Genie Lift Guard GR-12 User manual

Service Manual
(from serial number GR05-5001)
(from serial number GR05-5001)
(from serial number GR05-5001)
Refer to inside cover for additional serial number information
Part No. 84700
Rev B
November 2005

November 2005
GR-12 • GR-15 • GR-20 Part No. 84700ii
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenanceprocedure.
Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer
service center.
Technical Publications
Genie Industries has endeavored to deliver the
highest degree of accuracy possible. However,
continuous improvement of our products is a Genie
policy. Therefore, product specifications
are subject to change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Copyright © 2001 by Genie Industries
84700 Rev B November 2005
Second Edition, Second Printing
"Genie" is a registered trademark of Genie
Industries in the USA and many other countries.
"GR" is a trademark of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
Contact Us:
www.genieindustries.com
e-mail:[email protected]
Serial Number Information
Genie Industries offers the following Service
Manuals for these models:
Title Part No.
Genie Runabout Service Manual,
First Edition
(before serial number GR05-5001)....................... 72965
Introduction

November 2005
Part No. 84700 GR-12 • GR-15 • GR-20
Serial Number Legend
GS30 05 A - 12345
Model
Facility code
(
)
used only for models manufactured
in multiple facilities
Sequence
number
PN - 77055
Model:
Model year: Manufacture date:
Maximum allowable inclination of the chassis:
Country of manufacture: USA
This machine complies with:
Serial number:
Rated work load (including occupants):
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
Electrical schematic number:
Gradeability:
Maximum allowable side force :
Maximum number of platform occupants:
Machine unladen weight:
ANSI A92.6-1999
B354.2-01
GS-1930
GS3005A-12345
04/12/05
ES0141
2,714 lb / 1,231 kg
500 lb / 227 kg
N/A
N/A
100 lb / 445 kg
2
2005
Model year
iii
INTRODUCTION

November 2005
GR-12 • GR-15 • GR-20 Part No. 84700
This page intentionally left blank.
iv

November 2005
Part No. 84700 GR-12 • GR-15 • GR-20 v
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.
Safety Rules

November 2005
GR-12 • GR-15 • GR-20 Part No. 84700
SAFETY RULES
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure that your workshop or work area
is properly ventilated and well lit.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or other
fluids. Use an approved container. Please be
environmentally safe .
vi

November 2005
Part No. 84700 GR-12 • GR-15 • GR-20
Table of Contents
Introduction
ImportantInformation.........................................................................................ii
Section 1 Safety Rules
General Safety Rules........................................................................................ iii
Section 2 Rev Specifications
B Machine Specifications ................................................................................ 2 - 1
B Performance Specifications ......................................................................... 2 - 2
B Hydraulic Specifications............................................................................... 2 - 2
B Manifold Component Specifications ............................................................. 2 - 3
B Hydraulic Hose and Fitting Torque Specifications........................................ 2 - 4
B SAE and Metric Fasteners Torque Charts ................................................... 2 - 6
Section 3 Rev Scheduled Maintenance Procedures
Introduction.................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
AChecklist A Procedures
A-1 Perform Pre-operation Inspection....................................................... 3 - 6
A-2 Perform Function Tests ...................................................................... 3 - 6
A-3 Perform 30 Day Service ..................................................................... 3 - 7
A-4 Grease the Steer Yokes ..................................................................... 3 - 7
vii

November 2005
GR-12 • GR-15 • GR-20 Part No. 84700
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued
BChecklist B Procedures
B-1 Inspect the Batteries........................................................................... 3 - 8
B-2 Inspect the Electrical Wiring ............................................................. 3 - 10
B-3 Inspect the Tires and Wheels (including castle nut torque)............... 3 - 11
B-4 Check the Lifting Chain Adjustments ................................................ 3 - 11
B-5 Clean and Lubricate the Columns..................................................... 3 - 12
B-6 Adjust the Sequencing Cables.......................................................... 3 - 12
B-7 Test the Emergency Stop ................................................................. 3 - 13
B-8 Test the Key Switch.......................................................................... 3 - 14
B-9 Test the Automotive-style Horn (if equipped).................................... 3 - 14
B-10 Inspect the Voltage Inverter (if equipped) ......................................... 3 - 15
B-11 Test the Drive Brakes ....................................................................... 3 - 16
B-12 Test the Drive Speed - Stowed Position ........................................... 3 - 17
B-13 Test the Drive Speed - Raised Position ............................................ 3 - 18
B-14 Test the Slow Drive Speed ............................................................... 3 - 19
B-15 Test the Flashing Beacons ............................................................... 3 - 20
B-16 Test the Motion Alarm (if equipped).................................................. 3 - 20
B-17 Perform Hydraulic Oil Analysis ......................................................... 3 - 21
B-18 Inspect the Breather Cap.................................................................. 3 - 22
BChecklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) .................. 3 - 23
C-2 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil ................................................... 3 - 23
C-3 Test the Platform Overload System (if equipped) ............................. 3 - 24
BChecklist D Procedures
D-1 Calibrate the Platform Overload System (if equipped) ...................... 3 - 26
D-2 Inspect the Mast Assembly for Wear ................................................ 3 - 27
D-3 Inspect and Lubricate the Lifting Chains........................................... 3 - 29
D-4 Replace the Hydraulic Tank Return Filter ......................................... 3 - 29
AChecklist E Procedure
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 30
viii

November 2005
Part No. 84700 GR-12 • GR-15 • GR-20
TABLE OF CONTENTS
Section 4 Rev Repair Procedures
Introduction.................................................................................................. 4 - 1
BPlatform Controls
1-1 Circuit Boards .................................................................................... 4 - 2
1-2 Controller Adjustments ....................................................................... 4 - 3
1-3 SoftwareConfiguration....................................................................... 4 - 8
APlatform Components
2-1 Platform ........................................................................................... 4 - 12
2-2 Platform Extension ........................................................................... 4 - 12
BMast Components
3-1 Mast ................................................................................................. 4 - 13
3-2 Glide Pads ....................................................................................... 4 - 17
3-3 Lifting Chains ................................................................................... 4 - 17
3-4 Lift Cylinder ...................................................................................... 4 - 20
AGround Controls
4-1 Level Sensor .................................................................................... 4 - 21
AHydraulic Pump
5-1 Function Pump................................................................................. 4 - 24
AFunction Manifold
6-1 Function Manifold Components........................................................ 4 - 26
6-2 Valve Adjustments - Function Manifold ............................................ 4 - 28
6-3 Valve Coils ....................................................................................... 4 - 31
AHydraulic Tank
7-1 Hydraulic Tank ................................................................................. 4 - 33
ASteer Axle Components
8-1 Yoke and Drive Motor ...................................................................... 4 - 34
8-2 Steer Cylinder .................................................................................. 4 - 36
8-3 Steer Bellcrank................................................................................. 4 - 36
ANon-steer Axle Components
9-1 Drive Brake ...................................................................................... 4 - 37
ABrake Release Hand Pump Components
10-1 Brake Release Hand Pump Components......................................... 4 - 38
ix

November 2005
GR-12 • GR-15 • GR-20 Part No. 84700
Section 5 Rev Fault Codes
Introduction.................................................................................................. 5 - 1
A Fault Code Chart ......................................................................................... 5 - 3
Section 6 Rev Schematics
A Introduction.................................................................................................. 6 - 1
A Electrical Component and Wire Color Legends ........................................... 6 - 2
A Relay Layout and ECM Pin-out Legend ....................................................... 6 - 3
A Wiring Diagram - Ground and Platform Controls.......................................... 6 - 4
A Electrical Symbols Legend........................................................................... 6 - 5
B Electrical Schematic - ANSI and CSA Models
(all models without platform overload protection) ......................................... 6 - 6
B Electrical Schematic - CE models
(all models with platform overload protection) .............................................. 6 - 8
A Hydraulic Component Reference and Symbols Legend............................. 6 - 11
A Hydraulic Schematic .................................................................................. 6 - 12
TABLE OF CONTENTS
x

Section 2 • Specifications
REV B
November 2005
Part No. 84700 GR-12 • GR-15 • GR-20 2 - 1
Machine Specifications
Batteries, Standard
Voltage 6V DC
Group GC2
Type T-105
Quantity 4
Battery capacity, maximum 225AH
Reserve capacity @ 25A rate 447 minutes
Batteries, Maintenance-free (option)
Voltage 6V DC
Group GC2
Type 6V-AGM
Quantity 4
Battery capacity, maximum 200AH
Reserve capacity @ 25A rate 380 minutes
Fluid capacities
Hydraulic tank 1.5 gallons
5.7 liters
Hydraulic system 2.2 gallons
(including tank) 8.3 liters
Height, stowed maximum
GR-12 and GR-15 62 in
(ANSI, CSA and Australia models) 1.57 m
GR-12 and GR-15 68.1 in
(CE models) 1.73 m
GR-20 78 in
(all models) 1.98 m
For operational specifications, refer to the
Operator's Manual.
Tires and wheels
Tire size (solid rubber) 10 x 3 in
25.4 x 2.5 cm
Tire contact area 6 sq in
39 cm2
Castle nut torque, dry 221 ft-lbs
300 Nm
Castle nut torque, lubricated 165 ft-lbs
225 Nm
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Specifications

Section 2 • Specifications
REV B
November 2005
2 - 2 GR-12 • GR-15 • GR-20 Part No. 84700
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalent
ISO viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Premium ECO 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Use Chevron Aviation A hydraulic
oil when in ambient temperatures
consistently below 0°F / -17°C.
Use Shell Tellus T46 hydraulic oil
when oil temperatures consistently
exceed 205°F / 96°C.
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
SPECIFICATIONS
Performance Specifications
Drive speed, maximum
Platform stowed, fast 2.5 mph
40 ft / 10.9 sec
4 km/h
12.2 m / 10.9 sec
Platform stowed, slow 1.1 mph
40 ft / 24.8 sec
1.8 km/h
12.2 m / 24.8 sec
Platform raised 0.5 mph
40 ft / 55 sec
0.8 km/h
12.2 m / 55 sec
Braking distance, maximum
High range on paved surface 19 in ± 6 in
48 cm ± 15 cm
Gradeability 25%
Airborne noise emissions 70 dB
Maximum sound level at normal operation workstations
(A-weighted)
Function speed, maximum, from platform controls
(with 1 person in platform)
Platform up 23 to 27 seconds
Platform down 17 to 21 seconds
Rated work load at full height, maximum
Standard Platform 500 lbs
(GR-12 and GR-15 models) 227 kg
Standard Platform 350 lbs
(GR-20 models) 159 kg
AWP and Fiberglass Platform 350 lbs
(all models) 159 kg
Stockpicker Platform 500 lbs
(GR-12 and GR-15 models) 227 kg
Stockpicker Platform 350 lbs
(GR-20 models) 159 kg
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.

Section 2 • Specifications
REV B
November 2005
Part No. 84700 GR-12 • GR-15 • GR-20 2 - 3
SPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Valve Coil Resistance
Description Specification
Solenoid valve, 3 position 4 way 18 to 21Ω
20V DC with diode (schematic item E)
Solenoid valve, 3 position 4 way 25 to 28Ω
20V DC with diode (schematic item F)
Solenoid valve, 2 position 4 way 18 to 21Ω
20V DC with diode (schematic item H)
Solenoid valve, 2 position 2 way N.C. 7.5 to 10.5Ω
with manual override
12V DC with diode (schematic item N)
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice.
Function pump
Type Gear
Displacement per revolution 0.244 cu in
4 cc
Flow rate @ 2500 psi / 172 bar 4 gpm
15 L/min
Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar bypass
Function manifold
System relief valve pressure, maximum 3500 psi
241 bar
Lift relief valve pressure 1800 to 3500 psi
124 to 241 bar
Steer relief valve pressure 1500 psi
103 bar

Section 2 • Specifications
REV B
November 2005
2 - 4 GR-12 • GR-15 • GR-20 Part No. 84700
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with JIC 37° flared
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash size Thread Size Flats
-4 7/16-20 2
-6 9/16-18 1 1/4
-8 3/4-16 1
-10 7/8-14 1
-12 1 1/16-12 1
-16 1 5/16-12 1
-20 1 5/8-12 1
-24 1 7/8-12 1
SAE O-ring Boss Port
(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 40 ft-lbs / 54.2 Nm
-10 69 ft-lbs / 93.6 Nm
-12 93 ft-lbs / 126.1 Nm
-16 139 ft-lbs / 188.5 Nm
-20 172 ft-lbs / 233.2 Nm
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port
(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm
SPECIFICATIONS

Section 2 • Specifications
REV B
November 2005
Part No. 84700 GR-12 • GR-15 • GR-20 2 - 5
a
b
c
b
3 Working clockwise on the body hex fitting, make
a second mark with a permanent ink marker to
indicate the proper tightening position. Refer to
Figure 2.
Use the JIC 37° Fittings table on
the previous page to determine
the correct number of flats for the
proper tightening position.
The marks indicate that the correct
tightening positions have been
determined. Use the second mark
on the body hex fitting to properly
tighten the joint after it has been
loosened.
Figure 1
a hydraulic hose
b hex nut
c reference mark
d body hex fitting
b
c
a
d
Torque Procedure
JIC 37° fittings
1 Align the tube flare (hex nut) against the nose of
the fitting body (body hex fitting) and tighten the
hex nut to the body hex fitting to hand-tight,
approximately 30 in-lbs / 3.4 Nm.
2 Make a reference mark on one of the flats of the
hex nut, and continue it on to the body hex
fitting with a permanent ink marker. Refer to
Figure 1.
Figure 2
a body hex fitting
b reference mark
c second mark
4 Tighten the hex nut until the mark on the hex
nut is aligned with the second mark on the body
hex fitting.
5 Operate all machine functions and inspect the
hoses and fittings and related components to
confirm that there are no leaks.
SPECIFICATIONS

Section 2 • Specifications
REV B
November 2005
2 - 6 GR-12 • GR-15 • GR-20 Part No. 84700
SIZE THREAD
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20
100
11.3
80
9
140
15.8
110
12.4
130
14.7
28
90
10.1
120
13.5
120
13.5
160
18
140
15.8
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18
13
17.6
17
23
18
24
25
33.9
21
28.4
24
14
19
19
25.7
20
27.1
27
36.6
24
32.5
16
23
31.2
31
42
33
44.7
44
59.6
38
51.5
24
26
35.2
35
47.4
37
50.1
49
66.4
43
58.3
14
37
50.1
49
66.4
50
67.8
70
94.7
61
82.7
20
41
55.5
55
74.5
60
81.3
80
108.4
68
92.1
13
57
77.3
75
101.6
80
108.4
110
149
93
126
20
64
86.7
85
115
90
122
120
162
105
142
12
80
108.4
110
149
120
162
150
203
130
176
18
90
122
120
162
130
176
170
230
140
189
11
110
149
150
203
160
217
210
284
180
244
18
130
176
170
230
180
244
240
325
200
271
10
200
271
270
366
280
379
380
515
320
433
16
220
298
300
406
310
420
420
569
350
474
9
320
433
430
583
450
610
610
827
510
691
14
350
474
470
637
500
678
670
908
560
759
8
480
650
640
867
680
922
910
1233
770
1044
12
530
718
710
962
750
1016
990
1342
840
1139
7
590
800
790
1071
970
1315
1290
1749
1090
1477
12
670
908
890
1206
1080
1464
1440
1952
1220
1654
7
840
1138
1120
1518
1360
1844
1820
2467
1530
2074
12
930
1260
1240
1681
1510
2047
2010
2725
1700
2304
6
1460
1979
1950
2643
2370
3213
3160
4284
2670
3620
12
1640
2223
2190
2969
2670
3620
3560
4826
3000
4067
5/16
3/8
7/16
1/2
1.5
9/16
5/8
3/4
7/8
1
1.125
1.25
LUBED
1/4
LUBED DRY LUBED DRY
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYLUBED
• This chart is to be used as a guide only unless noted elsewhere in this manual •
A574 High Strength
Black Oxide Bolts
Grade 8
Size
(mm) in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
5
16
1.8
21
2.4
41
4.63
54
6.18
58
6.63
78
8.84
68
7.75
91
10.3
6
19
3.05
36
4.07
69
7.87
93
10.5
100
11.3
132
15
116
13.2
155
17.6
7
45
5.12
60
6.83
116
13.2
155
17.6
167
18.9
223
25.2
1.95
22.1
260
29.4
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
8
5.4
7.41
7.2
9.88
14
19.1
18.8
25.5
20.1
27.3
26.9
36.5
23.6
32
31.4
42.6
10
10.8
14.7
14.4
19.6
27.9
37.8
37.2
50.5
39.9
54.1
53.2
72.2
46.7
63.3
62.3
84.4
12
18.9
25.6
25.1
34.1
48.6
66
64.9
88
69.7
94.5
92.2
125
81
110
108
147
14
30.1
40.8
40
54.3
77.4
105
103
140
110
150
147
200
129
175
172
234
16
46.9
63.6
62.5
84.8
125
170
166
226
173
235
230
313
202
274
269
365
18
64.5
87.5
86.2
117
171
233
229
311
238
323
317
430
278
377
371
503
20
91
124
121
165
243
330
325
441
337
458
450
610
394
535
525
713
22
124
169
166
225
331
450
442
600
458
622
612
830
536
727
715
970
24
157
214
210
285
420
570
562
762
583
791
778
1055
682
925
909
1233
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Class 12.9Class 4.6
DRYLUBED
METRIC FASTENER TORQUE CHART
• This chartis tobe usedas a guide onlyunless notedelsewhere in this manual•
LUBED DRY
Class 10.9Class 8.8
DRY
10.9 12.98.84.6
SPECIFICATIONS

Section 3 • Scheduled Maintenance ProceduresNovember 2005
Part No. 84700 GR-12 • GR-15 • GR-20 3 - 1
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly and semi-annually,
annually and every two years as specified on
the Maintenance Inspection Report.
Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantialdamage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Keep records on all inspections for three years.
Machines that have been out of service for a
period longer than 3 months must complete the
quarterly inspection.
Unless otherwise specified, perform each
maintenance procedure with the machine in the
followingconfiguration:
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the key
removed
· The red Emergency Stop button in the off
position at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnected
from the machine
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

Section 3 • Scheduled Maintenance Procedures November 2005
3 - 2 GR-12 • GR-15 • GR-20 Part No. 84700
SCHEDULED MAINTENANCE PROCEDURES
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appears at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required
to perform this procedure.
Indicates that a cold motor or pump will
be required to perform this procedure.
Indicates that dealer service will be
required to perform this procedure.
Pre-delivery Preparation Report
The pre-delivery preparation report contains
checklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation report
to use for each inspection. Store completed forms
as required.
Maintenance Schedule
There are five types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly, semi-annually, annually, and
two year. The Scheduled Maintenance Procedures
Section and the Maintenance Inspection Report
have been divided into five subsections—A, B, C,
D, and E. Use the following chart to determine
which group(s) of procedures are required to
perform a scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Semi-annually or every 500 hours A + B + C
Annually or every 1000 hours A + B + C + D
Two year or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Store completed forms
for three years.

Section 3 • Scheduled Maintenance ProceduresNovember 2005
Part No. 84700 GR-12 • GR-15 • GR-20 3 - 3
Genie Industries USA
18340 NE 76th Street
PO Box 97030
Redmond, WA 98073-9730
[phone]
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie
Industries. Rev A
Genie UK
The Maltings, Wharf Road
Grantham,Lincolnshire
NG31- 6BH England
(44)1476-584333
Pre-Delivery Preparation
Pre-Delivery Preparation Y N R
Pre-operationinspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completing
the Pre-operation Inspection, the Maintenance items
and the Function Tests.
Use this form to record the results. Place a check in
the appropriate box after each part is completed.
Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the machine
from service, repair and re-inspect it. After repair,
place a check in the R box.
Legend
Y = yes, completed
N = no, unable to complete
R = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform the
Pre-delivery Preparation.
The Pre-delivery Preparation is performed prior to
each delivery. The inspection is designed to discover if
anything is apparently wrong with a machine before it
is put into service.
A damaged or modified machine must never be used.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged
and removed from service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer'sspecifications.
Scheduled maintenance inspections shall be
performed by qualified service technicians, according
to the manufacturer's specifications and the
requirements listed in the responsibilities manual.

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