Code Chart for configurationsettings.

9 Press and hold the slow speed select button fora minimum of 3 seconds or until the 'ones'setting stops flashing.



a

b

d

c

f

e


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Machine ConfigurationCode ChartA mark in the four right columns indicates that themachine configuration, at left, includes this feature.

PLATFORM CONTROLS

Machine Option / FeatureDefinitionsNon-slab Option: For the GRC to functioncorrectly, each model is configured with this option.Motion Alarm: The motion alarm will sound whenoperating any function.

Lift/Drive Cut Out: In addition to an alarmsounding, lift and drive functions are disabled whenthe platform is raised above the down limit switchand the incline of the chassis exceeds the rating onthe serial plate. Configured on all machines.

Battery Drain Alarm: When the machine is turnedon and in the stowed position, and no function isactivated for 2 minutes, an alarm will sound onceevery 3 seconds.When this option is configured, a dot in thediagnostic display window will remain continuouslyilluminated when the ECM is in the 'SC' mode ORwhen the platform up function is activated.

Machine Function Code at

Diagnostic Display

Non-slab Option

Motion Alarm

Lift/Drive Cut Out

05 • •29 • •30 • • •31 • • •


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PLATFORM CONTROLS

How to Activate theBattery Drain Alarm Option1 Pull out the red Emergency Stop button to the

on position at the ground controls.





5 Release the lift function select and speed selectbuttons.

Result: The diagnostic display will show thecurrent software configuration.


Result: The 'ones' digit setting will be activatedand the current 'ones' setting will flash in thediagnostic display.

7 Press the horn button.

Result: A dot, located at the lower right of thediagnostic display window, will becomeilluminated. This indicates that the battery drainalarm option has been activated.

8 Press and hold the speed select button for aminimum of 3 seconds or until the 'ones' settingstops flashing.


Note: To deactivate the battery drain alarm optionon a machine which has the option activated,repeat this procedure. When the ECM is in the 'SC'mode and the option is deactivated, there will notbe an illuminated dot in the diagnostic displaywindow.

How toDetermine the Battery VoltageThe diagnostic display on the platform controls isused to indicate the battery voltage at all timeswhen the machine is in normal operation.

Limp Mode: If the battery level falls to less than17.8V DC, the single bar in the diagnostic displaywill be flashing and machine drive speed is limitedto that of the raised drive speed. Refer to Section2, Specifications.

the battery level is 22.6V DC or higher

the battery level is 21.6 to 22.5V DC




the battery level is less than 17.8V DC


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2-1Platform

How to Remove the Platform1 Disconnect the platform controls from the

control cable at the platform, and remove theplatform controls from the platform. Set theplatform controls to the side.

2 Carefully cut all cable ties securing the controlcable to the platform.

Component damage hazard. Thecontrol cable can be damaged ifcut while removing the cable ties.

3 Attach a lifting strap of suitable capacity froman overhead crane and center it around theplatform railing. Support the platform. Do notapply any lifting pressure.

4 Remove the fasteners securing the platformto the mast and set the fasteners to the side.Remove the platform from the machine.

Crushing hazard. The platformcould become unbalanced and fallwhen removed from the machine.A properly centered lifting strapis essential when removing theplatform from the machine.

Note: During removal, the overhead crane strapwill need to be carefully adjusted for properbalancing.

Platform Components

2-2Platform Extension

How to Remove thePlatform Extension Deck1 Remove the fasteners and spring securing the

extension deck latch to the extension deck. Setthe fasteners, spring and the latch to the side.

2 Remove the fasteners securing the platformwear pads to the main deck at the steer endof the machine. Set the fasteners and the wearpads to the side.

3 Remove the fasteners securing the extensiondeck guide blocks to the extension deck andmain deck. Set the fasteners and the guideblocks to the side.

a extension deck latchb platform wear padc extension deck guide block


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4 Attach a lifting strap of suitable capacity froman overhead crane and center it around theextension deck railing. Remove the extensiondeck from the machine.

Crushing hazard. The extensiondeck could become unbalancedand fall when removed from themachine. A properly centeredlifting strap is essential whenremoving the extension deckfrom the machine.


PLATFORM COMPONENTS


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3-1Mast

How toRemove the Mast Assembly

Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

Note: Perform this procedure on a firm, levelsurface.

Note: Perform this procedure with the mast in thestowed position.

1 Remove the Platform. See 2-1, How to Removethe Platform.

2 Tag and disconnect the power to platform wireharness at the quick disconnect near theElectronic Control Module (ECM).

3 Tag and disconnect the up limit switch cablenear the Electronic Control Module (ECM).

Mast Components

4 Tag, disconnect and plug the lift cylinder hoseat the function manifold. Cap the fitting.


a AC outlet box junction boxb mast retaining fastenersc lift cylinder coild lift cylinder solenoid valvee mastf mast cover


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MAST COMPONENTS

5 Remove the fasteners securing the lower rearaccess cover to the chassis and remove thecover. Set the cover and the fasteners to theside.

6 Tag and disconnect the wire harness from theplatform down valve coil at the base of the liftcylinder.

7 Remove the retaining nut securing the platformdown coil to the platform down solenoid valveand remove the coil. Set the coil and retainingnut to the side.

8 Remove the platform down solenoid valve fromthe lift cylinder. Set the valve to the side andplug the cylinder port.


9 Remove the fasteners securing the top mastcover to the top of the mast. Set the cover andfasteners to the side.

10 Using an overhead crane, attach a slingequipped with the appropriate sized hooks tothe lifting eyes located inside the mastassembly. Support the mast. Do not apply anylifting pressure.

11 Working at the non-steer end of the lowerchassis, remove the mast retaining fastenersand set the fasteners to the side.

12 Carefully pull the cables and hydraulic hosesfree while removing the mast from the machine.

Crushing hazard. The mastassembly could becomeunbalanced and fall if not properlysupported when removed from themachine.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

13 Place the mast assembly on a suitable structurecapable of supporting it.


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MAST COMPONENTS

How to Disassemble the MastBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

1 Remove the mast. See 2-1, How to Remove thePlatform.

2 Remove the mast. See 3-1, How to Remove theMast Assembly.

3 Remove the lift cylinder. See 3-3, How toRemove the Lift Cylinder.

4 Remove the mast coil cord. See 3-4, How toRemove the Mast Coil Cord.

5 Remove the fasteners securing the AC outletjunction box to the upper half of the mast andremove the junction box. Set the junction boxand the fasteners to the side.

6 Remove the fasteners securing the work traysto the upper half of the mast and remove thework trays. Set the trays and the fasteners tothe side.

7 Remove the fasteners securing the down limitswitch assembly to the limit switch bracket andremove the limit switch assembly. Set the limitswitch assembly and the fasteners to the side.

8 With the chassis mount side up,stagger themast assembly to gain access to the rivetssecuring the inner wear pads, to the bottom halfof the number 2, number 3 and number 4 mastsections.

9 Using a drill, carefully drill out the rivetssecuring the number 2 inner wear pads to thebottom half of the number 2 mast section, thenumber 3 inner wear pads to the bottom half ofthe number 3 mast section and the number 4inner wear pads to the bottom half of thenumber 4 mast section. Refer to Illustration 1.

Note: While drilling the rivets out, be careful notdrill into the opposing mast section.

Note: While drilling the rivets out, be careful notenlarge the wearpad mounting holes.

Illustration 1

a rivetb wear padsc number 1 mastd number 2 maste number 3 mastf number 4 mast


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13 Using a drill, carefully drill out the rivetssecuring the number 4 inner wear pads to thebottom half of the number 4 mast section. Referto Illustration 3

MAST COMPONENTS

10 Attach a lifting strap from an overhead craneto the mast assembly and carefully rotate themast 180°. Set the mast assembly onto thework table and secure the mast to the table.

Crushing hazard. The mastassembly could becomeunbalanced and fall if not properlysupported.

Note: During installation, the overhead crane strapwill need to be carefully adjusted for properbalancing.

11 Slide the number 4 mast towards the bottom ofthe number 3 mast and align the upper andlower number 4 mast access holes to the upperand lower rivets on the number 3 mast. Refer toIllustration 2.

Illustration 2

a wear padsb rivetsc number 4 mastd number 3 maste number 2 mastf number 1 mast

12 Using a drill, carefully drill out the rivetssecuring the number 3 outer wear pads to thetop half of the number 3 mast section. Refer toIllustration 2.

Note: While drilling the rivets out, be careful notdrill into the number 2 mast section.


Illustration 3

a number 4 mastb rivetc wear padsd number 1 maste number 2 mastf number 3 mast



14 Attach a lifting strap from an overhead crane tothe number 4 mast section and carefullyremove the number 4 mast.

Crushing hazard. The number 4mast section could becomeunbalanced and fall if not properlysupported when removed from themast assembly.



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4 - 18 GRC-12 Part No. 115370

Illustration 4

a wear padsb rivetsc number 3 mastd number 2 maste number 1 mast




17 Using a drill, carefully drill out the rivetssecuring the number 3 inner wear pads to thebottom half of the number 3 mast section. Referto Illustration 5.


Illustration 5

a number 3 mastb rivetc wear padsd number 1 maste number 2 mast






MAST COMPONENTS


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Part No. 115370 GRC-12 4 - 19


Illustration 6

a wear padsb rivetsc number 2 mastd number 1 mast



21 Using a drill, carefully drill out the rivetssecuring the number 2 inner wear pads to thebottom half of the number 2 mast section. Referto Illustration 7.

Illustration 7







MAST COMPONENTS


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4 - 20 GRC-12 Part No. 115370

MAST COMPONENTS

How to Assemble the MastBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

1 Thoroughly clean all mast sections.

2 Attach a lifting strap from an overhead crane tothe number 1 mast, and place the number 1mast onto a work table capable of supporting acomplete mast assembly.

Crushing hazard. The number 1mast could become unbalancedand fall if not properly supported.


3 Secure the number 1 mast to the work table.

4 Using the appropriate rivets, securely install theupper corner wear pads, to the upper half of thenumber 1 mast. Refer to Illustration1.

Illustration 1

a wear padb rivetc number 1 mast

5 Attach a lifting strap from an overhead craneto the number 2 mast and carefully slide thenumber 2 mast onto the number 1 mast, withthe cylinder mount brackets facing the worktable.



6 Slide the lower, inner corner wear padsbetween the number 2 mast and the number 1mast. Align the holes on the wear pads to therivet holes on the lower half of the number 2mast and secure into place using theappropriate rivets. Refer to Illustration 2.

Illustration 2

a number 2 mastb rivetc wear padsd number 1 mast


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Part No. 115370 GRC-12 4 - 21

MAST COMPONENTS

11 Using the appropriate rivets, securely install theupper corner wear pads, to the upper half of thenumber 2 mast. Refer to Illustration 4.

7 Slide the number 2 mast towards the bottom ofthe number 1 mast and align the lower number2 mast access holes to the lower number 1 rivetholes. Refer to Illustration 3.

8 Working at the top of the number 2 mast,carefully slide the lower corner wear padsbetween the number 2 mast and the number 1mast. Refer to Illustration 3.

9 Align the the rivet holes on the wear pads to thenumber 2 mast access holes and to the number1 mast rivet holes. Refer to Illustration 3.

10 Using the appropriate rivets, securely install thelower corner wear pads, to the lower half of thenumber 1 mast. Refer to Illustration 3.

Note: After installing the first rivet, move and alignthe number 2 mast access hole to the second holeon the wear pad and install the second rivet. Referto Illustration 3.

Illustration 3

a wear padb rivetsc number 1 mastd number 2 mast

Illustration 4

a wear padb rivetc number 2 mastd number 1 mast


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Illustration 5







Illustration 6

a wear padb rivetsc number 3 mastd number 2 maste number 1 mast

MAST COMPONENTS


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Part No. 115370 GRC-12 4 - 23

18 Using the appropriate rivets, securely install theupper corner wear pads, to the upper half of thenumber 3 mast. Refer to Illustration 7.

Illustration 7

a wear padb rivetc number 3 mastd number 2 maste number 1 mast





Illustration 8

a number 4 mastb rivetc wear padsd number 1 maste number 2 mastf number 3 mast

MAST COMPONENTS


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4 - 24 GRC-12 Part No. 115370






26 Using Illustration 10 as a guide, stagger themast assembly.

27 Slide the lower, inner corner wear padsbetween mast sectiopns1 and 2, 2 and 3 and, 3and 4. Align the holes on the wear pads to therivet holes on the lower half of mast sections 2,3 and 4. Secure the wear pads into place usingthe appropriate rivets. Refer to Illustration 10.

Illustration 9

a wear padb rivetsc number 4 mastd number 3 maste number 2 mastf number 1 mast

25 Attach a lifting strap from an overhead craneto the mast assembly and carefully rotate themast 180°. Set the mast assemblty onto thework table and secure the mast to the table.

Crushing hazard. The mastassembly could becomeunbalanced and fall if not properlysupported.


MAST COMPONENTS

Illustration 10

a number 4 mastb rivetc wear padd limit switche number 1 mastf number 2 mastg number 3 mast

28 Carefully collapse the mast assembly.

29 Attach a lifting strap from an overhead crane tothe lift cylinder. Working from the lower half ofthe mast assembly, carefully slide the liftcylinder into the mast assembly, aligning therod ends of the cylinder, to the cylinder mastmounting brackets at the upper half of the mastassembly.

Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported.



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3-2Wear Pads

Wear pads on the GRC-12 are used to provide auniform fit between the mast sections, as the mastassembly extends and retracts. Over time, it maybe necessary to replace the wear pads to ensuregood machine performance.

How to Replace Wear Pads1 See 3-1, How to Remove the Mast Assembly

and How to Disassemble a Mast.

2 See 3-1, How to Assemble a Mast.

30 Working at the upper half of the mast assembly,securely install the lift cylinder nylock nuts ontothe lift cylinder. Torque to 300 ft-lbs / 406 Nm.

31 Working from the lower half of the mastassembly, install the mast cylinder pin into themounting holes of the number 1 mast and thelift cylinder.

32 Install the hair pin clips onto each side of themast cylinder pin.

33 Securely install the lift cylinder retaining boltonto the lower cylinder block. Do not overtighten the bolt.

34 Using the appropriate fasteners, install the limitswitch assembly onto the lower half of the mastassembly. Do not over tighten the fasteners.Refer to Illustration 10.

35 Securely install the hydraulic lift hose onto thelift cylinder. Refer to the note below for torquespecifications.

Note: When installing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

MAST COMPONENTS


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MAST COMPONENTS

3-3Lift Cylinder

The lift cylinder is equipped with a normally closedsolenoid valve to prevent movement in the event ofa hydraulic line failure.

How to Remove the Lift CylinderBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.

Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.


2 Remove the nylock nuts securing the liftcylinder, to the cylinder mast mount brackets,located inside the top half of the mastassembly. Set the nylock nuts to the side.

3 Tag, disconnect and plug the hydraulic hose onthe lift cylinder. Cap the fittings on the cylinder.

4 Remove the lift cylinder retaining bolt from thelower cylinder block and set to the side.

a number 4 mast cylinder mountbracket

b number 3 mast cylinder mountbracket

c number 2 mast cylinder mountbracket

d nylock nute lift cylinderf mast assembly


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MAST COMPONENTS

5 Remove the hair pin clips securing the mastcylinder pin to the lower half of the mastassembly. Set the clips to the side.

6 Support the lift cylinder and use a soft metaldrift to remove the mast cylinder pin from thelower mast assembly.

7 Attach a lifting strap from an overhead crane tothe cylinder and carefully slide the lift cylinderout of the mast assembly.

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


a lower mast assemblyb lift cylinderc hydraulic hosed hair pin clipe mast cylinder pinf cylinder retaining bolt

a lift cylinderb manual lowering valve knobc coild platform down solenoid valvee orificef connector fittingg hydraulic hose


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3-4Lift Cylinder Wear Block

How to Remove the Lift CylinderWear Block



2 Remove the mast. See 3-3, How to Remove theCylinder.

3 Working at the barrel end of the cylinders,remove the fasteners securing the number 2cylinder to the number 1 cylinder.

4 Separate the number 2 cylinder from thenumber 1 cylinder and remove the cylinderwear block at the rod end of the cylinders.

MAST COMPONENTS

3-5Mast Coil Cord

How toRemove the Mast Coil Cord



2 Loose the strain relief nut at the top of the ACoutlet junction box.

3 Remove the cover from the AC outlet junctionbox. Tag and disconnect the coil cord wiresfrom the control cable wires.

4 Cut the connectors from the coil cord wires andpull the coil cord from the strain relief.

5 Working at the rod end of the mast, cut the ziptie securing the coil cord and the spring to thenumber 4 cylinder mount bracket.

6 Working at the barrel end of the mast, cut thezip tie securing the coil cord and spring to the"L" bracket.

7 Remove the coil cord and the spring from themast assembly.

a cap screwb number 3 cylinderc number 2 cylinderd number 1 cylindere cylinder wear block


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Ground Controls

4-1Level Sensor

The Electronic Control Module (ECM) isprogrammed to deactivate the lift and drivefunctions and activate an alarm when a signal isreceived from the level sensor.

The tilt alarm sounds when the incline of thechassis exceeds 1.5° to the side, or 3° to the frontor rear.

How to Install and Calibrate theLevel Sensor

Tip-over hazard. Failure to installor calibrate the level sensor asinstructed will compromisemachine stability and cause themachine to tip over, resulting indeath or serious injury. Do notinstall or calibrate the level sensorother than specified in thisprocedure.



If you are not installing a new level sensor,proceed to step 6.

1 Tag and disconnect the level sensor wireharness from the chassis wire harness.

2 Remove the level sensor adjusting fasteners.Remove the level sensor from the machine.

3 Place the new level sensor onto the levelsensor base with the "X" on the level sensorclosest to the mast of the machine and the "Y"on the level sensor closest to the steer end ofthe machine.

Tip-over hazard. The level sensormust be installed with the "X" onthe level sensor closest to themast of the machine and the "Y"on the level sensor closest to thesteer end of the machine. Failureto install the tilt level sensor asinstructed could result in themachine tipping over, causingdeath or serious injury.

a chassisb level sensorc 'X' indicatord mast

a

b XY

b

c


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GROUND CONTROLS

4 Install the level sensor adjusting fastenersthrough the level sensor and springs, and intothe mount. Tighten the fasteners and measurethe distance between the level sensor and thelevel sensor mount.

Result: The measurement should beapproximately 3/8 inch / 10 mm.

5 Connect the chassis wire harness to the levelsensor wire harness.

6 Tighten the level sensor adjusting fastenersuntil the bubble in the top of the level sensor iscentered in the calibration circles.


Result: The tilt sensor alarm should not sound.

8 Center a lifting jack under the drive chassis atthe ground controls side of the machine.

9 Raise the machine approximately2 inches / 5 cm.

10 Place a 0.65 x 6 x 6 inch / 1.65 x 15 x 15 cmthick steel block under both wheels at theground controls side of the machine.

11 Lower the machine onto the blocks.

12 Raise the platform approximately 1 foot / 30 cm.

Result: The level sensor alarm should notsound.

Result: The level sensor alarm does sound.Adjust the level sensor retaining fasteners justuntil the level sensor alarm does not sound.


14 Raise the machine slightly.

15 Remove the blocks from under both wheels.

16 Lower the machine and remove the jack.

17 Center a lifting jack under the drive chassis atthe tank side of the machine.

a adjusting fastenerb calibration circlesc ground controls


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GROUND CONTROLS


19 Place a 0.79 x 6 x 6 inch / 2 x 15 x 15 cm thicksteel block under both wheels at the tank sideof the machine.



Result: The platform should stop and an alarmshould sound.

Result: The platform does not stop or the levelsensor alarm does not sound. Adjust the levelsensor until the alarm just begins to sound ORthe down limit switch may need to be adjusted.





26 Center a lifting jack under the drive chassis atthe steer end of the machine.


28 Place a 2.18 x 6 x 6 inch / 5.54 x 15 x 15 cmthick steel block under both wheels at the steerend of the machine.



Result: The level sensor alarm should notsound.

Result: The level sensor alarm does sound. Thelevel sensor is faulty and must be replaced.Repeat this procedure beginning with step 1.




34 Center a lifting jack under the drive chassis atthe non-steer end of the machine.


36 Place a 2.4 x 6 x 6 inch / 6.1 x 15 x 15 cm thicksteel block under both wheels at the non-steerend of the machine.


Result: The platform should stop and an alarmshould sound.

Result: The platform does not stop or the levelsensor alarm does not sound. The level sensoris faulty and must be replaced. Repeat thisprocedure beginning with step 1.






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Hydraulic Pump

5-1Function Pump

The hydraulic pump is attached to the motor whichmakes up the hydraulic power unit.

How to Test the Hydraulic PumpNote: When removing a hose assembly or fitting,the fitting and/or hose end must be torqued tospecification during installation. Refer to Section 2,Hydraulic Hose and Fitting Torque Specifications.

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


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


4 Activate the platform up function from theground controls.

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

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

Component damage hazard.There is no relief valve in thehydraulic pump and the pump canbe damaged if the pressure isallowed to exceed3200 psi / 221 bar. When testingthe pump, activate the pump inone second intervals until3200 psi / 221 bar is confirmed.Do not over-pressurize the pump.

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



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How to Remove theHydraulic PumpNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Tag, disconnect and plug the hydraulic supplyhard line at the pump. Cap the fitting on thepump.

2 Tag, disconnect and plug the high pressurehose at the pump. Cap the fitting on the pump.


3 Remove the pump mounting bolts. Carefullyremove the pump.

Tip-over hazard. After replacingthe hydraulic pump, it is critical toreturn the function speed settingsto original factory specifications.Failure to restore the machine tooriginal factory specificationscould cause the machine to tipover, resulting in death or seriousinjury.

HYDRAULIC PUMP


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Function Manifold

Index SchematicNo. Description Item Function Torque

— Coil nut (items E, F and H) .......................................................................................................... 5 ft-lbs / 7 Nm

1 Diagnostic nipple ....................................... A ......................... Testing

2 Check disc ................................................. B ......................... Steer circuit ............................ 18 ft-lbs / 24 Nm

3 Relief valve,1800 to 3500 psi / 124 to 241 bar ............. C ......................... Lift relief .................................. 20 ft-lbs / 27 Nm

4 Check valve, 10 psi / 0.7 bar ..................... D ......................... Drive circuit ............................. 20 ft-lbs / 27 Nm

5 Solenoid valve, 3 position 4 way ............... E ......................... Drive forward/reverse ............. 25 ft-lbs / 34 Nm

6 Solenoid valve, 3 position 4 way ............... F ......................... Steer left/right ......................... 25 ft-lbs / 34 Nm

7 Flow regulator and relief valve,0.75 gpm / 2.8 L/min,1500 psi / 103 bar ...................................... G......................... Steer circuit ............................ 26 ft-lbs / 35 Nm

8 Solenoid valve, 2 position 4 way ............... H ......................... Platform up ............................. 25 ft-lbs / 34 Nm

9 Relief valve,3500 psi / 241 bar maximum ..................... I .......................... System relief ........................... 20 ft-lbs / 27 Nm

6-1Function Manifold Components

The function manifold is mounted next to the hydraulic power unit.


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A

B

C

D

E

F

G

H

I

Y8

Y4

Y3

Y5

Y6

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

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

1 2

5

6

7

8

9

3

4

FUNCTION MANIFOLD


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4 - 36 GRC-12 Part No. 115370

6-2Valve Adjustments -Function Manifold

How to Adjust theSystem Relief ValveNote: Be sure that the hydraulic oil level is at theFULL mark on the hydraulic tank.

1 Locate the system relief valve on the functionmanifold (item I).

3 Chock both sides of the wheels at the steer endof the machine.

4 Remove the platform controls from the platform.

Note: Perform this test from the ground with theplatform controls. Do not stand in the platform.


6 Press and hold the function enable switch.

7 Move and hold the joystick fully in eitherdirection while observing the pressure readingon the pressure gauge. Note the pressure.Refer to Section 2, Specifications.

8 Turn the machine off. Hold the system reliefvalve with a wrench and remove the cap(schematic item I).

9 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure.

Tip-over hazard. Failure to adjustthe relief valves to specificationcould result in the machine tippingover, causing death or seriousinjury. Do not adjust the reliefvalve pressures higher thanspecifications.

10 Install the relief valve cap.

11 Repeat steps 5 through 7 to confirm the reliefvalve pressure.

a

b

a test portb system relief valve

2 Connect a 0 to 5000 psi / 0 to 350 barpressure gauge to the test port on the functionmanifold (schematic item A).

FUNCTION MANIFOLD


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September 2008

Part No. 115370 GRC-12 4 - 37

FUNCTION MANIFOLD

How to Adjust thePlatform Lift Relief ValveNote: Be sure that the hydraulic oil level is at theFULL mark on the hydraulic tank.

1 Locate the system relief valve on the functionmanifold (item I).


6 Press and hold the function enable switch.

7 Move and hold the joystick fully in eitherdirection while observing the pressure readingon the pressure gauge. Note the pressure.Refer to Section 2, Specifications.

8 Turn the machine off. Hold the system reliefvalve with a wrench and remove the cap(hydraulic schematic item I).

9 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure.

Tip-over hazard. Failure to adjustthe relief valves to specificationcould result in the machine tippingover, causing death or seriousinjury. Do not adjust the reliefvalve pressures higher thanspecifications.



12 Place maximum rated load into the platform.Secure the load to the platform. Refer toSection 2, Specifications.


a test portb system relief valvec lift relief valve

2 Connect a 0 to 5000 psi / 0 to 350 barpressure gauge to the test port on the functionmanifold (schematic item A).

3 Chock both sides of the wheels at the steer endof the machine.



a

bc


REV A

September 2008

4 - 38 GRC-12 Part No. 115370

14 Hold the lift relief valve with a wrench andremove the cap (schematic item C).

15 While activating the platform up function, adjustthe internal hex socket clockwise, just until theplatform fully raises.

16 Fully lower the platform.

17 Add an additional 50 pounds / 22.7 kg to theplatform. Secure the additional weight.

18 Attempt to raise the platform.

Result: The power unit should not be able to liftthe platform.

Result: If the power unit lifts the platform, adjustthe internal hex socket counterclockwise untilthe platform will not raise.


20 Remove the weight from the platform.

21 Bleed the hydraulic system by raising theplatform to full height. If the pump cavitates orthe platform fails to reach full height, addhydraulic oil until the pump is functioningcorrectly. Do not overfill the hydraulic tank.

Component damage hazard. Donot continue to operate themachine if the hydraulic pump iscavitating.

How to Adjust the Steer ReliefValveNote: Be sure that the hydraulic oil level is at theFULL mark on the hydraulic tank.

1 Locate the steer relief valve on the functionmanifold (schematic item G).

a test portb steer relief valve

2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the test port (schematic item A) on thefunction manifold.



a

b

FUNCTION MANIFOLD


REV A

September 2008

Part No. 115370 GRC-12 4 - 39


5 Activate the function enable switch and pressand hold the steer thumb rocker switch to theright. Allow the wheels to completely turn to theright. Continue holding the switch whileobserving the pressure reading on the pressuregauge. Note the pressure. Refer to Section 2,Specifications.

6 Press and hold the steer thumb rocker switch tothe left. Allow the wheels to completely turn tothe left. Continue holding the switch whileobserving the pressure reading on the pressuregauge.

7 Turn the machine off. Hold the steer relief valvestem with a wrench and loosen the locknut(schematic item G).

8 Adjust the internal valve stem. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure.

Component damage hazard. Donot adjust the relief valvepressures higher thanspecifications.

9 Tighten the locknut.


FUNCTION MANIFOLD


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September 2008

4 - 40 GRC-12 Part No. 115370

6-3Valve Coils

How to Test a CoilA properly functioning coil provides anelectromagnetic force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil. Zero resistance or infiniteresistance indicates the coil has failed.

Since coil resistance is sensitive to temperature,resistance values outside specification canproduce erratic operation. When coil resistancedecreases below specification, amperageincreases. As resistance rises above specification,voltage increases.

While valves may operate when coil resistance isoutside specification, maintaining coils withinspecification will help ensure proper valve functionover a wide range of operating temperatures.


Note: If the machine has been in operation, allowthe coil to cool at least 3 hours before performingthis test.

1 Tag and disconnect the wiring from the coil tobe tested.

2 Test the coil resistance using a multimeter setto resistance (Ω). Refer to the Valve CoilResistance Specification table.

Result: If the resistance is not within theadjusted specification, plus or minus 10%,replace the coil.

Valve Coil ResistanceSpecificationNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / -7.7°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.

Valve Coil Resistance Specifications

Description Specification

Solenoid valve, 3 position 4 way 18 to 21Ω20V DC with diode (schematic items E)

Solenoid valve, 3 position 4 way 25 to 28Ω20V DC with diode (schematic item F)

Solenoid valve, 2 position 4 way 18 to 21Ω20V DC with diode (schematic item H)

Solenoid valve, 2 position 2 way N.C. 7.5 to 10.5Ωwith manual override12V DC with diode (schematic item N)

FUNCTION MANIFOLD


REV A

September 2008

Part No. 115370 GRC-12 4 - 41

FUNCTION MANIFOLD

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


1 Test the coil for resistance. See 6-3, How toTest a Coil.

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

Note: The battery should read 9V DC or morewhen measured across the terminals.

Resistor, 10ΩΩΩΩΩGenie part number 27287

3 Set a multimeter to read DC amperage.

Note: The multimeter, when set to read DCamperage, should be capable of reading up to800 mA.

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

Note: If testing a single-terminal coil, connect thenegative lead to the internal metallic ring at eitherend of the coil.

9VBATTERY

10

RESISTOR

�

MULTIMETER

COIL

+

-

+

-

d

b

b

a

c

c

a multimeterb 9V DC batteryc 10Ω resistord coil

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

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

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

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

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


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September 2008

4 - 42 GRC-12 Part No. 115370

7-1Hydraulic Tank

The primary functions of the hydraulic tank are tocool and deaerate the hydraulic fluid duringoperation. It utilizes an internal suction strainer forthe pump supply line and has an external returnline filter.

How to Remove theHydraulic Tank

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

Note: When removing a hose assembly or fitting,the fitting and/or hose end must be torqued tospecification during installation. Refer to Section 2,Hydraulic Hose and Fitting Torque Specifications.


1 Tag, disconnect and plug the hydraulic supplyhard line at the pump. Cap the fitting on thepump. Remove the hard line from the tank.

Hydraulic Tank

2 Tag, disconnect and plug the return hard line atthe hydraulic filter. Cap the fitting on the filter.


3 Remove the hydraulic tank retaining fastenersand remove the hydraulic tank from themachine.


Hydraulic tank retaining fasteners, dry 35 in-lbs4 Nm

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


REV A

September 2008

Part No. 115370 GRC-12 4 - 43

Steer Axle Components

8-1Yoke and Drive Motor

How to Remove the Yokeand Drive Motor AssemblyNote: When removing a hose assembly or fitting,the fitting and/or hose end must be torqued tospecification during installation. Refer to Section 2,Hydraulic Hose and Fitting Torque Specifications.

1 Block the wheels at the non-steer end of themachine.

2 Remove the cotter pin from the wheel castle nutat the steer end of the machine.

Note: Always replace the cotter pin with a new onewhen removing the castle nut.

3 Loosen the wheel castle nut. Do not remove it.


5 Raise the machine approximately6 inches / 15 cm. Place blocks under thechassis for support.

Crushing hazard. The chassiscould fall if not properly supported.

6 Remove the wheel castle nut. Remove thewheel.

7 Tag, disconnect and plug the hydraulic hoseson the drive motor. Cap the fittings on the drivemotor.


Component damage hazard.Hoses can be damaged if they arekinked or pinched.

8 Support and secure the yoke assembly to anappropriate lifting device.

9 Remove the retaining fastener from the steerlink at the yoke assembly.

Note: Observe and note the quantity and locationof the spacers, when disconnecting the steer linkfrom the yoke assembly.

10 Remove the retaining fastener from the rear ofthe yoke pivot shaft.

Note: The pivot shaft retaining fastener is locatedbelow the main deck.

11 Lower the yoke assembly out of the chassis.

Bodily injury hazard. Theyoke/motor assembly may fall ifnot properly supported whenremoved from the machine.


REV A

September 2008

4 - 44 GRC-12 Part No. 115370

How to Remove a Drive Motor1 Block the wheels at the non-steer end of the

machine.

2 Remove the cotter pin from the wheel castle nutof the motor to be removed at the steer end ofthe machine.




5 Raise the machine approximately2 inches / 5 cm. Place blocks under the chassisfor support.



7 Tag, disconnect and plug the hydraulic hoseson the drive motor. Cap the fittings on the drivemotor.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly toallow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.


8 Remove the drive motor mounting fasteners.Remove the motor.


Drive motor mounting fasteners, dry 75 ft-lbs101.7 Nm

Drive motor mounting fasteners, lubricated 56 ft-lbs76.3 Nm

STEER AXLE COMPONENTS


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September 2008

Part No. 115370 GRC-12 4 - 45

8-2Steer Cylinder

How toRemove the Steer CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.

1 Block the wheels at the non-steer end of themachine.

2 Remove the steer cylinder hose guard bracketfrom the machine.

3 Remove the pin retaining fasteners from thesteer cylinder barrel-end pivot pin. Remove thepin.

Note: Observe and note the quantity and locationof the spacers when removing the pivot pin.

4 Remove the pin retaining fasteners from thesteer cylinder rod-end pivot pin. Remove thepin.

Note: Observe and note the quantity and locationof the spacers when removing the pivot pin.

5 Remove the steer cylinder from the machine.

6 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings.

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


STEER AXLE COMPONENTS

8-3Steer Bellcrank

How toRemove the Steer Bellcrank1 Remove the steer cylinder. See 8-2, How to

Remove the Steer Cylinder.


3 Raise the machine approximately14 inches / 36 cm. Place blocks under thechassis for support.


4 Turn the yokes fully to one side of the machine.

5 Remove the fasteners securing the bell crank tothe steer yoke.

Note: Observe and note the quantity and locationof the spacers between the bellcrank and the steerlinks.

6 Turn the yokes fully to the opposite side of themachine.

7 Remove the fasteners securing the bell crank tothe steer yoke.


8 Remove the bellcrank from the machine.



REV A

September 2008

4 - 46 GRC-12 Part No. 115370

9-1Drive Brake

How to Remove a Drive BrakeNote: When removing a hose assembly or fitting,the fitting and/or hose end must be torqued tospecification during installation. Refer to Section 2,Hydraulic Hose and Fitting Torque Specifications.

1 Block the wheels at the steer end of themachine.

2 Remove the cotter pin from the wheel castle nutat the non-steer end of the machine.



4 Center a lifting jack under the drive chassis atthe non-steer end.

5 Raise the machine approximately2 inches / 5 cm. Place blocks under the chassisfor support.



7 Tag, disconnect and plug the hydraulic hosefrom the brake. Cap the fitting on the brake.


8 Place a lifting jack under the brake for support.

9 Remove the fasteners that attach the brake tothe drive chassis. Remove the brake.

Crushing hazard. The brake willfall if not properly supported whenthe mounting fasteners areremoved.


Brake mounting fasteners, dry 75 ft-lbs102 Nm

Brake mounting fasteners, lubricated 56 ft-lbs76 Nm

Non-steer Axle Components


REV A

September 2008

Part No. 115370 GRC-12 4 - 47

Index SchematicNo. Description Item Function Torque

1 Hand pump ....................................... J ................ Manual brake release .............................. 30 ft-lbs / 41 Nm

2 Needle valve, pilot operated ............. K ............... Manual brake release enable .............. 45-50 in-lbs / 5 Nm

Brake Release Hand Pump Components

10-1Brake Release Hand Pump Components

The brake release hand pump manifold is mounted behind the hydraulic power unit.

J

K

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

1

2

Section 4 • Repair Procedures September 2008

4 - 48 GRC-12 Part No. 15370


Section 5 • Fault CodesSeptember 2008

Part No. 115370 GRC-12 5 - 1

Before Troubleshooting:


Be sure that all necessary tools and testequipment are available and ready for use.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.


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

Fault Codes

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



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





· Wheels chocked


Section 5 • Fault Codes September 2008

5 - 2 GRC-12 Part No. 115370

General Repair Process

About This SectionWhen a malfunction is discovered, the fault codechart in this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

LED Diagnostic Readout

FAULT CODES

The diagnostic readout displays numerical codesthat provide information about the machineoperating status and about malfunctions. The dotto the right of the numbers remain on when afault code is displayed.

The codes listed in the Fault Code Chartdescribe malfunctions and can aid introubleshooting the machine by pinpointing thearea or component affected.

Section 5 • Fault Codes

REV A

September 2008

Part No. 115370 GRC-12 5 - 3

Fault Code Chart

Fault Code Problem Possible Causes Solution

01 Internal ECM error. EPROM not programmed. Replace ECM.

02 ECM/Platform communication error.

Malfunctioning control cable OR malfunctioning platform controls.

Troubleshoot control cable OR troubleshoot platform controls.

03 Undefined platform DIP switch settings.

DIP switch settings incorrect.

Correct DIP switch settings.

12 Chassis up/down toggle closed at start up.

Malfunctioning up/down switch.

Troubleshoot up/down switch.

18 Pothole guard failure. Malfunctioning pothole switch OR obstruction in pothole guard linkage.

Troubleshoot pothole switch OR remove obstruction.

19 Limit switch failure. Malfunctioning limit switch OR wire disconnected from limit switch.

Troubleshoot limit switch OR inspect wire connection.

42 Platform left turn switch fault.

Malfunctioning steer left microswitch.

Troubleshoot steer left microswitch.

43 Platform right turn switch fault.

Malfunctioning steer right microswitch.

Troubleshoot steer right microswitch.

46 Platform drive enable switch fault.

Malfunctioning drive enable switch.

Troubleshoot drive enable switch.

47 Platform joystick fault. Joystick potentiometer not centered.

Verify potentiometer setting.

52 Forward coil fault. Malfunctioning coil OR wire disconnected from coil.

Troubleshoot coil OR inspect wire connection.

53 Reverse coil fault. Malfunctioning coil OR wire disconnected from coil.


54 Up coil fault. Malfunctioning coil OR wire disconnected from coil.


55 Down coil fault. Malfunctioning coil OR wire disconnected from coil.


56 Steer right coil fault. Malfunctioning coil OR wire disconnected from coil.


57 Steer left coil fault. Malfunctioning coil OR wire disconnected from coil.


58 Brake coil fault. Malfunctioning coil OR wire disconnected from coil.


59 Series/parallel coil fault. DIP switch settings are incorrect.

Troubleshoot and correct DIP switch settings.

68 Low battery voltage. Batteries discharged. Charge batteries.

88 ECM has been erased. Static strap may be missing from the machine.

Replace static strap.

Section 5 • Fault Codes September 2008

5 - 4 GRC-12 Part No. 115370


Section 6 • SchematicsSeptember 2008

Part No. 115370 GRC-12 6 - 1

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.



Before Troubleshooting:


Be sure that all necessary tools and testequipment are available and ready for use.

About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.

Electrical Schematics

Electrocution/burn hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.

Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test

Section 6 • Schematics September 2008

REV A

6 - 2 GRC-12 Part No. 115370

ELECTRICAL COMPONENT LEGEND Item Description B5 Battery

Button BN BN5 = Horn BN6 = High torque BN8 = Drive enable

BN9 = Lift enable CB2 Circuit breaker, 7A

Control relay CR CR5 = Horn relay (with H2 option) CR48 = Power relay to U5 (e-stop)

D7 Voltage regulator (Platform controls circuit board) EN4 Enclosure - AC outlet box F6 Fuse, 275A FB Flashing beacons

Gauge G G6 = Hour meter G8 = Diagnostic display

GND Ground Horn or alarm H H1 = Horn H2 = Automotive-style horn (option) H5 = Multifunction alarm

JC1 Joystick controller KS1 Key switch

LED or light L L16 = Lift L17 = Drive L21 = High torque Limit switch LS LS6 = Platform down LS7 = Pothole LS8 = Pothole

M5 Hydraulic power unit NC Normally closed NO Normally open NCHO Normally closed held open NOHC Normally open held closed

Power switch P P1 = Emergency Stop button at ground controls P2 = Emergency Stop button at platform controls Quick disconnect QD QD1 = Battery quick disconnect QD3 = Control cable to ground QD4 = Control cable to platform Switch SW SW5 = Function enable SW6 = Steer left/right

S7 Tilt level sensor TS66 Platform up/down toggle switch

Electronic component U U3 = Platform controls printed circuit board U5 = Electronic control module U6 = Motor controller U9 = Battery charger U13 = Voltage inverter (option) Valve coil Y Y3 = Steer right Y4 = Steer left Y5 = Drive reverse Y6 = Drive forward Y7 = Platform down Y8 = Platform up

Electrical Schematic Abbreviation and Wire Color Legends

WIRE COLOR LEGEND Color Description BK Black BK/WH Black/White BL Blue BN Brown GN Green GN/BK Green/Black GN/YL Green/Yellow GY Gray LB Light Blue OR Orange OR/BK Orange/Black PP Purple RD Red RD/BK Red/Black WH White WH/BK White/Black YL Yellow

Section 6 • SchematicsMay 2008

REV A

Part No. 115370 GRC-12 6 - 3

Relay Layout and ECM Pin-out Legend

ECM PIN-OUT LEGEND Item Description A1 Flashing beacon FB1 (output) A2 Ground from platform controls (input)

(White wire at platform controls) A3 Plug A4 Power from platform controls to ECM (input)

(Red wire at platform controls) A5 Level sensor power S7 (output) A6 Platform up coil Y8 (output) A7 Drive reverse coil Y5 (output) A8 Motor controller U6, terminal 1 A9 Motor controller U6, terminal 3 A10 Overload sensor PS2 (input) A11 Key switch to platform control (input) A12 Platform down TS66 (input) B1 Platform data link (high) (input)

(Blue wire at platform controls) B2 Plug B3 ECM ground (output) B4 Plug B5 Plug B6 Platform down coil Y7 (output) B7 Steer left coil Y4 (output) B8 Automotive-style horn H2 (option) (output) B9 Multi-function alarm H5 (output) B10 Pothole limit switch (input) B11 Drive enable power/up limit switch (input) B12 Platform up TS66 (input) C1 Platform data link (low) (input)

(Orange wire at platform controls) C2 Power to ECM (input) C3 Plug C4 Plug C5 Jumper C6 Drive forward coil Y6 (output) C7 Steer right coil Y3 (output) C8 Parallel coil Y1

(not available on GS-1530/32 and GS-1930/32) C9 Work light L30 (option) C10 Jumper C11 Level sensor signal S7 (input) C12 Down limit switch LS66 (input)

A 12

B

C

1

1

1

12

1212

Relay layout

a auto-style horn CR5 (option)b power relay CR48c ECM diagnostic display windowd electronic control module (ECM) U5e motor controller U6


REV A

6 - 4 GRC-12 Part No. 115370

Wiring DiagramGround and Platform Controls

NC

P1EMERGENCY STOP

TS66PLATFORM UP/DOWNTOGGLE SWITCH

CB27A CIRCUITBREAKER

KS1KEY SWITCH

B

1

1

3

4 2

2

B1

(UP)

(DOWN)

ECM PIN A11

ECM PIN B12

ECM PIN A12

MOTOR CONTROLLERTERMINAL B+

OR

RD

BL

WH

G6HOUR METER

MOTOR CONTROLLERTERMINAL 1

6-PIN CONNECTORPIN 1

WH

BN -

+

GROUND CONTROLS

CR48TERMINAL 30

WH

H1ALARM

RD

BK

1 4.2 5.

2 1N

CP2EMERGENCY

STOP

JC1JOYSTICKCONTROLLER

RD

BK

OR

WH

WH

/BL

PP

BL

GY

BN

YL

GY

WH

RD

BL

OR

TO COIL CORD

RD

BK

PLATFORM CONTROLS

RDBK


REV A

Part No. 115370 GRC-12 6 - 5

Electrical Symbols Legend

Wire withdescription or color

Circuits crossingno connection

Diode

Circuit connection

Connector

Hour meter

Flashing beacon

Limit switch

Button or switch

Toggle switch

Emergency Stop button

Circuit breaker

Control relay

Fuse

Horn or alarm

LED

Motor controller

Motor

Battery charger

6V DC battery

Level sensor

Solenoid valve with diode

Capacitor

Noise suppressioninductor

Key switch

Joystick


REV A

6 - 6 GRC-12 Part No. 115370

Electrical SchematicPart 1 of 2


REV A

Part No. 115370 GRC-12 6 - 7

Electrical SchematicPart 2 of 2

IN

C2

WH

GND

GN

D F

RO

M J

OY

ST

ICK

IN

A2

IN

C11 A5

RD

WH

BK

N.C.

S7LEVEL

SENSOR

LEVELSENSORCIRCUITBOARD

3

1

2

5

4

DA

TA

LIN

K (L

OW

)

DA

TA

LIN

K (H

IGH

)

IN IN

B1 C1

3

1

2

5

4

QD4

WH/BK

BL

RD

OR

OR/BK

WH

/BK

BL

OR

GN

RD

66

A

YL

BL

RD

OR

WH

U5ELECTRONIC CONTROL MODULE

OUT

CR48POWERRELAY TO U5(E-STOP)

8587

8630 4

3

1

2

GN

WH

BK

3

1

2

LB

GN/YL

BK

QD4A

RD/BK

DATA LINK (LOW)

DATA LINK (HIGH)

GROUND

POWER TO GROUND

POWER TO PLATFORMBK

3 3 RD

4 4

WH1 1

BL2 2

OR5 5

QD3

BL

BK

RD

OR

WH

Y6DRIVE

FORWARD

Y7PLATFORM

DOWN

Y8PLATFORM

UP

C6

OUT

WH

A6

OUT

BK

/WH

B6

OUT

GN

/BK

LB

GN/YL

BKAC

OUTLET

YL

BL

RD

OR

WH

EN4AC

OUTLET

BOX

BL

YL

RD

OR

WH

ES0126C

- NOTE -MACHINE SHOWNIN THE STOWEDPOSITION WITH

THE POWER OFF

RD/BK

PLATFORM

CONTROLLER

HORN BN5

DRIVE ENABLE BN8

HIGH TORQUE BN6PIN1

PIN2

PIN3

LIFT ENABLE BN9PIN4

DRIVE LED L17

LIFT LED L16

POUT2

POUT3 HIGH TORQUE LED L21

POUT1

PLATFORM CONTROLSMEMBRANE DECAL

H1ALARM

POUT11

PIN11

RD+

-BK

BK

P2EMERGENCY

STOPBK

RD

PIO3

PIO5

PIO4

D7VOLTAGE

REGULATOR

5V DC

24V DC

PIO2

U3PLATFORM CONTROLS

PRINTED CIRCUIT BOARD

GY

GN

BN

WH

PP

PIN8

PIN10

PIN9OR

BK

RD

JC1JOYSTICK

CONTROLLER

BL

SW6STEER

LEFT/ RIGHT

LE

FT

RIG

HT

SW5FUNCTION ENABLE

HALL EFFECTGENERATOR

POUT4G8

DIAGNOSTICDISPLAY

EC

M P

OW

ER

LE

VE

LS

NS

R - W

H

LE

VE

LS

NS

R - R

D


6 - 8 GRC-12 Part No. 115370



REV A

Part No. 115370 GRC-12 6 - 9

Hydraulic Component Reference andSymbols Legend

Orifice

Hydraulic cylinder

Relief valve

Solenoid operated2 position 2 waydirectional valvenormally closed

with manual override

Variable speed motor

Fixed displacement pump

Bi-directional motor

Priority flow regulator

Brake

Solenoid operated2 position 4 waydirectional valve

Filter

Hand pump

Check valve



Pilot operatedneedle valve

Function manifold

Brake manifold

Lift cylinder

Section 6 • Schematics May 2008

REV A

6 - 10 GRC-12 Part No. 115370

Hydraulic Schematic

CALL-OUT LEGEND Item Description

A Test port

B Check valve, steer circuit

C Relief valve, lift

D Check valve, brake circuit

E Drive forward/reverse

F Steer left/right

G Flow regulator/relief valve

H Platform up

I Relief valve, system

J Hand pump, manual brake release

K Check valve, manual brake release

N Platform lowering valve

O Orif ice, platform down circuit

Dis

trib

ute

d B

y:

Genie North America

Genie Australia Pty Ltd.

Genie China

Genie Malaysia

Genie Japan

Genie Korea

Genie Brasil

Genie Holland

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Phone +61 7 3375 1660

Fax +61 7 3375 1002

Phone +86 21 53852570

Fax +86 21 53852569

Phone +65 98 480 775

Fax +65 67 533 544

Phone +81 3 3453 6082

Fax +81 3 3453 6083

Phone +82 25 587 267

Fax +82 25 583 910

Phone +55 11 41 665 755

Fax +55 11 41 665 754

Phone +31 183 581 102

Fax +31 183 581 566

Genie Scandinavia

Genie France

Genie Iberica

Genie Germany

Genie U.K.

Genie Mexico City

Phone +46 31 575100

Fax +

Phone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Phone +34 93 579 5042

Fax +34 93 579 5059

Phone 0800 180 9017

Fax +49 422 149 1820

Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Phone +52 55 5666 5242

Fax +52 55 5666 3241

46 31 579020

Phone +49 422 149 1818

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115370 11 1 a - geniemanuals.gogenielift.com/parts and service manuals/data/service/material... ·...

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