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Section 3 • Scheduled Maintenance Procedures

November 2005

Part No. 84700

GR-12 • GR-15 • GR-20

3 - 1

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed by

a person trained and qualified on the
maintenance of this machine.

Scheduled maintenance inspections shall be

completed daily, quarterly and semi-annually,
annually and every two years as specified on
the Maintenance Inspection Report.

Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial damage.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Keep records on all inspections for three years.

Machines that have been out of service for a

period longer than 3 months must complete the
quarterly inspection.

Unless otherwise specified, perform each

maintenance procedure with the machine in the
following configuration:

· Machine parked on a firm, level surface

· Platform in the stowed position

· Key switch in the off position with the key

removed

· The red Emergency Stop 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 for each
scheduled maintenance inspection.

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

Symbols Legend

Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.

Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.

Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.

Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.

Green—used to indicate operation
or maintenance information.

Indicates that a specific result is expected after

performing a series of steps.

Indicates that an incorrect result has occurred

after performing a series of steps.

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Содержание GR05-5001

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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