Genie Genie Lift User manual

Service Manual
Serial Number Range
Genie Lift
from 1395 to 1301-23434
from GL02-23435 t
o
GL16G-80150
from GL16G-80151 t
o
GL16G-83799
from GLG-83800
Part No. 115417
Rev A2
September 2016

Service Manual September 2016
Introduction
ii Genie Lift Part No. 115417
Intr od ucti on Intr oducti o n
Impor tant Inf orm ati on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also provides troubleshooting and
repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Technical Publications
Genie 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:
Internet: www.genielift.com
E-mail: [e-mail]
Serial Number Information
Genie Industries offers the following Service
Manuals for these models:
Title
Part No.
Genie Lift Parts & Service Manual, First Edition
(from serial number 1395-103 to
1301-23434)..................................................22186
Genie Lift Parts & Service Manual, Second Edition
(from serial number
GL02-23435)................................................*35572
*Note: Genie Lift Service Manual 115417 and
Genie Lift Part's Manual 115418 replaces Genie
Lift Parts and Service Manual 35572.
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 1989 by Genie Industries
115417 Rev A, April 2009
Third Edition, First Printing
'Genie'' is registered trademark of Terex South Dakota. in the
U.S.A. and many other countries.

September 2016 Service Manual
Introduction
Part No. 115417 Genie Lift iii
Revision History
Revision History
Revision
Date
Section
Procedure / Page / Description
A 4/2009 Initial Release
A1 10/2010 Specifications Checklist A Procedures
A2 9/2016 Introduction Serial Number Legend
Reference Examples:
Section – Maintenance, B-3
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service Manual September 2016
Introduction
iv Genie Lift Part No. 115417
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label
6 Serial number (stamped on base)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label
5 Serial number (stamped on base)

September 2016 Service Manual
Safety Rules
Part No. 115417 Genie Lift v
Section 1 Safet y R ules Gener al Saf ety Rul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.

Service Manual September 2016
Safety Rules
vi Genie Lift Part No. 115417
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use
signal words to identify the following:
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a 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 mi
nor 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
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.
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 ex
tinguisher 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 cran
e 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 pi
ns 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.

September 2016
Table of Contents
Part No. 115417 Genie Lift vii
Introduction Introduction .......................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History .....................................................................................................iii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules .......................................................................................................... v
General Safety Rules ............................................................................................. v
Section 2 Specifications ....................................................................................................... 9
Machine Specifications........................................................................................... 9
Performance Specifications ................................................................................. 11
SAE and Metric Fasteners Torque Charts ........................................................... 12
Section 3 Scheduled Maintenance Procedures ............................................................... 13
Introduction ........................................................................................................... 13
Pre-Delivery Preparation Report .......................................................................... 16
Maintenance Inspection Report ........................................................................... 18
Checklist A Procedures ..................................................................................... 20
A-1 Inspect the Manuals and Decals ................................................................... 20
A-2 Perform Pre-operation Inspection .................................................................. 21
A-3 Perform Function Tests ................................................................................. 21
A-4 Inspect the Channels ..................................................................................... 22
A-5 Inspect the Cable and Cable Pulleys............................................................. 22
A-6 Inspect the Casters and Wheels .................................................................... 23
Checklist B Procedures ..................................................................................... 24
B-1 Inspect the Battery - Models with Electric Winch .......................................... 24
B-2 Inspect the Electrical Wiring - Models With Electric Winch ........................... 25
B-3 Perform Electric WinchMaintenance ............................................................. 25
B-4 Inspect the Carriage Hold-down Bar ............................................................. 26
B-5 Inspect All Welds ........................................................................................... 26
B-6 Clean the Channels ...................................................................................... 27
B-7 Inspect and Lubricate the Manual Winch ...................................................... 27

September 2016
Table of Contents
viii Genie Lift Part No. 115417
Checklist C Procedures ..................................................................................... 28
C-1 Lubricate the Casters and Wheels ................................................................ 28
C-2 Replace the Manual Winch Friction Disks .................................................... 29
C-3 Inspect the Painted Surfaces ........................................................................ 29
Section 4 Repair Procedures ............................................................................................. 30
Base Assembly................................................................................................... 31
1-1 How to Disassemble the GL -Models Equipped with a Manual Winch.......... 31
1-2 How to Disassemble the GL - Models Equipped with an Electric Winch....... 32
1-3 How to Disassemble the Manual Winch ........................................................ 33
1-4 How to Assemble the Manual Winch ............................................................. 34
Manual Winch Assembly ...................................................................................... 36
1-5 How to Replace the Lifting Pulley .................................................................. 37
1-6 How to Replace the Lifting Cable .................................................................. 37
1-7 How to Replace the Glide Buttons ................................................................. 39
1-8 How to Adjust the Brake (if equipped) ........................................................... 40
Rear Wheel Brake Assembly (option) .................................................................. 41
Section 5 Schematics ......................................................................................................... 42
Electrical Symbols Legend - Models With Electric Winch.................................... 43
Wiring Diagram - Models With Electric Winch ..................................................... 44

September 2016 Service Manual
Specifications
Part No. 115417 Genie Lift 9
Section 2 Specif ic ati ons
Machi ne S pec ific ati ons
Machine Specifications
Model
GL-4 GL-8 Gl-10 GL-12
Stowed Height*
5 ft 7.5 in 5 ft 7.5 in 6 ft 6.5 in 6 ft 6.5 in
1.7 m 1.7 m 2 m 2 m
Ground Clearance*
0.7 in 0.7 in 0.7 in 0.7 in
1.8 cm 1.8 cm 1.8 cm 1.8 cm
Standard Base
66 in 66 in 66 in 66 in
Width
- stowed 1.7 m 1.7 m 1.7 m 1.7 m
34 in 34 in 34 in 34 in
Length
- stowed 86.4 cm 86.4 cm 86.4 cm 86.4 cm
59 in 63 in 73 in 81 in
Length
- operating 1.5 m 1.6 m 1.9 m 2 m
Straddle Base
2 in 2 in 2 in 2 in
Width
- stowed 5.8 cm 5.8 cm 5.8 cm 5.8 cm
650 lbs 650 lbs 650 lbs 650 lbs
Length
- stowed 295 kg 295 kg 295 kg 295 kg
650 lbs 650 lbs 650 lbs 650 lbs
Length
- Operating 165 lbs 225 lbs 307 lbs 347 lbs
75 kg 102 kg 139 kg 157 kg
Counterweight Base
28.8 in 28.8 in 28.8 in 28.8 in
Width
- stowed 73 cm 73 cm 73 cm 73 cm
28 in 23 in 2.5 in 26.5 lbs
Length
- stowed 71.1 cm 58.4 cm 6.4 cm 12 kg
27.5 in 11.5 in to 30 in 2.5 in 52.5 lbs
Length
- operating 69.9 cm 29.2 cm to 76.2 cm 6.4 cm 23.8 kg
* The 1
0 inch pneumatic rear wheel option will add 1 inch / 2.5 cm to these specifications.
* The
4 point caster option B will add 1 inch / 2.5 cm to these specifications.
* The counterweight base will add
1 inch / 2.5 cm to these specifications.

Service Manual September 2016
Specifications
10 Genie Lift Part No. 115417
Machine Specifications cont.
Model
GL-4 GL-8 Gl-10 GL-12
Machine Weight
113 lbs 132 lbs NA NA
Standard base
51kg 60 kg
126 lbs 145 lbs 149 lbs 154 lbs
Straddle base
57 kg 66 kg 68 kg 70 kg
392 lbs 411 lbs 433 lbs NA
Counterweight base
178 kg 186 kg 196 kg
Standard base
117 lbs 136 lbs NA NA
(pneumatic caster option)
53 kg 60 kg
Straddle base
130 lbs 149 lbs 153 lbs 158 lbs
(pneumatic caster option)
59 kg 68 kg 69 kg 72 kg
Straddle base
137 lbs 158 lbs 162 lbs 167 lbs
(
4 point caster option A) 62 kg 72 kg 74 kg 76 kg
Straddle base
139 lbs 160 lbs 164 lbs 169 lbs
(
4 point caster option B) 63 kg 73 kg 75 kg 77 kg
The electric winch option will add an additional 10
3 lbs / 47 kg to the above machine weights.
Forks
22.5 in 22.5 in 22.5 in 22.5 in
Length
57.2 cm 57.2 cm 57.2 cm 57.2 cm
20.5 in 20.5 in 20.5 in 20.5 in
Width
52.1 cm 52.1 cm 52.1 cm 52.1cm
Load Platform
23 in 23 in 23 in 23 in
Length
58.4 cm 58.4 cm 58.4 cm 58.4 cm
22 in 22 in 22 in 22 in
Width
55.9 cm 55.9 cm 55.9 cm 55.9 cm

September 2016 Service Manual
Specifications
Part No. 115417 Genie Lift 11
Perf orma nce Speci fic ati ons
Performance Specifications
Model
GL-4 GL-8 GL-10 GL-12
Standard Forks
Maximum
working height 5 ft 11 in 10 ft 0.5 in 11 ft 8 in 13 ft 9.5 in
Forks up
1.8 m 3.1 m 3.6 m 4.2 m
Maximum working height
4 ft 1.5 in 8 ft 3 in 9 ft 10.5 in 12 ft
Forks down
1.3m 2.5 m 3 m 3.7 m
Boom
5 ft 1.5 in 9 ft 3 in 10 ft 10.5 in 13 ft
Maximum
working height 1.6 m 2.8 m 3.3 m 4 m
Load Platform
5 ft 1.5 in 9 ft 3 in 10 ft 10.5 in 13 ft
Maximum working height
1.6 m 2.8 m 3.3 m 4 m
Standard Base
3.5 in 3.5 in 3.5 in 3.5 in
Minimum working height
8.9 cm 8.9 cm 8.9 cm 8.9 cm
Straddle Base
3.5 in 3.5 in 3.5 in 3.5 in
Minimum working height
8.9 cm 8.9 cm 8.9 cm 8.9 cm
Load Capacity
Standard Forks
500 lbs 400 lbs 350 lbs 350 lbs
at 14 in / 36 cm load center 227 kg 182 kg 159 kg 159 kg
Boom
500 lbs 400 lbs 350 lbs 350 lbs
at 1
2 in / 30.5 cm load center 227 kg 182 kg 159 kg 159 kg
Boom
300 lbs 240 lbs 210 lbs 210 lbs
at 2
0 in / 51 cm load center 136 cm 109 kg 95 kg 95 kg
Airborne noise emissions by machinery
Manual winch
90 dB 90 dB 90 dB 90 dB
Electric winch
95 dB 95 dB 90 dB 90 dB
Maximum sound level at normal operating workstations (A
-weighted)

Service Manual September 2016
Specifications
12 Genie Lift Part No. 115417
SAE and M etr ic F ast ener s T orqu e C har ts

September 2016 Service Manual
Scheduled Maintenance Procedures
Part No. 115417 Genie Lift 13
Section 3 Sche duled Mai nt ena nce Proc ed ures
Intr od ucti o n
Observe and Obey:
 Maintenance inspections shall be completed
by a person trained and qualified on the
maintenance of this machine.
 Scheduled maintenance inspections shall be
completed daily, quarterly, and annually as
specified on the
Maintenance inspection
Report
. The frequency and extent of periodic
examinations and tests may also depend on
national regulations.
Failure to perform each
procedure as presented and
scheduled may cause death,
serious injury or substantial
damage.
 Immediately tag and remove from service a
damaged or malfunctioning machine.
 Repair any machine damage or malfunction
before operating the machine.
 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
• Carriage fully lowered
• Casters locked
• Red Emergency Stop button pushed in to
the off position (if equipped)
• Brakes locked (if equipped)
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
Safety alert symbol
—
used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could res
ult 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.

Service Manual September 2016
Scheduled Maintenance Procedures
14 Genie Lift Part No. 115417
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
appear at the beginning of a maintenance
procedure, it conveys the meaning below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required to
perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Pre-delivery Preparation Report
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies for each inspection. Store completed
forms as required.
Maintenance Schedule
The Scheduled Maintenance Procedures section
and the
Maintenance Inspection Report have been
divided into subsections. Use the following chart to
determine which group(s) of procedures are
required to perform a scheduled inspection.
Inspection
Checklist
Daily or every
8 hours
A
Quarterly or every 25
0 hours
A + B
Annually or every 100
0 hours
A + B + C
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the
Maintenance Inspection Repor t
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.

September 2016 Service Manual
Part No. 115417 Genie Lift 15
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Service Manual September 2016
Pre-Delivery Preparation Report
Pre-Deli ver y Pre parat ion Re por t
Fundamentals
It is the responsibility of the owner or 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 operator’s manual on your machine.
The Pre-delivery Preparation consists of
completing the Pre-operation Inspection, the
Maintenance items and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the
machine from service, repair and re-inspect it. After
repair, place a check in the R box.
Legend
Y = yes, acceptable
N = no, remove from service
R = repaired
Comments
Pre-delivery Preparation
Y
N
R
Pre
-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company

September 2016 Service Manual
Part No. 115417 Genie Lift 17
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Service Manual September 2016
Maintenance Inspection Report
18 Genie Lift Part No. 115417
Maint ena nc e Ins pec tio n Re port
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(s) to perform.
Daily or every
8 hours A
Quarterly or every
25
0 hours
A + B
Annually or every
100
0 hours
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
Checklist A
Y N R
A-1 Inspect the manuals
and decals
A-2 Pre-operation
inspection
A-3 Function tests
A-4 Inspect the
channels
A-5 Inspect cable and
pulleys
A-6 Inspect casters and
wheels
Checklist B Y N R
B-1 Battery
B-2 Electrical wiring
B-3 Electric winch
maintenance
B-4 Carriage hold-down
B-5 Inspect welds
B-6 Clean channels
B-7 Inspect and lubricate
manual winch
Checklist C Y N R
C-1 Caster and wheels
C-2 Winch friction disks
C-3 Inspect painted
surfaces
Comments

September 2016 Service Manual
Part No. 115417 Genie Lift 19
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Service Manual September 2016
Checklist A Procedures
20 Genie Lift Part No. 115417
Chec klist A Pro cedu re s
A-1 Insp ect the M anuals and Dec als
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 operator’s 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, safety
and responsibilities 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 if replacement manuals or decals are
needed.