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Genie GR-8 Service Manual

Genie GR-8 Service Manual

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Service Manual
(from serial number GR-101 to GR05-4999)
(from serial number GR-101 to GR05-4999)
(from serial number GR-101 to GR05-4999)
Part No. 72965
Rev B2
January 2007

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Summary of Contents for Genie GR-8

  • Page 1 Service Manual Part No. 72965 Rev B2 January 2007 (from serial number GR-101 to GR05-4999) (from serial number GR-101 to GR05-4999) (from serial number GR-101 to GR05-4999)

  • Page 2: Read, Understand And Obey The Safety Rules And Operating Instructions In The Appropriate Operator's Manual On Your Machine

    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.

  • Page 3: Serial Number Legend

    Country of manufacture: USA Facility code This machine complies with: used only for models manufactured ANSI A92.6-1999 in multiple facilities B354.2-01 Genie Industries 18340 NE 76th Street Redmond, WA 98052 PN - 77055 Part No. 72965 GR-8 • GR-12 • GR-15...
  • Page 4 August 2005 This page intentionally left blank. GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 5: Safety Rules

    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. Part No. 72965 GR-8 • GR-12 • GR-15...
  • Page 6 Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe . GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 7: Table Of Contents

    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 Part No. 72965 GR-8 • GR-12 • GR-15...
  • Page 8 D-3 Lubricate the Lifting Chains .............. 3 - 24 D-4 Replace the Hydraulic Tank Return Filter ......... 3 - 24 Checklist E Procedure E-1 Test or Replace the Hydraulic Oil ............. 3 - 25 viii GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 9 (after serial number GR01-248) ............4 - 28 6-4 Valve Adjustments - Function Manifold ..........4 - 30 Valve Coils ..................4 - 33 Hydraulic Tank Hydraulic Tank ................. 4 - 35 Part No. 72965 GR-8 • GR-12 • GR-15...
  • Page 10 Drive Forward Function Inoperative ..........5 - 15 Drive Reverse Function Inoperative ..........5 - 16 Machine Will Not Drive at Full Speed ..........5 - 17 Machine Drives At Full Speed With Platform Raised ....... 5 - 18 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 11 (after serial number GR04-4000) ............... 6 - 20 Hydraulic Component Reference and Symbols Legend ......6 - 22 Hydraulic Schematic (before serial number GR01-249) .............. 6 - 23 Hydraulic Schematic (after serial number GR01-248) ..............6 - 24 Part No. 72965 GR-8 • GR-12 • GR-15...
  • Page 12 August 2005 This page intentionally left blank. GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 13: B Machine Specifications

    Batteries, Standard including workstation tray 1.57 m Voltage 6V DC CE models 72.5 in including workstation tray 1.73 m Group Platform capacity, maximum (GR-8 and GR-12) Type T-105 Standard platform 500 lbs Quantity 227 kg Battery capacity, maximum 225AH Fiberglass platform...

  • Page 14: Performance Specifications

    19 in ± 6 in mixable with Shell Donax TG (Dexron III) oils. 48 cm ± 15 cm Genie specifications require hydraulic oils which are Function speed, maximum, from platform controls designed to give maximum protection to hydraulic (with 1 person in platform)

  • Page 15: Manifold Component Specifications

    Solenoid valve, 3 position 4 way 20V DC with diode (schematic item E) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 72965 GR-8 • GR-12 • GR-15 2 - 3...

  • Page 16: Hydraulic Hose And Fitting Torque 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.
  • Page 17 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks. Part No. 72965 GR-8 • GR-12 • GR-15 2 - 5...
  • Page 18 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 2 - 6 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 19 54.1 53.2 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 Part No. 72965 GR-8 • GR-12 • GR-15 2 - 7...
  • Page 20 Section 2 • Specifications September 2005 This page intentionally left blank. 2 - 8 GR-12 • GR-15 • GR-20 Part No. 84700...

  • Page 21: Observe And Obey

    Indicates that an incorrect result has occurred · Wheels chocked after performing a series of steps. · All external AC power supply disconnected from the machine Part No. 72965 GR-8 • GR-12 • GR-15 3 - 1...

  • Page 22: Pre-Delivery Preparation 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. 3 - 2 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 23 Genie UK 18340 NE 76th Street The Maltings, Wharf Road PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev B...
  • Page 24 Section 3 • Scheduled Maintenance Procedures August 2005 This page intentionally left blank. 3 - 4 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 25: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 72965 GR-8 • GR-12 • GR-15 3 - 5...

  • Page 26: Checklist A Procedures

    Complete information to perform this procedure is Refer to the Operator's Manual on your machine. available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. 3 - 6 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 27: Perform 30 Day Service

    Repeat this step for the other steer yoke. Grease specification Chevron Ultra-duty grease, EP NLGI 2 (lithium based) or equivalent Part No. 72965 GR-8 • GR-12 • GR-15 3 - 7...

  • Page 28: Checklist B Procedures

    3 Be sure that the battery retaining fasteners and operation, please contact the cable connections are tight. Genie Industries Scissor Service Department. 3 - 8 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 29: Inspect The Electrical Wiring

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

  • Page 30: Inspect The Tires And Wheels (Including Castle Nut Torque)

    4 Install a new cotter pin. Bend the cotter pin to lock it in place. 3 - 10 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 31: Clean And Lubricate The Columns

    Dealer service is strongly nylock nut recommended. spring upper sequencing bracket 4 If needed, apply a generous amount of sequencing cable Boe-lube wax to the inside and outside channels of each column. Part No. 72965 GR-8 • GR-12 • GR-15 3 - 11...

  • Page 32: Test The Emergency Stop

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

  • Page 33: Test The Key Switch

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

  • Page 34: Test The Drive Brakes

    Specifications . your machine reference point. Refer to Section 2, Specifications . The brakes must be able to hold the machine on any slope it is able to climb 3 - 14 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 35: Test The Drive Speed - Raised Position

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

  • Page 36: Test The Alarm Package (If Equipped)

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

  • Page 37: Perform Hydraulic Oil Analysis

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

  • Page 38: Checklist C Procedures

    2 Install a new cap onto the tank. 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. 3 - 18 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 39: Test The Platform Overload System (If Equipped)

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

  • Page 40: Calibrate The Platform Overload System (If Equipped)

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

  • Page 41: Inspect The Mast Assembly For Wear

    Crushing hazard. Keep hands clear of the jack stand when lowering the platform. GR-15 shown mast cover idler wheel spacer Part No. 72965 GR-8 • GR-12 • GR-15 3 - 21...

  • Page 42: Lubricate The Lifting Chains

    Performing this procedure without the proper skills and tools could result in death or serious injury. Dealer service is strongly recommended. 3 - 22 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 43: Replace The Hydraulic Tank Return Filter

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

  • Page 44: Checklist E Procedure

    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. 3 - 24 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 45 3.4 Nm Remove all rings, watches and other jewelry. 17 Fill the tank with hydraulic oil until the fluid is at indicator on the hydraulic tank. Do not FULL overfill. Part No. 72965 GR-8 • GR-12 • GR-15 3 - 25...
  • Page 46 Section 3 • Scheduled Maintenance Procedures April 2006 This page intentionally left blank. 3 - 26 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 47 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. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 1...

  • Page 48: Platform Controls

    There are no adjustments needed on the joystick. For further Remove the Circuit Board assistance, consult the Genie Industries Service Department. 1 Tag and disconnect the platform controls from the machine. Remove the control box from the For further information or assistance, consult the machine and place it on a workbench.

  • Page 49: Controller Adjustments

    12 Install the circuit board and fasteners onto the joystick. Securely tighten the fasteners. Do not over tighten. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 3...
  • Page 50 Do not over tighten. 5 Confirm the stowed drive speed. Refer to Maintenance Procedure B-11, Test the Drive Speed - Stowed Position . high speed trimpot circuit board potentiometer 4 - 4 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 51: Platform Components

    Bodily injury hazard. If a platform is being replaced, be sure that all appropriate safety and instructional decals are applied to the new platform. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 5...

  • Page 52: Mast Components

    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. 4 - 6 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 53 1 column battery box brace counterweight (GR-15 models) counterweight fasteners (GR-15 models) mast mounting fasteners Part No. 72965 GR-8 • GR-12 • GR-15 4 - 7...
  • Page 54 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. 4 - 8 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 55 Lifting Chains. 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. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 9...

  • Page 56: Glide Pads

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

  • Page 57: Lifting Chains

    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. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 11...
  • Page 58 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. Continued to the next page 4 - 12 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 59 Cracked Link Plates Visually inspect chain link Cracks in any chain link Replace entire chain. Do plates for cracks. plate. not repair just the affected portion of the chain. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 13...

  • Page 60: Lift Cylinders

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

  • Page 61: Ground Controls

    Terminals 7 and 8 represent the coil and should Terminal Numbers not be tested in any other combination. Control Relay Schematic (Relay shown deactivated) Part No. 72965 GR-8 • GR-12 • GR-15 4 - 15...

  • Page 62: Circuit Board

    Terminal Numbers 6 Remove the control box mounting fasteners. Remove the control box from the machine and place it on a workbench. Control Relay Schematic (Relay shown activated) 4 - 16 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 63: Controller Adjustments

    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. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 17...
  • Page 64 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 . 4 - 18 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 65: Level Sensor

    5 Raise the machine approximately 2 inches / 5 cm. The Genie Runabout is designed to deactivate the lift and drive functions and activate an alarm when 6 Place a 0.75 x 6 x 6 inch / 19.1 mm x a signal is received from the level sensor.
  • Page 66 18 Raise the platform slightly. Remove the lifting 23 Remove the blocks from the wheels at the strap from the platform. non-steer end of the machine. 19 Lower the platform to the stowed position. 4 - 20 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 67 36 Lower the machine onto the blocks. 37 Adjust the level sensor retaining fasteners just until the tilt sensor alarm does not sound. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 21...

  • Page 68: Hydraulic Pump

    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. 4 - 22 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 69 Do not allow oil to squirt gradually. Do not allow oil to squirt or spray. or spray. 6 Remove the pump mounting bolts. Carefully remove the pump. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 23...

  • Page 70: Manifolds

    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. 4 - 24 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 71 Section 4 • Repair Procedures REV B MANIFOLDS Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 72965 GR-8 • GR-12 • GR-15 4 - 25...

  • Page 72: Function Manifold Components (From Serial Number Gr01-225 To Gr01-248)

    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. 4 - 26 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 73 Section 4 • Repair Procedures REV B MANIFOLDS Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 72965 GR-8 • GR-12 • GR-15 4 - 27...

  • Page 74: Function Manifold Components (After Serial Number Gr01-248)

    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. 4 - 28 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 75 Section 4 • Repair Procedures REV B MANIFOLDS Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Part No. 72965 GR-8 • GR-12 • GR-15 4 - 29...

  • Page 76: Valve Adjustments - Function Manifold

    6 Chock both sides of the wheels at the steer end 13 Repeat steps 8 through 9 to confirm the relief of the machine. valve pressure. 14 Install the relief valve cap. Remove the pressure gauge. 4 - 30 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 77 9 Fully lower the platform. 10 Add an additional 50 pounds / 22.7 kg to the platform. Secure the additional weight. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 31...
  • Page 78 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. 4 - 32 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 79: Valve Coils

    REV B MANIFOLDS How to Test a Coil Diode Valve Coils Genie incorporates spike suppressing diodes in all of its coils. Properly functioning coil diodes protect How to Test a Coil the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function...
  • Page 80 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. 4 - 34 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 81: Hydraulic Tank

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

  • Page 82: Steer Axle Components

    Crushing hazard. The chassis will from the chassis. fall if it is not properly supported. 6 Remove the wheel castle nut. Remove the wheel. 4 - 36 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 83 35 in-lbs fall if it is not properly supported. 4 Nm 6 Remove the wheel castle nut. Remove the Drive motor mounting fasteners, lubricated 26 in-lbs wheel. 2.9 Nm Part No. 72965 GR-8 • GR-12 • GR-15 4 - 37...

  • Page 84: Steer Cylinder

    Remove the steer cylinder if they are used to lift the platform. from the machine. Do not attach the lifting strap to the platform railings. 4 Remove the drive chassis cover. 4 - 38 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 85 6 Center a lifting jack under the steer end of the 14 Install the drive chassis cover. Install and machine. securely tighten the drive cover retaining fasteners. Do not over tighten. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 39...

  • Page 86: Non-Steer Axle Components

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

  • Page 87: Platform Overload Components

    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. Part No. 72965 GR-8 • GR-12 • GR-15 4 - 41...
  • Page 88 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 4 - 42 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 89: Troubleshooting Flow Charts

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

  • Page 90: Return To Service

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

  • Page 91: All Functions Will Not Operate

    Repair open in wire wire on input side of key circuit through quick switch KS1. disconnect QD16, Emergency Stop button P2, enclosure EN4 to KS1. Continued on the next page. Part No. 72965 GR-8 • GR-12 • GR-15 5 - 3...
  • Page 92 Replace platform controls contract OR refer to Platform Controls Inoperative, Chart 5 OR consult Genie Industries Service Department. Troubleshoot lift and drive systems separately OR consult Genie Industries Service Department. 5 - 4 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 93: Pump Motor Will Not Operate

    M- from terminal M- to M5. on U6 to negative terminal on M5. continuity Replace U6 OR repair or replace M5 OR consult Genie Industries Service Department. Part No. 72965 GR-8 • GR-12 • GR-15 5 - 5...
  • Page 94 (See Repair Section). blown. good Be sure the batteries are fully Consult Genie Industries Service Department. charged and properly connected. Be sure the hydraulic tank is filled to the correct level. 5 - 6 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 95: Ground Controls Inoperative, Platform Controls Operate Normally

    TS66. Be sure the continuity batteries are properly connected. Consult the Genie Industries Service Department. Be sure the batteries are fully charged. Part No. 72965 GR-8 • GR-12 • GR-15 5 - 7...

  • Page 96: Platform Controls Inoperative, Ground Controls Operate Normally

    Consult Genie Industries batteries are Service Department. from terminal #6 on properly connected. TS16 to BK wire at platform control contact Be sure the on KS1. batteries are fully charged. 5 - 8 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 97: Platform Up Function Inoperative

    (See properly connected. Repair Section). 23 to 26 ohms Repair or replace the plaftorm up directional valve cartrige (item D or F) OR consult Genie Industries Service Department. Part No. 72965 GR-8 • GR-12 • GR-15 5 - 9...

  • Page 98: Platform Down Function Inoperative

    Repair Section. charged and properly connected. 23 to 26 ohms Repair or replace the plaftorm up directional valve cartrige (item K) OR consult Genie Industries Service Department. 5 - 10 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 99: Steer Left Function Inoperative

    Replace coil on Y4. Repair Section. 23 to 26 ohms Repair or replace the plaftorm up directional valve cartrige (item C, G or E) OR consult Genie Industries Service Department. Part No. 72965 GR-8 • GR-12 • GR-15 5 - 11...

  • Page 100: Steer Right Function Inoperative

    Replace coil on Y3. Repair Section. 23 to 26 ohms Repair or replace the plaftorm up directional valve cartrige (item C, G or E) OR consult Genie Industries Service Department. 5 - 12 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 101 Activate the Be sure the drive function. Does the batteries are fully drive function operate? charged and properly connected. Consult the Genie Industries Service Department. Part No. 72965 GR-8 • GR-12 • GR-15 5 - 13...

  • Page 102: Brake Release Function Inoperative

    Repair OR replace the less than brakes 2700 psi Adjust the system pressure relief valve (item H) (See Repair Section). 5 - 14 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 103: Drive Forward Function Inoperative

    Repair Section. charged and properly connected. 22 to 24 ohms Repair or replace the drive forward directional valve cartrige (item C or E) OR consult Genie Industries Service Department. Part No. 72965 GR-8 • GR-12 • GR-15 5 - 15...

  • Page 104: Drive Reverse Function Inoperative

    Repair Section. charged and properly connected. 22 to 24 ohms Repair or replace the drive forward directional valve cartrige (item C or E) OR consult Genie Industries Service Department. 5 - 16 GR-8 • GR-12 • GR-15 Part No. 72965...

  • Page 105: Machine Will Not Drive At Full Speed

    Check voltage batteries are fully on BL wire at terminal charged and #3 on motor controller properly connected. less than 3.18V Replace drive speed select printed circuit board U29. Part No. 72965 GR-8 • GR-12 • GR-15 5 - 17...
  • Page 106 SW5. Move the properly connected. joystick controller JC3 in the full drive forward direction. Check voltage on BL wire at terminal #3 on the motor controller U6. 1.23V Replace motor controller 5 - 18 GR-8 • GR-12 • GR-15 Part No. 72965...
  • Page 107 August 2005 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution hazard. Contact with electrically charged circuits could Troubleshooting and repair procedures shall be result in death or serious injury.

  • Page 108: (Before Serial Number Gr02-1800)

    Section 6 • Schematics August 2005 Ground Controls Layout and Electrical Component Legend REV B ELECTRICAL COMPONENT LEGEND Item Description CR54 CR53 CR56 Battery CR52 CR51 STEER STEER DRIVE Horn button RIGHT LEFT FORWARD PLATFORM PLATFORM Capacitor, 1.0 uF DOWN Circuit breaker, 7A Control relay CR51 = Platform down...
  • Page 109 August 2005 Section 6 • Schematics Electrical Symbols and Wire Color Legends REV B N.C. N.C.H.O. LEVEL SENSOR Motor CIRCUIT BOARD Circuits crossing Limit switch no connection Level sensor Diode Toggle switch Solenoid valve Battery charger Switch or button Circuit connection Battery Capacitor Fuse...
  • Page 110 Section 6 • Schematics January 2007 Electrical Schematic ANSI Models (before serial number GR02-1800) REV C Part 1 of 2 BK-2 LT BL-1 GR/ YL GR/YL-4 OR-7 RD-3 BN-4 RD/BK RD/BK-5 - NOTE - MACHINE SHOWN WH/BK-6 IN THE STOWED BL-8 POSITION WITH THE POWER OFF...
  • Page 111 January 2007 Section 6 • Schematics Electrical Schematic ANSI Models (before serial number GR02-1800) REV C Part 2 of 2 *N16 PLATFORM CONTROLLER QD16 TS16 OR-7 0-2000 GN/YL RD-3 BN-4 GN/BK GN/BK GN/BK BK-5 JUNCTION BOX WH-2 1000 BL-6 1000 R11A LS16 N.O.H.C.
  • Page 112 Section 6 • Schematics January 2007 Electrical Schematic ANSI and CSA Models (from serial number GR02-1800 to GR03-2407) REV C Part 1 of 2 LT BL-1 BK-2 GN/YL GN/YL-4 OR-7 RD-3 BN-4 RD/BK RD/BK-5 - NOTE - MACHINE SHOWN WH/BK-6 IN THE STOWED BL-8 POSITION WITH...
  • Page 113 January 2007 Section 6 • Schematics Electrical Schematic ANSI and CSA Models (from serial number GR02-1800 to GR03-2407) REV C Part 2 of 2 *N16 PLATFORM CONTROLLER QD16 TS16 OR-7 0-2000 GN/YL RD-3 BN-4 GN/BK GN/BK GN/BK BK-5 JUNCTION WH-2 1000 BL-6 1000...
  • Page 114 Section 6 • Schematics January 2007 Electrical Schematic ANSI and CSA Models (from serial number GR03-2408 to GR03-2432) REV B Part 1 of 2 LT BL-1 BK-2 GN/YL GN/YL-4 OR-7 RD-3 BN-4 RD/BK RD/BK-5 - NOTE - MACHINE SHOWN WH/BK-6 IN THE STOWED BL-8 POSITION WITH...
  • Page 115 January 2007 Section 6 • Schematics Electrical Schematic ANSI and CSA Models (from serial number GR03-2408 to GR03-2432) REV B Part 2 of 2 *N16 PLATFORM CONTROLLER TS16 QD16 OR-7 0-2000 GN/YL RD-3 BN-4 GN/BK GN/BK GN/BK BK-5 WH-2 1000 BL-6 1000 R11A...
  • Page 116 Section 6 • Schematics January 2007 Electrical Schematic ANSI and CSA Models (after serial number GR03-2432) REV B Part 1 of 2 LT BL-1 BK-2 GN/YL GN/YL-4 OR-7 RD-3 BN-4 RD/BK RD/BK-5 - NOTE - MACHINE SHOWN WH/BK-6 IN THE STOWED BL-8 POSITION WITH THE POWER OFF...
  • Page 117 January 2007 Section 6 • Schematics Electrical Schematic ANSI and CSA Models (after serial number GR03-2432) REV B Part 2 of 2 *N16 PLATFORM CONTROLLS QD16 TS16 OR-7 0-2000 GN/YL RD-3 BN-4 GN/BK GN/BK GN/BK BK-5 JUNCTION BOX WH-2 1000 BL-6 1000 R11A...

  • Page 118: Electrical Schematic - Ce Models (Before Serial Number Gr02-1800)

    Section 6 • Schematics January 2007 Electrical Schematic CE Models (before serial number GR02-1800) REV C Part 1 of 2 BK-2 LT BL-1 GR/ YL GR/YL-4 OR-7 RD-3 BN-4 RD/BK RD/BK-5 - NOTE - MACHINE SHOWN WH/BK-6 IN THE STOWED BL-8 POSITION WITH THE POWER OFF...
  • Page 119 January 2007 Section 6 • Schematics Electrical Schematic CE Models (before serial number GR02-1800) REV C Part 2 of 2 *N16 PLATFORM CONTROLLER BK-2 LT BL-1 QD16 TS16 GR/YL-4 OR-7 OR-7 GN/YL RD-3 RD-3 BN-4 BN-4 GN/BK GN/BK 0-2000W GN/BK RD/BK-5 BK-5 JUNCTION BOX...

  • Page 120: (From Serial Number Gr02-1800 To Gr03-2407)

    Section 6 • Schematics January 2007 Electrical Schematic CE Models (from serial number GR02-1800 to GR03-2407) REV C Part 1 of 2 LT BL-1 BK-2 GN/YL GN/YL-4 OR-7 RD-3 BN-4 RD/BK RD/BK-5 - NOTE - MACHINE SHOWN WH/BK-6 IN THE STOWED BL-8 POSITION WITH THE POWER OFF...
  • Page 121 January 2007 Section 6 • Schematics Electrical Schematic CE Models (from serial number GR02-1800 to GR03-2407) REV C Part 2 of 2 *N16 PLATFORM CONTROLLER LT BL-1 BK-2 QD16 TS16 GN/YL-4 OR-7 OR-7 0-2000 GN/YL RD-3 RD-3 BN-4 BN-4 GN/BK GN/BK GN/BK RD/BK-5...

  • Page 122: (From Serial Number Gr03-2408 To Gr03-2432)

    Section 6 • Schematics January 2007 Electrical Schematic CE Models (from serial number GR03-2408 to GR03-2432) REV B Part 1 of 2 LT BL-1 BK-2 GN/YL GN/YL-4 OR-7 RD-3 BN-4 RD/BK-5 RD/BK - NOTE - MACHINE SHOWN WH/BK-6 IN THE STOWED BL-8 POSITION WITH THE POWER OFF...
  • Page 123 January 2007 Section 6 • Schematics Electrical Schematic CE Models (from serial number GR03-2408 to GR03-2432) REV B Part 2 of 2 *N16 PLATFORM CONTROLLER LT BL-1 BK-2 TS16 QD16 GN/YL-4 OR-7 OR-7 0-2000 GN/YL RD-3 RD-3 BN-4 BN-4 GN/BK GN/BK GN/BK RD/BK-5...

  • Page 124: (From Serial Number Gr03-2433 To Gr04-4000)

    Section 6 • Schematics January 2007 Electrical Schematic CE Models (from serial number GR03-2433 to GR04-4000) REV B Part 1 of 2 LT BL-1 BK-2 GN/YL GN/YL-4 OR-7 RD-3 BN-4 RD/BK RD/BK-5 - NOTE - MACHINE SHOWN WH/BK-6 IN THE STOWED BL-8 POSITION WITH THE POWER OFF...
  • Page 125 January 2007 Section 6 • Schematics Electrical Schematic CE Models (from serial number GR03-2433 to GR04-4000) REV B Part 2 of 2 *N16 PLATFORM CONTROLLS TS16 QD16 OR-7 0-2000 GN/YL RD-3 BN-4 GN/BK GN/BK GN/BK BK-5 JUNCTION BOX WH-2 1000 BL-6 1000 R11A...

  • Page 126: Electrical Schematic - Ce Models (After Serial Number Gr04-4000)

    Section 6 • Schematics January 2007 Electrical Schematic CE Models (after serial number GR04-4000) REV B Part 1 of 2 LT BL-1 BK-2 GN/YL GN/YL-4 OR-7 OR-7 RD-3 RD-3 BN-4 BN-4 RD/BK RD/BK-5 BK-5 - NOTE - MACHINE SHOWN WH/BK-6 WH-2 IN THE STOWED BL-8...
  • Page 127 January 2007 Section 6 • Schematics Electrical Schematic CE Models (after serial number GR04-4000) REV B Part 2 of 2 PLATFORM CONTROLLER TS16 OR-7 0-2000 RD-3 BN-4 BK-5 WH-2 BL-6 1000 1000 R11A CR57 RELAY BOARD 1800 CR54 CR51 CR52 CR53 CR55 CR56...
  • Page 128 Section 6 • Schematics August 2005 Hydraulic Symbols Legend REV B Double acting cylinder Solenoid operated Brake 3 position 4 way Filter directional valve Variable speed Solenoid operated Bi-directional motor Relief Valve motor 3 position 4 way directional valve Flow regulator Fixed displacement Orifice Solenoid operated...

  • Page 129: Hydraulic Schematic (Before Serial Number Gr01-249)

    August 2005 Section 6 • Schematics Hydraulic Schematic REV B (before serial number GR01-249) STEER CYLINDER BRAKES DRIVE MOTORS LIFT CYLINDER LEFT RIGHT 1 gpm 3.78 L/min 1000 psi 69 bar 0.6 gpm 1.9 L/min 2200 psi 151.6 bar 2700 psi 186 bar FUNCTION MANIFOLD ABBREVIATION LEGEND...

  • Page 130: Hydraulic Schematic (After Serial Number Gr01-248)

    Section 6 • Schematics August 2005 Hydraulic Schematic (after serial number GR01-248) REV B STEER CYLINDER BRAKES DRIVE MOTORS LIFT CYLINDER LEFT RIGHT 200 psi 13.7 bar 1 gpm 3.78 L/min 1000 psi 69 bar 0.6 gpm 1.9 L/min 2200 psi 151.6 bar 2700 psi 186 bar...
  • Page 131 Part No. 72965 Rev B2...
  • Page 132 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie Scandinavia Genie China Phone +46 31 575100 Fax + 46 31 579020...

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