Genie GR05-5001 Service Manual Download Page 1

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Service Manual

(from serial number GR05-5001)

Refer to inside cover for additional serial number information

Part No. 84700
Rev B
November 2005

Summary of Contents for GR05-5001

Page 1: ...Service Manual from serial number GR05 5001 from serial number GR05 5001 from serial number GR05 5001 Refer to inside cover for additional serial number information Part No 84700 Rev B November 2005...

Page 2: ...owever continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in sugge...

Page 3: ...chassis Country of manufacture USA This machine complies with Serial number Rated work load including occupants Genie Industries 18340 NE 76th Street Redmond WA 98052 USA Electrical schematic number...

Page 4: ...November 2005 GR 12 GR 15 GR 20 Part No 84700 This page intentionally left blank iv...

Page 5: ...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 machin...

Page 6: ...rty damage Green used to indicate operation or maintenance information Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing haz...

Page 7: ...pecifications 2 2 B Manifold Component Specifications 2 3 B Hydraulic Hose and Fitting Torque Specifications 2 4 B SAE and Metric Fasteners Torque Charts 2 6 Section 3 Rev Scheduled Maintenance Proced...

Page 8: ...Test the Drive Speed Stowed Position 3 17 B 13 Test the Drive Speed Raised Position 3 18 B 14 Test the Slow Drive Speed 3 19 B 15 Test the Flashing Beacons 3 20 B 16 Test the Motion Alarm if equipped...

Page 9: ...4 17 3 3 Lifting Chains 4 17 3 4 Lift Cylinder 4 20 A Ground Controls 4 1 Level Sensor 4 21 A Hydraulic Pump 5 1 Function Pump 4 24 A Function Manifold 6 1 Function Manifold Components 4 26 6 2 Valve...

Page 10: ...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 B Electrical Schematic ANSI and CSA Models all models without platform over...

Page 11: ...tank 1 5 gallons 5 7 liters Hydraulic system 2 2 gallons including tank 8 3 liters Height stowed maximum GR 12 and GR 15 62 in ANSI CSA and Australia models 1 57 m GR 12 and GR 15 68 1 in CE models 1...

Page 12: ...ll Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Genie specifications require additional equipment and special installation instructions for the approved optional fluid...

Page 13: ...iode schematic item F Solenoid valve 2 position 4 way 18 to 21 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 7 5 to 10 5 with manual override 12V DC with diode schematic item...

Page 14: ...ze 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 1...

Page 15: ...Figure 1 a hydraulic hose b hex nut c reference mark d body hex fitting b c a d Torque Procedure JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting a...

Page 16: ...5 16 3 8 7 16 1 2 1 5 9 16 5 8 3 4 7 8 1 1 125 1 25 LUBED 1 4 LUBED DRY LUBED DRY LUBED DRY LUBED SAE FASTENER TORQUE CHART Grade 5 DRY LUBED This chart is to be used as a guide only unless noted els...

Page 17: ...button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine About This Section This section contains detailed procedures...

Page 18: ...nspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must...

Page 19: ...he appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair p...

Page 20: ...Section 3 Scheduled Maintenance Procedures November 2005 3 4 GR 12 GR 15 GR 20 Part No 84700 This page intentionally left blank...

Page 21: ...R E 1 Hydraulic oil Checklist A Rev A Y N R A 1 Pre operation inspection A 2 Function tests Perform after 40 hours A 3 30 day service Perform every 100 hours A 4 Grease steer yokes Instructions Make c...

Page 22: ...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 mac...

Page 23: ...luding castle nut torque D 4 Replace the Hydraulic Tank Return Filter A 4 Grease the Steer Yokes Genie specifications require that this procedure be performed every 100 hours of operation Regular appl...

Page 24: ...fter fully charging the batteries For a more accurate determination of battery condition fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow t...

Page 25: ...charger to a properly grounded 115V 60Hz or 230V 60Hz single phase AC power supply Result The charger should operate and begin charging the batteries If simultaneously the charger alarm sounds and the...

Page 26: ...round control panel Hydraulic power unit 4 Inspect for a liberal coating of dielectric grease in all wiring connections between the ECM and the platform controls and level sensor wiring 5 Turn the key...

Page 27: ...nut for proper torque Refer to Section 2 Specifications Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 4 Install a new cotter...

Page 28: ...Bodily injury hazard This procedure will require the use of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the pro...

Page 29: ...y Stop A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions result...

Page 30: ...m up down function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check the machine functions from the platform controls Result The...

Page 31: ...t or near the limit of the inverter for an extended period of time Reduce the power draw The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks two tim...

Page 32: ...Mark a test line on the ground for reference 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower th...

Page 33: ...ines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the pla...

Page 34: ...rol and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Press the lift function select button 4 Press and hold the function enable switch on the jo...

Page 35: ...es on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Lower the platf...

Page 36: ...e ground control box and when activated will sound at 60 beeps per minute 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and p...

Page 37: ...mb rocker switch for a moment to the right position and then release it Result The motion alarm should sound when the rocker switch is moved off center in either direction B 17 Perform Hydraulic Oil A...

Page 38: ...filter that can become clogged and may cause the power unit to operate improperly If the breather cap is damaged or improperly installed impurities can enter the hydraulic system which may cause compo...

Page 39: ...platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting using a multi...

Page 40: ...atform floor Result The diagnostic display at the ground controls will show two flat bars and a blinking light indicating a normal condition and the diagnostic display at the platform controls will sh...

Page 41: ...ing a normal condition and the diagnostic display at the platform controls will show the battery condition Result The diagnostic display will show OL at both the ground and platform controls The platf...

Page 42: ...platform Refer to the chart below Standard Platform GR 12 and GR 15 models 229 kg GR 20 models 159 kg AWP and Fiberglass Platform all models 159 kg Stockpicker Platform GR 12 and GR 15 models 229 kg...

Page 43: ...The platform overload system is operating properly Result The diagnostic display at the ground controls will show two flat bars and a blinking light and the diagnostic display at the platform controls...

Page 44: ...ack stand on the top of the battery cover centered under the platform Adjust the jack stand height to 24 inches 60 cm 7 Lower the platform onto the jack stand just enough to take the weight off the li...

Page 45: ...sult in death or serious injury Dealer service is strongly recommended D 4 Replace the Hydraulic Tank Return Filter Replacement of the hydraulic tank return filter is essential for good machine perfor...

Page 46: ...d other jewelry 2 Open the power unit module tray 3 Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and remove the hard line from the tank Cap the fitting on the...

Page 47: ...hydraulic filter head and torque to specification Refer to Section 2 Specifications 12 Fill the tank with hydraulic oil until the fluid is at the FULL indicator on the hydraulic tank Do not overfill 1...

Page 48: ...Section 3 Scheduled Maintenance Procedures November 2005 3 32 GR 12 GR 15 GR 20 Part No 84700 This page intentionally left blank...

Page 49: ...the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Per...

Page 50: ...trols Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the retaining fasteners securing the bottom to the platform control bo...

Page 51: ...ious injury Select a test area that is firm level and free of obstructions How to Determine the Revision Level 1 Remove the platform controls from the platform 2 Place the platform controls close to t...

Page 52: ...at the platform controls 3 Turn the key switch to platform control 4 At the platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the...

Page 53: ...atform control 4 At the platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show...

Page 54: ...rn the key switch to platform control 4 At the platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagn...

Page 55: ...platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift f...

Page 56: ...he ground and platform controls Result The diagnostic display at the platform controls will show the battery condition See 1 3 How to Determine the Battery Voltage 3 Press the lift function select but...

Page 57: ...nostic display Use the steering thumb rocker switch on the joystick to increase or decrease the value See 1 3 Machine Configuration Code Chart for configuration settings 7 Press and hold the lift func...

Page 58: ...sabled when the platform is raised above the down limit switch and the incline of the chassis exceeds the rating on the serial plate Configured on all machines Platform Overload When the platform over...

Page 59: ...d Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC 5 Release the lift function select and speed select buttons Result The diagno...

Page 60: ...cks Crushing hazard Keep hands clear when lowering the platform 3 Remove the platform control box from the platform and set it to the side 4 Remove the fasteners securing the platform mount to the mas...

Page 61: ...orm wire harness at the quick disconnect near the Electronic Control Module ECM 3 Tag and disconnect the ECM wire harness at the quick disconnect near the ECM 4 Attach a lifting strap of suitable capa...

Page 62: ...carriage is facing up 3 Remove the socket head retaining fastener from the clevis block on the lift cylinder rod end at the top of the number 1 column 4 Remove the lift cylinder barrel end mounting f...

Page 63: ...ts from the chain tension rocker on the carriage 13 Slide the carriage out the bottom of the mast assembly 14 Lay the chains out on the floor at the top of the mast Do not allow the chains to become t...

Page 64: ...he number 1 column chains Tighten the adjustment nuts until the lifting chains have equal tension and the chain tension rocker is centered in the inspection hole in the column 10 Lay the number 3 colu...

Page 65: ...lbs 1 35 Nm Be sure the glide pad bolt does not turn 5 Repeat step 5 for the upper and lower glide pads on both sides of the each column of the mast Start with the number 2 column and work toward the...

Page 66: ...40 and install chain Lubricate chain with motor oil SAE 40W If rust and corrosion is found refer to Failure Remedy for rust and corrosion If link plates or pins are bent or deformed replace entire ch...

Page 67: ...plate wear Broken chain anchor fingers Bent or damaged anchor Twisted or misaligned chain anchor Threaded rod not visible in inspection hole Idler wheels have badly worn flanges Idler wheels have groo...

Page 68: ...ced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the mast See 3 1 How to Remove the Mast Assembly 2 Rotate the m...

Page 69: ...the machine on a firm level surface that is free of obstructions Perform this procedure with the platform in the stowed position If you are not installing a new level sensor proceed to step 6 1 Tag an...

Page 70: ...ting jack under the drive chassis at the ground controls side of the machine 9 Raise the machine approximately 2 inches 5 cm 10 GR 12 and GR 15 Place a 0 65 x 6 x 6 inch 1 65 x 15 x 15 cm thick steel...

Page 71: ...ly 2 inches 5 cm 28 Place a 2 18 x 6 x 6 inch 5 54 x 15 x 15 cm thick steel block under both wheels at the steer end of the machine 29 Lower the machine onto the blocks 30 Raise the platform approxima...

Page 72: ...rt on the pump 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Activate the platform up function from t...

Page 73: ...2 Tag disconnect and plug the high pressure hose at the pump Cap the fitting on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowl...

Page 74: ...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...

Page 75: ...4700 GR 12 GR 15 GR 20 4 27 A B C D E F G H I Y8 Y4 Y3 Y5 Y6 Note alpha callouts refer to corresponding notes on the hydraulic schematic Note alpha numeric callouts refer to corresponding notes on the...

Page 76: ...ion enable switch 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machi...

Page 77: ...to increase the pressure or counterclockwise to decrease the pressure Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or ser...

Page 78: ...emove the weight from the platform 21 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or the platform fails to reach full height add hydraulic oil until the pum...

Page 79: ...relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat steps 5 through 6 to confirm the relief valve pressure FUNCTION MANIFOLD 6 3 Valve Coils How to Test a Coil A...

Page 80: ...when measured across the terminals Resistor 10W Genie part number 27287 3 Set a multimeter to read DC amperage The multimeter when set to read DC amperage should be capable of reading up to 800 mA 4 C...

Page 81: ...stallation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the platform in the stowed position 1 Tag disconnect and plug the hydraulic supply hard line...

Page 82: ...rd The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor...

Page 83: ...s under the chassis for support Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel 7 Tag disconnect and plug the hydraulic hoses on the dri...

Page 84: ...ng hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses...

Page 85: ...achine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel 7 Tag disc...

Page 86: ...anual 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 1 Brake Release Hand Pump Components The brake r...

Page 87: ...y hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Fault Codes Ob...

Page 88: ...er pressure gauges Malfunction discovered Identify symptoms Troubleshoot Perform repair Return to service problem solved problem still exists Inspect and test LED Diagnostic Readout FAULT CODES The di...

Page 89: ...atform drive enable switch fault Malfunctioning drive enable switch Troubleshoot drive enable switch 47 Platform joystick fault Joystick potentiometer not centered Verify potentiometer setting 52 Forw...

Page 90: ...Section 5 Fault Codes November 2005 5 4 GR 12 GR 15 GR 20 Part No 84700 This page intentionally left blank...

Page 91: ...ry tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Sche...

Page 92: ...eter G7 Battery charge indicator 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 L19...

Page 93: ...g 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 limi...

Page 94: ...BREAKER KS1 KEY SWITCH B 1 1 3 4 2 2 B1 UP DOWN ECM PIN A11 ECM PIN B12 ECM PIN A12 MOTOR CONTROLLER TERMINAL B OR RD BL WH G6 HOUR METER MOTOR CONTROLLER TERMINAL 1 6 PIN CONNECTOR PIN 1 WH BN GROUND...

Page 95: ...EFT RIGHT LEFT RIGHT SW5 FUNCTION ENABLE PLATFORM CONTROL GROUND CONTROL B B1 3 4 2 1 KS1 KEY SWITCH OR WH RD MOTOR CONTR ENABLE Circuits crossing no connection Diode Circuit connection Connector Hour...

Page 96: ...TROL MODULE PLATFORM CONTROL GROUND CONTROL B B1 3 4 2 1 KS1 KEY SWITCH OR WH LS7 POTHOLE GUARD SWITCH LS8 POTHOLE GUARD SWITCH IN B10 H5 ALARM OUT B9 N C H O N C H O BL RD OR BK WH IN IN A12 B12 IN A...

Page 97: ...BL RD OR WH Y6 DRIVE FORWARD Y7 PLATFORM DOWN Y8 PLATFORM UP C6 OUT WH A6 OUT BK WH B6 OUT GN BK LB GN YL BK AC OUTLET YL BL RD OR WH EN4 AC OUTLET BOX BK BL RD OR WH ES0126B NOTE MACHINE SHOWN IN THE...

Page 98: ...REAKER A8 OUT B8 OUT A1 OUT FB FLASHING BEACONS OPTION P1 EMERGENCY STOP U5 ELECTRONIC CONTROL MODULE PLATFORM CONTROL GROUND CONTROL B B1 3 4 2 1 KS1 KEY SWITCH OR WH LS7 POTHOLE GUARD SWITCH LS8 POT...

Page 99: ...SENSOR LEVEL SENSOR CIRCUIT BOARD 3 1 2 5 4 DATA LINK LOW DATA LINK HIGH IN IN B1 C1 3 1 2 5 4 QD4 WH BK BL RD OR OR BK WH BK BL OR GN RD C6 OUT WH A6 OUT BK WH CR48 POWER RELAY TO U5 E STOP CR27A OV...

Page 100: ...N IN THE STOWED POSITION WITH THE POWER OFF ES0127B PLATFORM CONTROLLER HORN BN5 DRIVE ENABLE BN8 HIGH TORQUE BN6 PIN1 PIN2 PIN3 LIFT ENABLE BN9 PIN4 DRIVE LED L17 LIFT LED L16 POUT2 POUT3 HIGH TORQUE...

Page 101: ...d operated 2 position 2 way directional valve normally closed with manual override Variable speed motor Fixed displacement pump Bi directional motor Priority flow regulator Brake Solenoid operated 2 p...

Page 102: ...I L Y8 HYDRAULIC TANK V P T LIFT CYLINDER N M Y7 L STEER LEFT STEER RIGHT S1 S2 Y3 Y4 0 75 gpm 2 8 L min 1500 psi 103 bar B G F HP FUNCTION MANIFOLD Y5 Y6 10 psi 0 7 bar D E M1 LEFT DRIVE MOTOR M4 RIG...

Page 103: ...70 86 21 53852569 65 98 480 775 65 67 533 544 81 3 3453 6082 81 3 3453 6083 82 25 587 267 82 25 583 910 55 11 41 665 755 55 11 41 665 754 31 183 581 102 31 183 581 566 Genie Scandinavia Genie France G...

Page 104: ...Part No 84700 Rev B Service Manual GR 12 GR 15 GR 20 from serial number GR05 5001...

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