Genie Genie Lift Service Manual Download

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September 2016

Table of Contents

Part No. 115417

Genie Lift

vii

Introduction

Introduction .......................................................................................................... ii

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

Find a Manual for this Model .................................................................................. ii

Revision History .....................................................................................................iii

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

Section 1

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

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

Section 2

Specifications ....................................................................................................... 9

Machine Specifications........................................................................................... 9

Performance Specifications ................................................................................. 11

SAE and Metric Fasteners Torque Charts ........................................................... 12

Section 3

Scheduled Maintenance Procedures ............................................................... 13

Introduction ........................................................................................................... 13

Pre-Delivery Preparation Report .......................................................................... 16

Maintenance Inspection Report ........................................................................... 18

Checklist A Procedures ..................................................................................... 20

A-1 Inspect the Manuals and Decals ................................................................... 20

A-2 Perform Pre-operation Inspection .................................................................. 21

A-3 Perform Function Tests ................................................................................. 21

A-4 Inspect the Channels ..................................................................................... 22

A-5 Inspect the Cable and Cable Pulleys............................................................. 22

A-6 Inspect the Casters and Wheels .................................................................... 23

Checklist B Procedures ..................................................................................... 24

B-1 Inspect the Battery - Models with Electric Winch .......................................... 24

B-2 Inspect the Electrical Wiring - Models With Electric Winch ........................... 25

B-3 Perform Electric WinchMaintenance ............................................................. 25

B-4 Inspect the Carriage Hold-down Bar ............................................................. 26

B-5 Inspect All Welds ........................................................................................... 26

B-6 Clean the Channels ...................................................................................... 27

B-7 Inspect and Lubricate the Manual Winch ...................................................... 27

Summary of Contents for Genie Lift

Page 1: ...Service Manual Serial Number Range Genie Lift from 1395 to 1301 23434 from GL02 23435 to GL16G 80150 from GL16G 80151 to GL16G 83799 from GLG 83800 Part No 115417 Rev A2 September 2016 ...

Page 2: ... of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us Internet www genielift com E mail awp techpub terex com Serial Number Information Genie Industri...

Page 3: ... 4 2009 Initial Release A1 10 2010 Specifications Checklist A Procedures A2 9 2016 Introduction Serial Number Legend Reference Examples Section Maintenance B 3 Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ... No 115417 Serial Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial label 6 Serial number stamped on base From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial label 5 Serial number stamped on base ...

Page 5: ...s injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulati...

Page 6: ...ng hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from flammable...

Page 7: ...e Delivery Preparation Report 16 Maintenance Inspection Report 18 Checklist A Procedures 20 A 1 Inspect the Manuals and Decals 20 A 2 Perform Pre operation Inspection 21 A 3 Perform Function Tests 21 A 4 Inspect the Channels 22 A 5 Inspect the Cable and Cable Pulleys 22 A 6 Inspect the Casters and Wheels 23 Checklist B Procedures 24 B 1 Inspect the Battery Models with Electric Winch 24 B 2 Inspect...

Page 8: ...nual Winch 31 1 2 How to Disassemble the GL Models Equipped with an Electric Winch 32 1 3 How to Disassemble the Manual Winch 33 1 4 How to Assemble the Manual Winch 34 Manual Winch Assembly 36 1 5 How to Replace the Lifting Pulley 37 1 6 How to Replace the Lifting Cable 37 1 7 How to Replace the Glide Buttons 39 1 8 How to Adjust the Brake if equipped 40 Rear Wheel Brake Assembly option 41 Sectio...

Page 9: ...ddle Base 2 in 2 in 2 in 2 in Width stowed 5 8 cm 5 8 cm 5 8 cm 5 8 cm 650 lbs 650 lbs 650 lbs 650 lbs Length stowed 295 kg 295 kg 295 kg 295 kg 650 lbs 650 lbs 650 lbs 650 lbs Length Operating 165 lbs 225 lbs 307 lbs 347 lbs 75 kg 102 kg 139 kg 157 kg Counterweight Base 28 8 in 28 8 in 28 8 in 28 8 in Width stowed 73 cm 73 cm 73 cm 73 cm 28 in 23 in 2 5 in 26 5 lbs Length stowed 71 1 cm 58 4 cm 6...

Page 10: ...s 153 lbs 158 lbs pneumatic caster option 59 kg 68 kg 69 kg 72 kg Straddle base 137 lbs 158 lbs 162 lbs 167 lbs 4 point caster option A 62 kg 72 kg 74 kg 76 kg Straddle base 139 lbs 160 lbs 164 lbs 169 lbs 4 point caster option B 63 kg 73 kg 75 kg 77 kg The electric winch option will add an additional 103 lbs 47 kg to the above machine weights Forks 22 5 in 22 5 in 22 5 in 22 5 in Length 57 2 cm 5...

Page 11: ... 13 ft Maximum working height 1 6 m 2 8 m 3 3 m 4 m Standard Base 3 5 in 3 5 in 3 5 in 3 5 in Minimum working height 8 9 cm 8 9 cm 8 9 cm 8 9 cm Straddle Base 3 5 in 3 5 in 3 5 in 3 5 in Minimum working height 8 9 cm 8 9 cm 8 9 cm 8 9 cm Load Capacity Standard Forks 500 lbs 400 lbs 350 lbs 350 lbs at 14 in 36 cm load center 227 kg 182 kg 159 kg 159 kg Boom 500 lbs 400 lbs 350 lbs 350 lbs at 12 in ...

Page 12: ...Service Manual September 2016 Specifications 12 Genie Lift Part No 115417 SAE and M etric Fasteners Tor que C harts ...

Page 13: ...each procedure with the machine in the following configuration Machine parked on a firm level surface Carriage fully lowered Casters locked Red Emergency Stop button pushed in to the off position if equipped Brakes locked if equipped About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step ...

Page 14: ...ns checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or e...

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Page 16: ...l be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropri...

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Page 18: ...d Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Y N R A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Function tests A 4 Inspec...

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Page 20: ...hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s safety and responsibilities manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Re...

Page 21: ...o serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Per form Functi on Tests A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function ...

Page 22: ...me if equipped should raise and lower smoothly free of hesitation and binding A 5 Inspect the C able and Cable Pulleys A 5 Inspect the Cable and Cable Pulleys Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Detection of damage to the cable or pulleys is essential for safe machine operation An unsafe working condition exists if these compon...

Page 23: ...mance Casters or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Extremely dirty conditions may require that the wheels and casters be inspected more often 1 Unlock the brake if equipped and move the machine on a firm smooth surface and check that the casters and wheels roll smoothly free of hesitatio...

Page 24: ...each battery cell with a hydrometer Note the results 6 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The batt...

Page 25: ...conditions and may cause component damage Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed pinched corroded and loose wires Control panel Battery pack Remote control Channel frame B 3 Per form Electric WinchM aintenance B 3 Perform Electric Winch Mai...

Page 26: ... hold down bar over the carriage 3 Raise the carriage Result The carriage should not move Component Damage Hazard Do not apply too much force on the carriage Raise it only enough to check the resistance against the hold down bar 4 Visually inspect the assembly for damage B 5 Inspect All W elds B 5 Inspect All Welds Genie specifications require that this procedure be performed every 250 hours or qu...

Page 27: ...Inspect and Lubricate the Manual Winch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Carefully lubricate the pivot poi...

Page 28: ... or Wheel is essential to good machine performance and service life Extremely dirty conditions may require that the casters and wheels be inspected and lubricated more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 Move the machine on a flat smooth surface to confirm the casters and wheels roll smoothly free of hesitation and binding 3 Pump grease into the caster ...

Page 29: ...f hesitation and binding 1 Replace the winch brake disks and lubricate the winch shaft Refer to Repair Procedure How to Disassemble the Manual Winch C 3 Inspect the Pai nted Surfaces C 3 Inspect the Painted Surfaces Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Inspecting the painted surfaces of your machine is essential to safe op...

Page 30: ...Brake locked if equipped All external AC power supply disconnected from the machine models with electric winch About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be com...

Page 31: ... handle bracket GL 8 GL 10 and GL 12 models Remove the cable mounting fastener from the upper inner frame casting Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable 10 Remove the base mounting fasteners from the outer frame channels and remove the base from the machine 11 GL 4 models Remove the carriage from the outer frame GL 8 GL 10 and GL 12 Remove the...

Page 32: ...ce 8 Remove the legs from the machine 9 GL 4 models Remove the cable mounting fastener from the handle bracket GL 8 GL 10 and GL 12 models Remove the cable mounting fastener from the upper inner frame casting 10 Remove the mounting fasteners from the electric winch cover 11 Tag and disconnect the wiring from the electric winch cover and remove the electric winch cover from the machine 12 Remove th...

Page 33: ...nual Wi nch 1 3 How to Disassemble the Manual Winch Note Refer to the illustration Winch Assembly for an exploded view 1 Fully lower the carriage 2 Remove the jam nut from the winch drum bolt Remove the winch drum cover from the machine 3 Remove the cable retaining fastener from the winch drum and remove the cable from the drum Bodily injury hazard Cables can fray Always wear adequate hand protect...

Page 34: ...not allow any oil on the brake or pressure plate 4 Install the winch housing onto the machine Be sure the winch drum is towards the right 5 Insert the threaded end of the pinion shaft through the large bushing Then insert the other end of the pinion shaft through the small bushing 6 Push the pinion shaft toward the small bushing Install the brake disk ratchet gear and pressure plate Note The teeth...

Page 35: ...e and attach it to the winch drum with the cable retaining fastener 13 While holding the cable tie on the drum rotate the winch until all the cable is spooled onto the drum neatly and evenly Be sure there are at least 4 wraps of cable on the winch drum Component damage hazard Improperly wound cable may result in poor winch performance and accelerate cable wear Be sure the cable winds onto the winc...

Page 36: ...Pawl Kit 13 Lock Pin 2 Cable Drum 14 Handle Adapter Nut 3 Carriage Bolt 15 Winch Handle Spring 4 Hex Nut 16 Handle Adapter 5 Gear Cover 17 Pinion Shaft Bushing 6 Cable Keeper 18 Pressure Plate 7 Nylock Nut 19 Ratchet Gear 8 Screw 20 Disk Brake 9 Lock Nut 21 Drive Shaft Assembly 10 Winch Frame 22 Retaining Ring 11 Winch Handle Assembly 23 Pinion Shaft Bushing 12 Flat Washer ...

Page 37: ...ulley and install the pulley on to the machine Note Be sure not to twist the cable when installing the new pulley 1 6 H ow to Replace the Lifting C abl e 1 6 How to Replace the Lifting Cable Models with manual winch 1 Fully lower the carriage 2 Remove the jam nut from the winch drum bolt and remove the winch drum cover 3 Remove the cable retaining fastener from the winch drum and unwind the cable ...

Page 38: ...e cable through the pulley GL 8 GL 10 and GL 12 models 7 Thread the cable through the upper inner frame pulley from back to front Pull all the cable through the pulley 8 From front to back thread the cable through the cable slot in front of the carriage pulley through the lower inner frame pulley Pull all the cable through the pulley All models 9 From front to back thread the cable through the han...

Page 39: ...dequate hand protection when handling cable Install the new cable following the instructions in the Owner s Manual for Rule Winches 9 Connect the winch wiring and install the winch cover on to the machine 1 7 H ow to Replace the Glide Buttons 1 7 How to Replace the Glide Buttons 1 Remove the load handling attachment from the carriage 2 Fully lower the carriage Models with counterweight base 3 Supp...

Page 40: ... Note Refer to the illustration Rear Wheel Brake Assembly option for an exploded view 1 Rotate the brake pedal to the up or unlocked position 2 Loosen the clamping bolts from all three of the brake cams 3 Rotate both of the wheel brake cams until they contact the tires Tighten the brake cam clamping bolts 4 With the pedal up rotate the brake cam rod until there is approximately 1 4 inch of gap bet...

Page 41: ...nkage Spring 2 Lock Washer 15 Axle Tube 3 Nut 16 Spring Retaining Washer 4 Stair Roller Mount Bracket Right Side 17 Screw 5 Stair Roller Spacer 18 Flat Washer 6 Stair Roller 19 Solid Rubber Wheel 7 Brake Cam Rod 20 Screw 8 Stair Roller Mount Bracket Left Side 21 Base 9 Brake Cam Spacer 22 Brake Pedal 10 Screw 23 Screw 11 Nylock Nut 24 Nylock Nut 12 Brake Cam 25 Brake Linkage Plate 13 Brake Pivot P...

Page 42: ...function before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section An illustration legend precedes the electrical schematics Electrical Schematics Electrocution burn hazard Contact ...

Page 43: ...September 2016 Service Manual Electrical Symbols Legend Models with Electric Winch Part No 115417 Genie Lift 43 Electrical Symbols Legend Models With El ectric Wi nch ...

Page 44: ...Service Manual September 2016 Wiring Diagram Models with Electric Winch 44 Genie Lift Part No 115417 Wiring Diagram Models With Electric Winch Genie Lift Part No 115417 Service M anual September 2016 ...

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