Service Manual

Part No. 72965

Rev B2

January 2007

Service Manual

(from serial number GR-101 to GR05-4999)

August 2005

GR-8 • GR-12 • GR-15 Part No. 72965

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

maintenance procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting and

repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical

skills are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer

service center.

Technical Publications

Genie Industries has endeavored to deliver the

highest degree of accuracy possible. However,

continuous improvement of our products is a Genie

policy. Therefore, product specifications

are subject to change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

72965 Rev B August 2005

First Edition, Second Printing

"Genie" is a registered trademark of Genie

Industries in the USA and many other countries.

"GR" is a trademark of Genie Industries.

Printed on recycled paper

Printed in U.S.A.

www.genieindustries.com

e-mail: [email protected]

Introduction

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15

iii

Serial Number Legend

GS30 05 A - 12345

Model

Facility code

(

)

used only for models manufactured

in multiple facilities

Sequence

number

PN - 77055

Model:

Model year: Manufacture date:

Maximum allowable inclination of the 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:

Gradeability:

Maximum allowable side force :

Maximum number of platform occupants:

Machine unladen weight:

ANSI A92.6-1999

B354.2-01

GS-1930

GS3005A-12345

04/12/05

ES0141

2,714 lb / 1,231 kg

500 lb / 227 kg

N/A

100 lb / 445 kg

2005

Model year

Serial Number Legend

August 2005

GR-8 • GR-12 • GR-15 Part No. 72965

This page intentionally left blank.

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15

Danger

Failure to obey the instructions and safety rules

in this manual and the appropriate Operator's

Manual on your machine will result in death or

serious injury.

Many of the hazards identified in the

operator’s manual are also safety hazards

when maintenance and repair procedures

are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Section 1 • Safety Rules

Safety Rules

August 2005

GR-8 • GR-12 • GR-15 Part No. 72965

SAFETY RULES

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

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.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an approved fire

extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure that your workshop or work area

is properly ventilated and well lit.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

Section 1 • Safety Rules

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15

Table of Contents

Introduction

Important Information .........................................................................................

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

iii

Section 1 Safety Rules

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

Section 2 Rev Specifications

B Machine Specifications ................................................................................ 2 - 1

B Performance Specifications ......................................................................... 2 - 2

B Hydraulic Specifications ............................................................................... 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 - 7

Section 3 Rev Scheduled Maintenance Procedures

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

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

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

B Checklist A Procedures

A-1 Perform Pre-operation Inspection ....................................................... 3 - 6

A-2 Perform Function Tests ...................................................................... 3 - 6

A-3 Perform 30 Day Service ..................................................................... 3 - 7

A-4 Grease the Steer Yokes ..................................................................... 3 - 7

vii

April 2006

GR-8 • GR-12 • GR-15 Part No. 72965

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

B Checklist B Procedures

B-1 Inspect the Batteries ........................................................................... 3 - 8

B-2 Inspect the Electrical Wiring ............................................................... 3 - 9

B-3 Inspect the Tires and Wheels (including castle nut torque) ............... 3 - 10

B-4 Check the Lifting Chain Adjustments ................................................ 3 - 10

B-5 Clean and Lubricate the Columns..................................................... 3 - 11

B-6 Adjust the Sequencing Cables .......................................................... 3 - 11

B-7 Test the Emergency Stop ................................................................. 3 - 12

B-8 Test the Key Switch .......................................................................... 3 - 13

B-9 Test the Automotive-style Horn (if equipped) .................................... 3 - 13

B-10 Test the Drive Brakes ....................................................................... 3 - 14

B-11 Test the Drive Speed - Stowed Position ........................................... 3 - 14

B-12 Test the Drive Speed - Raised Position ............................................ 3 - 15

B-13 Test the Flashing Beacon (if equipped) ............................................ 3 - 15

B-14 Test the Alarm Package (if equipped)............................................... 3 - 16

B-15 Perform Hydraulic Oil Analysis ......................................................... 3 - 17

B-16 Inspect the Hydraulic Tank Cap Venting System .............................. 3 - 17

C Checklist C Procedures

C-1 Replace the Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil.................................................... 3 - 18

C-2 Grease the Platform Overload Mechanism (if equipped) .................. 3 - 18

C-3 Test the Platform Overload System (if equipped) ............................. 3 - 19

C Checklist D Procedures

D-1 Calibrate the Platform Overload System (if equipped) ...................... 3 - 21

D-2 Inspect the Mast Assembly for Wear ................................................ 3 - 22

D-3 Lubricate the Lifting Chains .............................................................. 3 - 24

D-4 Replace the Hydraulic Tank Return Filter ......................................... 3 - 24

B Checklist E Procedure

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 25

viii

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15

TABLE OF CONTENTS

Section 4 Rev Repair Procedures

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

B Platform Controls

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

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

B Platform Components

2-1 Platform ............................................................................................. 4 - 5

2-2 Platform Extension ............................................................................. 4 - 5

B Mast Components

3-1 Mast ................................................................................................... 4 - 6

3-2 Glide Pads ....................................................................................... 4 - 10

3-3 Lifting Chains ................................................................................... 4 - 11

3-4 Lift Cylinders .................................................................................... 4 - 14

B Ground Controls

4-1 Control Relays ................................................................................. 4 - 15

4-2 Circuit Board .................................................................................... 4 - 16

4-3 Controller Adjustments ..................................................................... 4 - 17

4-4 Level Sensor .................................................................................... 4 - 19

B Hydraulic Pump

5-1 Function Pump ................................................................................. 4 - 22

B Manifolds

6-1 Function Manifold Components

(before serial number GR01-225) .................................................... 4 - 24

6-2 Function Manifold Components

(from serial number GR01-225 to GR01-248) .................................. 4 - 26

6-3 Function Manifold Components

(after serial number GR01-248) ....................................................... 4 - 28

6-4 Valve Adjustments - Function Manifold ............................................. 4 - 30

6-5 Valve Coils ....................................................................................... 4 - 33

B Hydraulic Tank

7-1 Hydraulic Tank ................................................................................. 4 - 35

April 2006

GR-8 • GR-12 • GR-15 Part No. 72965

Section 4 Rev Repair Procedures, continued

B Steer Axle Components

8-1 Yoke and Drive Motor ...................................................................... 4 - 36

8-2 Steer Cylinder .................................................................................. 4 - 38

A Non-steer Axle Components

9-1 Wheel Brake .................................................................................... 4 - 40

A Platform Overload Components

10-1 Platform Overload System ............................................................... 4 - 41

Section 5 Rev Troubleshooting Flow Charts

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

Chart Chart

Number Title

A 1 All Functions Will Not Operate ........................................................... 5 - 3

A 2 Pump Motor Will Not Operate............................................................ 5 - 5

A 3 All Function Inoperative, Power Unit Starts and Runs ....................... 5 - 6

A 4 Ground Controls Inoperative, Platform Controls Operate Normally ... 5 - 7

A 5 Platform Controls Inoperative, Ground Controls Operate Normally ... 5 - 8

A 6 Platform Up Function Inoperative ...................................................... 5 - 9

A 7 Platform Down Function Inoperative................................................ 5 - 10

A 8 Steer Left Function Inoperative ....................................................... 5 - 11

A 9 Steer Right Function Inoperative ..................................................... 5 - 12

A 10 All Drive Functions Inoperative, All Other

Functions Operate Normally ............................................................ 5 - 13

A 10A Brake Release Function Inoperative................................................ 5 - 14

A 11 Drive Forward Function Inoperative................................................. 5 - 15

A 12 Drive Reverse Function Inoperative ................................................ 5 - 16

A 13 Machine Will Not Drive at Full Speed .............................................. 5 - 17

A 14 Machine Drives At Full Speed With Platform Raised ....................... 5 - 18

TABLE OF CONTENTS

January 2007

Part No. 72965 GR-8 • GR-12 • GR-15

Section 6 Rev Schematics

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

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

B Electrical Symbols Legend ........................................................................... 6 - 3

C Electrical Schematic - ANSI Models

(before serial number GR02-1800) .............................................................. 6 - 4

C Electrical Schematic - ANSI and CSA Models

(from serial number GR02-1800 to GR03-2407) .......................................... 6 - 6

B Electrical Schematic - ANSI and CSA Models

(from serial number GR03-2408 to GR03-2432) .......................................... 6 - 8

B Electrical Schematic - ANSI and CSA Models

(after serial number GR03-2432) ............................................................... 6 - 10

C Electrical Schematic - CE Models

(before serial number GR02-1800) ............................................................ 6 - 12

C Electrical Schematic - CE Models

(from serial number GR02-1800 to GR03-2407) ........................................ 6 - 14

B Electrical Schematic - CE Models

(from serial number GR03-2408 to GR03-2432) ........................................ 6 - 16

B Electrical Schematic - CE Models

(from serial number GR03-2433 to GR04-4000) ........................................ 6 - 18

B Electrical Schematic - CE Models

(after serial number GR04-4000) ............................................................... 6 - 20

B Hydraulic Component Reference and Symbols Legend ............................. 6 - 22

B Hydraulic Schematic

(before serial number GR01-249) .............................................................. 6 - 23

B Hydraulic Schematic

(after serial number GR01-248) ................................................................. 6 - 24

TABLE OF CONTENTS

August 2005

GR-8 • GR-12 • GR-15 Part No. 72965

This page intentionally left blank.

Section 2 • Specifications

REV B

September 2005

Part No. 72965 GR-8 • GR-12 • GR-15 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 2.75 gallons

10.4 liters

Hydraulic system 3.5 gallons

(including tank) 13.2 liters

Tires and wheels

Tire size (solid rubber) 10 x 3 in

25.4 x 2.5 cm

Tire contact area 6 sq in

39 cm

Castle nut torque, dry 221 ft-lbs

300 Nm

Castle nut torque, lubricated 165 ft-lbs

225 Nm

For operational specifications, refer to the

Operator's Manual.

Height, stowed maximum

ANSI, CSA and Australia models 68 in

including workstation tray 1.57 m

CE models 72.5 in

including workstation tray 1.73 m

Platform capacity, maximum (GR-8 and GR-12)

Standard platform 500 lbs

227 kg

Fiberglass platform 350 lbs

159 kg

Stockpicker platform 500 lbs

227 kg

Platform capacity, maximum (GR-15)

Standard platform 350 lbs

159 kg

Fiberglass platform 350 lbs

159 kg

Stockpicker platform 450 lbs

204 kg

Continuous improvement of our products is a

Genie policy. Product specifications are

subject to change without notice.

Specifications

Section 2 • Specifications

REV B

September 2005

2 - 2 GR-8 • GR-12 • GR-15 Part No. 72965

SPECIFICATIONS

Performance Specifications

Drive speed, maximum

Platform stowed, maximum 2.5 mph

40 ft / 10.7 sec

4 km/h

12.2 m / 10.7 sec

Platform raised or extended, maximum 0.5 mph

40 ft / 55 sec

0.8 km/h

12.2 m / 55 sec

Braking distance, maximum

High range on paved surface 19 in ± 6 in

48 cm ± 15 cm

Function speed, maximum, from platform controls

(with 1 person in platform)

Platform up 30 to 31 seconds

Platform down 21 to 22 seconds

Gradeability 30%

Airborne noise emissions 70 dB

Maximum sound level at normal operation workstations

(A-weighted)

Continuous improvement of our products is a

Genie policy. Product specifications are

subject to change without notice.

Hydraulic Specifications

Hydraulic Oil Specifications

Before serial number GR02-1687

Hydraulic oil type Shell Donax TG (Dexron III)

After serial number GS02-1686

Hydraulic oil type Chevron Rykon MV equivalent

Approximate SAE grade Multu-viscosity

Viscosity index rating 200

Cleanliness level, minimum 15/13

Water content, maximum 200 ppm

Chevron Rykon MV oil is fully compatible and

mixable with Shell Donax TG (Dexron III) oils.

Genie specifications require hydraulic oils which are

designed to give maximum protection to hydraulic

systems, have the ability to perform over a wide

temperature range, and have a minimum viscosity index

rating of 150. They should provide excellent antiwear,

oxidation, corrosion inhibition, seal conditioning, and

foam and aeration suppression properties.

Optional fluids

Biodegradable Petro Canada Premium ECO 46

Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

Fire resistant UCON Hydrolube HP-5046

Quintolubric 822

Mineral based Shell Tellus T32

Shell Tellus T46

Chevron Aviation A

Use Chevron Aviation A hydraulic

oil when in ambient temperatures

consistently below 0°F / -17°C.

Use Shell 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 fluids. Consult

the Genie Industries Service

Department before use.

Section 2 • Specifications

REV B

September 2005

Part No. 72965 GR-8 • GR-12 • GR-15 2 - 3

SPECIFICATIONS

Manifold Component

Specifications

Plug torque

SAE No. 2 50 in-lbs / 6 Nm

SAE No. 4 13 ft-lbs / 18 Nm

SAE No. 6 18 ft-lbs / 24 Nm

SAE No. 8 50 ft-lbs / 68 Nm

SAE No. 10 55 ft-lbs / 75 Nm

SAE No. 12 75 ft-lbs / 102 Nm

Valve Coil Resistance

Description Specification

Solenoid valve, 3 position 4 way 22 to 24 Ω

20V DC with diode

(schematic items C, AC and AE)

Solenoid valve, 2 position 4 way 23 to 26 Ω

20V DC with diode

(schematic items D and AD)

Solenoid valve, 3 position 4 way 23 to 26 Ω

20V DC with diode

(schematic item E)

Continuous improvement of our products is a

Genie policy. Product specifications are

subject to change without notice.

Function pump

Type Gear

Displacement per revolution 0.244 cu in

4 cc

Displacement 1.4 gpm @ 3000 psi

5.lL/m @ 206.8 bar

Flow rate @ 2500 psi / 172 bar 4 gpm

15 L/min

Hydraulic tank return filter 10 micron with

25 psi / 1.7 bar bypass

Function manifold

System relief valve pressure, maximum 2700 psi

186 bar

Lift relief valve pressure 2200 psi

151.6 bar

Steer relief valve pressure 1000 psi

69 bar

Brake release pressure 265 psi

18.2 bar

Section 2 • Specifications

REV B

September 2005

2 - 4 GR-8 • GR-12 • GR-15 Part No. 72965

SPECIFICATIONS

Hydraulic Hose and Fitting

Torque Specifications

Your machine is equipped with JIC 37° flared

fittings and hose ends. Genie specifications require

that fittings and hose ends be torqued to

specification when they are removed and installed

or when new hoses or fittings are installed.

JIC 37° Fittings

(swivel nut or hose connection)

SAE Dash size Thread Size Flats

-4

/16-20 2

-6

/16-18 1

-8

/4-16 1

-10

/8-14 1

-12 1

/16-12 1

-16 1

/16-12 1

-20 1

/8-12 1

-24 1

/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

Seal-Lok

Fittings

(hose end)

SAE Dash size Torque

-4 18 ft-lbs / 25 Nm

-6 30 ft-lbs / 40 Nm

-8 40 ft-lbs / 55 Nm

-10 60 ft-lbs / 80 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

Section 2 • Specifications

REV B

September 2005

Part No. 72965 GR-8 • GR-12 • GR-15 2 - 5

3 Working clockwise on the body hex fitting, make

a second mark with a permanent ink marker to

indicate the proper tightening position. Refer to

Figure 2.

Use the

JIC 37° Fittings

table on

the previous page to determine

the correct number of flats for the

proper tightening position.

The marks indicate that the correct

tightening positions have been

determined. Use the second mark

on the body hex fitting to properly

tighten the joint after it has been

loosened.

Figure 1

a hydraulic hose

b hex nut

c reference mark

d body hex fitting

Torque Procedure

JIC 37° fittings

1 Align the tube flare (hex nut) against the nose of

the fitting body (body hex fitting) and tighten the

hex nut to the body hex fitting to hand-tight,

approximately 30 in-lbs / 3.4 Nm.

2 Make a reference mark on one of the flats of the

hex nut, and continue it on to the body hex

fitting with a permanent ink marker. Refer to

Figure 1.

SPECIFICATIONS

Figure 2

a body hex fitting

b reference mark

c second mark

4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the body

hex fitting.

5 Operate all machine functions and inspect the

hoses and fittings and related components to

confirm that there are no leaks.

Section 2 • Specifications

REV B

September 2005

2 - 6 GR-8 • GR-12 • GR-15 Part No. 72965

Seal-Lok® fittings

1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken.

The O-ring cannot be re-used if the fitting or

hose end has been tightened beyond finger

tight.

The O-rings used in the Parker

Seal Lok® fittings and hose ends

are custom-size O-rings. They are

not standard SAE size O-rings.

They are available in the O-ring

field service kit (Genie part

number 49612).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated and

retained properly.

4 Position the tube and nut squarely on the face

seal end of the fitting and tighten the nut finger

tight.

5 Tighten the nut or fitting to the appropriate

torque per given size as shown in the table.

6 Operate all machine functions and inspect the

hoses and fittings and related components to

SPECIFICATIONS

Section 2 • Specifications

REV B

September 2005

Part No. 72965 GR-8 • GR-12 • GR-15 2 - 7

SPECIFICATIONS

SIZE THREAD

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

100 11.3 80 9 140 15.8 110 12.4 130 14.7

90 10.1 120 13.5 120 13.5 160 18 140 15.8

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

13 17.6 17 23 18 24 25 33.9 21 28.4

14 19 19 25.7 20 27.1 27 36.6 24 32.5

23 31.2 31 42 33 44.7 44 59.6 38 51.5

26 35.2 35 47.4 37 50.1 49 66.4 43 58.3

37 50.1 49 66.4 50 67.8 70 94.7 61 82.7

41 55.5 55 74.5 60 81.3 80 108.4 68 92.1

57 77.3 75 101.6 80 108.4 110 149 93 126

64 86.7 85 115 90 122 120 162 105 142

80 108.4 110 149 120 162 150 203 130 176

90 122 120 162 130 176 170 230 140 189

110 149 150 203 160 217 210 284 180 244

130 176 170 230 180 244 240 325 200 271

200 271 270 366 280 379 380 515 320 433

220 298 300 406 310 420 420 569 350 474

320 433 430 583 450 610 610 827 510 691

350 474 470 637 500 678 670 908 560 759

480 650 640 867 680 922 910 1233 770 1044

530 718 710 962 750 1016 990 1342 840 1139

590 800 790 1071 970 1315 1290 1749 1090 1477

670 908 890 1206 1080 1464 1440 1952 1220 1654

840 1138 1120 1518 1360 1844 1820 2467 1530 2074

930 1260 1240 1681 1510 2047 2010 2725 1700 2304

1460 1979 1950 2643 2370 3213 3160 4284 2670 3620

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 Bolts

Grade 8

LUBED

1/4

LUBED DRY LUBED DRY

1 1/2

9/16

5/8

3/4

7/8

1 1/8

1 1/4

5/16

3/8

7/16

1/2

Size

(mm)

in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm

16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3

19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6

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

ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm

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 42.6

10.814.714.419.627.937.837.250.539.954.153.272.246.763.3 62.384.4

18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147

30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234

46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365

64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503

91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713

124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970

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

MET RIC FASTENER T ORQUE 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

10.9 12.98.84.6

Section 2 • Specifications September 2005

2 - 8 GR-12 • GR-15 • GR-20 Part No. 84700

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Section 3 • Scheduled Maintenance ProceduresAugust 2005

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 1

Scheduled Maintenance Procedures

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.

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

Section 3 • Scheduled Maintenance Procedures August 2005

3 - 2 GR-8 • GR-12 • GR-15 Part No. 72965

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend

The following symbols have been

used in this manual to help

communicate the intent of the

instructions. When one or more of

the symbols appears at the

beginning of a maintenance

procedure, it conveys the meaning

below.

Indicates that tools will be required to

perform this procedure.

Indicates that new parts will be required

to perform this procedure.

Indicates that a cold motor or pump will

be required to perform this procedure.

Indicates that dealer service will be

required to perform this procedure.

Pre-delivery Preparation Report

The pre-delivery preparation report contains

checklists for each type of scheduled inspection.

Make copies of the

Pre-delivery Preparation

report

to use for each inspection. Store completed forms

as required.

Maintenance Schedule

There are five types of maintenance inspections

that must be performed according to a schedule—

daily, quarterly, semi-annually, annually, and

two year. The

Scheduled Maintenance Procedures

Section and the Maintenance Inspection Report

have been divided into five subsections—A, B, C,

D, and E. Use the following chart to determine

which group(s) of procedures are required to

perform a scheduled inspection.

Inspection Checklist

Daily or every 8 hours A

Quarterly or every 250 hours 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 contains

checklists for each type of scheduled inspection.

Make copies of the

Maintenance Inspection Report

to use for each inspection. Store completed forms

for three years.

Genie Industries USA

18340 NE 76th Street

PO Box 97030

Redmond, WA 98073-9730

(425) 881-1800

Industries. Rev B

Genie UK

The Maltings, Wharf Road

Grantham, Lincolnshire

NG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-Deliver

Pre-Deliver

y Preparationy Preparation

y Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspection

completed

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 completing

the Pre-operation Inspection, the Maintenance items

and the Function Tests.

Use this form to record the results. Place a check in

the appropriate box after each part is completed.

Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machine

from service, repair and re-inspect it. After repair,

place a check in the R box.

Legend

Y = yes, completed

N = no, unable to complete

R = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform the

Pre-delivery Preparation.

The Pre-delivery Preparation is performed prior to

each delivery. The inspection is designed to discover if

anything is apparently wrong with a machine before it

is put into service.

A damaged or modified machine must never be used.

If damage or any variation from factory delivered

condition is discovered, the machine must be tagged

and removed from service.

Repairs to the machine may only be made by a

qualified service technician, according to the

manufacturer's specifications.

Scheduled maintenance inspections shall be

performed by qualified service technicians, according

to the manufacturer's specifications and the

requirements listed in the responsibilities manual.

Section 3 • Scheduled Maintenance Procedures August 2005

3 - 4 GR-8 • GR-12 • GR-15 Part No. 72965

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Section 3 • Scheduled Maintenance ProceduresApril 2006

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 5

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Checklist A - Rev B YNR

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

Checklist B - Rev B YNR

B-1 Batteries

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Lifting chain

B-5 Clean columns

B-6 Sequencing cables

B-7 Emergency stop

B-8 Key switch

B-9 Horn (if equipped)

B-10 Drive brakes

B-11 Drive speed - stowed

B-12 Drive speed - raised

B-13 Flashing beacon

(if equipped)

B-14 Alarm (if equipped)

B-15 Hydraulic oil analysis

B-16 Breather cap

Checklist C - Rev C YNR

C-1 Grease platform

overload (if equipped)

C-2 Test platform overload

(if equipped)

Checklist D - Rev C YNR

D-1 Inspect Mast

D-2 Lubricate lifting chains

D-3 Hydraulic filter

Checklist E - Rev B YNR

E-1 Hydraulic oil

Instructions

· Make copies of this report to use for

each inspection.

· Select the appropriate checklist(s) for

the type of inspection to be

performed.

Daily or 8 hours

Inspection: A

Quarterly or 250 hours

Inspection: A+B

Semi-annually or

500 hours

Inspection: A+B+C

Annually or

1000 hours

Inspection: A+B+C+D

Two year or

2000 hours

Inspection: A+B+C+D+E

· Place a check in the appropriate box

after each inspection procedure is

completed.

· Use the step-by-step procedures in

this section to learn how to perform

these inspections.

· If any inspection receives an “N”, tag

and remove the machine from service,

repair and re-inspect it. After repair,

place a check in the “R” box.

Legend

Y = yes, acceptable

N = no, remove from service

R = repaired

Comments

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

3 - 6 GR-8 • GR-12 • GR-15 Part No. 72965

A-1

Perform Pre-operation Inspection

Completing a Pre-operation Inspection is essential

to safe machine operation. The Pre-operation

Inspection is a visual inspection performed by the

operator prior to each work shift. The inspection is

designed to discover if anything is apparently

wrong with a machine before the operator performs

the function tests. The Pre-operation Inspection

also serves to determine if routine maintenance

procedures are required.

Complete information to perform this procedure is

available in the appropriate operator's manual.

Refer to the Operator's Manual on your machine.

Checklist A Procedures

A-2

Perform Function Tests

Completing the function tests is essential to safe

machine operation. Function tests are designed to

discover any malfunctions before the machine is

put into service. A malfunctioning machine must

never be used. If malfunctions are discovered, the

machine must be tagged and removed from

service.

Complete information to perform this procedure is

available in the appropriate operator's manual.

Refer to the Operator's Manual on your machine.

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 7

CHECKLIST A PROCEDURES

A-3

Perform 30 Day Service

The 30 day maintenance procedure is a one time

procedure to be performed after the first 30 days or

40 hours of usage. After this interval, refer to the

maintenance tables for continued scheduled

maintenance.

1 Perform the following maintenance procedures:

· B-3 Inspect the Tires and Wheels

(including 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 application of lubrication to the steer yokes

is essential to good machine performance and

service life. Continued use of an insufficiently

greased steer yoke will result in component

damage.

1 Locate the grease fitting on the top of the steer

yoke.

2 Pump multipurpose grease into the steer yoke

until the steer yoke is full and grease is being

forced past the bearings. Repeat this step for

the other steer yoke.

Grease specification

Chevron Ultra-duty grease, EP NLGI 2 (lithium based)

or equivalent

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

3 - 8 GR-8 • GR-12 • GR-15 Part No. 72965

Checklist B Procedures

B-1

Inspect the Batteries

Proper battery condition is essential to good

machine performance and operational safety.

Improper fluid levels or damaged cables and

connections can result in component damage and

hazardous conditions.

Electrocution hazard. Contact with

electrically charged circuits could

result in death or serious injury.

Remove all rings, watches and

other jewelry.

Bodily injury hazard. Batteries

contain acid. Avoid spilling or

contacting battery acid. Neutralize

battery acid spills with baking soda

and water.

Perform this procedure after 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

the battery cells to equalize.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections are

free of corrosion.

3 Be sure that the battery retaining fasteners and

cable connections are tight.

Models without maintenance-free or sealed

batteries:

4 Remove the battery vent caps from all batteries

and check the specific gravity of each battery

cell with a hydrometer.

Result: If any battery cell displays a specific

gravity of less than 1.026, the battery must be

replaced.

5 Check the battery acid level of each battery. If

needed, replenish with distilled water to the

bottom of the battery fill tube. Do not overfill.

6 Install the battery vent caps.

All models:

7 Check each battery pack and verify that the

batteries are wired correctly. Refer to the

Battery Connection Diagram

decal on the

machine.

8 Inspect the battery charger plug and pigtail for

damage or excessive insulation wear. Replace

as required.

9 Connect the battery 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.

For best results, use an extension

of adequate size with a length no

longer than 50 feet / 15 m.

If you have any further questions

regarding the battery charger

operation, please contact the

Genie Industries Scissor Service

Department.

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 9

CHECKLIST B PROCEDURES

B-2

Inspect the Electrical Wiring

Maintaining electrical wiring in good condition is

essential to safe operation and good machine

performance. Failure to find and replace burnt,

chafed, corroded or pinched wires could result in

unsafe operating conditions and may cause

component damage.

Electrocution hazard. Contact with

hot or live circuits could result in

death or serious injury. Remove all

rings, watches and other jewelry.

1 Inspect the underside of the chassis for

damaged 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 grease

in the following locations:

· Between the ECM and platform controls

· All wire harness connectors

· Level sensor

5 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.

6 Raise the platform approximately 8 feet / 2.4 m

from the ground.

7 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the 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 and

pinched cables.

11 Close the battery tray cover.

12 Remove the strap from the platform.

13 Lower the platform to the stowed position and

turn the machine off.

REV B

Section 3 • Scheduled Maintenance Procedures

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3 - 10 GR-8 • GR-12 • GR-15 Part No. 72965

B-3

Inspect the Tires and Wheels

(including castle nut torque)

Maintaining the tires and wheels in good

condition is essential to safe operation and good

performance. Tire and/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.

1 Check the tire surface and sidewalls for cuts,

cracks, punctures and unusual wear.

2 Check each wheel for damage, bends and

cracks.

3 Remove the cotter pin and check each castle

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 pin. Bend the cotter pin to

lock it in place.

B-4

Check the Lifting Chain

Adjustments

Maintaining proper adjustment of the lifting chains

is essential to safe machine operation. Failure to

maintain proper chain adjustment could result in an

unsafe operating condition and may cause

component damage.

1 Fully lower the platform and measure the

maximum height of the machine. Refer to

Section 2,

Specifications

Result: The machine is not within specification.

Adjust the chains. Refer to Repair Procedure

3-4,

How to Adjust the Lifting Chains.

CHECKLIST B PROCEDURES

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 11

B-5

Clean and Lubricate the Columns

Clean and properly lubricated columns are

essential to good machine performance and safe

operation. Extremely dirty conditions may require

that the columns be cleaned and lubricated more

often.

1 Raise the platform to the maximum height.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Visually inspect the inner and outer channels of

the columns for debris or foreign material. If

necessary, use a mild cleaning solvent to clean

the columns.

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 proper skills and tools could

result in death or serious injury.

Dealer service is strongly

recommended.

4 If needed, apply a generous amount of

Boe-lube wax to the inside and outside

channels of each column.

CHECKLIST B PROCEDURES

B-6

Adjust the Sequencing Cables

Maintaining proper adjustment of the sequencing

cables is essential for safe machine operation. An

unsafe working condition exists if the sequencing

cables are improperly adjusted. A frequent check

allows the inspector to identify changes in the

sequencing cables operating condition that might

indicate damage.

1 Fully lower the platform.

2 Locate the compression spring on each

sequencing cable.

The spring is located between the

nylock nut and the upper

sequencing bracket.

a nylock nut

b spring

c upper sequencing bracket

d sequencing cable

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

3 - 12 GR-8 • GR-12 • GR-15 Part No. 72965

3 Confirm proper tension of each sequencing

cable by measuring the height of the spring

between the nylock nut and the upper

sequencing bracket.

Result: The measurement is within

specification. Proceed to step 7.

Result: The measurement is not within

specification. Proceed to step 4.

Sequencing cable spring specification

Measurement, compressed

/16 inch

2.4 cm

4 Adjust the spring compressed length by turning

the nylock nut clockwise to decrease the spring

length or counterclockwise to increase the

spring length.

Component damage hazard. Do

not compress the spring to less

than specification.

5 Raise and lower the platform through three

complete cycles.

6 Repeat this procedure beginning with step 3.

7 Repeat steps 3 through 5 for each sequencing

cable as required.

B-7

Test the Emergency Stop

A properly functioning Emergency Stop is essential

for safe machine operation. An improperly

operating red Emergency Stop button will fail to

shut off power and stop all machine functions,

resulting in a hazardous situation.

As a safety feature, selecting

and operating the ground controls

will override the platform controls,

except the platform red

Emergency Stop button.

1 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on

position at both the ground and platform

controls.

2 Push in the red Emergency Stop button at the

ground controls to the off position.

Result: No machine functions should operate.

3 Turn the key switch to platform control and pull

out the red Emergency Stop button to the on

position at both the ground and platform

controls.

4 Push down the red Emergency Stop button at

the platform controls to the off position.

Result: No machine functions should operate.

The red Emergency Stop button at

the ground controls will stop all

machine operation, even if the key

switch is switched to platform

control.

CHECKLIST B PROCEDURES

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 13

B-8

Test the Key Switch

Proper key switch action and response is essential

to safe machine operation. The machine can be

operated from the ground or platform controls and

the activation of one or the other is accomplished

with the key switch. Failure of the key switch to

activate the appropriate control panel could cause

a hazardous operating situation.

Perform this procedure from the

ground using the platform controls.

Do not stand in the platform.

1 Pull out the red Emergency Stop button to the

on position at both the ground and platform

controls.

2 Turn the key switch to platform control.

3 Check the platform up/down function from the

ground controls.

Result: The machine functions should not

operate.

4 Turn the key switch to ground control.

5 Check the machine functions from the platform

controls.

Result: The machine functions should not

operate.

6 Turn the key switch to the off position.

7 Test the machine functions from the ground and

platform controls.

Result: No machine functions should operate.

CHECKLIST B PROCEDURES

B-9

Test the Automotive-style Horn

(if equipped)

The horn is activated at the platform controls and

sounds at the ground as a warning to ground

personnel. An improperly functioning horn will

prevent the operator from alerting ground

personnel of hazards or unsafe conditions.

1 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.

2 Push down the horn button at the platform

controls.

Result: The horn should sound.

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

3 - 14 GR-8 • GR-12 • GR-15 Part No. 72965

B-11

Test the Drive Speed -

Stowed Position

Proper drive functions are essential to safe

machine operation. The drive function should

respond quickly and smoothly to operator control.

Drive performance should also be free of

hesitation, jerking and unusual noise over the

entire proportionally controlled speed range.

Perform this procedure with the

machine on a firm, level surface

that is free of obstructions.

1 Create start and finish lines by marking two

lines 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 platform to the stowed position.

4 Move the lift/drive toggle switch to the drive

position.

5 Press the drive speed button (if equipped) until

the high speed (rabbit) light is illuminated.

6 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use

when crossing the start and finish lines.

7 Bring the machine to top drive speed before

reaching the start line. Begin timing when your

reference point on the machine crosses the

start line.

8 Continue at full speed and note the time when

your reference point on the machine passes

over the finish line. Refer to Section 2,

Specifications

B-10

Test the Drive Brakes

Proper brake action is essential to safe machine

operation. The drive brake function should operate

smoothly, free of hesitation, jerking and unusual

noise. Hydraulically-released individual wheel

brakes can appear to operate normally when not

fully operational.

Perform this procedure with the

machine on a firm, level surface

that is free of obstructions.

Be sure the platform extension

deck is fully retracted and the

platform is in the stowed position.

1 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 the platform to the stowed position.

4 Move the lift/drive toggle switch to the drive

position.

5 Press the drive speed button (if equipped) until

the high speed (rabbit) light is illuminated.

6 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use

when crossing the test line.

7 Bring the machine to top drive speed before

reaching the test line. Release the function

enable switch or the joystick when your

reference point on the machine crosses the test

line.

8 Measure the distance between the test line and

your machine reference point. Refer to Section

Specifications

The brakes must be able to hold

the machine on any slope it is able

to climb

CHECKLIST B PROCEDURES

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 15

CHECKLIST B PROCEDURES

B-12

Test the Drive Speed -

Raised Position

Proper drive functions are essential to safe

machine operation. The drive function should

respond quickly and smoothly to operator control.

Drive performance should also be free of

hesitation, jerking and unusual noise over the

entire proportionally controlled speed range.

Perform this procedure with the

machine on a firm, level surface

that is free of obstructions.

1 Create start and finish lines by marking two

lines 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 Raise the platform approximately 4 feet / 1.2 m

from the ground.

4 Move the lift/drive toggle switch to the drive

position.

5 Press the drive speed button (if equipped) until

the high speed (rabbit) light is illuminated..

6 Choose a point on the machine; i.e., contact

patch of a tire, as a visual reference for use

when crossing the start and finish lines.

7 Bring the machine to top drive speed before

reaching the start line. Begin timing when your

reference point on the machine crosses the

start line.

8 Continue at full speed and note the time when

your reference point on the machine passes

over the finish line. Refer to Section 2,

Specifications

B-13

Test the Flashing Beacon

(if equipped)

Flashing beacons are used to alert operators and

ground personnel of machine proximity and

motion. The flashing beacons are located on both

sides of the mast.

1 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on

position at both the ground and platform

controls.

Result: The beacons should flash.

2 Turn the key switch to platform controls.

Result: The beacons should flash.

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

3 - 16 GR-8 • GR-12 • GR-15 Part No. 72965

CHECKLIST B PROCEDURES

B-14

Test the Alarm Package

(if equipped)

The alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacons

Alarms and beacons are used to alert operators

and ground personnel of machine proximity and

motion. The descent alarm and travel alarm are

located in the ground control box. The flashing

beacons are located on both sides of the mast.

The alarms and beacons will

operate with key switch turned to

either ground or platform controls.

1 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on

position at both the ground and platform

controls.

Result: Both flashing beacons should be on and

flashing.

2 Activate the platform up/down toggle switch in

the down position, hold for a moment and then

release it.

Result: The descent alarm should sound when

the toggle switch is held down.

3 Turn the key switch to platform controls.

Result: bopth flashing beacons should be on

and flashing.

4 Move the lift/drive select switch to the lift

position.

5 Press and hold the function enable switch on

the joystick controller (joystick). Move the

joystick in the direction indicated by the yellow

arrow on the control panel, hold for a moment

and then release it.

Result: The descent alarm should sound when

the joystick is held down.

6 Move the lift/drive selector switch to the drive

position.

7 Press and hold the function enable switch on

the joystick. Move the joystick off center, hold

for a moment and then release it. Move the

joystick off center in the opposite direction, hold

for a moment and then release it.

Result: The travel alarm should sound when the

joystick is moved off center in either direction.

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 17

CHECKLIST B PROCEDURES

B-15

Perform Hydraulic Oil Analysis

Replacement or testing of the hydraulic oil is

essential for good machine performance and

service life. Dirty oil may cause the machine to

perform poorly and continued use may cause

component damage. Extremely dirty conditions

may require oil changes to be performed more

often.

Before replacing the hydraulic oil,

the oil may be tested by an oil

distributor for specific levels of

contamination to verify that

changing the oil is necessary. If

the hydraulic oil is not replaced

at the two year inspection, test

the oil quarterly. Replace the oil

when it fails the test. See E-1,

Test or Replace the Hydraulic Oil.

B-16

Inspect the Hydraulic Tank Cap

Venting System

The hydraulic tank is a vented-type tank. The

breather cap has an internal air 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 component

damage. Extremely dirty conditions may require

that the cap be inspected more often.

1 Remove the breather cap from the hydraulic

tank.

2 Check for proper venting.

Result: Air passes through the fuel tank cap.

Proceed to step 4.

Result: If air does not pass through the cap,

clean or replace the cap. Proceed to step 3.

When checking for positive tank

cap venting, air should pass freely

through the cap.

3 Using a mild solvent, carefully wash the cap

venting system. Dry using low pressure

compressed air. Repeat this procedure

beginning with step 2.

4 Install the breather cap onto the hydraulic tank.

REV C

Section 3 • Scheduled Maintenance Procedures

April 2006

3 - 18 GR-8 • GR-12 • GR-15 Part No. 72965

C-1

Replace the

Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil

The hydraulic tank is a vented-type tank. The

breather cap has an internal air filter that can

become clogged or, over time, can deteriorate. If

the breather cap is faulty or improperly installed,

impurities can enter the hydraulic system which

may cause component damage. Extremely dirty

conditions may require that the cap be inspected

more often.

1 Remove and discard the hydraulic tank breather

cap.

2 Install a new cap onto the tank.

Checklist C Procedures

C-2

Grease the Platform Overload

Mechanism (if equipped)

Genie specifications require

that this procedure be performed

every 500 hours or 6 months,

whichever comes first. Perform

this procedure more often if dusty

conditions exist.

Application of lubrication to the platform overload

mechanism is essential to safe machine operation.

Continued use of an improperly greased platform

overload mechanism could result in the system not

sensing an overloaded platform condition and will

result in component damage.

1 Locate the grease fittings on each pivot pin of

the platform overload assembly.

2 Thoroughly pump grease into each grease

fitting using a multi-purpose grease.

REV C

Section 3 • Scheduled Maintenance Procedures

April 2006

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 19

C-3

Test the Platform Overload

System (if equipped)

Genie specifications require that

this procedure be performed every

500 hours or 6 months, whichever

comes first.

Testing the platform overload system regularly is

essential to safe machine operation. Continued

use of an improperly operating platform overload

system could result in the system not sensing an

overloaded platform condition. Machine stability

could be compromised resulting in the machine

tipping over.

Perform this procedure with the

machine on a firm, level surface.

1 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.

2 Determine the maximum platform capacity.

Refer to the machine serial plate.

3 Using a suitable lifting device, place an

appropriate test weight equal to the maximum

platform capacity in the center of the platform

floor. Refer to Section 2,

Specifications

Result: The overload alarm at the platform

controls should not sound, indicating a normal

condition.

Result: The overload alarm at the platform

controls sounds. The platform overload system

is not operating properly. Refer to Repair

Procedure 10-1,

Calibrate the Platform

Overload System (if equipped).

4 Add an additional weight to the platform not to

exceed 20% of the maximum rated load. Refer

to the machine serial plate.

Result: The overload alarm at the platform

controls sounds. The platform overload system

is operating properly.

Result: The overload alarm at the platform

controls does not sound. The platform overload

system is not operating properly. Refer to

Repair Procedure 10-1,

Calibrate the Platform

Overload System (if equipped).

5 Test all machine functions from the platform

controls.

Result: All platform control functions should not

operate.

6 Turn the key switch to ground control.

7 Test all machine functions from the ground

controls.

Result: All ground control functions should not

operate.

CHECKLIST C PROCEDURES

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Section 3 • Scheduled Maintenance Procedures

April 2006

3 - 20 GR-8 • GR-12 • GR-15 Part No. 72965

8 Lift the test weight off the platform floor using a

suitable lifting device.

Result: The overload alarm at the platform

controls should not sound, indicating a normal

condition.

Result: The overload alarm at the platform

controls sounds. The platform overload system

is not operating properly. See D-1,

Calibrate the

Platform Overload System (if equipped).

9 Test all machine functions from the ground

controls.

Result: All ground control functions should

operate normally.

10 Turn the key switch to platform control.

11 Test all machine functions from the platform

controls.

Result: All platform control functions should

operate.

If the platform overload system is

not operating properly, see D-1,

Calibrate the Platform Overload

System (if equipped).

CHECKLIST C PROCEDURES

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Section 3 • Scheduled Maintenance Procedures

April 2006

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 21

Checklist D Procedures

D-1

Inspect the Mast Assembly

for Wear

Detection of excessive or unusual wear in the mast

assembly is essential for safe machine operation.

An unsafe working condition exists if the mast

assembly has excessive wear and/or does not

operate smoothly, free of hesitation and binding.

1 Remove the mast covers.

2 Raise the platform until approximately

4 inches / 10 cm of each column is visible.

3 Visually inspect the top of each column for

clearance between the roller wheels and the

adjacent column surface.

Result: There should be an equal amount of

distance between the roller wheel/slider block

and the column on each side.

If mast inspection results in a

measurement that is not within

specification, refer to Repair

procedure 3-2,

How to Adjust the

Glide Pads.

4 Loosen but do not remove the adjustment nut

on the sequencing cable located at the top of

the first column.

5 Raise the platform approximately 3 feet / 1 m

above the top of the drive chassis.

6 Place piece of 0.75 inch / 1.9 cm thick plywood

ont top of the drive chassis.

7 Place a jack stand on the top of the plywood,

centered under the platform. Adjust the jack

stand height to 24 inches / 61 cm.

8 Lower the platform onto the jack stand just

enough to take the weight off the lifting chains.

Crushing hazard. Keep hands

clear of the jack stand when

lowering the platform.

GR-15 shown

a mast cover

b idler wheel

c spacer

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Section 3 • Scheduled Maintenance Procedures

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3 - 22 GR-8 • GR-12 • GR-15 Part No. 72965

CHECKLIST D PROCEDURES

9 Inspect each idler wheel for the following:

· Excessive wear on the side flanges

· Unusual wear

· Movement side to side in excess of

0.040 inch / 1 mm

· Any wheel movement front to back

If idler wheel inspection results in

a condition that is not within

specification, refer to Repair

Procedure 3-1,

How to Assemble

the Mast.

10 Raise the platform slightly and remove the jack

stand and the piece of plywood. Lower the

platform to the stowed position.

11 Install the mast covers and adjust the

sequencing cable. See B-6,

Adjust the

Sequencing Cables.

D-2

Lubricate the Lifting Chains

Lubricated chains are essential to good machine

performance and safe operation. Extremely dirty

conditions may require that the chains be cleaned

and lubricated more often.

1 Raise the platform to the maximum height.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Lubricate each chain with a dry-type spray

lubricant.

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 proper skills and tools could

result in death or serious injury.

Dealer service is strongly

recommended.

REV C

Section 3 • Scheduled Maintenance Procedures

April 2006

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 23

D-3

Replace the Hydraulic Tank

Return Filter

Replacement of the hydraulic tank return filter is

essential for good machine performance and

service life. A dirty or clogged filter may cause the

machine to perform poorly and continued use may

cause component damage. Extremely dirty

conditions may require that the filter be replaced

more often.

Burn hazard. Beware of hot oil.

Contact with hot oil may cause

severe burns.

The hydraulic tank return filter is

mounted on the function manifold

next to the hydraulic power unit.

1 Clean the area around the oil filter. Remove the

filter with an oil filter wrench.

2 Apply a thin layer of oil to the new oil filter

gasket.

3 Install the new filter and tighten it securely by

hand.

4 Use a permanent ink marker to write the date

and number of hours from the hour meter onto

the filter.

CHECKLIST D PROCEDURES

5 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.

6 Activate and hold the platform up toggle switch.

7 Inspect the filter and related components to

be sure that there are no leaks.

8 Clean up any oil that may have spilled.

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Section 3 • Scheduled Maintenance Procedures

August 2005

3 - 24 GR-8 • GR-12 • GR-15 Part No. 72965

Checklist E Procedure

E-1

Test or Replace the Hydraulic Oil

Replacement or testing of the hydraulic oil is

essential for good machine performance and

service life. Dirty oil and suction strainers may

cause the machine to perform poorly and

continued use may cause component damage.

Extremely dirty conditions may require oil changes

to be performed more frequently.

The machine uses Dexron

equivalent hydraulic oil. Before

replacing the hydraulic oil, the oil

may be tested by an oil distributor

for specific levels of contamination

to verify that changing the oil is

necessary. If the hydraulic oil is

not replaced at the two year

inspection, test the oil quarterly.

Replace the oil when it fails the

test.

When removing a hose assembly

or fitting, the O-ring on the fitting

and/or hose end must be replaced

and then torqued to specification

during installation. Refer to

Section 2,

Hydraulic Hose and

Fitting Torque Specifications.

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Disconnect the battery pack from the machine.

Electrocution hazard. Contact with

electrically charged circuits could

result in death or serious injury.

Remove all rings, watches and

other jewelry.

4 Remove the drive chassis cover.

5 Remove the drain plug from the hydraulic tank

and allow all of the oil to drain into a suitable

container. Refer to Section 2,

Specifications

Bodily injury hazard Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to squirt

or spray.

6 Tag, disconnect and plug the supply hose from

the hydraulic power unit to the tank.

7 Before serial number GR01-249: Tag,

disconnect and plug the return hose from the

function manifold to tank at the return filter. Cap

the fitting on the return filter housing.

After serial number GR01-248: Tag,

disconnect and plug the return hose from the

return filter to tank at the tank.

REV B

Section 3 • Scheduled Maintenance Procedures

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 3 - 25

CHECKLIST E PROCEDURE

8 Remove the hydraulic tank mounting fasteners

and remove the tank from the machine.

9 Remove the suction strainer from the tank and

clean it using a mild solvent.

10 Clean the inside of the hydraulic tank using a

mild solvent.

11 Install the suction strainer using thread sealant

on the threads. Torque to specification.

12 Install and tighten the hydraulic tank drain plug

using thread sealant on the threads. Torque to

specification.

13 Install the hydraulic tank and install and tighten

the hydraulic tank retaining fasteners. Torque to

specification.

14 Connect the suction hose to the strainer and

torque to specification.

15 Before serial number GR01-249: Connect the

return hose to the return filter and torque to

specification.

After serial number GR01-248: Connect the

return hose to the tank and torque to

specification.

16 Connect the battery pack to the machine.

Electrocution hazard. Contact with

electrically charged circuits could

result in death or serious injury.

Remove all rings, watches and

other jewelry.

17 Fill the tank with hydraulic oil until the fluid is at

the FULL indicator on the hydraulic tank. Do not

overfill.

18 Activate the pump to fill the hydraulic system

with oil and bleed the system of air.

Component damage hazard. The

pump can be damaged if operated

without oil. Be careful not to empty

the hydraulic tank while in the

process of filling the hydraulic

system. Do not allow the pump to

cavitate.

19 Repeat steps 17 through 18 until the hydraulic

system and tank are both full.

20 Clean up any oil that may have spilled. Properly

discard the used oil.

21 Install the drive chassis cover and securely

tighten the fasteners. Do not over tighten.

22 Lower the platform to the stowed position.

Hydraulic tank torque specifications

Hydraulic tank retaining fasteners, dry 35 in-lbs

4 Nm

Hydraulic tank retaining fasteners, lubricated 26 in-lbs

2.9 Nm

Hydraulic tank drain plug, dry 40 in-lbs

4.5 Nm

Hydraulic tank drain plug, lubricated 30 in-lbs

3.4 Nm

Section 3 • Scheduled Maintenance Procedures April 2006

3 - 26 GR-8 • GR-12 • GR-15 Part No. 72965

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Section 4 • Repair ProceduresAugust 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 1

Repair Procedures

Observe and Obey:

Repair procedures shall be completed by a

person trained and qualified on the repair of this

machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Before Repairs Start:

Read, understand and obey the safety rules

and operating instructions in the appropriate

operator's manual on your machine.

Be sure that all necessary tools and parts are

available and ready for use.

Read each procedure completely and adhere to

the instructions. Attempting shortcuts may

produce hazardous conditions.

Unless otherwise specified, perform each repair

procedure with the machine in the following

configuration:

· Machine 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

Most of the procedures in this section should only

be performed by a trained service professional

in a suitably equipped workshop. Select the

appropriate repair procedure after troubleshooting

the problem. Perform disassembly procedures to

the point where repairs can be completed. To

re-assemble, perform the disassembly steps in

reverse order.

Symbols Legend

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

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.

Section 4 • Repair Procedures

REV B

August 2005

4 - 2 GR-8 • GR-12 • GR-15 Part No. 72965

Platform Controls

The joystick controller (joystick) should operate

smoothly and provide proportional drive speed

control over its entire range of motion.

The joystick is connected to the motor controller

located in the drive chassis. There are no

adjustments needed on the joystick. For further

assistance, consult the Genie Industries Service

Department.

For further information or assistance, consult the

Genie Industries Service Department.

1-1

Circuit Board

How to

Remove the Circuit Board

1 Tag and disconnect the platform controls from

the machine. Remove the control box from the

machine and place it on a workbench.

2 Remove the fasteners securing the base to the

platform control box. Open the box.

3 Remove the ties securing the wire harness.

4 Remove the alarm and horn assembly button

from the platform control box (if equipped).

5 Tag and disconnect the wire harnesses

connectors from the circuit board.

Component damage hazard.

Electrostatic discharge (ESD) can

damage printed circuit board

components. Maintain firm contact

with a metal part of the machine

that is grounded at all times when

handling printed circuit boards OR

use a grounded wrist strap.

6 Remove the circuit board retaining fasteners

and remove the circuit board from the box.

a joystick controller JC3

b horn H3

c lift/drive select toggle switch TS16

d horn button BN5

e red Emergency Stop button P2

f platform controls circuit board U3

HORN

BN5

HORN

EMERGENCY

STOP

JC3

JOYSTICK

CONTROLLER

TS16

LIFT/DRIVE SELECT

TOGGLE SWITCH

PLATFORM

CONTROLS

CIRCUIT

BOARD

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 3

PLATFORM CONTROLS

1-2

Controller Adjustments

How to

Calibrate the Potentiometer

1 Tag and disconnect the platform controls from

the machine. Remove the control box from the

machine and place it on a workbench.

2 Remove the retaining fasteners securing the

base to the platform control box. Open the box.

3 Remove the ties securing the wire harness.

4 Tag and disconnect the joystick from the wire

harnesses.

Component damage hazard.

Electrostatic discharge (ESD) can

damage printed circuit board

components. Maintain firm contact

with a metal part of the machine

that is grounded at all times when

handling printed circuit boards OR

use a grounded wrist strap.

5 Remove the joystick retaining fasteners and

remove the joystick from the control box.

6 Remove the circuit board from the joystick. Turn

the circuit board over to access the

potentiometer shaft.

When installed, the potentiometer

shaft and joystick coupler engages

the joystick slave gear.

7 Set a multimeter to read ohm resistance.

The multimeter, when set to read

ohm resistance, should be

capable of reading 20k ohms.

8 Connect the leads from the multi meter to the

yellow and red wires of the joystick harness at

the harness connector.

9 Note the orientation of the joystick coupler

installed onto the potentiometer shaft. Loosen

the set-screw and remove the coupler. Set the

coupler to the side.

a circuit board

b potentiometer shaft

c coupler

d set screw

e circuit board bottom edge

10 Using the multi meter as a guide, rotate the

potentiometer shaft until reaching the highest

reading on the meter. Note the result.

11 Install the coupler onto the potentiometer shaft

in the same orientation as removed, with the

set-screw side of the coupler installed parallel

to the bottom edge of the circuit board.

12 Install the circuit board and fasteners onto the

joystick. Securely tighten the fasteners. Do not

over tighten.

Section 4 • Repair Procedures

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August 2005

4 - 4 GR-8 • GR-12 • GR-15 Part No. 72965

13 Note the reading on the multi meter display.

Result: The reading is within 10% of the result

from step 10.

Result: The reading is not within 10% of the

result from step 10. Repeat this procedure

beginning with step 11.

14 Install the joystick into the platform control box.

Install and securely tighten the retaining

fasteners. Do not over tighten.

15 Securely connect the joystick to the control box

wire harness.

16 Install the base onto the control box. Install and

securely tighten the retaining fasteners. Do not

over tighten.

How to

Calibrate the High Speed Trimpot

(Adjusting the Stowed Drive Speed)

To calibrate the raised drive

speed, see 4-3,

How to Calibrate

the Raised Drive Speed Trimpot

(Adjusting the Raised Drive

Speed).

1 Remove the base from the platform control box.

2 Locate the high speed trimpot on the circuit

board of the joystick assembly.

The high speed trimpot is located

adjacent to the potentiometer and

the single red wire on the circuit

board of the joystick.

3 Adjust the trimpot to acheive the specified drive

speed. Turn the trimpot screw clockwise to

decrease the drive speed or counterclockwise

to increase the drive speed.

4 Install the base onto the control box. Install and

securely tighten the fasteners. Do not over

tighten.

5 Confirm the stowed drive speed. Refer to

Maintenance Procedure B-11,

Test the Drive

Speed - Stowed Position

a high speed trimpot

b circuit board

c potentiometer

PLATFORM CONTROLS

Section 4 • Repair Procedures

REV A

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 5

Platform Components

2-1

Platform

How to

Remove the Platform

1 Raise the platform approximately 3 feet / 1 m.

2 Place support blocks between the platform and

the drive chassis. Lower the platform onto the

blocks.

Crushing hazard. Keep away from

the lowering platform.

3 Unlatch and remove the platform control box

from the platform and set it aside.

4 Tag and disconnect the extension deck limit

switch (if equipped) wiring at the junction box.

5 Remove the mounting fasteners from the

platform.

6 Pull the platform away from the mast and

remove it from the machine.

Bodily injury hazard. If a platform

is being replaced, be sure that all

appropriate safety and

instructional decals are applied to

the new platform.

2-2

Platform Extension

How to

Remove the Platform Extension

1 Remove the Platform, See 2-1,

How to Remove

the Platform

2 Remove the outer platform railing assembly.

3 Remove the slide blocks from the outer

platform.

4 Activate the foot release latch and slide the

extension platform out from under the platform.

Section 4 • Repair Procedures

REV B

August 2005

4 - 6 GR-8 • GR-12 • GR-15 Part No. 72965

Mast Components

3-1

Mast

Bodily injury hazard. This

procedure requires specific repair

skills, lifting equipment and a

suitable workshop. Attempting this

procedure without these skills and

tools could result in death or

serious injury and significant

component damage. Dealer

service is strongly recommended.

How to

Remove the Mast Assembly

Perform this procedure on a firm,

level surface.

Perform this procedure with the

mast in the stowed position.

When removing a hose assembly

or fitting, the O-ring on the fitting

and/or hose end must be replaced

and then torqued to specification

during installation. Refer to

Section 2,

Hydraulic Hose and

Fitting Torque Specifications.

1 Remove the platform. See 2-1,

How to Remove

the Platform

2 Open the battery covers.

3 Remove the fasteners securing the rear access

cover to the chassis. Remove the cover.

4 Tag and disconnect the wire harness from the

valve coil at the base of the lift cylinder.

5 Tag, disconnect and plug the lift cylinder

hydraulic hoses. Cap the fittings on the

cylinder.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to squirt

or spray.

6 Remove the solenoid valve from the lift cylinder.

Plug the opening in the cylinder manifold.

7 Remove the fasteners from the drive speed limit

switch (LS5) mounted at the top of the number

1 column. Do not disconnect the wiring.

8 Remove the platform controls. Remove the

fasteners from the power to platform junction

box mounting bracket. Do not disconnect the

wiring.

Component damage hazard.

Cables can be damaged if they

are kinked or pinched.

9 Attach a lifting strap of suitable capacity from an

overhead crane to the lifting eye at the top of

the mast. Support the mast. Do not apply any

lifting pressure.

10 Place two 4 x 4 x 24 inch / 10 x 10 x 60 cm

blocks across the top of the drive chassis.

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 7

MAST COMPONENTS

11 Remove the mast mounting fasteners and lower

the mast assembly onto the blocks.

Crushing hazard. The mast

assembly could become

unbalanced and fall if not properly

supported when the fasteners are

removed.

12 Remove the control cable from the pulleys and

set it aside.

Component damage hazard.

Cables can be damaged if they

are kinked or pinched.

13 With the carriage facing down, place the mast

assembly on a suitable structure capable of

supporting it.

Crushing hazard. The mast

assembly could become

unbalanced and fall if not properly

supported when removed from the

machine.

a number 1 column

b battery box brace

c counterweight (GR-15 models)

d counterweight fasteners (GR-15 models)

e mast mounting fasteners

Section 4 • Repair Procedures

REV B

August 2005

4 - 8 GR-8 • GR-12 • GR-15 Part No. 72965

MAST COMPONENTS

How to

Disassemble the Mast

Bodily injury hazard. This

procedure requires specific repair

skills, lifting equipment and a

suitable workshop. Attempting this

procedure without these skills and

tools could result in death or

serious injury and significant

component damage. Dealer

service is strongly recommended.

1 Remove the mast. See 3-1.

How to Remove the

Mast Assembly.

2 Remove the lift cylinder. See 3-4,

How to

Remove the Lift Cylinder.

3 Rotate the mast until the carriage is facing up.

4 Remove the mast covers.

5 Remove the adjustment nuts from all of the

sequencing cables.

6 Slide the carriage toward the top of the mast

assembly enough to remove the tension on the

lifting chains.

7 Slide the column below the carriage toward the

top of the mast assembly approximately

6 inches / 15 cm to access the idler wheel

mounting fasteners.

8 Hold the idler wheel axle from turning by placing

a screwdriver through the hole in the axle.

Remove the axle mounting fasteners and

remove the idler wheel assembly.

Label the location and orientation

of each idler wheel assembly.

9 Remove the adjustment nuts from the chain

tension rocker on the carriage.

10 Slide the carriage out the bottom of the mast

assembly.

11 Lay the chains out on the floor at the top of the

mast. Do not allow the chains to become

twisted or dirty.

12 Remove the adjustment nuts from the chain

tension rocker on the column.

13 Slide the column out the bottom of the mast.

14 Push the next column toward the top of the

mast to access the idler wheel assembly

mounting fasteners.

15 Hold the idler wheel axle from turning by placing

a screwdriver through the hole in the axle.

Remove the axle mounting fasteners, and

remove the idler wheel assembly.

16 Remove the adjustment nuts from the chain

tension rocker on the column.

17 Slide the column out the bottom of the mast.

18 Repeat steps 14 through 17 for each remaining

column.

If the chains are to be removed,

mark the location and label each

chain before removal.

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 9

MAST COMPONENTS

How to

Assemble the Mast

Bodily injury hazard. This

procedure requires specific repair

skills, lifting equipment and a

suitable workshop. Attempting this

procedure without these skills and

tools could result in death or

serious injury and significant

component damage. Dealer

service is strongly recommended.

1 Thoroughly clean all columns.

2 Secure the number 1 column to the work table

and lay the chains out on the floor. Do not allow

the chains to become twisted or dirty.

3 Apply a generous amount of Boe-lube wax to

the inside and outside channels of each

column.

4 Slide the number 2 column into the number 1

column.

5 Lay the number 2 column chains on the floor.

Do not allow the chains to become twisted or

dirty.

6 Lay the number 1 column chains inside the

number 2 column.

7 Slide the number 3 column into the number 2

column.

8 When the number 3 column is almost all the

way in, guide the number 1 column chains into

the chain tension rocker on the number 3

column.

9 Install the adjustment nuts on the 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 column chains on the floor.

Do not allow the chains to become twisted or

dirty.

11 Lay the number 2 column chains inside the

number 3 column.

12 Follow steps 4 through 11 for each remaining

column and the carriage.

13 After all the columns are assembled, the idler

wheel assemblies can be installed.

14 Remove the tension from the lifting chains on

the number 2 column by pushing the number 3

column towards the top of the mast.

15 Install the idler wheel assembly in the top of the

number 2 column. Tighten the mounting

fasteners.

Confirm that all idler wheels rotate

smoothly with no excessive side

movement. Confirm that they do

not rub on the inside of the

column. Replace worn shims if

necessary.

16 Repeat steps 14 and 15 for each remaining

idler wheel assembly.

17 Confirm that all of the idler wheel axle mounting

fasteners are flush with the column.

Component damage hazard. The

roller wheels may be damaged if

the idler wheel axle mounting

fasteners are not flush with the

column.

18 Install the mast assembly on the drive chassis.

Adjust the lifting chains. See 3-3,

How to Adjust

the Lifting Chains.

Section 4 • Repair Procedures

REV B

August 2005

4 - 10 GR-8 • GR-12 • GR-15 Part No. 72965

MAST COMPONENTS

3-2

Glide Pads

Glide pads are used to provide a uniform fit

between the columns as the mast extends and

retracts. Over time, it may be necessary to adjust

the glide pads to ensure good machine

performance.

Slide pads are not adjustable and do not require

servicing.

1 Fully lower the platform. Turn the key switch to

the off position and remove the key.

2 Locate the upper and lower glide pad

adjustment bolts below each upper roller bolt,

on both sides of each column.

3 Hold the glide pad adjustment bolt and loosen

the lock nut on all glide pads.

4 Turn the glide pad adjustment bolt clockwise

until the glide pad makes contact with the

column. Adjust the glide pads on both sides of

all columns. Be sure the sides of the columns

are even to within

/8 inch / 3.17 mm of each

other.

5 Starting at the number 1 column, torque the

upper and lower glide pad bolts to

12 in-lbs / 1.35 Nm. Hold the glide pad

adjustment bolt and tighten the lock nut. Be

sure the glide pad bolt does not turn.

6 Repeat step 5 for each remaining upper and

lower glide pads on both sides of the mast.

Start at the number 1 column and work toward

the carriage.

7 Repeat step 5 for all of the upper and lower

glide pads .

Confirm that the glide pad bolts

are adjusted evenly on each side

to maintain squareness of the

mast assembly.

Section 4 • Repair Procedures

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August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 11

3-3

Lifting Chains

How to Adjust the Lifting Chains

1 Mark the column to be adjusted.

2 Raise the platform approximately 6 feet / 2 m.

3 Place a lifting strap of suitable capacity from an

overhead crane under the platform. Support the

platform. Do not apply any lifting pressure.

Component damage hazard. The

platform railings and platform

extension deck (if equipped) can

be damaged if they are used to lift

the platform. Do not attach the

lifting strap to the platform railings

or the platform extension deck.

4 Turn the adjustment lock nuts evenly on both

sides of the chain tension rocker clockwise to

raise the column or counterclockwise to lower

the column.

The chain tensioner rocker is

located near the bottom of each

column.

5 Fully lower the platform and confirm the

alignment of the columns. Repeat steps 2

through 5 if necessary.

6 Confirm that the chain tensioner bracket is

centered in the inspection hole.

a lifting chain

b chain terminal

c chain tension rocker

d adjustment lock nut

e mast column

f inspection hole

MAST COMPONENTS

Section 4 • Repair Procedures

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4 - 12 GR-8 • GR-12 • GR-15 Part No. 72965

MAST COMPONENTS

How to Inspect the Lifting Chains

Inspection

Visually inspect the

chains for rust and

corrosion.

Visually inspect the

chains for lubrication.

Inspect chain link joints

for easy movement.

Inspection Failure

Evidence of rust or

corrosion.

When external surfaces

are not protected with a

layer of oil.

Joints that do not flex

freely or are binding.

Inspection Remedy

Remove chain and

inspect for cracked plates

(see inspection of

cracked plates). If no

cracks are found,

lubricate chain with motor

oil (SAE 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 chain.

Replace both chains on

that column. Do not

repair just the affected

portion of the chain.

Wear

Rust and Corrosion

Tight Joints

Procedure

Count out 16 chain links

and measure pin to pin

centerline dimension with

a steel measuring tape.

Note: Measure a section

of chain that moves over

the idler wheels.

When the length of the

16 links (pin to pin)

measure more than

8.25 inches / 21 cm for

/2 inch / 12.7 mm chain

or 10.31 inches / 26.1 cm

for

/8 inch / 15.9 mm

chain.

Replace both chains on

that column. Replace

entire chain. Do not

repair just the affected

portion of the chain.

Continued to the next page

Section 4 • Repair Procedures

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August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 13

MAST COMPONENTS

Inspection

Raised or Turned Pins

Chain Side

Chain Anchors

Idler Wheels

Cracked Link Plates

Procedure

Visually inspect for raised

pins.

Visually inspect for

turned pins by insuring all

the flats on the "V" heads

are aligned.

Visually inspect for wear

patterns on heads of link

pins and outside link

plates where they contact

the idler wheel.

Visually inspect chain

anchors.

chain

anchors

threaded

rod

Visually inspect chain

idler wheels.

idler wheel

Visually inspect chain link

plates for cracks.

Inspection Failure

Raised pins.

Misalignment of flats on

all "V" heads.

Wear on pin heads or

noticeable wear in the

profile of the outside link

plate.

link 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

grooves worn into chain

contact surface.

Cracks in any chain link

plate.

Inspection Remedy

Replace both chains on

that column section. Do

not repair just the

affected portion of the

chain.

Replace both chains on

that column section. Do

not repair just the

affected portion of the

chain.

Replace both chains on

that column section. Do

not repair just the

affected portion of the

chain.

Check alignment of chain

anchors and idler wheels.

Replace chain anchor.

Replace chain anchor

and threaded rod.

Re-align chain anchor to

ensure even loading of

chain.

Replace idler wheel and

check chain alignment.

Replace idler wheel.

Replace both chains on

that column section.

Replace entire chain. Do

not repair just the

affected portion of the

chain.

Section 4 • Repair Procedures

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4 - 14 GR-8 • GR-12 • GR-15 Part No. 72965

MAST COMPONENTS

e d f

3-4

Lift Cylinder

How to Remove the Lift Cylinder

Bodily injury hazard. This

procedure requires specific repair

skills, lifting equipment and a

suitable workshop. Attempting this

procedure without these skills and

tools could result in death or

serious injury and significant

component damage. Dealer

service is strongly recommended.

When removing a hose assembly

or fitting, the O-ring on the fitting

and/or hose end must be replaced

and then torqued to specification

during installation.

Refer to Section Two,

Hydraulic

Hose and Fitting Torque

Specifications.

1 Remove the mast. See 3-1,

How to Remove the

Mast Assembly

2 Remove the socket head retaining fastener

from the clevis block on the lift cylinder rod end

at the top of the number 1 column.

3 Remove the lift cylinder barrel end mounting

fasteners.

4 Loosen the lift cylinder mounting bracket

fasteners.

5 Support the cylinder and carefully slide it out of

the mast assembly.

Crushing hazard. The lift cylinder

could become unbalanced and fall

if not properly supported when

removed from the machine.

a top of number 1 column

b clevis block (hidden from view)

c clevis block fastener

d lift cylinder

e cylinder mounting plate

f cylinder mounting fasteners

g lift cylinder

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 15

Ground Controls

4-1

Control Relays

Relays used for dual function switching are double

pole double throw (DPDT) relays.

How to Test a

Double Pole Double Throw Relay

Electrocution hazard.

Contact with electrically charged

circuits may cause death or

serious injury. Remove all rings,

watches and other jewelry.

This procedure covers fundamental relay testing

and does not specifically apply to all varieties

of relays.

1 Turn the key switch to the off position and

remove the key.

2 Remove the velcro strap and unplug the relay to

be tested from its socket in the printed circuit

board.

3 Connect the leads from an ohmmeter to each

terminal combination and check for continuity.

Terminals 7 and 8 represent the coil and should

not be tested in any other combination.

Test Desired result

terminal 7 to 8 155 to 158Ω

terminal 3 to 1 and 5 no continuity

(infinite Ω)

terminal 4 to 2 and 6 no continuity

(infinite Ω)

terminal 5 to 1 continuity

(zero Ω)

terminal 6 to 2 continuity

(zero Ω)

Terminal Numbers

Control Relay Schematic

(Relay shown deactivated)

Section 4 • Repair Procedures

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4 - 16 GR-8 • GR-12 • GR-15 Part No. 72965

GROUND CONTROLS

4 Connect 12V DC to terminal 7 and a ground

wire to terminal 8, then test the following

terminal combinations.

Test Desired result

terminal 3 to 1 and 5 no continuity

(infinite Ω)

terminal 2 to 4 and 6 no continuity

(infinite Ω)

terminal 5 to 3 continuity

(zero Ω)

terminal 6 to 4 continuity

(zero Ω)

Terminal Numbers

Control Relay Schematic

(Relay shown activated)

4-2

Circuit Board

How to

Remove the Circuit Board

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Remove the drive chassis cover.

4 Disconnect the battery pack from the machine.

Electrocution hazard.

Contact with electrically charged

circuits may cause death or

serious injury. Remove all rings,

watches and other jewelry.

5 Tag and disconnect the machine wire

harnesses from the ground control box at the

control box.

6 Remove the control box mounting fasteners.

Remove the control box from the machine and

place it on a workbench.

Section 4 • Repair Procedures

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August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 17

GROUND CONTROLS

7 Remove the fasteners securing the top to the

ground control box. Open the box.

8 Tag and disconnect the wires from both

terminal strips of the circuit board inside the

control box.

Component damage hazard.

Electrostatic discharge (ESD) can

damage printed circuit board

components. Maintain firm contact

with a metal part of the machine

that is grounded at all times when

handling printed circuit boards OR

use a grounded wrist strap.

9 Remove the circuit board retaining fasteners

and remove the circuit board from the box.

4-3

Controller Adjustments

How to Calibrate the

Raised Drive Speed Trimpot

(Adjusting the Raised Drive Speed)

To calibrate the stowed drive

speed, see 1-2,

How to Calibrate

the Stowed Drive Speed Trimpot

(Adjusting the Stowed Drive

Speed).

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Remove the drive chassis cover.

4 Remove the ground control box cover. Locate

the circuit board inside the control box.

Section 4 • Repair Procedures

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4 - 18 GR-8 • GR-12 • GR-15 Part No. 72965

GROUND CONTROLS

5 Locate the raised drive speed trimpot on the

circuit board.

The raised drive speed trimpot is

approximately

/4 inch / 6 mm

square, and is located next to the

power LED on the circuit board.

6 Adjust the trimpot to acheive the specified drive

speed. Turn the trimpot screw clockwise to

decrease the drive speed or counterclockwise

to increase the drive speed.

Component damage hazard. The

trimpot has a 270° range of

movement, and requires a gentle

touch during calibration. Use

caution when adjusting the trimpot

screw.

7 Install the cover onto the control box. Install and

securely tighten the fasteners. Do not over

tighten.

8 Install the cover onto the drive chassis. Install

and securely tighten the fasteners. Do not over

tighten.

9 Remove the strap from the platform. Lower the

platform to the stowed position.

10 Confirm the raised drive speed. Refer to

Maintenance Procedure B-12,

Test the Drive

Speed - Raised Position

a circuit board

b LED

c raised drive speed trimpot

a b c

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 19

4-4

Level Sensor

The Genie Runabout is designed to deactivate the

lift and drive functions and activate an alarm when

a signal is received from the level sensor.

The tilt alarm sounds when the incline of the

chassis exceeds 2° to the side, 3° to the front or 5°

to the rear.

How to Install and Calibrate the

Level Sensor

Tip-over hazard. Failure to install

or calibrate the level sensor as

instructed will compromise

machine stability and cause the

machine to tip over, resulting in

death or serious injury. Do not

install or calibrate the level sensor

other than specified in this

procedure.

Perform this procedure with the

machine on a firm, level surface

that is free of obstructions.

1 Remove the platform controls from the platform.

2 Turn the key switch to platform control and pull

out the red Emergency Stop buttons to the ON

position at both the ground and platform

controls.

3 Block the wheels at the non-steer end of the

machine.

4 Center a lifting jack under the drive chassis at

the steer end of the machine.

5 Raise the machine approximately

2 inches / 5 cm.

6 Place a 0.75 x 6 x 6 inch / 19.1 mm x

15 cm x 15 cm thick steel block under both

wheels at the steer end of the machine.

7 Lower the machine onto the blocks.

8 Raise the platform approximately 4 feet / 1.2 m.

9 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

10 Remove the drive chassis cover.

11 Locate the level sensor inside the chassis.

If you are not installing a new level sensor,

proceed to step 17.

12 Tag and disconnect the wiring harness from the

level sensor.

13 Remove the level sensor retaining fasteners

and remove the level sensor from the machine.

GROUND CONTROLS

Section 4 • Repair Procedures

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August 2005

4 - 20 GR-8 • GR-12 • GR-15 Part No. 72965

GROUND CONTROLS

14 Install the new level sensor into the chassis with

the "X" on the level sensor base closest to the

side of the machine and the "Y" on the level

sensor base closest to the front of the machine.

Tip-over hazard. The level sensor

must be installed with the "X" on

the level sensor base closest to

the side of the machine and the

"Y" on the level sensor base

closest to the front of the machine.

Failure to install the level sensor

as instructed will compromise

machine stability and cause the

machine to tip over, resulting in

death or serious injury. Do not

install or calibrate the level sensor

other than specified in this

procedure.

15 Install and securely tighten the level sensor

retaining fasteners. Do not over tighten.

16 Connect the wiring harness to the level sensor.

17 Adjust the level sensor retaining fasteners until

the bubble in the top of the level sensor is

centered in the circles.

Be sure there are threads showing

through the top of the adjusting

fasteners.

Result: The tilt sensor alarm should not sound.

18 Raise the platform slightly. Remove the lifting

strap from the platform.

19 Lower the platform to the stowed position.

Steer end

Non-steer end

a chassis

b tilt level sensor (after serial number GR01-248)

c tilt level sensor (before serial number GR01-248)

d mast

e hydraulic tank

f "X" indicator

20 Raise the machine slightly.

21 Remove the blocks from under both wheels.

22 Lower the machine and remove the jack.

23 Remove the blocks from the wheels at the

non-steer end of the machine.

Section 4 • Repair Procedures

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August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 21

24 Block the wheels at the steer end of the

machine.

25 Center a lifting jack under the drive chassis at

the non-steer end of the machine.

26 Raise the machine approximately

5 inches / 13 cm.

27 Place a 3.91 x 6 x 6 inch / 99.3 mm x

15 cm x 15 cm thick steel block under both

wheels at the non-steer end of the machine.

28 Lower the machine onto the blocks.

Result: The tilt sensor alarm should sound.

29 Raise the machine slightly.

30 Remove the blocks from under both wheels.

31 Lower the machine and remove the jack.

32 Remove the blocks from the wheels at the steer

end of the machine.

33 Center a lifting jack under the drive chassis at

the ground controls side of the machine.

34 Raise the machine approximately

2 inches / 5 cm.

35 Place a 0.88 x 6 x 6 inch / 22.3 mm x

15 cm x 15 cm thick steel block under both

wheels at the ground controls side of the

machine.

36 Lower the machine onto the blocks.

37 Adjust the level sensor retaining fasteners just

until the tilt sensor alarm does not sound.

GROUND CONTROLS

38 Raise the machine slightly.

39 Remove the blocks from under both wheels.

40 Lower the machine and remove the jack.

41 Center a lifting jack under the drive chassis at

the side of the machine opposite the ground

controls.

42 Raise the machine approximately

2 inches / 5 cm.

43 Place a 1.02 x 6 x 6 inch / 25.9 mm x

15 cm x 15 cm thick steel block under both

wheels at the side of the machine opposite the

ground controls.

44 Lower the machine onto the blocks.

Result: The tilt sensor alarm should sound.

Result: If the tilt sensor alarm does not sound,

adjust the level sensor until the alarm just

begins to sound OR the level sensor may be

faulty.

45 Raise the machine slightly.

46 Remove the blocks from under both wheels.

47 Lower the machine and remove the jack.

Section 4 • Repair Procedures

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August 2005

4 - 22 GR-8 • GR-12 • GR-15 Part No. 72965

Hydraulic Pump

5-1

Function Pump

The hydraulic pump is attached to the motor which

makes up the hydraulic power unit.

How to Test the Hydraulic Pump

When removing a hose assembly

or fitting, the fitting and/or hose

end must be torqued to

specification during installation.

Refer to Section 2,

Hydraulic Hose

and Fitting Torque Specifications.

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Remove the drive chassis cover.

4 Locate the hydraulic power unit inside the

chassis.

a hydraulic power unit

b hydraulic tank

5 Tag, disconnect and plug the high pressure

hydraulic hose from the hydraulic pump.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to squirt

or spray.

6 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the high pressure port on the pump.

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 23

7 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.

8 Activate the platform up function from the

ground controls.

Result: If the pressure gauge reads

3000 psi / 207 bar, immediately stop. The pump

is good.

Result: If pressure fails to reach

3000 psi / 207 bar, the pump is bad and will

need to be serviced or replaced.

Component damage hazard.

There is no relief valve in the

hydraulic pump and the pump can

be damaged if the pressure is

allowed to exceed

3000 psi / 207 bar. When testing

the pump, activate the pump in

one second intervals until

3000 psi / 207 bar is confirmed.

Do not over-pressurize the pump.

9 Remove the pressure gauge and reconnect the

hydraulic hose. Torque to specification.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to squirt

or spray.

How to

Remove the Hydraulic Pump

When removing a hose assembly

or fitting, the O-ring on the fitting

and/or hose end must be replaced

and then torqued to specification

during installation. Refer to

Section 2,

Hydraulic Hose and

Fitting Torque Specifications.

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Remove the drive chassis cover.

4 Locate the hydraulic power unit inside the

chassis.

5 Tag, disconnect and plug the hydraulic hoses

on the pump. Cap the fittings on the pump.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to squirt

or spray.

6 Remove the pump mounting bolts. Carefully

remove the pump.

HYDRAULIC PUMP

Section 4 • Repair Procedures

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August 2005

4 - 24 GR-8 • GR-12 • GR-15 Part No. 72965

Manifolds

How to Install a Valve Cartridge

1. Dip the cartridge in clean oil to lube the O-rings.

2 Screw the cartridge in by hand until the top

O-ring is met, then torque to specification.

3 If required, install the valve coil(s) onto the valve

stem. Install the coil nut onto the valve stem and

torque to specification.

6-1

Function Manifold Components

(before serial number GR01-225)

The function manifold is mounted under the drive chassis cover.

Index Schematic

No. Description Item Function Torque

— Coil nut (items C, D and E) ................................................................................................... 4-6 ft-lbs / 5-8 Nm

1 Diagnostic nipple ....................................... A ..................Testing ........................................... 10 ft-lbs / 14 Nm

2 Relief valve, 1000 psi / 69 bar ................... B ..................Steer relief ..................................... 20 ft-lbs / 27 Nm

3 Solenoid valve, 3 position 4 way ............... C .................. Drive forward/reverse .................... 20 ft-lbs / 27 Nm

4 Solenoid valve, 2 position 4 way ............... D .................. Lift/drive select ............................... 25 ft-lbs / 34 Nm

5 Solenoid valve, 3 position 4 way ............... E ..................Steer left/right ................................ 20 ft-lbs / 27 Nm

6 Relief valve, 2200 psi / 151.6 bar .............. F .................. Lift relief ......................................... 20 ft-lbs / 27 Nm

7 Flow regulator, 0.6 gpm / 2.27 L/min ......... G ..................Steer circuit .................................... 35 ft-lbs / 47 Nm

8 Relief valve, 2700 psi / 186 bar ................. H ..................System relief .................................. 20 ft-lbs / 27 Nm

Section 4 • Repair Procedures

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August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 25

1 2

Note: 'alpha' callouts refer

to corresponding notes on

the hydraulic schematic

Note: 'alpha-numeric' callouts

refer to corresponding notes

on the electrical schematic

MANIFOLDS

Section 4 • Repair Procedures

REV B

August 2005

4 - 26 GR-8 • GR-12 • GR-15 Part No. 72965

How to Install a Valve Cartridge

1. Dip the cartridge in clean oil to lube the O-rings.

2 Screw the cartridge in by hand until the top

O-ring is met, then torque to specification.

3 If required, install the valve coil(s) onto the valve

stem. Install the coil nut onto the valve stem and

torque to specification.

MANIFOLDS

6-2

Function Manifold Components

(from serial number GR01-225 to GR01-248)

The function manifold is mounted under the drive chassis cover.

Index Schematic

No. Description Item Function Torque

— Coil nut (items C, D and E) ................................................................................................... 4-6 ft-lbs / 5-8 Nm

1 Diagnostic nipple ....................................... A ..................Testing ........................................... 10 ft-lbs / 14 Nm

2 Relief valve, 1000 psi / 69 bar ................... B ..................Steer relief ..................................... 20 ft-lbs / 27 Nm

3 Relief valve, 2200 psi / 151.6 bar .............. F .................. Lift relief ......................................... 20 ft-lbs / 27 Nm

4 Relief valve, 2700 psi / 186 bar ................. H ..................System relief .................................. 20 ft-lbs / 27 Nm

5 Solenoid valve, 3 position 4 way ............... C .................. Drive forward/reverse .................... 20 ft-lbs / 27 Nm

6 Solenoid valve, 2 position 4 way ............... D .................. Lift/drive select ............................... 25 ft-lbs / 34 Nm

7 Solenoid valve, 3 position 4 way ............... E ..................Steer left/right ................................ 20 ft-lbs / 27 Nm

8 Flow regulator, 0.6 gpm / 2.27 L/min ......... G ..................Steer circuit .................................... 35 ft-lbs / 47 Nm

Section 4 • Repair Procedures

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August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 27

4 3

1 2

Note: 'alpha' callouts refer

to corresponding notes on

the hydraulic schematic

Note: 'alpha-numeric' callouts

refer to corresponding notes

on the electrical schematic

MANIFOLDS

Section 4 • Repair Procedures

REV B

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4 - 28 GR-8 • GR-12 • GR-15 Part No. 72965

MANIFOLDS

How to Install a Valve Cartridge

1. Dip the cartridge in clean oil to lube the O-rings.

2 Screw the cartridge in by hand until the top

O-ring is met, then torque to specification.

3 If required, install the valve coil(s) onto the valve

stem. Install the coil nut onto the valve stem and

torque to specification.

6-3

Function Manifold Components

(after serial number GR01-248)

The function manifold is mounted under the drive chassis cover.

Index Schematic

No. Description Item Function Torque

— Coil nut (items AC, AD and AE) ............................................................................................ 4-6 ft-lbs / 5-8 Nm

1 Diagnostic nipple ....................................... AA ............... Testing ........................................... 10 ft-lbs / 14 Nm

2 Relief valve, 2700 psi / 186 bar ................. AB ............... Steer relief ..................................... 20 ft-lbs / 27 Nm

3 Solenoid valve, 3 position 4 way ............... AC ............... Steer left/right ................................ 20 ft-lbs / 27 Nm

4 Solenoid valve, 2 position 4 way ............... AD ............... Lift/drive select ............................... 25 ft-lbs / 34 Nm

5 Solenoid valve, 3 position 4 way ............... AE ............... Drive forward/reverse .................... 25 ft-lbs / 27 Nm

6 Flow regulator, 0.6 gpm / 2.27 L/min ......... AF ................ Steer circuit .................................... 35 ft-lbs / 47 Nm

7 Relief valve, 1000 psi / 69 bar ................... AG ............... System relief .................................. 20 ft-lbs / 27 Nm

8 Relief valve, 2200 psi / 151.6 bar .............. AH ...............Lift relief ......................................... 20 ft-lbs / 27 Nm

9 Needle valve, 2 position 2 way .................. AI .................Brake circuit ................................... 20 ft-lbs / 27 Nm

10 Check valve, 200 psi / 13.8 bar ................. AJ ................Brake circuit ................................... 25 ft-lbs / 34 Nm

Section 4 • Repair Procedures

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August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 29

MANIFOLDS

1 2

Note: 'alpha' callouts refer

to corresponding notes on

the hydraulic schematic

Note: 'alpha-numeric' callouts

refer to corresponding notes

on the electrical schematic

Section 4 • Repair Procedures

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August 2005

4 - 30 GR-8 • GR-12 • GR-15 Part No. 72965

MANIFOLDS

6-4

Valve Adjustments -

Function Manifold

How to

Adjust the System Relief Valve

Be sure that the hydraulic oil level

is at the FULL mark on the hydraulic

tank.

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Remove the drive chassis cover.

4 Locate the system relief valve on the function

manifold (item H or AG).

5 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port on the function manifold

(item A or AA).

6 Chock both sides of the wheels at the steer end

of the machine.

7 Remove the platform controls from the platform.

Perform this test from the ground

with the platform controls. Do not

stand in the platform.

8 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.

9 Press and hold the function enable switch.

Move the joystick in the full forward direction.

while observing the pressure reading on the

pressure gauge. Note the pressure. Refer to

Section 2,

Specifications

10 Turn the machine off. Hold the system relief

valve with a wrench and remove the cap.

11 Adjust the internal hex socket. Turn it clockwise

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 serious

injury. Do not adjust the relief

valve pressures higher than

specifications.

12 Install the relief valve cap.

13 Repeat steps 8 through 9 to confirm the relief

valve pressure.

14 Install the relief valve cap. Remove the

pressure gauge.

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 31

MANIFOLDS

How to

Adjust the Lift Relief Valve

Be sure that the hydraulic oil level

is at the FULL mark on the hydraulic

tank.

1 Raise the platform approximately 4 feet / 1.2 m.

2 Remove the drive chassis cover.

3 Place two 4 x 4 x 48 inch / 10 x 10 x 120 cm

blocks across the drive chassis to support the

platform.

4 Locate the lift relief valve on the function

manifold (item F or AH).

5 Hold the system relief valve with a wrench and

remove the cap.

6 Lower the platform onto the blocks.

7 Place the maximum rated load in the platform.

Secure the load to the platform. Refer to

Section 2,

Specifications

8 While activating the platform up function, adjust

the internal hex socket until the platform begins

to raise.

9 Fully lower the platform.

10 Add an additional 50 pounds / 22.7 kg to the

platform. Secure the additional weight.

11 Activate the platform up function.

Result: The platform does not raise.

Result: The platform raises. Adjust the internal

hex socket of the lift relief valve just until the

platform will not raise.

12 Install the relief valve cap.

13 Remove the weight from the platform.

14 Bleed the hydraulic system by raising the

platform to full height. If the pump cavitates or if

the platform fails to reach full height, add

hydraulic oil until the pump is functioning

correctly. Do not overfill the hydraulic tank.

Component damage hazard. Do

not continue to operate the

machine if the hydraulic pump is

cavitating.

Section 4 • Repair Procedures

REV B

August 2005

4 - 32 GR-8 • GR-12 • GR-15 Part No. 72965

MANIFOLDS

How to

Adjust the Steer Relief Valve

Be sure that the hydraulic oil level

is at the FULL mark on the hydraulic

tank.

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Remove the drive chassis cover.

4 Locate the steer relief valve on the function

manifold (item B or AB).

5 Connect a 0 to 5000 psi / 0 to 350 bar pressure

gauge to the test port on the function manifold

(item A or AA).

6 Remove the platform controls from the platform.

Perform this test from the ground

with the platform controls. Do not

stand in the platform.

7 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.

8 Press and hold the function enable switch and

press and hold the steer thumb rocker switch to

the right. Allow the wheels to completely turn to

the right. Continue holding the switch while

observing the pressure reading on the pressure

gauge. Note the pressure. Refer to Section 2,

Specifications

9 Press and hold the steer thumb rocker switch to

the left. Allow the wheels to completely turn to

the left. Continue holding the switch while

observing the pressure reading on the pressure

gauge.

10 Hold the steer relief valve with a wrench and

remove the cap.

11 Adjust the internal hex socket. Turn it clockwise

to increase the pressure or counterclockwise to

decrease the pressure.

Component damage hazard.

Do not adjust the relief valve

higher than specified.

12 Repeat steps 8 through 9 to confirm the relief

valve pressure.

13 Install the relief valve cap. Remove the

pressure gauge.

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 33

BATTERY

RESISTOR

MULTI

METER

COIL

MANIFOLDS

6-5

Valve Coils

How to Test a Coil

A properly functioning coil provides an

electromotive force which operates the solenoid

valve. Critical to normal operation is continuity

within the coil that provides this force field.

Electrocution hazard. Contact with

electrically charged circuits could

result in death or serious injury.

Remove all rings, watches and

other jewelry.

1 Tag and disconnect the wire harness from the

coil to be tested.

2 Test the coil resistance.

Result: The resistance should be within

specification, plus or minus 30%.

Result: If the resistance is not within

specification, plus or minus 30%, replace the

coil.

Valve Coil Resistance Specifications

Description Specification

Solenoid valve, 3 position 4 way 22 to 24 Ω

20V DC with diode (schematic items C, AC and AE)

Solenoid valve, 2 position 4 way 23 to 26 Ω

20V DC with diode (schematic items D and AD)

Solenoid valve, 3 position 4 way 23 to 26 Ω

20V DC with diode (schematic item E)

How to Test a Coil Diode

Genie incorporates spike suppressing diodes in all

of its coils. Properly functioning coil diodes protect

the electrical circuit by suppressing voltage spikes.

Voltage spikes naturally occur within a function

circuit following the interruption of electrical current

to a coil. Faulty diodes can fail to protect the

electrical system, resulting in a tripped circuit

breaker or component damage.

Electrocution hazard. Contact with

electrically charged circuits could

result in death or serious injury.

Remove all rings, watches and

other jewelry.

1 Test the coil for resistance. See 6-5

How to

Test a Coil.

2 Connect a 10Ω resistor to the negative terminal

of a known good 9V DC battery. Connect the

other end of the resistor to a terminal on the

coil.

The battery should read 9V DC or

more when measured across the

terminals.

Resistor, 10

ΩΩ

Genie part number 27287

a multimeter

b 9V DC battery

c10Ω resistor

d coil

Note: Dotted lines in illustration indicate a reversed connection

as specified in step 6

Section 4 • Repair Procedures

REV B

August 2005

4 - 34 GR-8 • GR-12 • GR-15 Part No. 72965

MANIFOLDS

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 Connect the negative lead to the other terminal

on the coil.

If testing a single-terminal coil,

connect the negative lead to the

internal metallic ring at either end

of the coil.

5 Momentarily connect the positive lead from the

multimeter to the positive terminal on the 9V

battery. Note and record the current reading.

6 At the battery or coil terminals, reverse the

connections. Note and record the current

reading.

Result: Both current readings are greater than

0 mA and are different by a minimum of 20%.

The coil is good.

Result: If one or both of the current readings are

0 mA, or if the two current readings do not differ

by a minimum of 20%, the coil and/or its

internal diode are faulty and the coil should be

replaced.

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 35

Hydraulic Tank

7-1

Hydraulic Tank

The primary functions of the hydraulic tank are to

cool and deaerate the hydraulic fluid during

operation. It utilizes internal suction strainers for

the pump supply lines and has an external return

line filter.

How to

Remove the Hydraulic Tank

Component damage hazard.

The work area and surfaces

where this procedure will be

performed must be clean and

free of debris that could get

into the hydraulic system.

When removing a hose assembly

or fitting, the O-ring on the fitting

and/or hose end must be replaced

and then torqued to specification

during installation. Refer to

Section 2,

Hydraulic Hose and

Fitting Torque Specifications.

1 Raise the platform approximately 4 feet / 1.2 m.

2 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

3 Disconnect the battery pack from the machine.

Electrocution hazard. Contact with

electrically charged circuits could

result in death or serious injury.

Remove all rings, watches and

other jewelry.

4 Remove the drive chassis cover.

5 Remove the drain plug from the hydraulic tank

and allow all of the oil to drain into a suitable

container. Refer to Section 2,

Specifications

Bodily injury hazard Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to squirt

or spray.

6 Tag, disconnect and plug the supply hose from

the hydraulic power unit to the tank.

7 Before serial number GR01-249: Tag,

disconnect and plug the return hose from the

function manifold to tank at the return filter. Cap

the fitting on the return filter housing.

After serial number GR01-248: Tag,

disconnect and plug the return hose from the

return filter to tank at the tank.

8 Remove the hydraulic tank mounting fasteners

and remove the tank from the machine.

Torque specifications

Hydraulic tank retaining fasteners, dry 35 in-lbs

4 Nm

Hydraulic tank retaining fasteners, lubricated 26 in-lbs

2.9 Nm

Hydraulic tank drain plug, dry 40 in-lbs

4.5 Nm

Hydraulic tank drain plug, lubricated 30 in-lbs

3.4 Nm

Section 4 • Repair Procedures

REV B

August 2005

4 - 36 GR-8 • GR-12 • GR-15 Part No. 72965

Steer Axle Components

8-1

Yoke and Drive Motor

How to Remove the Yoke

and Drive Motor

When removing a hose assembly

or fitting, the O-ring on the fitting

and/or hose end must be replaced

and then torqued to specification

during installation. Refer to

Section 2,

Hydraulic Hose and

Fitting Torque Specifications.

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

machine.

2 Center a lifting jack under the drive chassis at

the steer end of the machine.

3 Remove the cotter pin from the wheel castle

nut.

Always replace the cotter pin with

a new one when removing the

castle nut or when checking the

torque of the castle nut.

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

5 Raise the machine approximately

14 inches / 36 cm. Place blocks under the

chassis for support.

Crushing hazard. The chassis will

fall if it is not properly supported.

6 Remove the wheel castle nut. Remove the

wheel.

7 Tag, disconnect and plug the hydraulic hoses

on the drive motor.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to

allow the oil pressure to

dissipate gradually. Do not

allow oil to squirt or spray.

Component damage hazard.

Cables and hoses can be

damaged if they are kinked or

pinched.

8 Support and secure the yoke assembly to an

appropriate lifting device.

9 Remove the retaining fastener from the drive

chassis that secures the yoke assembly.

10 Remove the cotter pin from the steer link on the

yoke pivot shaft.

Always replace the cotter pin with

a new one when removing a steer

link.

11 Remove the steer link from the yoke..

12 Lower the yoke assembly out of the chassis.

Bodily injury hazard. The yoke/

motor assembly may fall if not

properly supported when removed

from the chassis.

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 37

STEER AXLE COMPONENTS

How to

Remove a Drive Motor

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

machine.

2 Center a lifting jack under the drive chassis at

the steer end of the machine.

3 Remove the cotter pin on the wheel castle nut

of the motor to be removed.

Always replace the cotter pin with

a new one when removing the

castle nut or when checking the

torque of the castle nut.

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

5 Raise the machine approximately 2 inches / 5

cm. Place blocks under the chassis for support.

Crushing hazard. The chassis will

fall if it is 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.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to

allow the oil pressure to

dissipate gradually. Do not

allow oil to squirt or spray.

Component damage hazard.

Cables and hoses can be

damaged if they are kinked or

pinched.

8 Remove the drive motor mounting fasteners.

Remove the drive motor.

Torque specifications

Drive motor mounting fasteners, dry 35 in-lbs

4 Nm

Drive motor mounting fasteners, lubricated 26 in-lbs

2.9 Nm

Section 4 • Repair Procedures

REV B

August 2005

4 - 38 GR-8 • GR-12 • GR-15 Part No. 72965

STEER AXLE COMPONENTS

8-2

Steer Cylinder

How to

Remove the Steer Cylinder

When removing a hose assembly

or fitting, the O-ring on the fitting

and/or hose end must be replaced

and then torqued to specification

during installation. Refer to

Section 2,

Hydraulic Hose and

Fitting Torque Specifications.

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

machine.

2 Raise the platform approximately 4 feet / 1.2 m.

3 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

4 Remove the drive chassis cover.

5 Tag, disconnect and plug the hydraulic hoses

from the steering cylinder. Cap the fittings on

the cylinder.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to

squirt or spray.

Component damage hazard.

Cables and hoses can be

damaged if they are kinked or

pinched.

6 Remove the cotter pins and the clevis pins from

the steer links at both ends of the steer

cylinder.

Always replace the cotter pin with

a new one when removing a steer

link.

7 Remove the cylinder retaining fasteners from

the steer cylinder. Remove the steer cylinder

from the machine.

Section 4 • Repair Procedures

REV B

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 39

STEER AXLE COMPONENTS

How to

Perform the Toe-in Adjustment

Perform this procedure with the

machine on a firm, level surface

that is free of obstructions.

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

machine.

2 Raise the platform approximately 4 feet / 1.2 m.

3 Place a lifting strap from an overhead crane

under the platform. Support the platform. Do not

apply any lifting pressure.

Component damage hazard. The

platform railings can be damaged

if they are used to lift the platform.

Do not attach the lifting strap to

the platform railings.

4 Remove the drive chassis cover.

5 Measure the steer tires, front to front and back

to back, using a measuring fixture.

Toe-in specification

Range 0 ±

/8 inch

0 ± 6 mm

6 Center a lifting jack under the steer end of the

machine.

7 Raise the machine approximately

2 inches / 5 cm. Place blocks under the chassis

for support.

Crushing hazard. The chassis will

fall if it is not properly supported.

8 Loosen the jam nut on the adjustable lugs at the

ends of the steer cylinder.

9 Remove the cotter pins and the clevis pins from

the steer links at both ends of the steer

cylinder.

Always replace the cotter pin with

a new one when removing a steer

link.

10 Rotate the lugs at the one or both ends of the

cylinder to adjust the toe-in.

11 Install the cylinder lugs into both steer links.

Install the clevis pins to secure.

12 Tighten the jam nut against the steer cylinder.

13 Lower the machine and measure the steer tires,

front to front and back to back, using a

measuring fixture.

Result: The machine is within specification.

Proceed to step 14.

Result: The machine is not within specification.

Repeat this procedure beginning with step 6.

14 Install the drive chassis cover. Install and

securely tighten the drive cover retaining

fasteners. Do not over tighten.

Section 4 • Repair Procedures

REV A

August 2005

4 - 40 GR-8 • GR-12 • GR-15 Part No. 72965

Non-steer Axle Components

9-1

Wheel Brake

How to Remove a Wheel Brake

When removing a hose assembly

or fitting, the O-ring on the fitting

and/or hose end must be replaced

and then torqued to specification

during installation. Refer to

Section 2,

Hydraulic Hose and

Fitting Torque Specifications.

Perform this procedure with the

machine on a firm, level surface

that is free of obstructions.

1 Block the wheels at the steer end of the

machine.

2 Center a lifting jack under the drive chassis at

the non-steer end of the machine.

3 Remove the cotter pin from the wheel castle

nut.

Always replace the cotter pin with

a new one when removing the

castle nut or when checking the

torque of the castle nut.

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

5 Raise the machine approximately

2 inches / 5 cm. Place blocks under the chassis

for support.

Crushing hazard. The chassis will

fall if it is not properly supported.

6 Remove the wheel castle nut. Remove the

wheel.

7 Remove the rear access cover fasteners at the

non-steer end of the machine. Remove the

cover.

8 Tag, disconnect and plug the hydraulic hose

from the brake. Cap the fitting on the brake.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to squirt

or spray.

Section 4 • Repair Procedures

REV A

April 2006

Part No. 72965 GR-8 • GR-12 • GR-15 4 - 41

10-1

Platform Overload System

Calibrate the Platform Overload

System (if equipped)

Perform this procedure with the

machine on a firm, level surface.

1 Raise the platform approximately 2 feet / 70 cm.

2 Tag and disconnect the wire harness from the

load sense limit switch.

The load sense limit switch is

located near the platform support.

3 Set a multi-meter to measure continuity.

Connect the leads from the multi-meter to the

black and red wires disconnected from the limit

switch in step 2.

4 Determine the maximum platform capacity.

Refer to the machine serial plate.

5 Using a suitable lifting device, place an

appropriate test weight equal to that of the

maximum platform capacity at the center of the

platform floor. Refer to Section 2,

Specifications

Determine the limit switch trigger point:

6 Gently move the platform up and down by hand,

so it bounces 1 to 2 inches / 2.5 to 5 cm.

7 Check the continuity between the black and red

wires originating from the limit switch of the

platform overload assembly.

Result: There is no continuity. Slowly tighten

the load spring adjustment nut by turning it

clockwise just until the limit switch closes and

shows continuity.

Result: There is continuity. Slowly loosen the

load spring adjustment nut by turning it

counterclockwise just until the limit switch

opens and shows no continuity.

The platform will need to be

continuously moved up and down

while making adjustments.

Fine adjustment of the switch trigger point:

8 Continue moving the platform up and down and

adjust the load spring adjustment nut clockwise

or counterclockwise just until the limit switch is

alternately opening and closing.

When the limit switch is adjusted

correctly, there will be continuity

slightly longer than no continuity.

9 Remove the continuity tester from the limit

switch wires. Securely install the wires onto the

limit switch.

Platform Overload Components

Section 4 • Repair Procedures

REV A

April 2006

4 - 42 GR-8 • GR-12 • GR-15 Part No. 72965

Confirm the setting:

10 Turn the key switch to platform control.

11 Lift the test weight off the platform floor using a

suitable lifting device.

12 Place the test weight back onto the platform

floor using a suitable lifting device.

Result: The overload alarm at the platform

controls should not sound, indicating a normal

condition.

13 Add an additional weight to the platform not to

exceed 20% of the maximum rated load. Refer

to the machine serial plate.

Result: The overload alarm at the platform

controls sounds. The platform overload system

is operating properly.

Result: The overload alarm at the platform

controls does not sound. The platform overload

system is not operating properly. Repeat this

procedure beginning with step 1.

14 Test all machine functions from the platform

controls.

Result: All platform control functions should not

operate.

15 Turn the key switch to ground control.

16 Test all machine functions from the ground

controls.

Result: All ground control functions should not

PLATFORM OVERLOAD COMPONENTS

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 1

Before Troubleshooting:

Read, understand and obey the safety rules

and operating instructions printed in the

appropriate

Genie Runabout Operator’s

Manual.

Be sure that all necessary tools and test

equipment are available and ready for use.

Read each appropiate flow chart thoroughly.

Attempting shortcuts may produce hazardous

conditions.

Be aware of the following hazards and follow

generally accepted safe workshop practices.

Crushing hazard. When testing

or replacing any hydraulic

component, always support

the structure and secure it

from movement.

Electrocution hazard. Contact

with electrically charged circuits

could result in death or serious

injury. Remove all rings, watches

and other jewelry.

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to

squirt or spray.

Perform all troubleshooting on a

firm, level surface.

Two persons will be required to

safely perform some

troubleshooting procedures.

Troubleshooting Flow Charts

Observe and Obey:

Troubleshooting and repair procedures shall be

completed by a person trained and qualified on

the repair of this machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Unless otherwise specified, perform each

repair 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

August 2005Section 5 • Troubleshooting Flow Charts

5 - 2 GR-8 • GR-12 • GR-15 Part No. 72965

About This Section

When a malfunction is discovered, the flow charts

in this section will help a service professional

pinpoint the cause of the problem. To use this

section, basic hand tools and certain pieces of test

equipment are required—voltmeter, ohmmeter,

pressure gauges.

The location of terminals mentioned in this section

can be found on the appropriate electrical or

hydraulic schematics provided in Section 7,

Schematics

Since various degrees of a particular function

loss may occur, selecting the appropriate flow

chart may be troublesome. When a function will not

operate with the same speed or power as a

machine in good working condition, refer to the

flow chart which most closely describes the

problem.

TROUBLESHOOTING FLOW CHARTS

Malfunction

discovered

Identify

symptoms

Troubleshoot

Perform

repair

Return to

service

problem

solved

problem

still exists

Inspect

and test

General Repair Process

REV A

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 3

All Functions

Will Not

Operate

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure both

Emergency Stop

switches are pulled

out to the ON

position.

Be sure the

batteries are fully

charged and

properly connected.

Be sure the

hydraulic tank is

filled to the correct

level.

Chart 1

Repair open in 24V

supply cables (positive

and negative) from

battery pack B5.

With the key switch

turned to platform

controls and both

Emergency Stop buttons

pulled out to the

position, check voltage

at input side of ground

control Emergency Stop

button P1.

Repair open in RD wire

from input side of P1

contact to 7 amp circuit

breaker CB1.

24V

Check voltage across

the terminals at the

battery quick disconnect

QD1.

Check voltage at output

side of P1.

24V

Replace P1 contact.

24V

Repair open in GN/YL

wire from terminal #1 on

U6 to the positive

terminal on the pump

motor M5.

Check voltage on

GN/YL wire at terminal

#1 of the motor

controller U6.

Continued on the next

page.

Check voltage at RD/BK

wire on input side of key

switch KS1.

24V

Repair open in wire

circuit through quick

disconnect QD16,

Emergency Stop button

P2, enclosure EN4 to

KS1.

REV A

August 2005Section 5 • Troubleshooting Flow Charts

5 - 4 GR-8 • GR-12 • GR-15 Part No. 72965

CHART 1

Continued from the

previous page.

Turn key switch to

ground controls and

check voltage on RD

wire at output side of

ground control contact.

Check to see if cam on

key switch is activating

the contact.

bad

Repair or replace key

switch contact.

good

Replace ground controls

contract OR refer to

Ground Controls

Inoperative, Chart 4 OR

consult Genie Industries

Service Department.

24V

Turn key swith to

platform controls and

check voltage on RD

wire at output side of

platform control contact.

Check to see if cam on

key switch is activating

the contact.

bad

Repair or replace key

switch contact.

good

Replace platform

controls contract OR

refer to Platform

Controls Inoperative,

Chart 5 OR consult

Genie Industries Service

Department.

24V

Troubleshoot lift and

drive systems

separately OR consult

Genie Industries Service

Department.

REV A

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 5

Chart 2

Pump Motor

Will Not

Operate

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

With key switch turned

to ground controls and

both Emergency Stop

buttons pulled out to the

position, move the

platform up/down toggle

switch TS66 in the

direction and check

voltage at terminal #3 on

the motor controller U6.

Repair open circuit from

BLU wire at terminal #3

on U6 to platform up

control relay CR52 to

10 A fuse F15 to voltage

divider U14.

1-5V

Check continuity to

ground from terminal B-

on U6 to battery pack

B5.

continuity

Repair open in circuit

from terminal B- to B5.

Check voltage at

terminal B+ on U6.

24V

Repair open in circuit

from B+ to positive

terminal on hydraulic

power unit M5 to 275

amp fuse F8.

continuity

Check voltage at GN/YL

wire at terminal #1 on

U6.

Repair open in circuit

from terminal #1 to F8.

24V

Check continuity to

ground from terminal M-

on U6 to negative

terminal on M5.

Repair open in circuit

from terminal M- to M5.

Replace U6 OR repair

or replace M5 OR

consult Genie Industries

Service Department.

continuity

REV A

August 2005Section 5 • Troubleshooting Flow Charts

5 - 6 GR-8 • GR-12 • GR-15 Part No. 72965

Chart 3

All Functions

Inoperative,

Power Unit

Starts and

Runs

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

Be sure the

hydraulic tank is

filled to the correct

level.

Check for a positive

connection between

electric motor and pump

on the hydraulic power

unit M5. Visually inspect

the pump splined shaft

for damage.

bad

Replace the pump OR

replace the motor.

good

Test the hydraulic pump.

(See Repair Section).

bad

good

Replace the pump.

Consult Genie Industries

Service Department.

REV A

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 7

Ground

Controls

Inoperative,

Platform

Controls

Operate

Normally

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are

properly connected.

Be sure the

batteries are fully

charged.

Chart 4

With key switch turned

to ground control and,

both Emergency Stop

buttons pulled out to the

position, activate and

hold the platform

up/down toggle switch

TS66 in the

position.

Check for continuity to

ground on the OR wire

at the center terminal on

TS66.

Replace contact for

ground controls at KS1.

continuity

Check for continuity to

ground on the OR wire

at the output terminal on

TS66.

Test or replace TS66

(See Repair Section).

continuity

Consult the Genie

Industries Service

Department.

Check if internal cam at

KS1 is activating the

ground control contact.

yes

Replace KS1.

continuity

REV A

August 2005Section 5 • Troubleshooting Flow Charts

5 - 8 GR-8 • GR-12 • GR-15 Part No. 72965

Chart 5

Platform

Controls

Inoperative,

Ground

Controls

Operate

Normally

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are

properly connected.

Be sure the

batteries are fully

charged.

With key switch turned

to platform control and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the

LIFT

position. Press and hold

the function enable

switch SW5 and move

the joystick controller

JC3 in the direction

indicated by the blue

arrow. Check for

continuity to ground on

the BK wire at the

platform control contact

on key switch KS1.

continuity

Check if internal cam at

KS1 is activating the

platform control contact.

continuity

Consult Genie Industries

Service Department.

continuity

Repair open in circuit

from terminal #6 on

TS16 to BK wire at

platform control contact

on KS1.

Replace KS1.

yes

Replace contact for

platform control at KS1

REV A

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 9

Platform Up

Function

Inoperative

Be sure all other

functions operate

normally.

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

Chart 6

With key switch turned

to platform control and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the

LIFT

position. Press and hold

the function enable

switch SW5 and move

the joystick controller

JC3 in the direction

indicated by the blue

arrow. Check voltage on

YL/BK wire at platform

up solenoid valve Y8.

Repair open in circuit

from Y8 through

platform up disable relay

CR31 (if equipped) and

platform up relay CR52

to voltage divider U14.

24V

Disconnect the wires

from Y8 and measure

the coil resistance (See

Repair Section).

0 or

infinite

ohms

Replace coil on Y8.

23 to 26 ohms

Repair or replace the

plaftorm up directional

valve cartrige (item D or

F) OR consult Genie

Industries Service

Department.

REV A

August 2005Section 5 • Troubleshooting Flow Charts

5 - 10 GR-8 • GR-12 • GR-15 Part No. 72965

Chart 7

Platform

Down

Function

Inoperative

Be sure all other

functions operate

normally.

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the

LIFT

position. Press and hold

the function enable

switch SW5 and move

the joystick controller

JC3 in the direction

indicated by the yellow

arrow. Check voltage on

YL wire at platform

down solenoid valve Y7.

Repair open in circuit

from Y7 through

platform down control

relay CR51 to voltage

divider U14.

24V

Disconnect the wires

from Y7 and measure

the coil resistance See

Repair Section.

0 or

infinite

ohms

Replace coil on Y7.

23 to 26 ohms

Repair or replace the

plaftorm up directional

valve cartrige (item K)

OR consult Genie

Industries Service

Department.

REV A

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 11

Chart 8

Steer Left

Function

Inoperative

Be sure all other

functions operate

normally.

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the drive

position. Press and hold

the function enable

switch SW5. Press the

thumb rocker switch

SW5 on top of the

joystick controller JC3 in

the direction indicated

by the blue arrow.

Check voltage on OR

wire at steer left

solenoid valve Y4.

Repair open in circuit

from Y4 through steer

left control relay CR53

to voltage divider U14.

24V

Disconnect the wires

from Y4 and measure

the coil resistance See

Repair Section.

0 or

infinite

ohms

Replace coil on Y4.

23 to 26 ohms

Repair or replace the

plaftorm up directional

valve cartrige (item C, G

or E) OR consult Genie

Industries Service

Department.

REV A

August 2005Section 5 • Troubleshooting Flow Charts

5 - 12 GR-8 • GR-12 • GR-15 Part No. 72965

Chart 9

Steer Right

Function

Inoperative

Be sure all other

functions operate

normally.

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the drive

position. Press and hold

the function enable

switch SW5. Press the

thumb rocker switch

SW5 on top of the

joystick controller JC3 in

the direction indicated

by the blue arrow.

Check voltage on

OR/BK wire at steer

right solenoid valve Y3.

Repair open in circuit

from Y3 through steer

left control relay CR54

to voltage divider U14.

24V

Disconnect the wires

from Y3 and measure

the coil resistance See

Repair Section.

0 or

infinite

ohms

Replace coil on Y3.

23 to 26 ohms

Repair or replace the

plaftorm up directional

valve cartrige (item C, G

or E) OR consult Genie

Industries Service

Department.

REV A

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 13

Chart 10

All Drive

Functions

Inoperative,

All Other

Functions

Operate

Normally

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

power

unit runs

Test OR replace TS16,

(See Repair Section).

power unit

not runnig

Replace the platform

controls with a known

operating platform

controls. Activate the

drive function. Does the

drive function operate?

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

ON position, move the

lift/drive select switch

TS16 to the drive

position. Press and hold

the function enable

switch SW5. Move the

joystick controller JC3 in

the drive forward, then

the drive reverse

direction. Check if the

hydraulic power unit is

running.

yes

Replace the platform

controls.

Consult the Genie

Industries Service

Department.

REV A

August 2005Section 5 • Troubleshooting Flow Charts

5 - 14 GR-8 • GR-12 • GR-15 Part No. 72965

Chart 10A

Brake

Release

Function

Inoperative

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

Connect a 0 to 3000 PSI

(207 bar) pressure

gauge to the test port on

the function manifold

(item A). Activate drive

forward and record the

reading on the pressure

gauge.

wheels

turn

The machine is

functioning properly.

less than

2700 psi

Adjust the system

pressure relief valve

(item H) (See Repair

Section).

Chock the wheels at the

steer end of the

manchine. Raise the

non-steer end of the

machine and place

blocks under the chassis

for support.

After serial number

248:

Activate the brake

release valve (item I) on

the function manifold.

All models:

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the drive

position. Press and hold

the function enable

switch SW5. Move the

joystick controller JC3 in

the drive forward

direction, then release it.

Turn each wheel by

hand. Each wheel

should turn freely

without much effort.

wheels do

not turn

2700

psi or

Remove both brake

hoses from the brake

fittings and place them

in a suitable container.

Activate drive forward

and check for hydraulic

fluid from each hose.

hydraulic oil

Repair OR replace the

brakes

hydraulic

oil

Consult the Genie

Industries Service

Department.

REV A

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 15

Chart 11

Drive

Forward

Function

Inoperative

Be sure all other

functions operate

normally.

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the drive

position. Press and hold

the function enable

switch SW5. Move the

joystick controller JC3 in

the drive forward

direction. Check voltage

on BN/BK wire at drive

forward directional valve

coil Y6.

Repair open in circuit

from Y6 through steer

left control relay CR56

to voltage divider U14.

24 Volts

Disconnect the wires

from Y6 and measure

the coil resistance See

Repair Section.

0 or

infinite

ohms

Replace coil Y6.

22 to 24 ohms

Repair or replace the

drive forward directional

valve cartrige (item C or

E) OR consult Genie

Industries Service

Department.

REV A

August 2005Section 5 • Troubleshooting Flow Charts

5 - 16 GR-8 • GR-12 • GR-15 Part No. 72965

Chart 12

Drive

Reverse

Function

Inoperative

Be sure all other

functions operate

normally.

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the drive

position. Press and hold

the function enable

switch SW5. Move the

joystick controller JC3 in

the drive forward

direction. Check voltage

on BN wire at drive

forward directional valve

coil Y5.

Repair open in circuit

from Y5 through steer

left control relay CR55

to voltage divider U14.

24 Volts

Disconnect the wires

from Y5 and measure

the coil resistance See

Repair Section.

0 or

infinite

ohms

Replace coil Y5.

22 to 24 ohms

Repair or replace the

drive forward directional

valve cartrige (item C or

E) OR consult Genie

Industries Service

Department.

REV A

August 2005

Section 5 • Troubleshooting Flow Charts

Part No. 72965 GR-8 • GR-12 • GR-15 5 - 17

Chart 13

Machine Will

Not Drive At

Full Speed

Be sure all other

functions operate

normally.

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

position, move the

lift/drive select switch

TS16 to the drive

position. Activate the

drive speed select

Before serial number

248:

button BN25, OR

After serial number

247:

toggle switch TS5,

until all three drive

speed indicator lights

are on.. Press and hold

the function enable

switch SW5. Move the

joystick controller JC3 in

the full drive forward

direction. Check voltage

on BL wire at terminal

#3 on motor controller

U6.

Replace motor controller

U6.

less than

3.18V

Replace drive speed

select printed circuit

board U29.

3.18V

REV A

August 2005Section 5 • Troubleshooting Flow Charts

5 - 18 GR-8 • GR-12 • GR-15 Part No. 72965

Chart 14

Machine

Drives At

Full Speed

With

Platform

Raised

Be sure the circuit

breaker and fuses

are not tripped or

blown.

Be sure the

batteries are fully

charged and

properly connected.

more than

1.23V

Test resistors R11,

R11A, and R13 for

proper resistance.

Replace motor controller

U6.

Replace drive speed

select printed circuit

board U29 OR replace

JC3 OR consult Genie

Industries Service

Department.

bad

Replace faulty resistor

and repeat voltage test

on BL wire at terminal

#3 on U6.

Test limit switch LS5 for

proper adjustment and

operation.

bad

Replace LS5.

Raise the steer end of

the machine and place

blocks under the drive

chassis for support.

With key switch turned

to platform controls and

both Emergency Stop

buttons pulled out to the

position, raise the

platform approximately 2

feet. Move the lift/drive

select toggle switch

TS16 to the drive

position. Activate the

drive speed select

Before serial number

248:

button BN25, OR

After serial number

247:

toggle switch TS5,

until all three drive

speed indicator lights

are on. Press and hold

the function enable

switch SW5. Move the

joystick controller JC3 in

the full drive forward

direction. Check voltage

on BL wire at terminal

#3 on the motor

controller U6.

Section 6 • SchematicsAugust 2005

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 1

Schematics

Observe and Obey:

Troubleshooting and repair procedures shall be

completed by a person trained and qualified on

the repair of this machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Before 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

There are two groups of schematics in this section.

An illustration legend precedes each group of

drawings.

Electrical Schematics

Electrocution hazard. Contact with

electrically charged circuits could

result in death or serious injury.

Remove all rings, watches and

other jewelry.

Hydraulic Schematics

Bodily injury hazard. Spraying

hydraulic oil can penetrate and

burn skin. Loosen hydraulic

connections very slowly to allow

the oil pressure to dissipate

gradually. Do not allow oil to squirt

or spray.

General Repair Process

Malfunction

discovered

Identify

symptoms

Troubleshoot

Perform

repair

Return to

service

problem

solved

problem

still exists

Inspect

and test

Section 6 • Schematics August 2005

REV B

6 - 2 GS-8 • GR-12 • GR-15 Part No. 72965

Ground Controls Layout and Electrical Component Legend

K12

c d e f g k ij

CR51

PLATFORM

DOWN

CR52

PLATFORM

CR53

STEER

LEFT

CR54

STEER

RIGHT

CR55

DRIVE

REVERSE

CR56

DRIVE

FORWARD

OFF

b c d e f g h ia

CR51

PLATFORM

DOWN

CR52

PLATFORM

CR53

STEER

LEFT

CR54

STEER

RIGHT

CR55

DRIVE

REVERSE

CR56

DRIVE

FORWARD

Ground Controls Circuit Board

(after serial number GR02-1799)

Ground Controls Circuit Board

(before serial number GR02-1800)

Circuit Board Legend

a 9-pin terminal strip W4

b DIP switch

c relay - platform up CR52

d relay - steer right CR54

e relay - steer left CR53

f relay - drive reverse CR55

g relay - drive forward CR56

h 14-pin terminal strip W3

i relay - platform down CR51

j 8-pin terminal strip W4

k 12-pin terminal strip W3

ELECTRICAL COMPONENT LEGEND

Item Description

B5 Battery

BN5 Horn button

C3 Capacitor, 1.0 uF

CB2 Circuit breaker, 7A

Control relay CR

CR51 = Platform down

CR52 = Platform up

CR53 = Steer left

CR54 = Steer right

CR55 = Drive reverse

CR56 = Drive forward

CR57 = Tilt alarm

D6 AC power outlet

EN4 Enclosure, junction box

F8 Fuse, 275A

FB1 Flashing beacons

G G6 = Hour meter

GND Ground

Horn or alarm H

H1 = Horn

H2 = Automotive-style horn (option)

H5 = Multifunction alarm

JC3 Joystick controller

KS1 Key switch

Limit switch LS

LS1 = Platform extend

LS5 = Platform up (option)

LS16 = Drive cut out

M5 Hydraulic power unit

NC Normally closed

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

QD5 = Battery charger

QD16 = AC box to platform control box

Resistor R

R8 = 2500 ohms, lift speed

R9 = 3000 ohms, steer speed

R10 = 250 ohms, motor controller

R11 = 1000 ohms, drive

R12 = 0 to 2000 ohms, drive speed

R13 = 1800 ohms, platform raised drive speed

Switch SW

SW5 = Function enable

SW6 = Steer left/right

S7 Tilt level sensor

Toggle switch TS

TS16 = Lift/drive select

TS66 = Platform up/down

Electronic component U

U6 = Motor controller

U10 = Machine functions printed circuit board

U11 = Battery charger

U14 = Voltage divider

U29 = Drive speed select printed circuit board

U31 = 1000W charger/inverter

U32 = Inverter remote panel

Valve coil Y

Y3 = Steer right

Y4 = Steer left

Y5 = Drive reverse

Y6 = Drive forward

Y7 = Platform down

Y8 = Platform up

Section 6 • SchematicsAugust 2005

REV B

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 3

Electrical Symbols and Wire Color Legends

CB2

N.C.H.O.

N.C.

LEVEL SENSOR

CIRCUIT BOARD

Circuits crossing

no connection

Diode

Circuit connection

Hour meter

Limit switch

Toggle switch

Switch or button

Connector Emergency Stop button

Circuit breaker

Motor

Level sensor

Battery charger

Battery

Fuse

Control relay

Solenoid valve

Capacitor

Horn or alarm

Flashing beacon

WIRE COLOR LEGEND

Color Description

BK Black

BL Blue

BN Brown

GN Green

sLT BL Light Blue

OR Orange

RD Red

WH White

YL Yellow

Section 6 • Schematics January 2007

REV C

6 - 4 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

ANSI Models (before serial number GR02-1800)

Part 1 of 2

ES0067H

RD/BK-5

WH/BK-6

BL-8

GR/YL-4

BN-4

RD-3

LT BL-1

OR-7

1800

R13

RD/BK

GR/ YL

LS5

275A

B+

(+)

QD1

QD5

TILT LEVEL SENSOR

CB2

PLATFORM

GROUND

KS1

GN/YL

PLATFORM

(DOWN)

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

GN/YL

TILT ALARM

GND

CR57

R10

GN/YL

U11

U32

U31

GN/YL

FB1

U14

N.O.H.C.

N.C.

GN/YL

24V DC

12V DC

BK-2

DOWN

RD/WH

GROUND

CONTROLLER

-NOTE-

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

Section 6 • SchematicsJanuary 2007

REV C

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 5

Electrical Schematic

ANSI Models (before serial number GR02-1800)

Part 2 of 2

ES0067H

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

GN/YL

EN4

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

FWD

REV

GN/BK

SW5

GN/YL

20k

GN/BK

BN5

JC3

TS16

QD16

U24

1000

R11

1000

R11A

0-2000

R12

GN/BK

GN/YL

LS16

N.O.H.C.

LS1

BL BL

U29

SW6

*N16

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE REVERSE

DRIVE FORWARD

STEER LEFT

PLATFORM DOWN

DECENT/DRIVE/

STEER ALARM

YL/BK

BN/BK

OR/BK

GN/YL

YL/BK

GND

JUNCTION BOX

PLATFORM CONTROLLER

RELAY BOARD

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

Section 6 • Schematics January 2007

REV C

6 - 6 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

ANSI and CSA Models (from serial number GR02-1800 to GR03-2407)

Part 1 of 2

ES0083B

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

RD/BK

BK-2

LT BL-1

LS5

275A

B+

(+)

QD1

QD5

CB2

PLATFORM

GROUND

KS1

PLATFORM

DOWN

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

10A FUSE

GND

R10

GN/YL

U11

U32

U31

GROUND

CONTROLLER

FB1

U14

N.O.H.C.

GN/YL

24V DC

12V DC

GN/YL GN/YL-4

GND

TILT LEVEL

SENSOR

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THEPOWEROFF

Section 6 • SchematicsJanuary 2007

REV C

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 7

Electrical Schematic

ANSI and CSA Models (from serial number GR02-1800 to GR03-2407)

Part 2 of 2

ES0083B

1800

RELAY BOARD

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE

REVERSE

DRIVE

FORWARD

STEER LEFT

PLATFORM

DOWN

TILT ALARM

DECENT/DRIVE/

STEER ALARM

YL/BK

BN/BK

OR/BK

GN/YL

JUNCTION

BOX

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

FWD

REV

GN/BK

SW5

GN/YL

20k

GN/BK

BN5

JC3

LS16

N.O.H.C.

LS1

PLATFORM CONTROLLER

TS16

QD16

U24

1000

R11

1000

R11A

0-2000

R12

GN/BK

GN/YL

BL BL

U29

SW6

*N16

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

U10

9 8

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

Section 6 • Schematics January 2007

REV B

6 - 8 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

ANSI and CSA Models (from serial number GR03-2408 to GR03-2432)

Part 1 of 2

ES0083C

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

RD/BK

BK-2

LT BL-1

LS5

275A

B+

(+)

QD1

QD5

CB2

PLATFORM

GROUND

KS1

DOWN

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

10A FUSE

GND

R10

GN/YL

U11

U32

U31

GROUND

CONTROLLER

FB1

U14

N.O.H.C.

GN/YL

24V DC

12V DC

GN/YL GN/YL-4

GND

TILT LEVEL

SENSOR

PLATFORM

GROUND

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THEPOWEROFF

Section 6 • SchematicsJanuary 2007

REV B

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 9

Electrical Schematic

ANSI and CSA Models (from serial number GR03-2408 to GR03-2432)

Part 2 of 2

ES0083C

1800

RELAY BOARD

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE

REVERSE

DRIVE

FORWARD

STEER LEFT

PLATFORM

DOWN

TILT ALARM

DECENT/DRIVE/

STEER ALARM

YL/BK

BN/BK

OR/BK

GN/YL

EN4

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

FWD

REV

GN/BK

SW5

GN/YL

20k

GN/BK

BN5

JC3

LS16

N.O.H.C.

LS1

PLATFORM CONTROLLER

TS16

QD16

U24

1000

R11

1000

R11A

0-2000

R12

GN/BK

GN/YL

BL BL

U29

SW6

*N16

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

U10

9 8

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

Section 6 • Schematics January 2007

REV B

6 - 10 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

ANSI and CSA Models (after serial number GR03-2432)

Part 1 of 2

ES0083D

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

RD/BK

BK-2

LT BL-1

LS5

275A

B+

(+)

QD1

QD5

CB2

PLATFORM

GROUND

KS1

DOWN

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

10A FUSE

GND

R10

GN/YL

U11

U32

U31

GROUND

CONTROLLS

FB1

U14

N.O.H.C.

GN/YL

24V DC

12V DC

GN/YL GN/YL-4

GND

TILT LEVEL

SENSOR

PLATFORM

GROUND

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THEPOWEROFF

Section 6 • SchematicsJanuary 2007

REV B

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 11

Electrical Schematic

ANSI and CSA Models (after serial number GR03-2432)

Part 2 of 2

ES0083D

1800

RELAY BOARD

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE

REVERSE

DRIVE

FORWARD

STEER LEFT

PLATFORM

DOWN

TILT ALARM

DECENT/DRIVE/

STEER ALARM

YL/BK

BN/BK

OR/BK

GN/YL

JUNCTION BOX

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

FWD

REV

GN/BK

SW5

GN/YL

20k

GN/BK

BN5

JC3

LS16

N.O.H.C.

LS1

PLATFORM CONTROLLS

TS16

QD16

U24

1000

R11

1000

R11A

0-2000

R12

GN/BK

GN/YL

BL BL

U29

SW6

*N16

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

U10

9 8

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

Section 6 • Schematics January 2007

REV C

6 - 12 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

CE Models (before serial number GR02-1800)

Part 1 of 2

ES0068J

RD/BK-5

WH/BK-6

BL-8

GR/YL-4

BN-4

RD-3

LT BL-1

OR-7

1800

R13

RD/BK

GR/ YL

LS5

275A

B+

(+)

QD1

QD5

LEVEL SENSOR

CB2

KS1

GN/YL

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

TILT ALARM

GND

R10

GN/YL

U11

U32

U31

FB1

U14

N.O.H.C.

GN/YL

24V DC

12V DC

BK-2

DOWN

RD/WH

GROUND

CONTROLLER

CR57

GN/YL

N.C.

PLATFORM

GROUND

H1S7

YL/BK

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

RELAY BOARD

Section 6 • SchematicsJanuary 2007

REV C

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 13

Electrical Schematic

CE Models (before serial number GR02-1800)

Part 2 of 2

ES0068J

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE REVERSE

DRIVE FORWARD

STEER LEFT

PLATFORM DOWN

DECENT/DRIVE/

STEER ALARM

YL/BK

BN/BK

OR/BK

GN/YL

YL/BK

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

YL/BK

RELAY BOARD

PLATFORM CONTROLLER

TS16

SW5

R12

0-2000W

JC3

GN/YL

GN/BK

1000W

U24

20K

SW6

R11

R11A

GN/BK

REV

FWD

GN/YL

U29

BN5

GN/YL

GND

GN/BK

*N16

OR-7

RD-3

BN-4

BK-5

WH-2

BL-6

BL-8

WH/BK-6

RD/BK-5

OR-7

RD-3

BN-4

GR/YL-4

LT BL-1

BK-2

LS16

N.O.H.C.

LS1

N.O.H.C.

QD16

JUNCTION BOX

EN4

Section 6 • Schematics January 2007

REV C

6 - 14 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

CE Models (from serial number GR02-1800 to GR03-2407)

Part 1 of 2

ES0083B

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

RD/BK

BK-2

LT BL-1

LS5

275A

B+

(+)

QD1

QD5

CB2

PLATFORM

GROUND

KS1

PLATFORM

DOWN

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

10A FUSE

GND

R10

GN/YL

U11

U32

U31

GROUND

CONTROLLER

FB1

U14

N.O.H.C.

GN/YL

24V DC

12V DC

GN/YL GN/YL-4

GND

TILT LEVEL

SENSOR

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THEPOWEROFF

RELAY BOARD

Section 6 • SchematicsJanuary 2007

REV C

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 15

Electrical Schematic

CE Models (from serial number GR02-1800 to GR03-2407)

Part 2 of 2

ES0083B

1800

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE

REVERSE

DRIVE

FORWARD

STEER LEFT

PLATFORM

DOWN

TILT ALARM

DECENT/DRIVE/

STEER ALARM

YL/BK

BN/BK

OR/BK

GN/YL

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

FWD

REV

GN/BK

SW5

GN/YL

20k

GN/BK

BN5

JC3

LS16

N.O.H.C.

LS1

PLATFORM CONTROLLER

TS16

QD16

U24

1000

R11

1000

R11A

0-2000

R12

GN/BK

GN/YL

BL BL

U29

SW6

*N16

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

U10

9 8

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

BK-2

LT BL-1

GN/YL-4

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

RELAY BOARD

EN4

JUNCTION BOX

Section 6 • Schematics January 2007

REV B

6 - 16 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

CE Models (from serial number GR03-2408 to GR03-2432)

Part 1 of 2

ES0083C

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

RD/BK

BK-2

LT BL-1

LS5

275A

B+

(+)

QD1

QD5

CB2

PLATFORM

GROUND

KS1

DOWN

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

10A FUSE

GND

R10

GN/YL

U11

U32

U31

GROUND

CONTROLLER

FB1

U14

N.O.H.C.

GN/YL

24V DC

12V DC

GN/YL GN/YL-4

GND

PLATFORM

GROUND

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THEPOWEROFF

RELAY BOARD

LEVEL SENSOR

Section 6 • SchematicsJanuary 2007

REV B

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 17

Electrical Schematic

CE Models (from serial number GR03-2408 to GR03-2432)

Part 2 of 2

ES0083C

1800

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE

REVERSE

DRIVE

FORWARD

STEER LEFT

PLATFORM

DOWN

TILT ALARM

ALARM

YL/BK

BN/BK

OR/BK

GN/YL

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

FWD

REV

GN/BK

SW5

GN/YL

20k

GN/BK

BN5

JC3

LS16

N.O.H.C.

LS1

PLATFORM CONTROLLER

TS16

QD16

U24

1000

R11

1000

R11A

0-2000

R12

GN/BK

GN/YL

BL BL

U29

SW6

*N16

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

U10

9 8

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

BK-2

LT BL-1

GN/YL-4

EN4

JUNCTION BOX

RELAY BOARD

Section 6 • Schematics January 2007

REV B

6 - 18 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

CE Models (from serial number GR03-2433 to GR04-4000)

Part 1 of 2

ES0083D

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

RD/BK

BK-2

LT BL-1

LS5

275A

B+

(+)

QD1

QD5

CB2

PLATFORM

GROUND

KS1

DOWN

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

10A FUSE

GND

R10

GN/YL

U11

U32

U31

GROUND

CONTROLLS

FB1

U14

N.O.H.C.

GN/YL

24V DC

12V DC

GN/YL GN/YL-4

GND

TILT LEVEL

SENSOR

PLATFORM

GROUND

-NOTE-

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

Section 6 • SchematicsJanuary 2007

REV B

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 19

Electrical Schematic

CE Models (from serial number GR03-2433 to GR04-4000)

Part 2 of 2

ES0083D

1800

RELAY BOARD

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE

REVERSE

DRIVE

FORWARD

STEER LEFT

PLATFORM

DOWN

TILT ALARM

DECENT/DRIVE/

STEER ALARM

YL/BK

BN/BK

OR/BK

GN/YL

JUNCTION BOX

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

FWD

REV

GN/BK

SW5

GN/YL

20k

GN/BK

BN5

JC3

LS16

N.O.H.C.

LS1

PLATFORM CONTROLLS

TS16

QD16

U24

1000

R11

1000

R11A

0-2000

R12

GN/BK

GN/YL

BL BL

U29

SW6

*N16

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

U10

9 8

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

Section 6 • Schematics January 2007

REV B

6 - 20 GS-8 • GR-12 • GR-15 Part No. 72965

Electrical Schematic

CE Models (after serial number GR04-4000)

Part 1 of 2

ES0086A

RD/BK-5

WH/BK-6

BL-8

BN-4

RD-3

OR-7

RD/BK

BK-2

LT BL-1

LS5

275A

B+

(+)

QD1

QD5

CB2

PLATFORM

GROUND

KS1

DOWN

PLATFORM

BL/WH

PLATFORM

GROUND

TS66

RD/BK

(OPTION)

INVERTER

CHARGER

1000 W

PANEL

REMOTE

INVERTER

QD1

(

)

1.0

250

10A FUSE

GND

R10

GN/YL

U11

U32

U31

GROUND

CONTROLLER

FB1

U14

N.O.H.C.

GN/YL

24V DC

12V DC

GN/YL GN/YL-4

GND

TILT LEVEL

SENSOR

EN4

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

LS16

N.O.H.C.

LS1

BL BL

PLATFORM

GROUND

- NOTE -

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THEPOWEROFF

Section 6 • SchematicsJanuary 2007

REV B

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 21

Electrical Schematic

CE Models (after serial number GR04-4000)

Part 2 of 2

ES0086A

1800

RELAY BOARD

HOURMETER

DRIVE/

PLATFORM UP

STEER RIGHT

DRIVE

REVERSE

DRIVE

FORWARD

STEER LEFT

PLATFORM

DOWN

TILT ALARM

DECENT/DRIVE/

STEER ALARM

BN/BK

OR/BK

GN/YL

YL/BK

0-2000

R12

3000

2500

CR52

FORWARD

DRIVE

RIGHT

STEER

LEFT

PLATFORM

DOWN

PLATFORM

CR51

N.O.

N.C.

CR53

N.O.

CR54

N.O.

CR55

N.C.

CR56

N.C.

REVERSE

DRIVE

U10

9 8

1000

R11A

1000

R11

WH-2

BL-6

BK-5

BN-4

RD-3

OR-7

U29

U24

SW6

TS16

CR57

PLATFORM

CONTROLLER

-NOTE-

MACHINE SHOWN

IN THE STOWED

POSITION WITH

THE POWER OFF

Section 6 • Schematics August 2005

REV B

6 - 22 GS-8 • GR-12 • GR-15 Part No. 72965

Hydraulic Symbols Legend

Double acting cylinder

Relief Valve

Solenoid operated

2 position 2 way

directional valve

Brake release valve

Single acting cylinder

Solenoid operated

3 position 4 way

directional valve

Solenoid operated

3 position 4 way

directional valve

Flow regulator

Priority flow regulator

Solenoid operated

2 position 2 way

directional valve

with manual over ride

Brake

Bi-directional motor

Fixed displacement

pump

Check valve

Filter

Variable speed

motor

Orifice

Section 6 • SchematicsAugust 2005

REV B

Part No. 72965 GS-8 • GR-12 • GR-15 6 - 23

Hydraulic Schematic

(before serial number GR01-249)

ABBREVIATION LEGEND

Item Description

A Test port

B Relief valve, steer circuit

C Drive forward/reverse

D Lift/drive select

E Steer left/right

F Relief valve, lift circuit

G Flow regulator, steer circuit

H Relief valve, system

K Platform down

L Flow regulator, platform up/down circuit

M Check valve, platform up circuit

HS0051C

STEER CYLINDER BRAKES DRIVE MOTORS LIFT CYLINDER

Y3 Y4

1 gpm

3.78 L/min

1000 psi

69 bar

Y42

0.6 gpm

1.9 L/min

2700 psi

186 bar

2200 psi

151.6 bar

T2P

3.5 gpm

13.25 L/min

100 MESH

10 MICRON

LEFT RIGHT

S1 S2 BRK M1 M2

Y5 Y6

FUNCTION MANIFOLD

HYDRAULIC TANK

Section 6 • Schematics August 2005

REV B

6 - 24 GS-8 • GR-12 • GR-15 Part No. 72965

Hydraulic Schematic

(after serial number GR01-248)

ABBREVIATION LEGEND

Item Description

AA Test port

AB Relief valve, steer circuit

AC Steer left/right

AD Lift/drive select

AE Drive forward/reverse

AF Flow regulator, steer circuit

AG Relief valve, system

AH Relief valve, lift circuit

AI Needle valve, manual brake release

AJ Check valve, brake release circuit

K Platform down

L Flow regulator, platform up/down circuit

M Check valve, platform up circuit

HS0051D

STEER CYLINDER BRAKES DRIVE MOTORS LIFT CYLINDER

Y3 Y4

Y5 Y6

1 gpm

3.78 L/min

1000 psi

69 bar

Y42

0.6 gpm

1.9 L/min

2700 psi

186 bar

2200 psi

151.6 bar

T2P

3.5 gpm

13.25 L/min

100 MESH

10 MICRON

200 psi

13.7 bar

LEFT RIGHT

S1 S2 BRK M1 M2

FUNCTION MANIFOLD

HYDRAULIC TANK

Service Manual

GR-8•GR-12•GR-15

Rev B2

Part No.

72965

(from serial number GR-101 to GS05-4999)

Distributed By:

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Phone 425.881.1800

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