July 2012

Introduction
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. 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.

Compliance
Machine Classification Group B/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance.

Technical Publications
Genie 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.

Contact Us:
www.genielift.com e-mail: [email protected]

Copyright 2011 by Terex Corporation 227656 Rev C July 2012 First Edition, Third Printing "Genie" is a registered trademark of Terex South Dakota in the U.S.A. and many other countries. "GS" is a trademark of Terex South Dakota, Inc. Printed on recycled paper Printed in U.S.A.

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Revision History
Revision
A B B1 C

Date
4/2011 6/2011 9/2011 7/2012

Section

Procedure / Schematic Page / Description

New release

4 - Repair 3 - Maint. 2 - Spec. 3 - Maint. 6 - Schem.

4-8 3-22 2-1, 2-2, 2-4, 2-5, 2-6 3-8, 3-24 6-2, 6-3, 6-4, 6-5, 6-6, 6-8

REFERENCE EXAMPLES: Section 3_Maintenance, B-3. Section 4_Repair Procedure, 4-2. Section 5_Diagnostic Codes, All charts. Section 6_Schematics, Legends diagrams and schematics. Electronic Version Click on any procedure or page number highlighted in blue to view the update.

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REVISION HISTORY, CONTINUED

Revision

Date

Section

Procedure / Schematic Page / Description

REFERENCE EXAMPLES: Section 3_Maintenance, B-3. Section 4_Repair Procedure, 4-2. Section 5_Diagnostic Codes, All charts. Section 6_Schematics, Legends diagrams and schematics. Electronic Version Click on any procedure or page number highlighted in blue to view the update.

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INTRODUCTION

Serial Number Legend

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Section 1 Safety Rules

July 2012

Safety Rules

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 operators 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: - manufacturers instructions and safety rules - employers safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop.

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Section 1 Safety Rules

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 symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. 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 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 . Be sure that your workshop or work area is properly ventilated and well lit.

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Table of Contents
Introduction Important Information ......................................................................................... ii Revision History ................................................................................................ iii Serial Number Legend ...................................................................................... v Section 1 Safety Rules General Safety Rules ........................................................................................ vi Section 2 Specifications Machine Specifications ................................................................................ 2 - 1 Performance Specifications ......................................................................... 2 - 2 Hydraulic Specifications ............................................................................... 2 - 2 Manifold Component Specifications ............................................................. 2 - 3 Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 4 SAE and Metric Fasteners Torque Charts ................................................... 2 - 6 Section 3 Scheduled Maintenance Procedures Introduction .................................................................................................. 3 - 1 Pre-delivery Preparation Report .................................................................. 3 - 3 Maintenance Inspection Report ................................................................... 3 - 5 Checklist A Procedures A-1 A-2 A-3 A-4 A-5 Inspect the Manuals and Decals ......................................................... 3 - 7 Perform Pre-operation Inspection ....................................................... 3 - 8 Perform Function Tests ...................................................................... 3 - 8 Perform 30 Day Service ..................................................................... 3 - 8 Hydraulic Suction Strainer .................................................................. 3 - 9

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TABLE OF CONTENTS

Section 3

Scheduled Maintenance Procedures, continued Checklist B Procedures B-1 B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9 Inspect the Batteries ......................................................................... 3 - 10 Inspect the Electrical Wiring ............................................................. 3 - 11 Inspect the Tires, Wheels ................................................................. 3 - 12 Test the Emergency Stop ................................................................. 3 - 13 Test the Horn .................................................................................... 3 - 13 Test the Key Switch .......................................................................... 3 - 14 Test the Drive Brakes ....................................................................... 3 - 15 Test the Drive Speed - Stowed Position ........................................... 3 - 16 Test the Drive Speed - Raised Position ............................................ 3 - 17

B-10 Inspect the Flashing Beacons (if equipped) ...................................... 3 - 18 B-11 Test the Motion Alarm ...................................................................... 3 - 19 B-12 Perform Hydraulic Oil Analysis ......................................................... 3 - 20 B-13 Inspect the Breather Cap .................................................................. 3 - 20 B-14 Inspect the Rear Axle Free-wheeling ................................................ 3 - 21 B-15 Inspect the Lateral Offset of the Mast ............................................... 3 - 22 B-16 Inspect the Mast Wear Pads ............................................................ 3 - 23 Checklist C Procedures C-1 Calibrate the Platform Overload System (if equipped) ...................... 3 - 24 C-2 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil ................................................... 3 - 25 Checklist D Procedures D-1 Replace the Hydraulic Tank Return Filter Element ........................... 3 - 26 Checklist E Procedure E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 27

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TABLE OF CONTENTS

Section 4

Repair Procedures Introduction .................................................................................................. 4 - 1 Platform Controls 1-1 1-2 Circuit Boards .................................................................................... 4 - 2 Controller Adjustments ....................................................................... 4 - 3

Platform Components 2-1 2-2 Platform ............................................................................................. 4 - 7 Platform Overload System ................................................................. 4 - 8

Jib Components 3-1 Jib Cylinder ...................................................................................... 4 - 10

Mast Components 4-1 4-2 Mast Assembly ................................................................................. 4 - 11 Lift Cylinder ...................................................................................... 4 - 24

Ground Controls 5-1 Level Sensor .................................................................................... 4 - 26

Hydraulic Pump 6-1 Function Pump ................................................................................. 4 - 27

Function Manifold 7-1 7-2 Function Manifold Components ........................................................ 4 - 30 Valve Adjustments - Function Manifold ............................................ 4 - 32

Steer Axle Components 8-1 Hydraulic Tank ................................................................................. 4 - 35

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Section 4

Repair Procedures, continued Turntable Components 9-1 9-2 9-3 Turntable Rotation Motor .................................................................. 4 - 36 Battery ............................................................................................. 4 - 38 Battery Charger ................................................................................ 4 - 39

Steer Axle Components 10-1 Yoke ................................................................................................. 4 - 40 10-2 Steer Cylinder .................................................................................. 4 - 41 10-3 Steering Rod .................................................................................... 4 - 42 10-4 Steer Angle Sensor .......................................................................... 4 - 42 Non-steer Axle Components 11-1 Drive Motors ..................................................................................... 4 - 44 11-2 Drive Brake ...................................................................................... 4 - 46 Section 5 Fault Codes Introduction .................................................................................................. 5 - 1 Fault Code Chart ......................................................................................... 5 - 3 Section 6 Schematics Introduction .................................................................................................. 6 - 1 Electrical Component and Wire Color Legend ............................................. 6 - 2 ECM Pin-out legend ..................................................................................... 6 - 3 Limit Switch and Sensor Legend .................................................................. 6 - 4 Electrical Symbols Legend ........................................................................... 6 - 5 Electrical Schematics - ANSI Models GR-26J ........................................................................................................ 6 - 6 Electrical Schematics - CE Models GR-20J and GR-26J .................................................................................... 6 - 8 Hydraulic Schematic Component Reference and Hydraulic Symbols Legend ............................. 6 - 10 GR-20J and GR-26J .................................................................................. 6 - 11

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Section 2 Specifications

Specifications
Machine Specifications
Battery, Standard Voltage Group Quantity Battery capacity, maximum Fluid capacities Hydraulic tank Height, stowed maximum GR-20J (CE only) & GR-26J 78 in 1.99 m 5.8 gallons 22 liters 2V DC C5 Castle nut torque, lubricated (non-steer end) 12 ANSI - 280 AH CE - 250 AH Lug bolt torque, dry (steer end) Lug bolt torque, lubricated (steer end) Tires and wheels Tire size (solid rubber) Castle nut torque, dry (non-steer end) 16 x 5 x 11 in 40.6 x 12.7 x 28 cm 89 ft-lbs 120 Nm 66 ft-lbs 90 Nm 132 ft-lbs 180 Nm 96 ft-lbs 130 Nm

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

For operational specifications, refer to the Operator's Manual.

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SPECIFICATIONS

Performance Specifications
Drive speed, maximum Platform stowed 2.8 mph 40 ft / 9.8 sec 4.5 km/h 12.2 m / 9.8 sec 0.4 mph 40 ft / 54.8 sec 0.65 km/h 12.2 m / 54.8 sec

Hydraulic Specifications
Hydraulic Oil Specifications Hydraulic oil type Viscosity grade Viscosity index Cleanliness level, minimum Water content, maximum Shell PW 46 Multi-viscosity 152 15/13 200 ppm

Platform raised

Braking distance, maximum High range on paved surface Gradeability Airborne noise emissions Sound pressure level at ground workstation Sound pressure level at platform workstation Function speed, maximum GR-20J Platform up Platform down GR-26J 24 to 26 seconds 19 to 21 seconds <70 dBA <70 dBA 60 in 152 cm 25%

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 the viscosity index should exceed 140. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties. Optional fluids Biodegradable Texaco Hydra 46 Shell Naturelle HF-E 46

Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult the Genie Industries Service Department before use.
Function pump Type Gear 0.256 cu in 4.2 cc

Platform up Platform down

54 to 56 seconds 40 to 42 seconds

Displacement per revolution Function manifold

Rated work load at full height, maximum Platform, ANSI (GR-20J) Platform, CE (GR-20J & GR-26J) 500 lbs 227 kg 440 lbs 200 kg System relief valve pressure, maximum Lift relief valve pressure Filter cap torque 2030 psi 140 bar 930 psi 64 bar 37 ft-lbs 50 Nm

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

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SPECIFICATIONS

Torque specifications Brake mounting fasteners, dry Brake mounting fasteners, lubricated Grease Specification RETINAX HDX2 grease, NLGI (lithium based) or equivalent 75 ft-lbs 102 Nm 56 ft-lbs 76 Nm

Manifold Component Specifications

Plug torque SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 SAE No. 12 50 in-lbs / 6 Nm 13 ft-lbs / 18 Nm 18 ft-lbs / 24 Nm 50 ft-lbs / 68 Nm 55 ft-lbs / 75 Nm 75 ft-lbs / 102 Nm

Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice.

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SPECIFICATIONS

Hydraulic Hose and Fitting Torque Specifications

Your machine is equipped with Parker Seal-Lok ORFS or 37 JIC 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. Seal-Lok Fittings
(hose end - ORFS) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Torque 10 ft-lbs / 13.6 Nm 30 ft-lbs / 40.7 Nm 40 ft-lbs / 54.2 Nm 60 ft-lbs / 81.3 Nm 85 ft-lbs / 115 Nm 110 ft-lbs / 150 Nm 140 ft-lbs / 190 Nm 180 ft-lbs / 245 Nm

SAE O-ring Boss Port

(tube fitting - installed into Aluminum) (all types) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Torque 14 ft-lbs / 19 Nm 23 ft-lbs / 31.2 Nm 36 ft-lbs / 54.2 Nm 62 ft-lbs / 84 Nm 84 ft-lbs / 114 Nm 125 ft-lbs / 169.5 Nm 151 ft-lbs / 204.7 Nm 184 ft-lbs / 249.5 Nm

Jamb nut Adjustable fitting (Adj)

Non-adjustable fitting (Nonadj)

SAE O-ring Boss Port

(tube fitting - installed into Steel) SAE Dash size Torque 15 ft-lbs / 20.3 Nm 26 ft-lbs / 35.3 Nm 22 ft-lbs / 30 Nm 35 ft-lbs / 47.5 Nm 29 ft-lbs / 39.3 Nm 60 ft-lbs / 81.3 Nm 52 ft-lbs / 70.5 Nm 100 ft-lbs / 135.6 Nm 85 ft-lbs / 115.3 Nm 135 ft-lbs / 183 Nm 200 ft-lbs / 271.2 Nm 250 ft-lbs / 339 Nm 305 ft-lbs / 413.5 Nm

JIC 37 Fittings
(swivel nut or hose connection) SAE Dash size -4 -6 -8 -10 -12 -16 -20 -24 Thread Size
7/16-20 9/16-18 3/4-16 7/8-14

-4

ORFS / 37 (Adj) ORFS (Non-adj) 37 (Non-adj) ORFS (Adj / Non-adj) 37 (Adj / Non-adj) ORFS (Adj / Non-adj) 37 (Adj / Non-adj)

Flats
-6

2 1 1 /4 1 1 1 1 1 1
-8

-10 ORFS (Adj / Non-adj) 37 (Adj / Non-adj) -12 (All types) -16 (All types) -20 (All types) -24 (All types)

1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12

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Section 2 Specifications

Torque Procedure
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. Note: 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 confirm that there are no leaks. 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 handtight, 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.
b a c b a c b

Figure 1 a b c hex nut reference mark body hex fitting

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. Note: Use the JIC 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position. Note: 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 2 a b c body hex fitting reference mark 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.

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SPECIFICATIONS

SAE FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual

SIZE THREAD
LUBED
in-lbs

Grade 5
DRY
in-lbs Nm

Grade 8
LUBED
in-lbs Nm in-lbs

DRY
Nm

A574 High Strength Black Oxide Bolts LUBED

in-lbs Nm

Nm

1/4

20 28

80 90
ft-lbs

9 10.1
Nm

100 120 DRY

ft-lbs

11.3 13.5
Nm

110 120
ft-lbs

12.4 13.5
Nm

140 160 DRY

ft-lbs

15.8 18
Nm

130 140 LUBED

ft-lbs

14.7 15.8
Nm

LUBED 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 13 14 23 26 37 41 57 64 80 90 110 130 200 220 320 350 480 530 590 670 840 930 1460 1640 17.6 19 31.2 35.2 50.1 55.5 77.3 86.7 108.4 122 149 176 271 298 433 474 650 718 800 908 1138 1260 1979 2223 17 19 31 35 49 55 75 85 110 120 150 170 270 300 430 470 640 710 790 890 1120 1240 1950 2190

LUBED 18 20 33 37 50 60 80 90 120 130 160 180 280 310 450 500 680 750 970 1080 1360 1510 2370 2670 24 27.1 44.7 50.1 67.8 81.3 108.4 122 162 176 217 244 379 420 610 678 922 1016 1315 1464 1844 2047 3213 3620 25 27 44 49 70 80 110 120 150 170 210 240 380 420 610 670 910 990 1290 1440 1820 2010 3160 3560

1 1 /8 1 /4 1 1/2
1 1

23 25.7 42 47.4 66.4 74.5 101.6 115 149 162 203 230 366 406 583 637 867 962 1071 1206 1518 1681 2643 2969

33.9 36.6 59.6 66.4 94.7 108.4 149 162 203 230 284 325 515 569 827 908 1233 1342 1749 1952 2467 2725 4284 4826

21 24 38 43 61 68 93 105 130 140 180 200 320 350 510 560 770 840 1090 1220 1530 1700 2670 3000

28.4 32.5 51.5 58.3 82.7 92.1 126 142 176 189 244 271 433 474 691 759 1044 1139 1477 1654 2074 2304 3620 4067

METRIC FASTENER TORQUE CHART

This chart is to be used as a guide only unless noted elsewhere in this manual

Size
(mm) 5 6 7
in-lbs

Class 4.6
LUBED
Nm

Class 8.8
LUBED
Nm in-lbs Nm

Class 10.9
LUBED
Nm in-lbs Nm

Class 12.9
LUBED
Nm in-lbs Nm

DRY
in-lbs

DRY
in-lbs

DRY
in-lbs

DRY
in-lbs Nm

16 19 45
ft-lbs

1.8 3.05 5.12

Nm

21 36 60
ft-lbs

2.4 4.07 6.83 DRY

Nm

41 69 116
ft-lbs

4.63 7.87 13.2

Nm

54 93 155
ft-lbs

6.18 10.5 17.6

Nm

58 100 167
ft-lbs

6.63 11.3 18.9

Nm

78 132 223
ft-lbs

8.84 15 25.2
Nm

68 116 1.95
ft-lbs

7.75 13.2 22.1

Nm

91 155 260
ft-lbs

10.3 17.6 29.4

Nm

LUBED 8 10 12 14 16 18 20 22 24 5.4 10.8 18.9 30.1 46.9 64.5 91 124 157 7.41 14.7 25.6 40.8 63.6 87.5 124 169 214

LUBED 14 27.9 48.6 77.4 125 171 243 331 420 19.1 37.8 66 105 170 233 330 450 570

DRY 18.8 37.2 64.9 103 166 229 325 442 562 25.5 50.5 88 140 226 311 441 600 762

LUBED 20.1 39.9 69.7 110 173 238 337 458 583 27.3 54.1 94.5 150 235 323 458 622 791

DRY 26.9 53.2 92.2 147 230 317 450 612 778 36.5 72.2 125 200 313 430 610 830 1055

LUBED 23.6 46.7 81 129 202 278 394 536 682 32 63.3 110 175 274 377 535 727 925

DRY 31.4 62.3 108 172 269 371 525 715 909 42.6 84.4 147 234 365 503 713 970 1233

7.2 14.4 25.1 40 62.5 86.2 121 166 210

9.88 19.6 34.1 54.3 84.8 117 165 225 285

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Section 3 Scheduled Maintenance Procedures

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 symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. 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, semi-annually, annually and every 2 years as specified on the Maintenance Inspection Report. Failure to properly complete each inspection when required may cause death, serious injury or substantial machine damage. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Use only Genie approved replacement parts. Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection. Unless otherwise specified, perform each 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

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SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend Note: 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.

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

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.

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 subsectionsA, 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 A A+B A+B+C A+B+C+D A+B+C+D+E

Indicates that dealer service will be required to perform this procedure.

Daily or every 8 hours Quarterly or every 250 hours Semi-annually or every 500 hours Annually or every 1000 hours Two year or every 2000 hours

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. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements.

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Pre-Delivery Pre-Delivery Preparation

July 2012 Section 3 Scheduled Maintenance Procedures

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.

Instructions
Use the operators 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 operators manual. If any inspection receives an N, remove the machine from service, repair and reinspect it. After repair, place a check in the R box. Legend Y = yes, completed N = no, unable to complete R = repaired Comments

Pre-Delivery Preparation 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
Terex South Dakota, Inc USA 500 Oak Wood Road PO Box 1150 Watertown, SD 57201-6150 (605) 882-4000 Genie UK The Maltings, Wharf Road Grantham, Lincolnshire NG31- 6BH England (44) 1476-584333

Copyright 2011 Terex Corporation. Genie is a registered trademark of Terex South Dakota, Inc. 133192 Rev D

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Maintenance Inspection Report

Model Serial number Date Hour meter Machine owner Inspected by (print) Inspector signature Inspector title Inspector company 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: Quarterly or 250 hours Inspection: Semi-annually or 500 hours Inspection: Annually or 1000 hours Inspection: Two year or 2000 hours Inspection: Checklist A A-1 Inspect the manuals and decals A-2 Pre-operation inspection A-3 Function tests Perform after 40 hours: A-4 30 day service Perform every 100 hours: A-5 Hydraulic suction strainer Y N R Checklist B B-1 Inspect the battery B-2 Electrical wiring B-3 Tires and wheels B-4 Emergency stop B-5 Horn B-6 Key switch B-7 Drive brakes B-8 Drive speed - stowed B-9 Drive speed - raised B-10 Flashing beacon (if equipped) B-11 Motion alarm B-12 Hydraulic oil analysis B-13 Breather cap B-14 Rear axle free-wheeling B-15 Lateral offset of the mast B-16 Mast wear pads Checklist C A A+B C-1 Calibrate platform overload (if equipped) C-2 Breather cap - models with optional oil Checklist D D-1 Tank return filter A+B+C+D Checklist E E-1 Hydraulic oil A+B+C+D+E Comments Y N R Y N R Y N R Y N R

A+B+C

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

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Checklist A Procedures
A-1 Inspect the Manuals and Decals
Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Maintaining the operators and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition. In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions. 1 Check to make sure that the operator's and safety manuals are present and complete in the storage container on the platform. 2 Examine the pages of each manual to be sure that they are legible and in good condition. Result: The operator's manual is appropriate for the machine and all manuals are legible and in good condition. Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or is illegible. Remove the machine from service until the manual is replaced. 3 Open the operator's manual to the decals inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage. Result: The machine is equipped with all required decals, and all decals are legible and in good condition. Result: The machine is not equipped with all required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced. 4 Always return the manuals to the storage container after use. Note: Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed.

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CHECKLIST A

PROCEDURES

A-2 Perform Pre-operation Inspection

Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. 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.

A-3 Perform Function Tests

Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. 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.

A-4 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 D-1 Inspect the Tires and Wheels (including castle nut torque) Replace the Hydraulic Tank Return Filter

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CHECKLIST A

PROCEDURES

A-5 Replace the Hydraulic Suction Strainer

5 Tag and disconnect the cables from the motor. 6 Tag, disconnect and plug the hydraulic hoses at the function manifold. Cap the fittings on the manifold. 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. 7 Place a suitable container under the hydraulic tank. Refer to Section 2, Specifications. 8 Locate and remove the hydraulic tank filler cap. Set the filler cap to the side. 9 Remove the drain plug and drain all of the oil into a suitable container. 10 Clean up any oil that may have spilled. Properly discard the used oil. 11 Remove the fasteners securing the function manifold to the hydraulic tank. Set the fasteners to the side. 12 Loosen the clamp securing the hydraulic power unit to the hydraulic tank. Do not remove the clamp. 13 Remove the clamp securing the hydraulic power unit to the chassis. Set the clamp to the side. 14 Carefully remove the hydraulic power unit from the tank and place it on a clean work bench. Note: If necessary, loosen the bottom connector of auxiliary pump to more easily remove the hydraulic power unit. 15 Remove the suction strainer from the end of the plastic tube. 16 Install the new suction strainer at the end of the plastic tube.

Genie specifications require that this procedure be performed every 100 hours or monthly, whichever comes first. Replacement of the hydraulic suction strainer is essential for good machine performance and service life. A dirty or clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the suction strainer be replaced more often. Beware of hot oil. Contact with hot oil may cause severe burns. Note: 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. Note: Perform this procedure with the machine in stowed position. 1 Disconnect the battery pack from the machine. 2 Open and remove the turntable cover at the hydraulic power unit side of the machine. 3 Working next to the hydraulic tank, remove the fasteners securing the chassis side cover to the chassis. Remove the side cover. Lay the side cover and fasteners to the side. 4 Tag and disconnect the wire harness connectors from the function manifold.

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Checklist B Procedures
B-1 Inspect the Battery
F9
250A Fuse

a b

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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/burn 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. 1 Open the turntable covers of the machine. 2 Confirm that the battery cable connections are tight and free of corrosion. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. 3 Locate the bolts between the battery pack and the counterweight. Confirm that the head of each bolt is firmly in contact with the battery pack so that the battery pack does not move.

e f

G7

U9
Battery Charger

P1

B9
12-2V

U6
Motor Controller

a b c d e f

battery B9 fuse 250A F9 emergency stop button P1 motor controller U6 battery charger indicator G7 battery charger U9

4 Put on protective clothing and eye wear. 5 Remove the battery vent caps and check the battery acid level. If needed, replenish with distilled water to 1/8 inch / 3 mm below the bottom of the battery fill tube. Do not overfill. 6 Install the vent caps and neutralize any electrolyte that may have spilled.

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CHECKLIST B

PROCEDURES

B-2 Inspect the Electrical Wiring

4 Turn the key switch to off position and push in the red Emergency Stop button to the off position at the ground control. 5 Tag and disconnect the cables from the ground terminal of the battery.

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Open and remove the turntable covers from the machine. 2 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 3 Raise the jib boom until the platform is approximately 8 feet / 2.4 m from the ground.

6 Remove the fasteners securing the rear chassis cover to the chassis at the non-steer end of the machine. Remove the chassis cover. Lay the cover and fasteners to the side. 7 Inspect the drive motors connections for burnt, chafed, pinched cables and loose connections. 8 Install the rear chassis cover at the non-steer end of the machine and securely install the fasteners. 9 Install the cables onto the ground terminal of the battery, and securely tighten. 10 Inspect the battery pack for burnt, chafed and pinched cables. 11 Inspect the following areas for burnt, chafed, corroded and loose wires: Ground control panel Battery charger Hydraulic power unit 12 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at the ground control. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position.

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CHECKLIST B

PROCEDURES

13 Lower the jib boom until the platform is approximately 2 feet / 0.5 m from the ground. 14 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 15 Inspect the following areas for burnt, chafed, corroded and loose wires: Mast cable Platform controls Power to platform wiring 16 Inspect for a liberal coating of dielectric grease in all wiring connections between the ground control panel and the platform controls, and level sensor wiring. 17 Install both the turntable covers on the machine.

B-3 Inspect the Tires and Wheels

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Maintaining the tires and wheels in good condition, including proper castle nut torque, 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 and unusual wear. 2 Check each wheel for damage, bends and cracks. Non-steer end: 3 Remove the lock washer flange from the slot of the castle nut. Check the castle nut for proper torque. Refer to Section 2, Specifications. 4 Install the lock washer flange into a slot of the castle nut. Steer end: 5 Check each lug bolt for proper torque. Refer to Section 2, Specifications.

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CHECKLIST B

PROCEDURES

B-4 Test the Emergency Stop

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Push in the red Emergency Stop button at the ground controls to the off position. 3 Check the machine functions from the ground controls. Result: The machine functions should not operate. 4 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. 5 Push the red Emergency Stop button at the platform controls to the off position. 6 Check the machine functions from the platform controls. Result: The machine functions should not operate. Note: The red Emergency Stop button at the ground controls will stop all machine operations, even if the key switch is turned to the platform control.

B-5 Test the Horn

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Push down the horn button at the platform controls. Result: The horn should sound.

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CHECKLIST B

PROCEDURES

B-6 Test the Key Switch

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Check the machine functions from the ground controls. Result: The machine functions should not operate.

OFF
c

a b c

platform control machine switch off ground control

3 Turn the key switch to ground control. 4 Check the machine functions from the platform controls. Result: The machine functions should not operate. 5 Turn the key switch to the off position. 6 Test the machine functions from the ground and platform controls. Result: The machine functions should not operate.

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CHECKLIST B

PROCEDURES

B-7 Test the Drive Brakes

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 3 Lower the platform to the stowed position. 4 Press the drive function select button.

drive function select button BN130

5 Choose a point on the machine i.e. contact patch of a tire, as a visual reference for use when crossing the test line. 6 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. 7 Measure the distance between the test line and your machine reference point. Refer to Section 2, Specifications. Note: The brakes must be able to hold the machine on any slope it is able to climb.

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CHECKLIST B

PROCEDURES

B-8 Test the Drive Speed Stowed Position

a
Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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. Note: 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 3 Lower the platform to the stowed position. 4 Press the drive function select button.

drive function select button BN130

5 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. 6 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. 7 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.

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CHECKLIST B

PROCEDURES

B-9 Test the Drive Speed Raised Position

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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. Note: 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 3 Press the lift function select button. 4 Press and hold the function enable switch on the joystick.

a
a b lift function select button BN63 drive function select button BN130

5 Raise the platform approximately 2 feet / 70 cm from the ground. 6 Press the drive function select button. 7 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. 8 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. 9 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.

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CHECKLIST B

PROCEDURES

B-10 Test the Flashing Beacon (if equipped)

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Flashing beacon is used to alert operators and ground personnel of machine proximity and motion. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Activate any machine function from the ground control (as indicated on the ground control box). Result: The beacon should flash. 3 Turn the key switch to platform controls. 4 Activate any machine function from the platform control (as indicated on the platform control box). Result: The beacon should flash. Note: Beacon will flash only when you activate any machine function either from ground control or platform control.

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CHECKLIST B

PROCEDURES

B-11 Test the Motion Alarm

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Alarm is used to alert operators and ground personnel of machine proximity and motion. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Raise the platform approximately 1 ft / 30.5 cm. Result: When raising the platform, the motion alarm will sound. 3 Lower the platform to the stowed position. Result: When lowering the platform, the motion alarm will sound. 4 Turn the key switch to platform controls. 5 Press the lift function select button.

6 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 motion alarm will sound when the joystick is moved off center in either direction. 7 Press the drive function select button. 8 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 motion alarm will sound when the joystick is moved off center in either direction. 9 Press and hold the function enable switch on the joystick. Press and hold the thumb rocker switch for a moment to the left position and then release it. Press and hold the thumb rocker switch for a moment to the right position and then release it. Result: The motion alarm will sound when the rocker switch is moved off center in either direction.

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CHECKLIST B

PROCEDURES

B-12 Perform Hydraulic Oil Analysis

B-13 Inspect the Breather Cap

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist. A free-breathing hydraulic tank cap is essential for good machine performance and service life. A dirty or clogged cap may cause the machine to perform poorly. Extremely dirty conditions may require that the cap be inspected more often. 1 Open the turntable cover at the hydraulic power unit side of the machine. 2 Locate and remove the breather cap from the hydraulic tank. 3 Check the breather cap for proper venting. Result: Air passes through the breather cap. Proceed to step 5. Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 4. Note: When checking the hydraulic tank breather cap for venting, air should pass freely through the cap. 4 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 3. 5 Install the breather cap onto the hydraulic tank.

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. 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. Refer to Section 2, Specifications. 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.

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CHECKLIST B

PROCEDURES

B-14 Inspect the Rear Axle Free-wheeling

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions, with the wheels chocked. 1 Secure the steer end of the machine to a forklift or similar device using a connecting bar no greater than 3 ft / 1 m in length. Set the brakes on forklift. 2 Open the turntable cover at the ground control side of the machine. 3 Using the illustration as a guide, locate the free-wheel selector switch on the top of the ground control box. 4 Move the free-wheel selector switch to the right to set the machine to free-wheel condition. Result: The parking brakes will release and the horn will sound softly. 5 Remove the wheel chocks and, using a fork lift or similar device, apply force to the machine. Result: The machine will move freely. Component damage hazard. The machine can be damaged if it breaks free from the forklift. Do not attempt to test the free-wheeling function unless a connecting bar of adequate size and strength is used to secure the GR-J to the forklift or similar device.

a b

free-wheel selector switch ground control box

6 Move the free-wheel selector switch to the left. Result: The parking brakes will set and the horn will not sound. 7 Using a fork lift or similar device, apply force to the machine. Result: The machine will not move freely.

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CHECKLIST B

PROCEDURES

B-15 Inspect the Lateral Offset of the Mast

4 Using a suitable torque measuring device, apply a lateral force of 29.5 ft-lb / 40 Nm near the floor of the platform at location "F". Refer to the illustration. Result: Lateral offset of the mast i.e. distance L1 and L2 as shown in the illustration should not exceed 13.75 inches / 350 mm.

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions, with the wheels chocked. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Raise the jib boom to a horizontal position. 3 Raise the mast head approximately 8 inches / 20 cm.

L1

L2

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CHECKLIST B

PROCEDURES

B-16 Inspect the Mast Wear Pads

Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Mast wear pads should always be in good condition and greased for good machine performance and service life. A damaged wear pads may cause the unsafe machine operation. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions. Note: Perform this procedure in a location that is sheltered from the wind. 1 Using the illustration as a guide, install a plumb line of a suitable length onto the platform. 2 Using a suitable lifting device, place a 440 lbs / 200 Kg test weight in the center of the platform. Secure the weight to the platform. 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position.
a b number 1 mast plumb line

b a

4 Raise the jib boom to a horizontal position. 5 Activate the mast up function and fully raise the mast. 6 Using a suitable measuring device, measure the distance between plumb line and the face of the number 1 mast. Refer to illustration. Result: The distance between the plumb line and the face of the number 1 mast does not exceed 66.9 inches / 1700 mm. The wear pads are in good condition. Result: The distance between the plumb line and the face of the number 1 mast exceeds 66.9 inches / 1700 mm. The wear pads are not in good condition. Install new wear pads. Refer to Repair Procedure 4-1, How to Remove the Mast Assembly.

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Checklist C Procedure
C-1 Calibrate the Platform Overload System (if equipped)
Models equipped with the platform overload option are provided with additional machine components: an adjustable spring-loaded subassembly, a limit switch harness, an electronic module which receives the overload signal and interrupts power, and an audio/visual warning indication to alert the operator of the overload. Refer to Repair Procedure 2-2, How to Calibrate the Platform Overload System (if equipped).

Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load. Calibrating 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. The platform overload system is designed to prevent machine operation in the event the platform is overloaded. Models equipped with the platform overload option are provided with two overload pressure sensors.

adjustable spring-loaded subassembly and limit switch harness

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CHECKLIST

C PROCEDURES

C-2 Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil

Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load. 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 breather cap from the hydraulic tank. Discard the breather cap. Note: The tank filler cap and breather are one piece component. 2 Install a new breather cap onto the hydraulic tank.

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Checklist D Procedure
D-1 Replace the Hydraulic Tank Return Filter
a
Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. 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. Beware of hot oil. Contact with hot oil may cause severe burns. Note: Perform this procedure on a firm, level surface. 1 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Using the illustration as a guide, locate the filter cap of the function manifold. Clean the area around the filter cap. 3 Remove the filter cap from the function manifold. Set it to the side. 4 Remove the oil filter placed underneath the filter cap. 5 Apply a thin layer of oil to the new oil filter gasket.

filter cap

6 Install the new filter into the function manifold, and securely tighten. 7 Install the filter cap onto the function manifold and torque to specification. Refer to Section 2, Specifications. 8 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 9 Press and hold the function enable button. 10 Activate the mast up function and raise the mast slightly. 11 Inspect the filter and related components to be sure that there are no oil leaks. 12 Clean up any oil that may have spilled.

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Checklist E Procedure
E-1 Test or Replace the Hydraulic Oil
4 Place a suitable container under the hydraulic tank. Refer to Section 2, Specifications. 5 Locate and remove the hydraulic tank filler cap. Set the filler cap to the side. Genie specifications require that this procedure be performed every 2000 hours or every two years, whichever comes first. 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. Note: Perform this procedure with the machine in the stowed position. 1 Open the turntable covers of the machine. 2 Disconnect the battery pack from the machine. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Remove the fasteners securing the chassis side cover next to the tank to the chassis. Remove the side cover. Lay the side cover and fasteners to the side. 6 Remove the drain plug and drain all of the oil into a suitable container. 7 Clean up any oil that may have spilled. Properly discard the used oil. Note: To clean the inside of the hydraulic tank using a mild solvent, it may be helpful to remove the hydraulic power unit from the tank. Refer to Repair Procedure 6-1, How to Remove the Function Pump. 8 Install the drain plug onto the hydraulic tank and torque to specification.
Torque specification Hydraulic tank drain plug 44 in-lbs 5 Nm

9 Fill the tank with hydraulic oil until the fluid is at the full indicator on the hydraulic tank. Do not overfill. 10 Install the filler cap onto the hydraulic tank, and securely tighten. Do not over tighten. 11 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 activate.

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Repair Procedures
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. Then to reassemble, perform the disassembly steps in reverse order. Symbols Legend Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, may result in property damage. 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:

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. Use only Genie approved replacement parts. 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

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Platform Controls
The platform controls, used to operate the machine from the platform. The platform controls are used to operate the various machine functions. The platform controls consist of an electronic circuit board, joystick, alarm, buttons and LEDs. For further information or assistance, consult the Genie Industries Service Department.

1-1 Circuit Boards How to Remove the Platform Controls Circuit Board
1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Remove the fasteners securing the top plate assembly to the platform control box. Carefully remove the top plate assembly from the box to expose the circuit boards. 3 Tag and disconnect the wire harness connectors from the platform controls circuit board. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 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. 4 Remove the fasteners securing the platform controls circuit board to the top plate assembly. Set the fasteners to the side. 5 Remove the platform controls circuit boards from the top plate assembly.

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Section 4 Repair Procedures

PLATFORM CONTROLS

1-2 Controller Adjustments How to Activate or Deactivate the Motion Alarm

The alarm is activated at the platform controls and sounds at the ground as a warning to ground personnel. An improperly functioning alarm 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Simultaneously press and hold all three function buttons for 3 seconds. Result: A beep sounds and three function indicator lights will flash one after another. 3 Simultaneously press and hold the drive function and the lift function buttons for 3 seconds. Result: All three function indicator lights will stop flashing. 4 Briefly press and release the drive function button. Result: The drive function indicator light is on.

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joystick function enable switch thumb rocker switch joystick jib boom function button BN97 lift function and turntable rotate function button BN63 drive function button BN130 function indicator lights red Emergency Stop button P2

5 Press and hold the drive function button for 3 seconds. 6 Push in the red Emergency Stop button at platform controls to confirm the procedure. Result: The motion alarm will sound during all machine movements. Note: To deactivate the motion alarm, perform this procedure beginning with step 1.

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PLATFORM CONTROLS

How to Activate or Deactivate the Flashing Beacon (if equipped)

The Flashing Beacon is installed to alert operators and ground personnel of machine proximity and motion. The Flashing Beacon is installed on the ground control side of the mast. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Simultaneously press and hold all three function buttons for 3 seconds. Result: A beep sounds and three function indicator lights will flash one after another. 3 Simultaneously press and hold the drive function and lift function buttons for 3 seconds. Result: All three function indicator lights will stop flashing. 4 Briefly press and release the lift function button. Result: The drive function indicator light is on.

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joystick function enable switch thumb rocker switch joystick jib boom function button BN97 lift function and turntable rotate function button BN63 drive function button BN130 function indicator lights red Emergency Stop button P2

5 Press and hold the drive function button for 3 seconds. 6 Push in the red Emergency Stop button at platform controls to confirm the procedure. Result: The beacon will flash during all machine movements. Note: To deactivate the flashing beacon option, perform this procedure beginning with step 1.

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PLATFORM CONTROLS

How to Calibrate the Joystick

Calibration of the joystick is essential for safe machine operation. The joystick on this machine utilize Hall Effect technology for proportional control. If a joystick is disconnected or replaced, it must be calibrated before operating the machine. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Simultaneously press and hold all three function buttons for 3 seconds. Result: A beep sounds and three function indicator lights will flash one after another. 3 Simultaneously press and hold the drive function and jib boom function buttons for 3 seconds. Result: All three function indicator lights will stop flashing. 4 Using the illustration as a guide, move the joystick fully to the left, then return the joystick to the neutral position. Note: Do not squeeze or activate the joystick function enable switch. No machine function should operate while performing the joystick calibration procedure.
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a b c d e f g h

joystick function enable switch thumb rocker switch joystick jib boom function button BN97 lift function and turntable rotate function button BN63 drive function button BN130 function indicator lights red Emergency Stop button P2

5 Move the joystick fully to the right, then return the joystick to the neutral position. 6 Move the joystick fully to the rear, then return the joystick to the neutral position. 7 Move the joystick fully to the front, then return the joystick to the neutral position. 8 Press and hold the drive function button for 3 seconds. Result: All three function indicator lights will flash three times. Joystick calibration is complete.

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PLATFORM CONTROLS

How to Calibrate the Steer Angle Sensor

Calibration of the Steer Angle Sensor is essential for safe machine operation. The Steer Angle Sensor controls the maximum steering angle that can be attained. 1 Adjust the wheels at the steer end of the machine so they are in straight driving position. 2 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 3 Tag and disconnect the steer angle sensor wire harness from the machine wire harness. 4 With a multimeter set to read 4K0.2 ohms, connect the leads to the green and black wires of the potentiometer. Result: The reading is 4K0.2 ohms. Proceed to step 5. Result: The reading is not 4K0.2 ohms. See 10-4, How to Replace the Steer Angle Sensor. 5 Connect the steer angle sensor wire harness to the machine wire harness. 6 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 7 Simultaneously press and hold all three function select buttons for 3 seconds. Result: A beep sounds and three function indicator lights will flash one after another.

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joystick function enable switch thumb rocker switch joystick jib boom function button BN97 lift function and turntable rotate function button BN63 drive function button BN130 function indicator lights red Emergency Stop button P2

8 Simultaneously press and hold the lift function and jib boom function buttons for 3 seconds. Result: All three function indicator lights will stop flashing. 9 Press and hold the joystick function enable switch and activate the thumb rocker switch turning the wheels fully to the left. 10 Press the drive function button for 1 second to validate the left side steering limit. 11 Press and hold the joystick function enable switch and activate the thumb rocker switch turning the wheels fully to the right. 12 Press the jib boom function button for 1 second to validate the right side steering limit. 13 Press and hold the joystick function enable switch and activate the thumb rocker switch placing the wheels in line with the chassis. 14 Press the lift function button for 1 second. 15 Press the drive function button for 3 seconds. Steer Sensor calibration is complete.

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Platform Components
2-1 Platform How to Remove the Platform
1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Disconnect the battery pack from the machine. 3 Remove the fasteners securing the top plate assembly to the platform control box. 4 Tag and disconnect the wire harness connectors from the platform controls circuit boards. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 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 Tag and disconnect the wire harness connectors from the joystick. Set the top plate assembly to the side. 6 Remove the fasteners securing the bottom plate assembly to the platform control box. Lay the bottom plate assembly and fasteners to the side. 7 Remove the fasteners securing the outlet mounting plate to the platform. Set the mounting plate assembly and fasteners to the side. 8 Attach a lifting strap of suitable capacity from an overhead crane to the bottom of 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 or put pressure on the railings. 9 Remove the platform mounting pins retaining fasteners. Set the fasteners to the side. 10 Remove the pins securing the platform to the jib boom. 11 Remove the platform from the machine. Crushing hazard. The platform could become unbalanced and fall when removed from the machine. Use caution when removing the platform from the machine. Note: During platform removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

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PLATFORM COMPONENTS

2-2 Platform Overload System How to Calibrate the Platform Overload System (if equipped)
Calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions, and the machine in stowed position. 1 Block the wheels at the steer end of the machine. 2 Remove all weight, tools and accessories from the platform. Note: Failure to remove all weight, tools and accessories from the platform will result in an incorrect calibration. 3 Fully tighten the adjusting screws of both the overload sensors. Do not over tighten. 4 Using a suitable lifting device, place a 440 lbs / 200 Kg test weight in the center of the platform. Secure the weight to the platform. 5 Tighten the overload spring adjustment screw just until the screw and lock nut will rotate freely, and the clearance between the lock nut and sensor mounting bracket is minimal.
e
a b c d e f g

adjusting screw overload sensor number 1 overload spring adjustment screw overload sensor number 2 overload sensor mounting bracket overload spring spacer

6 Place an additional 44 lbs / 20 kg test weight in the center of the platform. Secure the weight to 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position.

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PLATFORM COMPONENTS

8 Turn the adjusting screw of the number 1 overload sensor 10 in a counterclockwise direction. Result: The overload indicator lights are flashing at the ground and platform controls, and the alarm is sounding intermittently. Proceed to step 9. Result: The overload indicator lights are off at the ground and platform controls and the alarm does not sound intermittently. Repeat the procedure beginning with step 8. 9 Turn the adjusting screw of the number 2 overload sensor 10 in a counterclockwise direction. Result: The overload indicator lights are flashing at the ground and platform controls, and the alarm is sounding continuously. Proceed to step 10. Result: The overload indicator lights are off at the ground and platform controls and the alarm does not sound continuously. Repeat the procedure beginning with step 9. 10 Test all machine functions from the platform controls. Result: All platform control functions should not operate.

11 Turn the key switch to the ground control. 12 Test all machine functions from the ground controls. Result: All ground control functions should not operate. 13 Using a suitable lifting device, remove the test weight from the platform. Result: The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound. 14 Test all machine functions from ground controls. Result: All ground control functions should operate normally. 15 Turn the key switch to the platform control. 16 Test all machine functions from the platform controls. Result: All platform control functions should operate normally.

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Jib Components
3-1 Jib Cylinder How to Remove the Jib 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. Note: 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 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Raise the jib boom to a comfortable working height and place blocks under the platform for support. Lower the jib boom until the platform is resting on the blocks. 3 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls.

c
a b c

b
jib boom jib cylinder platform

4 Tag, disconnect and plug the jib 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. 5 Remove the pin retaining fasteners from the jib cylinder rod-end pivot pin. Do not remove the pin. 6 Remove the pin retaining fasteners from the jib cylinder barrel-end pivot pin. Do not remove the pin. 7 Attach a lifting strap from an overhead crane to the lug on the rod-end of the jib cylinder. 8 Place a block across both sides of the jib boom under the jib cylinder. 9 Use a soft metal drift to remove the barrel-end pivot pin and rod-end pivot pin. 10 Carefully remove the jib cylinder from the machine. Crushing hazard. The jib cylinder could become unbalanced and fall if not properly supported when removed from the machine.

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Mast Components
4-1 Mast Assembly How to Remove the Mast Assembly
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. Note: 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. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions, and the machine in stowed position. 1 Check the condition of the wear pads. Refer to Maintenance Procedure B-16, Inspect the Mast Wear Pads. 2 Using Illustration 1 as a guide, create a safety steel plate using the dimensions specified.
25 mm 50 mm

3 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 4 Open and remove the turntable covers. 5 Remove the fasteners securing the mast head cover to the mast. Set the fasteners to the side. 6 Remove the mast head cover from the mast head. 7 Tag and disconnect the proximity sensor. Lay the proximity sensor to the side. 8 Tag, disconnect and plug the hydraulic hose at the top of the lift cylinder. Remove the hose connector from the lift cylinder. Plug the lift 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.
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2 x 18 mm

30

0m

d
a

10 mm

13 85 mm

0m

Illustration 2 a b c d e f g h mast head cover mast head cover fasteners mast head jib boom proximity sensor lift cylinder mast head fasteners lift cylinder fasteners

Illustration 1 a safety steel plate

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MAST COMPONENTS

9 Attach a lifting strap of suitable capacity from an overhead crane to the mast head, jib boom and platform assembly. Support the assembly. Do not apply any lifting pressure. Component damage hazard. The platform railings can be damaged if they are used to lift the assembly. Do not attach the lifting strap to the platform railings or put pressure on the railings. 10 Remove the fasteners securing the mast head to the mast assembly. Set the fasteners to the side. 11 Raise the mast head, jib boom and platform assembly and move the assembly approximately 20 inches / 50 cm towards the non-steer end of the machine. Crushing hazard. The mast head, jib boom and platform assembly could become unbalanced and fall when removed from the machine. Component damage hazard. Cables and hose can be damaged if they are kinked or pinched. Note: During removal the mast head, jib boom and platform assembly, the overhead crane strap will need to be carefully adjusted for proper balancing. A properly balanced lifting strap is essential when removing the assembly from the machine. 12 Remove the fasteners securing the lift cylinder to the mast head. Set the fasteners to the side. 13 Using Illustration 3 as a guide, remove the fasteners securing the stops to the mast assembly and remove the stops. Set the fasteners and stops to the side.
Illustration 4 a b c M16 shackles mast assembly safety steel plate

a b

P
Illustration 3 a b stops mast assembly

14 Using the mast head fasteners, install the safety steel plate onto the top of the mast assembly. Securely tighten the fasteners. Do not over tighten.
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MAST COMPONENTS

15 Using an overhead crane, attach a lifting strap of suitable capacity equipped with the M16 shackles to the threaded rings at the top of the outer mast. 16 Lift the mast assembly approximately 12 inches / 30 cm. Use a permanent marker to indicate the face closest to the platform with the mark 'P' on the number 1 mast. Refer to Illustration 3. 17 Remove the mast assembly from the machine, while carefully pulling the cables and hydraulic hose from the mast. With the 'P' mark facing upwards, place the mast assembly on a level workbench capable of supporting it. Crushing hazard. The mast assembly could become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

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MAST COMPONENTS

TOP P
1

P
8

2 3

BOTTOM
4 5 6 7

Illustration 1 1 2 3 4 5 6 7 8 9 number 1 mast shims wear pads fasteners stops number 2 mast number 3 mast number 4 mast cover plate

Ground Controls Side

Steer End

Platform (Non-Steer End)

Power Unit Side

Illustration 2

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MAST COMPONENTS

How to Disassemble the Mast, GR-26J

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 assembly. See 4-1, How to Remove the Mast Assembly. 2 With the 'P' mark facing upwards, use a clamp to secure the mast assembly to the workbench. Securely tighten the clamp. Do not over tighten. 3 Working from the top of the mast assembly, pull the number 2, 3 and 4 mast sections approximately 12 inches / 30 cm. Out of mast 1, use a permanent marker to indicate the face closest to the platform with the 'P' mark on the number 2, 3 and 4 mast sections corresponding to the 'P' mark on mast 1. Refer to Illustration 3. 4 Working from the top of the mast assembly, push the number 2, 3 and 4 mast sections fully into the number 1 mast. 5 Remove the fasteners securing the safety steel plate to the mast assembly. Remove the safety steel plate. Set the fasteners and safety steel plate to the side.

BOTTOM

TOP
P P P P
c a
Illustration 3 a b c d number 1 mast number 2 mast number 3 mast number 4 mast

6 Working from the bottom of the mast assembly, pull the number 4 mast half way out. 7 Attach a lifting strap from an overhead crane to the number 4 mast section. Remove the number 4 mast while carefully pulling it out from the bottom of the number 3 mast. With the 'P' mark facing upwards, place the number 4 mast on a level workbench capable of supporting it. Crushing hazard. The mast section could become unbalanced and fall if not properly supported when removed from the mast assembly. Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

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MAST COMPONENTS

8 Slide the number 2 mast and the number 3 mast towards the top of the number 1 mast to gain the access to the stops at the bottom of the number 1 mast. 9 Remove the fasteners securing stops to the inside of the number 1 mast. Remove the stops. Set the fasteners and stops to the side. 10 Push the number 3 mast fully into the number 2 mast. Working from the bottom of the number 1 mast, pull the number 2 mast and the number 3 mast half way out. 11 Attach a lifting strap from an overhead crane to the number 2 mast section. Remove both the number 2 mast and the number 3 mast while carefully pulling the assembly out from the bottom of the number 1 mast. With the 'P' mark facing upwards, place the number 2 mast and the number 3 mast assembly on a level workbench capable of supporting it. Crushing hazard. The mast sections could become unbalanced and fall if not properly supported when removed from the mast assembly. Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. 12 Slide the number 3 mast towards the top of the number 2 mast to gain the access to the stops at the bottom of the number 2 mast. 13 Remove the fasteners securing stops to the inside of the number 2 mast. Remove the stops. Set the fasteners and stops to the side.

14 Working from the bottom of the number 2 mast, pull the number 3 mast half way out. 15 Attach a lifting strap from an overhead crane to the number 3 mast section. Remove the number 3 mast while carefully pulling the it out from the bottom of the number 2 mast. With the 'P' mark facing upwards, place the number 3 mast on a level workbench capable of supporting it. Crushing hazard. The mast section could become unbalanced and fall if not properly supported when removed from the mast assembly. Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. 16 Using Illustration 1 as a guide, tag and remove the outer wear pads and shims from the bottom of the number 4 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. 17 Using Illustration 1 as a guide, carefully tag and remove the outer wear pads and shims from the bottom of the number 3 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of reassembly of the mast, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast.

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MAST COMPONENTS

18 Using Illustration 1 as a guide, tag and remove the inner wear pads from the top of the number 3 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. 19 Using Illustration 1 as a guide, tag and remove the outer wear pads and shims from the bottom of the number 2 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. 20 Using Illustration 1 as a guide, tag and remove the inner wear pads from the top of the number 2 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast.

21 Using Illustration 1 as a guide, tag and remove the outer wear pads and shims from the bottom of the number 1 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. 22 Using Illustration 1 as a guide, tag and remove the inner wear pads and shims from the top of the number 1 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast.

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MAST COMPONENTS

How to Assemble the Mast, GR-26J

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 Using Illustration 1 as a guide, install two 10 mm wear pads, and the corresponding shims removed in the mast disassembly process, onto the bottom of mast sections 1, 2, 3 and 4.
a b a

2 Install six 12 mm wear pads, and the corresponding shims removed in the mast disassembly process, onto the bottom of mast sections 1, 2, 3 and 4. 3 Using Illustration 1 as a guide, install two 10 mm wear pads, and the corresponding shims removed in the mast disassembly process, onto the top of mast sections 1, 2 and 3. 4 Install six 12 mm wear pads, and the corresponding shims removed in the mast disassembly process, onto the top of mast sections 1, 2 and 3. 5 Using Illustration 2 as a guide, apply grease onto the inner faces of the mast sections 1, 2 and 3.
Grease Specification RETINAX HDX2 grease, NLGI (lithium based) or equivalent

BOTTOM

TOP
P
Illustration 1 a b wear pad 10 mm mast section (mast 1 shown)

b
Illustration 2 a b

grease mast section (mast 1 shown)

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MAST COMPONENTS

6 Using Illustration 3 as a guide, apply grease onto the outer faces of the mast sections 1, 2, 3 and 4. 7 Carefully assemble the mast sections using the mast disassembly procedure in reverse order. See 4-1, How to Disassemble the Mast, GR-26J.

Illustration 3 a b grease mast section (mast 4 shown)

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MAST COMPONENTS

TOP

BOTTOM
2

3
Illustration 1 1 2 3 4 5 6 number 1 mast stops shims wear pads number 2 mast cover plate

Ground Controls Side

Steer End

Platform (Non-Steer End)

Power Unit Side

Illustration 2

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Section 4 Repair Procedures

MAST COMPONENTS

How to Disassemble the Mast, GR-20J

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 assembly. See 4-1, How to Remove the Mast Assembly. 2 With the 'P' mark facing upwards, use a clamp to secure the mast assembly to the workbench. Securely tighten the clamp. Do not over tighten. 3 Working from the top of the mast assembly, pull the number 2 mast section approximately 12 inches / 30 cm. Out of mast 1, use a permanent marker to indicate the face closest to the platform with the 'P' mark on the number 2 mast section corresponding to the 'P' mark on mast 1. Refer to Illustration 3. 4 Remove the fasteners securing the safety steel plate to the mast assembly. Remove the safety steel plate. Set the fasteners and safety steel plate to the side. 5 Remove the fasteners securing stops to the inside of the number 1 mast. Remove the stops. Set the fasteners and stops to the side. 6 Working from the bottom of the number 1 mast, pull the number 2 mast half way out.

BOTTOM

TOP

P P
a
Illustration 3 a b number 1 mast number 2 mast

7 Attach a lifting strap from an overhead crane to the number 2 mast section. Remove the number 2 mast while carefully pulling the it out from the bottom of the number 1 mast. With the 'P' mark facing upwards, place the number 2 mast on a level workbench capable of supporting it. Crushing hazard. The mast section could become unbalanced and fall if not properly supported when removed from the mast assembly. Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing.

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MAST COMPONENTS

8 Using Illustration 1 as a guide, tag and remove the outer wear pads and shims from the bottom of the number 2 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. 9 Using Illustration 1 as a guide, tag and remove the outer wear pads and shims from the bottom of the number 1 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast. 10 Using Illustration 1 as a guide, tag and remove the inner wear pads and shims from the top of the number 1 mast section. Set the shims to the side. Discard the wear pads. Note: For ease of mast reassembly, make careful note of the location, order and orientation of the shims. Note: Use a hammer and chisel if necessary to gently loosen the wear pads from the mast.

How to Assemble the Mast, GR-20J

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 Using Illustration 1 as a guide, install two 10 mm wear pads, and the corresponding shims removed in the mast disassembly process, onto the bottom of mast sections 1 and 2.

BOTTOM

TOP
P

Illustration 1 a b wear pad 10 mm mast section (mast 1 shown)

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MAST COMPONENTS

2 Install six 12 mm wear pads, and the corresponding shims removed in the mast disassembly process, onto the bottom mast sections 1 and 2. 3 Using Illustration 1 as a guide, install two 10 mm wear pads, and the corresponding shims removed in the mast disassembly process, onto the top of mast section 1. 4 Install six 12 mm wear pads, and the corresponding shims removed in the mast disassembly process, onto the top mast section 1. 5 Using Illustration 2 as a guide, apply the grease onto the inner faces of the mast section 1.
Grease Specification RETINAX HDX2 grease, NLGI (lithium based) or equivalent

6 Using Illustration 3 as a guide, apply grease onto the outer faces of the mast sections 1 and 2. 7 Carefully assemble the mast sections using the mast disassembly procedure in reverse order. See 4-1, How to Disassemble the Mast, GR-20J.

Illustration 3 a b grease mast section (mast 2 shown)

b
Illustration 2 a b

grease mast section (mast 1 shown)

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MAST COMPONENTS

4-2 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. Note: 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. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions, and the machine in stowed position. 1 Block the wheels at the non-steer end of the machine. 2 Open and remove the turntable covers of the machine. 3 Center a lifting jack under the drive chassis at the steer end of the machine. 4 Raise the steer end of the machine approximately 10 inches / 25 cm to access the nut at the bottom of the lift cylinder. 5 Place blocks under the chassis for support. Lower the machine onto the blocks. Crushing hazard. The chassis could fall if not properly supported.

a h g f e c b

a b c d e f g h

mast head cover mast head cover fasteners mast head jib boom proximity sensor lift cylinder mast head fasteners lift cylinder fasteners

6 Remove the nut securing the bottom of the lift cylinder to the chassis. Set it to the side. 7 Raise the machine slightly. Remove the blocks from under the chassis and lower the machine onto the ground. Remove the jack. 8 Remove the fasteners securing the mast head cover to the mast. Remove the mast head cover. Set the mast head cover and fasteners to the side. 9 Tag and disconnect the proximity sensor. Lay the proximity sensor to the side.

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MAST COMPONENTS

10 Tag, disconnect and plug the hydraulic hose at the top of the lift cylinder. Remove the hose connector from the lift cylinder. Plug the lift 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. 11 Attach a lifting strap of suitable capacity from an overhead crane to the mast head, jib boom and platform assembly. Support the assembly. Do not apply any lifting pressure. Component damage hazard. The platform railings can be damaged if they are used to lift the assembly. Do not attach the lifting strap to the platform railings or put pressure on the railings. 12 Remove the fasteners securing the mast head to the mast assembly. Set the fasteners to the side.

13 Raise the mast head, jib boom and platform assembly and move the assembly approximately 20 inches / 50 cm towards the non-steer end of the machine. Crushing hazard. The mast head, jib boom and platform assembly could become unbalanced and fall when removed from the machine. Component damage hazard. Cables and hose can be damaged if they are kinked or pinched. Note: During removal the mast head, jib boom and platform assembly, the overhead crane strap will need to be carefully adjusted for proper balancing. 14 Remove the fasteners securing the lift cylinder to the mast head. Set the fasteners to the side. 15 Attach a lifting strap from an overhead crane to the lift cylinder. 16 Carefully remove the lift cylinder from the machine. Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported when removed from the machine. Component damage hazard. The lift cylinder can be damaged if it falls.

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Ground Controls
5-1 Level Sensor
The tilt alarm sounds when the incline of the chassis exceeds 2 to the side, front or rear. 6 Securely install the level sensor pigtail into the machine wire harness, disconnected in step 3. 7 Remove the plastic cap from the end of the level sensor calibration wire. 8 Using a length of wire approximately 40 inches / 1 m long, connect the level sensor calibration wire to the negative post of the battery. Result: The green LED underneath the level sensor flashes several times and stops. The level sensor calibration is complete. Result: The green LED underneath the level sensor does not flash. Check the calibration wire connection. Contact Genie Industries Service Department. Note: The green LED is on during normal machine operation and it only goes out when the tilt angle of the machine exceeds 2. 9 After the green LED stops flashing, disconnect the calibration wire from the battery, and securely install the plastic cap removed in step 7.

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. Note: Perform this procedure with the machine on a firm, level surface that is free of obstructions, and the machine in stowed position. 1 Open the turntable cover at the ground control side of the machine. 2 Locate the level sensor which is mounted on the turntable base below the battery charger. 3 Tag and disconnect the level sensor pigtail from the machine wire harness. 4 After noting the orientation of level sensor assembly, remove the fasteners securing the base of level sensor assembly to the chassis. 5 Install the new level sensor onto the machine. Install and securely tighten the fasteners. Do not over tighten.

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Hydraulic Pump
6-1 Function Pump
The hydraulic pump is attached to the motor which makes up the hydraulic power unit.

How to Remove the Function Pump

Note: 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. Note: Perform this procedure with the machine in stowed position. 1 Disconnect the battery pack from the machine. 2 Open and remove the turntable cover at the hydraulic power unit side of the machine. 3 Tag and disconnect the wire harness connectors from the function manifold. 4 Tag and disconnect the cables from the motor.

How to Test the Function Pump

See 7-2, How to Adjust the System Relief Valve.

a e b d c

Illustration 1 a b c d e motor function manifold hydraulic tank connector fittings hydraulic hoses

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HYDRAULIC PUMP

5 Tag, disconnect and plug the hydraulic hoses at the function manifold. Cap the fittings on the manifold. 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 fasteners securing the function manifold to the hydraulic tank. Set the fasteners to the side. 7 Loosen the clamp securing the hydraulic power unit to the hydraulic tank. Do not remove the clamp. 8 Remove the clamp securing the hydraulic power unit to the chassis. Set the clamp to the side. 9 Carefully remove the hydraulic power unit from the tank and place it on a clean work bench. Note: If necessary, loosen the bottom connector of auxiliary pump to more easily remove the hydraulic

power unit.
Illustration 2 a b function pump hydraulic tank

10 Remove the fasteners securing the function pump to the function manifold. Set the fasteners to the side. 11 Carefully remove the function pump from the hydraulic power unit. Tip-over hazard. After replacing the hydraulic pump, it is critical to return the relief valve settings to original factory specifications. Failure to restore the machine to original factory specifications could cause the machine to tip over, resulting in death or serious injury.

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Function Manifold
7-1 Function Manifold Components
The function manifold is mounted underneath the hydraulic power unit.
Index No. 1 2 3 4 5 6 7 8 9 Description Schematic Item Function Torque

Filter, Filter cap .................................................... H ......................... Suction filter ............................ 37 ft-lbs / 50 Nm Solenoid valve, 2 position 4 way ............... B ......................... Steer/Turntable directional ..... 18 ft-lbs / 25 Nm Check valve ............................................... I .......................... Blocks flow from auxiliary pump to function pump . 29 ft-lbs / 40 Nm Solenoid valve, 2 position 2 way ............... D ......................... Platform up ............................. 18 ft-lbs / 25 Nm Solenoid valve, 2 position 4 way ............... C ......................... Turntable rotate left/right ........ 18 ft-lbs / 25 Nm Solenoid valve, 2 position 2 way ............... E ......................... Platform down and jib down ... 18 ft-lbs / 25 Nm Relief valve, 930 psi / 64 bar .......................................... G ......................... Platform up ............................. 18 ft-lbs / 25 Nm Solenoid valve, 2 position 4 way ............... A ......................... Steer left/right ......................... 18 ft-lbs / 25 Nm Relief valve, 2030 psi / 140 bar ...................................... F ......................... System relief ........................... 18 ft-lbs / 25 Nm

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FUNCTION MANIFOLD

Y117
8 A

Y116

D 6 E

Y21

Y118

Y22

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic

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FUNCTION MANIFOLD

7-2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve
Note: Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank. 1 Block the wheels at the steer end of the machine. 2 Open the turntable cover at the hydraulic power unit side of the machine. 3 Remove the fasteners securing the function manifold to the hydraulic tank. Set the fasteners to the side. 4 Loosen the clamp securing the hydraulic power unit to the hydraulic tank. Do not remove the clamp. 5 Remove the clamp securing the hydraulic power unit to the chassis. Set the clamp to the side. 6 Rotate the function manifold and locate the system relief valve on the function manifold (schematic item F). 7 Connect a 0 to 2500 psi / 0 to 175 bar pressure gauge to the test port on the hydraulic hose reel.
a

system relief valve

8 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 9 At the ground controls, press and hold the function enable button.

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FUNCTION MANIFOLD

10 Press and hold the jib function button to fully raise the jib boom, then continue to activate the jib lift function while observing the pressure reading on the pressure gauge. Note the pressure. Refer to Section 2, Specifications. 11 Turn the key switch to the off position. 12 Hold the system relief valve with a wrench and remove the cap. 13 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. 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. 14 Turn the key switch to the ground controls. 15 Repeat this procedure, beginning with step 8, to confirm the system relief valve pressure. 16 Turn the key switch to the off position. 17 Install and tighten the fasteners securing the function manifold to the hydraulic tank. 18 Install and securely tighten the hydraulic power unit clamps. Do not over tighten.

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FUNCTION MANIFOLD

How to Adjust the Platform Lift Relief Valve

Note: Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank. 1 Block the wheels at the steer end of the machine. 2 Using a suitable lifting device, place a 660 lbs / 300 Kg test weight in the center of the platform. Secure the weight to the platform. 3 Locate the lift relief valve on the function manifold (schematic item G). 4 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 5 Press and hold the function enable button. 6 Press and hold the lift function button and raise the platform approximately 12 inches / 30 cm. Result: The platform should lift the weight. Proceed to step 12. Result: The platform does not lift the weight. Proceed to step 7. Component damage hazard. Do not continue to operate the machine if the hydraulic pump is cavitating. 7 Turn the key switch to the off position. 8 Hold the lift relief valve with a wrench and remove the cap (schematic item G).

b a

a b

lift relief valve system relief valve

9 Adjust the internal hex socket. Turn it clockwise to increase the pressure. Install the relief valve cap. 10 Turn the key switch to ground control. 11 Repeat the procedure beginning with step 5. 12 Lower the platform to the stowed position. 13 Turn the key switch to the off position. 14 Adjust the internal hex socket. Turn it counterclockwise to decrease the pressure just until the platform will not lift the weight. Install the relief valve cap. 15 Turn the key switch to the ground control. 16 Activate the platform up function and attempt to raise the platform. Result: The platform does not lift the weight. Proceed to step 18. Result: The platform lifts the weight. Proceed to step 12. 17 Turn the key switch to the off position and remove the weight from the platform.

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Hydraulic Tank
8-1 Hydraulic Tank
The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during operation. 7 Place a suitable container under the hydraulic tank. Refer to Section 2, Specifications. 8 Locate and remove the hydraulic tank filler cap. Set the filler cap to the side. 9 Remove the drain plug and drain all of the oil into a suitable container. 10 Clean up any oil that may have spilled. Properly discard the used oil. 11 Install the drain plug onto the hydraulic tank and tighten to finger tight. 12 Install the filler cap onto the hydraulic tank and tighten to finger tight. 13 Remove the clamp securing the hydraulic power unit to the chassis. Set the clamp to the side. 14 Carefully remove the hydraulic tank along with hydraulic power unit from the machine and place it on a clean work bench. 15 Remove the fasteners securing the function manifold to the hydraulic tank. Set the fasteners to the side. 16 Remove the clamp securing the hydraulic power unit to the hydraulic tank. Set the clamp to the side. 17 Remove the hydraulic power unit from the hydraulic tank.
Torque specifications Hydraulic oil reservoir drain plug Manifold to tank fasteners 44 in-lbs 5 Nm 40 in-lbs 4.5 Nm

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. Note: Perform this procedure with the machine in stowed position. 1 Disconnect the battery pack from the machine. 2 Open and remove the turntable cover at the hydraulic power unit side of the machine. 3 Working next to the hydraulic tank, remove the fasteners securing the chassis side cover to the chassis. Remove the side cover. Lay the side cover and fasteners to the side. 4 Tag and disconnect the wire harness connectors from the function manifold. 5 Tag and disconnect the cables from the motor. 6 Tag, disconnect and plug the hydraulic hoses at the function manifold. Cap the fittings on the manifold. 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.

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Turntable Components
9-1 Turntable Rotation Motor How to Remove the Turntable Rotation Motor
Note: 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. 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 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Raise the jib boom to the maximum height. 3 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls.
a b c turntable rotation motor fasteners hydraulic hoses

a b c

4 Remove the fasteners securing the rear chassis cover to the chassis at the non-steer end of the machine. Remove the chassis cover. Lay the cover and fasteners to the side. 5 Remove the fasteners securing the side covers to the chassis. Remove the side covers from the machine. Lay the side covers and fasteners to the side. 6 Remove the fasteners securing the turntable motor protection plate to the chassis. Remove the protection plate from the machine. Lay the protection plate and fasteners to the side. Note: The turntable motor protection plate is located above the turntable rotation motor.

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TURNTABLE COMPONENTS

7 Tag, disconnect and plug the hydraulic hoses at the turntable rotation motor. Cap the fittings. 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. 8 Remove fasteners securing the turntable rotation motor to the chassis. Set the fasteners to the side. 9 Carefully remove the turntable rotation motor from the machine. Bodily injury hazard. The turntable rotation motor may fall if not properly supported when removed from the machine.

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TURNTABLE COMPONENTS

9-2 Battery How to Remove the Battery

Electrocution/burn 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. Note: Perform this procedure with the machine in stowed position. 1 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Open and remove the turntable covers. 3 Tag and disconnect the cables connected to the ground terminal of the battery. 4 Tag and disconnect the cables connected to the positive terminal of the battery. 5 Locate the bolts between the battery pack and the counterweight. Loosen the bolts holding the battery pack in position.

battery

6 Attach a lifting strap from an overhead 1100 lbs / 500 Kg crane to the battery pack. 7 Carefully remove the battery pack from the machine. Crushing hazard. The battery pack could become unbalanced and fall if not properly supported. Component damage hazard. The battery pack can be damaged if it falls.

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TURNTABLE COMPONENTS

9-3 Battery Charger How to Remove the Battery Charger

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Open and remove the turntable cover at the ground control side of the machine. 3 Tag and disconnect the cables connected to the ground terminal of the battery. 4 Tag and disconnect the black and red battery charger wires from the battery. 5 Tag and disconnect the power cable from the battery charger. 6 Locate the LED at the bottom of the bulkhead. Tag and disconnect the LED wire harness connector. 7 Tag and disconnect the charger cutout harness connector.

a b c d

power cable charger cutout harness connector LED charger-to-battery wires

8 Locate and remove the nut holding the ground control box closed, and open the ground control box. 9 Remove the fasteners securing the top of the battery charger to the machine. Set the fasteners to the side. 10 Close the ground control box and install the nut. 11 Remove the fasteners securing the bottom of the battery charger to the machine. Set the fasteners to the side. 12 Lower the battery charger towards the tilt sensor, and remove the battery charger from the machine.

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Steer Axle Components

10-1 Yoke How to Remove the Yoke
Note: 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 Block the wheels at the non-steer end of the machine. 2 Loosen the bolts of the wheel at the steer end of the machine. Do not remove the bolts. 3 Center a lifting jack under the drive chassis at the steer end of the machine. 4 Raise the machine approximately 6 inches / 15 cm. Place blocks under the chassis for support. Lower the chassis onto blocks. Crushing hazard. The chassis could fall if not properly supported. 5 Remove the bolts from the wheel at the steer end of the machine. Remove the wheel from the machine. 6 Support and secure the yoke assembly to an appropriate lifting device. 7 Remove the top cir-clip from the pin at the steering rod. 8 Remove the plastic cap above the yoke pivot shaft. Set the cap to the side. 9 Ground control side: Remove the steer sensor from the yoke pivot. 10 Remove the retaining fasteners from the yoke pivot shaft. Set the fasteners to the side. 11 Remove the yoke assembly from the machine. Bodily injury hazard. The yoke assembly may fall if not properly supported when removed from the machine.

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STEER AXLE COMPONENTS

10-2 Steer Cylinder How to Remove the Steer Cylinder

Note: 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 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 2 Turn the wheels at the steer end of the machine, 20 to 25 to the right. 3 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 4 Block the wheels at the non-steer end of the machine. 5 Remove the pin retaining fasteners from the top of the steer cylinder barrel-end pivot pin.

6 Center a lifting jack under the drive chassis at the steer end of the machine. 7 Raise the machine approximately 6 inches / 15 cm. Place blocks under the chassis for support. Crushing hazard. The chassis could fall if not properly supported. 8 Turn the wheels at the steer end of the machine fully to the left. 9 Tag, disconnect and plug the steer 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. 10 Remove the pin retaining fasteners from the steer cylinder rod-end pivot pin. Set the washers to the side. Discard the cotter pin. Note: Always replace the cotter pin with a new one when removing the fasteners. 11 Carefully remove the steer cylinder from the machine.

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STEER AXLE COMPONENTS

10-3 Steering Rod How to Remove the Steering Rod

1 Remove the steer cylinder. See 10-2, How to Remove the Steer Cylinder. 2 Remove the top cir-clips securing the steering rod to the steer yoke at both the ends of the steering rod. 3 Lift the steering rod up and off of the yoke, and remove the steering rod from the machine.

10-4 Steer Angle Sensor How to Replace the Steer Angle Sensor
1 Adjust the wheels at the steer end of the machine so they are in straight driving position. 2 Turn the key switch to off position and push in the red Emergency Stop button to the off position at both the ground and platform controls. 3 Tag and disconnect the steer angle sensor wire harness from the machine wire harness. 4 Remove the plastic cap above the steer yoke pivot. Set the cap to the side. 5 Carefully remove the sensor activator pin from the steer yoke pivot. Set the pin to the side. Note: Inspect the sensor activator pin to confirm it is not broken or twisted. If the sensor activator pin is broken or twisted, it must be replaced. Note the installation and orientation of the old sensor to be sure the new one is installed correctly. 6 Remove the steer angle sensor retaining fasteners. Remove the steer angle sensor assembly. 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position.

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STEER AXLE COMPONENTS

8 Using the illustration as a guide, mount the potentiometer on to the plate and securely tighten with the nut.
a b c d h g f e

11 Install the bottom plate and it's fasteners on the steer yoke pivot. 12 Install the sensor activator pin on to the steer yoke pivot. Note: Be sure the sensor activator pin is engaged into the sensor. 13 Install the plate along with potentiometer on the steer yoke pivot and securely tighten the potentiometer stem with the screw. Do not over tighten. 14 Install the plastic cap on to the steer yoke pivot. 15 Connect the steer angle sensor wire harness to the machine wire harness. 16 Calibrate the steer sensor. See 1-2, Controller Adjustments for How to Calibrate the Steer Sensor.

a b c d e f g h

steer yoke pivot cap potentiometer potentiometer mounting plate fasteners bottom plate sensor activator pin chassis screw

9 With a multimeter set to read 4K0.2 ohms, connect the leads to the green and black wires of the potentiometer. 10 Adjust the potentiometer until a reading of 4K0.2 ohms is obtained.

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Non-steer Axle Components

11-1 Drive Motors
e

How to Remove the Drive Motors

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 Block the wheels at the steer end of the machine. 2 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 3 Raise the jib boom to the maximum height. 4 Turn the key switch to off position and push in the red Emergency Stop button to the off position at the ground control. 5 Open the turntable cover at the ground control side of the machine.

a c b
a b c d e cable guard right drive motor assembly left drive motor assembly fasteners chassis

6 Tag and disconnect the cables from the ground terminal of the battery. 7 Remove the fasteners securing the rear chassis cover to the chassis at the non-steer end of the machine. Remove the chassis cover. Lay the cover and fasteners to the side. 8 Tag and disconnect the two wire harness connectors at the steel bar above the drive motors. 9 Remove the fasteners securing the steel bar to the chassis. Set the fasteners to the side. 10 Turn over the steel bar and cut the zip ties attaching the two wire harness connectors to the steel bar. Lay the steel bar to the side.

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Section 4 Repair Procedures

NON-STEER AXLE COMPONENTS

11 Tag and disconnect the cables from the drive motor assembly. 12 Loosen the castle nut of the wheel at the non-steer end of the machine. Do not remove the castle nut. Note: To remove the right drive motor assembly, first it is necessary to remove the left drive motor assembly. 13 Center a lifting jack under the drive chassis at the non-steer end of the machine. 14 Raise the machine approximately 6 inches / 15 cm. Place blocks under the chassis for support. Lower the chassis onto the blocks. Crushing hazard. The chassis could fall if not properly supported. 15 Remove the castle nut from the wheel at the non-steer end of the machine. Remove the wheel from the machine. Note: A properly sized puller may be needed to remove the wheel from the tapered shaft.

16 Place a 2 x 4 x 6 inch / 5 x 10 x 15 cm long wood block under the left drive motor. Note: The wood block will support to the drive motor assembly when the fasteners are removed. 17 Remove the fasteners securing the left drive motor assembly to the chassis. Set the fasteners to the side. 18 Carefully remove the left drive motor assembly from the machine. Place it onto a suitable workbench capable of supporting it. Bodily injury hazard. The drive motor assembly may fall if not properly supported when removed from the machine.

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NON-STEER AXLE COMPONENTS

11-2 Drive Brake How to Remove the Drive Brake

1 Block the wheels at the steer end of the machine. 2 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. Note: Rotate the red Emergency Stop button at platform control one quarter turn in a clockwise direction to restore the power supply. The red Emergency Stop button returns automatically to the out, or on position. 3 Raise the jib boom to the maximum height. 4 Turn the key switch to off position and push in the red Emergency Stop button to the off position at the ground control. 5 Open the turntable cover at the ground control side of the machine. 6 Tag and disconnect the cables from the ground terminal of the battery. 7 Remove the fasteners securing the rear chassis cover to the chassis at the non-steer end of the machine. Remove the chassis cover. Lay the cover and fasteners to the side. 8 Tag and disconnect the two wire harness connectors at the steel bar.

a b c d e

drive brake drive motor assembly speed reducer assembly mounting plate fasteners

9 Remove the fasteners securing the steel bar to the chassis. Set the fasteners to the side. 10 Turn over the steel bar and cut the zip ties attaching the two wire harness connectors to the steel bar. Lay the steel bar to the side. 11 Remove the fasteners securing the drive brake to the drive motor assembly. Set the fasteners to the side. 12 Carefully remove the drive brake from the drive motor assembly.
Torque specifications Brake mounting fasteners, dry 75 ft-lbs 102 Nm 56 ft-lbs 76 Nm

Brake mounting fasteners, lubricated

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Section 5 Fault Codes

Fault Codes
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. 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/burn 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.

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

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FAULT CODES

About This Section

When a malfunction is discovered, the fault code chart 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 requiredvoltmeter, ohmmeter, pressure gauges. General Repair Process

LED Diagnostic Readout

The diagnostic readout displays numerical codes that provide the information about the machine operating status and malfunctions.

Malfunction discovered

Identify symptoms

Troubleshoot
b

problem still exists

Return to service

problem solved

Inspect and test

Perform repair

a Error Source: First two digits indicates the affected machine area or component. '01' '02' '08' '16' Controller interface board Controller logic board Platform controls circuit board Diagnostic display

b Third digit always an alphabet "A" when fault code is displayed. c Error Type: Last two digits indicates the fault number. The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected.

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Section 5 Fault Codes

Fault Code Chart

Error Source ID Name Controller 01 interface board Error Type ID Name Condition Solution
This alarm may appear from time to time upon starting. Any initialization delay can cause this alarm to appear. If the alarm appears too often or if it is permanent, there is an internal error. Check the current software version or replace the controller.

02

Logic fault #1

The base board is waiting for the controller to complete its internal test.

03

Valv. Drv. off line

04

Output mismatch overcharge

The internal device which controls all the auxiliary outputs has a problem and is not communicating correctly with the microcontroller. This alarm is due to a disparity between the operating states detected by the two computers. The controller has asked the base board to activate the output for the drive or the pump but the interface does not identify a command or an operating state where the drive or pump must be allowed. There is a fault in the management/verification of the internal EEPROM. The algorithm used to verify the main memory is working with erroneous data. Incorrect software downloaded or the Flash memory is corrupted. There is a fault in the A/D converter of the microcontroller.

Replace the controller.

Check whether the software versions installed on the two consoles are correct. If so, there must be an internal fault.

05

EEPROM

It is an internal fault. Replace the controller. The platform can still function but the controller will use default values for the internal parameters. Try to break the contact. If the alarm is still present, replace the controller. Check the installed software version or replace the controller. Replace the controller.

06

Wrong RAM memory

10 15

Flash check

Analog input

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FAULT CODE CHART

Error Source ID Name 01 Controller interface board

Error Type ID Name 19

Serial error #1

Condition
The controller has not responded to the request from the base board as expected.

Solution
Replace the controller. If the fault occurs on starting or during an alarm, the fault is most likely to be linked to an under-voltage. Check whether the main voltage SI is stable. If the fault occurs on acceleration of the motor or activation of the pump, the fault may be due to under-voltage. Check the charge and the battery connections. If the fault is detected during braking, the fault may be due to overvoltage: Check the battery voltage during braking. In any other case, the fault may be due to an internal fault of the controller then replace it. Check whether there is contact or low impedance between pin A12 and the battery. Otherwise the circuit is damaged. Check whether there is a short circuit or low impedance between pin A10 and the battery. Check whether there is a short circuit in parallel with the brake solenoid valve coil. Otherwise the conductor circuit is damaged and the controller must be replaced. Repair wire on the emergency button. Replace the controller. Replace the controller. Check the wiring or change the controller.

32

Logic failure #1

Under-voltage or overvoltage has been detected.

33

Eb. Drv. Shorted

The electric cable of the brake is in short-circuit.

34

Driver shorted

The main conductor of the driver is short-circuited.

36 37 40 41

Emergency button wire Eb. Drv. / coil fail Mc enable short. Eb. enable short

Excitation wire on emergency button is disconnected. The electric circuit of the break is open. The EB coil can not activate. The power contactor is short-circuited.

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Section 5 Fault Codes

FAULT CODE CHART

Error Source ID Name Controller 01 interface board

Error Type ID Name 50

Multi selection

Condition
The electric brake is shortcircuited. Several movements activated simultaneously. The controller receives several commands simultaneously from the platform controls circuit board. The controller receives several commands simultaneously from the platform controls circuit board. Tilt triggers audible warning beep. Overload of HBT2 and HBT1 signals Overload incoherence. Overload fault. Low battery voltage. The interface board has not received the CAN signal. There is a large disparity between the hour counter stored in the diagnostic display and the hour counter stored in the controller. The maximum acceptable difference is 10 hours. If it is greater, this alarm will appear. The temperature sensor of the pump has detected a high temperature.

Solution
Check the conformity of the control selectors.

51

Plat. double required

Check the wiring or change the controller.

52

GND double required

Check the wiring or change the controller. Check the conformity of the tilt sensor and its connection or change the controller. Check the condition of the overload sensors or change the controller. The battery must be recharged to avoid damaging it. If the alarm is triggered when the battery is fully charged, change the controller. Check the BUSCAN connection between the modules or change the controller.

53 54 55 56 57

Tilted Overload HBT Overcharge Battery low No CAN signal

58

No alarm on the console

After two minutes, the hour counter of the controller will automatically find the diagnostic display.

59

Temperature of pump high

The alarm should disappear as soon as the pump motor cools down. If this does not happen, there is a problem with the connection of terminal A16 or the temperature sensor.

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FAULT CODE CHART

Error Source ID Name 01 Controller interface board

Error Type ID Name 61

Joystick

Condition
Joystick is pushed when machine is switching on. The function switch has been closed for more than 2.5 seconds.

Solution
Repair or replace the joystick. It should be possible to stop the alarm by stopping the main contactor or via the emergency stop. If the problem persists, check the wiring connection. If there is no problem, the alarm is due to an internal fault. Check the battery type parameter. If the alarm appears with the charger disconnected from the mains, there may be a problem with the connection of terminal A17. Otherwise, it is an internal fault of the controller. Check that the angle sensor potentiometer is functioning correctly. Otherwise, check the wiring. Check the condition of the valves and their connections. Otherwise, it is an internal fault of the controller.

62

Short-circuit on function switches

63

Battery out of adjustment

The battery parameter differs by more than 20% from the nominal battery voltage. The platform has been started up with the battery charger in operation. The value read by the potentiometer is different from the programmed value. There is a problem on one of the following outputs: terminal A32, terminal A26.

64

Charge in progress

65

Value of angle sensor incorrect

80

Lifting valve

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Section 5 Fault Codes

FAULT CODE CHART

Error Source Name 01 Controller interface board ID

ID 81

Error Type Name

Descent valve

Condition
There is a problem on one or other of the following outputs: terminal A30, terminal A26. There is a problem on one or other of the following outputs: terminal A34, terminal A25. There is a problem on one or other of the following outputs: terminal A34, terminal A26. There is a problem on one or other of the following outputs: "FLASHING LIGHT" and "TILT LAMP" The main driver coil is not connected to pin A12 of NEB. There is a problem (short-circuit to negative or positive, to absent horn) on the "WARNING" product.

Solution
Check the condition of the valves and their connections. Otherwise, it is an internal fault of the controller. Check the condition of the valves and their connections. Otherwise, it is an internal fault of the controller. Check the condition of the valves and their connections. Otherwise, it is an internal fault of the controller. Repair or replace the option. Check the connections of the BRAKE coil. Otherwise the conductor circuit is damaged and the controller must be replaced. Check the horn and its wiring. If the wiring is correct and the alarm persists, there is an internal fault.

82

Rotation valve

83

Steering valve

84

Aux. Valve

86

Brake coil open

89

Horn conductor

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FAULT CODE CHART

Error Source Name 02 Controller logic board ID

ID 7

Error Type Name

Type disparity

Condition
The controller and the base board are not suitable for the type of operation chosen by the operator. The HBT status is verified by the controller and the base board. If a difference is found between the two, this alarm appears. The algorithm used to verify the main memory detects an error. The file is corrupt. The instantaneous sum is different from that expected. Incorrect software has been downloaded or the flash memory is corrupted. The thermal sensor is not functioning correctly: its output voltage is outside the acceptable range. The right armature current sensor detects a current other than zero when the right motor is not running. The left armature current sensor detects a current other than zero when the left motor is not running. A current other than zero passes through the field circuit even if the field conductor is not active. There is a fault in the A/D converter of the microcontroller. The current sensor for the armature of motor 1 and/or motor 2 is not functioning correctly: its output voltage is outside the acceptable range.

Solution
It is an internal fault. Replace the controller.

HBT disparity

It is an internal fault. Replace the controller.

Faulty RAM

Disconnect the key and then, if the alarm is still present, replace the controller.

10

Instantaneous sum

It is an internal fault. Replace the controller.

11

Thermal sensor faulty Stand by motor right

It is an internal fault. Replace the controller.

12

It is an internal fault. Replace the controller.

13

Stand by motor left

It is an internal fault. Replace the controller.

14

High field current

It is an internal fault. Replace the controller. It is an internal fault. Replace the controller.

15

Analog input

16

Trac. I sensor

It is an internal fault. Replace the controller.

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Section 5 Fault Codes

FAULT CODE CHART

Error Source Name 02 Controller logic board ID

ID 17

Error Type Name

Stand by pump

Condition
The current sensor of the pump detects a current other than zero when the pump is not working. The current sensor of the pump detects a current of zero even though the pump is working. The base board has not responded to the request as expected. Th e controller board has asked the base board to leave its drive input inactive but it is active. 1) An external charge is in parallel with the capacitor and reduces the current of the recharge circuit, thereby preventing the capacitors from charging. 2) There is a problem with the charging circuit and the controller must be replaced. During stand-by the field voltage should be approx. V. This alarm is generated if the field voltage differs from this value.

Solution
It is an internal fault. Replace the controller. Check the connection of the pump: if the pump is not connected, current cannot flow and the diagnostic fails. Otherwise, it is an internal problem.

18

Pump I=0

19

Periodic error #1

It is an internal fault. Replace the controller.

20

Capacitor charge

When the key is connected, the controller tries to charge the power capacitors via a resistor and checks whether the capacitors are charged. If they do not charge, an alarm is generated. The main driver is not closed. The possible external causes are: incorrect connection of the excitation wires, leakage to the framework of the platform. Otherwise, it is an internal fault. This alarm appears during stand-by. Check : internal motor connections; electric cable connections; leakage from the motor to the framework of the platform. If everything is OK, the controller has an internal fault

21

Charge control lamp incorrect

22

VMN low

The VMN voltage of one of the drive motors is low.

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FAULT CODE CHART

Error Source ID Name 02 Controller logic board

Error Type ID Name

Condition
The VMN voltage of one of the motors is high when it should be low.

Solution
This alarm appears only on start-up. Check: internal motor connections. Electric cable connections, leakage from the motor to the framework of the lorry. If everything is OK, the controller has an internal fault. This alarm may appear during stand-by or during pump operation. Check: internal pum p connections. Electric cable connections, leakage from the pump to the framework of the platform. If everything is OK, the controller has an internal fault. This alarm appears while the pump is working. Check: internal pump connections. Electric cable connections, leakage from the pump to the framework of the platform. If everything is OK, the controller has an internal fault. This alarm only appears when the drive motors are activated. Check: internal motor connections. Electric cable connections, leakage from the motors to the framework of the platform. If everything is OK, the controller has an internal fault. This alarm only appears when the drive motors are activated. Check: internal motor connections. Electric cable connections, leakage from the motor to the framework of the platform. If everything is OK, the controller has an internal fault.

23

VMN high

24

Pump VMN low

The VMN voltage of the pump is low when it should be high.

25

Pump VMN high

The VMN voltage of the pump is high when it should be low.

26

VMN right low

The VMN voltage of the right motor is low when it should be high.

27

VMN right high

The VMN voltage of the right motor is high when it should be low.

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Section 5 Fault Codes

FAULT CODE CHART

Error Source ID Name 02 Controller logic board

Error Type ID Name

Condition

Solution
This alarm only appears when the drive motors are activated. Check: internal motor connections. Electric cable connections, leakage from the motor to the framework of the platform. If everything is OK, the controller has an internal fault. This alarm only appears when the drive motors are activated. Check: internal motor connections. Electric cable connections, leakage from the motor to the framework of the platform. If everything is OK, the controller has an internal fault. Check the contacts of the power relay. Replace the power relay if necessary.

28

VMN left low

The VMN voltage of the left motor is low when it should be high.

29

VMN left high

The VMN voltage of the left motor is high when it should be low.

30

Driver closed

31

Driver open

Before activating the power relay, the controller checks whether the driver is closed. If the test is not conclusive, this alarm appears. The power relay is controlled by the controller, but this will not close.

The power relay is probably not working. Replace it. If the fault is detected on starting or during an alarm, it is most likely to be under-voltage. Check whether the main voltage SI is stable. If the fault is detected during acceleration of the drive motors or pump, the fault may be due to undervoltage: check the battery charge and connections. If the fault is detected during braking, the fault may be due to overvoltage: check the battery voltage during braking.

32

Logic fault #1

Under-voltage or overvoltage has been detected

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FAULT CODE CHART

Error Source ID Name 02 Controller logic board

Error Type ID Name 42

Drive shorted

Condition
The drive output of the base board is shortcircuited. The base board and the controller have performed a check of the signals for the drive conductor. If the controller board detects a problem in its own control circuit (right or left motor), this alarm will appear. The base board and the controller perform a check of the signals for the pump. If the controller board detects a problem in its own control circuit, this alarm appears. The interface and logic board performs a countercheck of signals for the steering choice. If the logic detects a problem in its own control circuit (field conductor circuit), this alarm appears. Although the ground conductor is active, no current through the field is detected. The current sensor of the pump is not working correctly. Its output voltage is outside the acceptable range.

Solution
It is an internal fault. Replace the controller.

42

Driver 3

It is an internal fault. Replace the controller.

43

Driver2

It is an internal fault. Replace the controller.

44

Driver1

It is an internal fault. Replace the controller.

46

No ground current

Check the connection of the motor to the controller or look for possible leakage to the framework of the platform. If everything is OK, the controller has an internal fault. It is an internal fault. Replace the controller.

47

Pump sensor

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Section 5 Fault Codes

FAULT CODE CHART

Error Source Name 02 Controller logic board ID

ID 49

Error Type Name

Pump shorted

Condition
The pump inputs of the base board are shortcircuited. The interface board has not received the message from CAN "N" (1= CMD+TRAC 2=MESG_EV+INTERFACE 5 = MESG_EV +IN_TRAC) The power section of the fuse has reached the temperature limit: the maximum current is automatically reduced. The value read by the potentiometer is different from the programmed value. The controller board asks the base board to activate the drive motors or the pump. If they are not activated after 400 ms, this alarm is activated.

Solution
It is an internal fault. Replace the controller. Check the BUSCAN connection between the modules. Otherwise, there is an internal fault in a module which causes a transmission error, or there is excessive noise on the BUSCAN line which is interfering with the signal. The alarm disappears as soon as the cutout cools down. If this does not happen, there is a problem with the internal temperature sensor. Check that the angle sensor potentiometer is functioning correctly. Otherwise, check the wiring. Check the software versions installed on the interface and logic board. This alarm may be due to a software disparity. Otherwise, there is an internal fault.

57

No CAN message

60

High temperatures

65

Value of angle sensor incorrect

87

Time delay

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FAULT CODE CHART

Error Source ID Name 08 Platform controls circuit board

Error Type ID Name

Condition
Internal system surveillance has been put into operation. If the surveillance detects a fault in the execution of this surveillance, this alarm appears. There is a problem (short-circuit to ground or to positive) on output CNE-10. There is a problem (short-circuit to ground or to positive) on output CNE-5. There is a problem (short-circuit to negative or to positive) on output CNE-1 or CNE-3.

Solution

70

System surveillance

It is an internal fault. Replace the controller.

72

SV1 incorrect

73

SV2 incorrect

74

SV3-4 incorrect

75

BUSCAN incorrect

The platform controls circuit board is not receiving the CAN signal from the controller.

Check the wiring. If the wiring is correct and the alarm persists, there is an internal fault. Check the wiring. If the wiring is correct and the alarm persists, there is an internal fault. Check the wiring. If the wiring is correct and the alarm persists, there is an internal fault. There may be an interruption of the BUSCAN signal. Check the connection of the BUSCAN between the modules. Otherwise, there is an internal fault in a module which causes a transmission error, or there is excessive noise on the BUSCAN line.

ID

Error Source Name Diagnostic display

ID 06

Error Type Name

No communication

Condition
The diagnostic display is not working properly.

Solution
Check wire connections. Repair or replace the diagnostic display.

16

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Part No. 227656

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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:

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.

Electrocution/burn 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

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.

Malfunction discovered

Identify symptoms
problem still exists

Troubleshoot

Return to service

problem solved

Inspect and test

Perform repair

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Section 6 Schematics

July 2012

Electrical Schematic Abbreviation and Wire Color Legends

6-2

GR-20J GR-26J

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Section 6 Schematics

ECM Pin-out Legend

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Section 6 Schematics

July 2012

Limit Switch and Sensor Legend

Limit and Sensor Legend a b c d e Platform overload LS31 Mast down LS18 Steer angle S21 Tilt sensor S7 Jib down LS11

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Section 6 Schematics

Electrical Symbols Legend

Circuits Crossing (no connection)

Switch or Button Motor Level Sensor

Diode Toggle Switch Solenoid Valve Connection (no terminal) Battery Charger

Emergency Stop Button

Parking Brake Connector Battery Key Switch Fuse Horn or Alarm Flashing Beacon Electric Motor Control Relay

LED

Sensor (hydraulic oil temperature)

Joystick Controller

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July 2012

Electrical Schematic - GR-26J

ANSI - Part 1 of 2

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Section 6 Schematics

Electrical Schematic - GR-26J

ANSI - Part 2 of 2

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Section 6 Schematics

July 2012

Electrical Schematic - GR-20J and GR-26J

CE - Part 1 of 2

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Section 6 Schematics

Electrical Schematic - GR-20J and GR-26J

CE - Part 2 of 2

Part No. 227656

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Section 6 Schematics

July 2012

Hydraulic Component Reference and Symbols Legend

M
Auxiliary pump Variable speed motor Fixed displacement pump Check valve

Hydraulic cylinder

Filter

Relief valve

Bi-directional motor

Solenoid operated 2 position 2 way directional valve

Solenoid operated 2 position 2 way directional valve

Solenoid operated 2 position 2 way directional valve

Solenoid operated 2 position 4 way directional valve

Hose reel

Solenoid operated 2 position 2 way directional valve

Solenoid operated 2 position 4 way directional valve

H F

Y117

B
Y116

A G I

Y21

Y118

Y22

Fucntion pump and manifold

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Section 6 Schematics

Hydraulic Schematic

TURNTABLE ROTATE

(GR26-J ONLY)
Y119

P
HOSE REEL
Y101 Y121 Y102

J
STEER CYLINDER
1450 psi 100 bar

JIB MANIFOLD JIB CYLINDER

1450 psi 100 bar

A P2 P3

DR P5 P6 T2

+
TP

L
LIFT CYLINDER P1 P4

C A
Y117 Y118

B
Y116

E D H
B10 = 100
Y22 Y21

F I
2030 psi 140 bar

930 psi 64 bar

FUNCTION MANIFOLD

T1 AUXILIARY PUMP

POWER UNIT

HYDRAULIC TANK

Hydraulic Component Legend

A = Steer select B = Steer/Turntable Directional C = Turntable select D = Platform up E = Platform down F = System relief G = Platform up/down relief H = Filter I = Check valve J = Turntable rotate right relief K = Turntable rotate left relief L = Test port M = Lift cylinder select N = Jib up O = Jib down P = Jib up/down flow control

FUNCTION STEER RIGHT STEER LEFT TURNTABLE ROTATE RIGHT TURNTABLE ROTATE LEFT MAST CYLINDER RAISE MAST CYLINDER LOWER JIB CYLINDER RAISE JIB CYLINDER LOWER

VALVE ACTIVATION Y21 Y22 Y101 Y102 Y116 Y117 Y118 Y121

HS0255A

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July 2012

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GR-20J GR-26J

Part No. 227656

Genie North America

Genie Australia Pty Ltd.

Phone +61 7 3375 1660 Fax +61 7 3375 1002

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Phone +46 31 575100 Fax +46 31 579020

Genie China
Phone +86 21 53852570 Fax +86 21 53852569

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Phone +81 3 3453 6082 Fax +81 3 3453 6083

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Phone +82 25 587 267 Fax +82 25 583 910

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Phone +44 (0)1476 584333 Fax +44 (0)1476 584334

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Phone +52 55 5666 5242 Fax +52 55 5666 3241

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