Genie Lift Guard GRC-12 User manual

Service Manual
Part No. 227123
Rev B1
September 2016
GRC -12
Serial Number Range
from GRC11-1000
to GRC16-2369
from GRC16P-2370
to GRC16P-4599
from GRCP-4600

September 2016
GRC Part No. 227123
ii
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 A/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.
Copyright © 2001 by Terex Corporation
227123 Rev B October 2011
Second Edition, Second Printing
"Genie" is a registered trademark of Terex South
Dakota in the U.S.A. and many other countries.
"GR" is a trademark of Terex South Dakota. Inc.
Printed on recycled paper
Printed in U.S.A.
Contact Us:
www.genielift.com
e-mail: [email protected]
Serial Number Information
Genie offers the following Service Manuals for this
model:
Title Part No.
Genie Runabout Contractor Service Manual,
First Edition
(before serial number 999) ................................. 115370
Introduction

September 2016
Part No. 227123 GRC
Serial Number Legend
iii
INTRODUCTION
Model: Serial number:
Model year:
Elec/Hydr Schematic:
Manufacture date:
Power supply voltage/Pneumatic Pressure:
Maximum Wind Speed:
Maximum allowable inclination of the chassis:
Gradeability:
Maximum platform height:
Maximum allowable side force:
Machine unladen weight:
Max Load:
Occupants and Equipment must not exceed:
Indoor:
Outdoor:
Nominal Power:
GRC16P-1234
2016
01/02/2010
GRC 16 P - 1234
2
1 43
5
6
Model: Serial number:
Elec/Hydr Schematic:
Year of Manufacture :
Power supply voltage/Pneumatic Pressure:
Maximum Wind Speed:
Maximum allowable inclination of the chassis:
Gradeability:
Maximum platform height:
Maximum allowable side force:
Machine unladen weight:
Max Load:
Occupants and Equipment must not exceed:
Indoor:
Outdoor:
Nominal Power:
GRP-12345
2016
GR P - 12345
2
13
4
5
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label (behind covers)
6 Serial number stamped on chassis
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label (behind covers)
5 Serial number stamped on chassis

September 2016
GRC Part No. 227123
This page intentionally left blank.
iv

September 2016
Part No. 227123 GRC
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

September 2016
GRC Part No. 227123
SAFETY RULES
vi
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.
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 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.

September 2016
Part No. 227123 GRC
Table of Contents
Introduction
Important Information ......................................................................................... ii
Serial Number Information ................................................................................. ii
Serial Number Legend ...................................................................................... iii
Section 1 Safety Rules
General Safety Rules ........................................................................................ v
Section 2 Rev Specifications
B 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 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
AChecklist A Procedures
A-1 Inspect the Manuals and Decals ......................................................... 3 - 6
A-2 Perform Pre-operation Inspection ....................................................... 3 - 7
A-3 Perform Function Tests ...................................................................... 3 - 7
A-4 Perform 30 Day Service ..................................................................... 3 - 8
A-5 Grease the Steer Yokes ..................................................................... 3 - 8
vii

September 2016
GRC Part No. 227123
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued
BChecklist B Procedures
B-1 Inspect the Batteries ........................................................................... 3 - 9
B-2 Inspect the Electrical Wiring ............................................................. 3 - 12
B-3 Inspect the Tires and Wheels (including castle nut torque) ............... 3 - 13
B-4 Test the Emergency Stop ................................................................. 3 - 13
B-5 Test the Key Switch .......................................................................... 3 - 14
B-6 Test the Automotive-style Horn (if equipped) .................................... 3 - 14
B-7 Inspect the Voltage Inverter (if equipped) ......................................... 3 - 15
B-8 Test the Drive Brakes ....................................................................... 3 - 16
B-9 Test the Drive Speed - Stowed Position ........................................... 3 - 17
B-10 Test the Drive Speed - Raised Position ............................................ 3 - 18
B-11 Test the Slow Drive Speed ............................................................... 3 - 19
B-12 Test the Flashing Beacons ............................................................... 3 - 20
B-13 Test the Motion Alarm (if equipped) .................................................. 3 - 20
B-14 Perform Hydraulic Oil Analysis ......................................................... 3 - 22
B-15 Inspect the Breather Cap .................................................................. 3 - 22
B-16 Inspect the Electrical Contactor ........................................................ 3 - 23
AChecklist C Procedures
C-1 Replace the Hydraulic Tank Breather Cap -
Models with Optional Hydraulic Oil ................................................... 3 - 24
AChecklist D Procedures
D-1 Replace the Hydraulic Tank Return Filter ......................................... 3 - 25
AChecklist E Procedure
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 26
viii

September 2016
Part No. 227123 GRC
TABLE OF CONTENTS
Section 4 Rev Repair Procedures
Introduction .................................................................................................. 4 - 1
APlatform Controls
1-1 Circuit Board ...................................................................................... 4 - 3
1-2 Joystick .............................................................................................. 4 - 4
1-3 Platform Controls Alarm ..................................................................... 4 - 4
1-4 Platform Emergency Stop Button ....................................................... 4 - 5
AGround Controls
2-1 Software Revision Level ..................................................................... 4 - 7
2-2 Machine Setup ................................................................................... 4 - 8
2-3 Level Sensor ...................................................................................... 4 - 9
AHydraulic Pump
3-1 Function Pump ................................................................................. 4 - 12
AFunction Manifold
4-1 Function Manifold Components ........................................................ 4 - 14
4-2 Valve Adjustments - Function Manifold ............................................ 4 - 16
4-3 Valve Coils ....................................................................................... 4 - 20
ABrake Release Hand Pump Components
5-1 Brake Release Hand Pump Components ......................................... 4 - 22
ix

September 2016
GRC Part No. 227123
TABLE OF CONTENTS
x
Section 4 Rev Repair Procedures, continued
AHydraulic Tank
6-1 Hydraulic Tank ................................................................................. 4 - 23
ASteer Axle Components
7-1 Yoke and Drive Motor ...................................................................... 4 - 24
7-2 Steer Cylinder .................................................................................. 4 - 26
7-3 Steer Bellcrank ................................................................................. 4 - 26
ANon-steer Axle Components
8-1 Drive Brake ...................................................................................... 4 - 27
APlatform Components
9-1 Platform ........................................................................................... 4 - 28
9-2 Platform Extension ........................................................................... 4 - 28
AMast Components
10-1 Mast ................................................................................................. 4 - 30
10-2 Wear Pads ....................................................................................... 4 - 41
10-3 Lift Cylinder ...................................................................................... 4 - 42
10-4 Lift Cylinder Wear Block ................................................................... 4 - 44
10-5 Mast Coil Cord ................................................................................. 4 - 44

September 2016
Part No. 227123 GRC
Section 5 Rev Diagnostics
Introduction .................................................................................................. 5 - 1
A GCON I/O Map ............................................................................................ 5 - 3
A Operational Indicator Codes ........................................................................ 5 - 4
A Diagnostic Indicator Codes .......................................................................... 5 - 4
A Troubleshooting "HXX" and "PXXX" Faults ................................................. 5 - 5
A Fault Inspection Procedure .......................................................................... 5 - 6
A Type "HXXX" Faults .................................................................................... 5 - 8
A Type "PXXX" Faults ..................................................................................... 5 - 9
A Type "UXXX" Faults .................................................................................. 5 - 10
A Type "FXXX" Faults ................................................................................... 5 - 11
A Type "CXXX" Faults .................................................................................. 5 - 12
Section 6 Rev Schematics
Introduction .................................................................................................. 6 - 1
B Electrical Component and Wire Color Legends ........................................... 6 - 2
B Wiring Diagram - Ground and Platform Controls .......................................... 6 - 3
B Electrical Symbols Legend............................................................................ 6 -4
B Electrical Schematic (from serial number GRC11-1000 to GRC11-1078) .... 6 - 6
B Electrical Schematic (from serial number GRC11-1079)............................ 6 - 10
A Hydraulic Component Reference and Symbols Legend ............................. 6 - 13
B Hydraulic Schematic .................................................................................. 6 - 14
xi

September 2016
GRC Part No. 227123
This page intentionally left blank.

Section 2 • Specifications
REV B
September 2016
Part No. 227123 GRC 2 - 1
Machine Specifications
Batteries, Standard
Voltage 6V DC
Group GC2
Type T-105
Quantity 4
Battery capacity, maximum C20 = 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
DC Motor
Voltage 24 V
Horse Power 4.5 HP @ 2950 RPM
Kilowatts 3.3 kW @ 2950 RPM
Fluid capacities
Hydraulic tank 1.5 gallons
5.7 liters
Hydraulic system 2.2 gallons
(including tank) 8.3 liters
For operational specifications, refer to the
Operator's Manual.Tires and wheels
Height, stowed maximum
GRC-12 66.8 in
1.69 m
Tires and wheels
Tire size (solid rubber) 10 x 3 in
25.4 x 7.62 cm
Tire contact area 6.5 sq in
41.9 cm2
Castle nut torque, lubricated 150 ft-lbs
203 Nm
Specifications

Section 2 • Specifications
REV B
September 2016
2 - 2 GRC Part No. 227123
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 30%
Airborne noise emissions
Sound pressure level at ground workstation < 70 dBA
Sound pressure level at platform workstation < 70 dBA
Maximum slope rating,
Function speed, maximum, from platform controls
(with 1 person in platform)
Platform up (fast mode) 10 to 14 seconds
Platform up (slow mode) 34 to 36 seconds
Platform down 14 to 18 seconds
Rated work load at full height, maximum
Platform 500 lbs
227 kg
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalent
Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum ISO 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 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 Petro Canada Environ MV 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
Continued use of Chevron
Aviation A hydraulic fluid when
ambient temperatures are
consistently above 32°F / 0°C may
result in component damage.
Note: Use Chevron Aviation A hydraulic fluid
when ambient temperatures are consistently
below 0°F / -17°C.
Note: Use Shell Tellus T46 hydraulic oil when oil
temperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult the Genie
Service Department before use.

Section 2 • Specifications
REV B
September 2016
Part No. 227123 GRC 2 - 3
SPECIFICATIONS
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
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
Note: The following coil resistance specifications are at
an ambient temperature of 68°F / 20°C. As valve coil
resistance is sensitive to changes in air temperature,
the coil resistance will typically increase or decrease by
4% for each 18°F / -7.7°C that your air temperature
increases or decreases from 68°F / 20°C.
Description Specification
Solenoid valve, 3 position 4 way 27.2Ω
20V DC with diode (schematic item E)
Solenoid valve, 3 position 4 way 19Ω
20V DC with diode (schematic item F)
Solenoid valve, 2 position 4 way 25Ω
20V DC with diode (schematic item H)
Solenoid valve, 2 position 2 way N.C. 6.25Ω
with manual override
12V DC with diode (schematic item N)

Section 2 • Specifications
REV B
September 2016
2 - 4 GRC Part No. 227123
SPECIFICATIONS
Hydraulic Hose and Fitting
Torque Specifications
Your machine is equipped with JIC 37° flared
fittings and hose ends. Genie specifications require
that fittings and hose ends be torqued to
specification when they are removed and installed
or when new hoses or fittings are installed.
JIC 37° Fittings
(swivel nut or hose connection)
SAE Dash size Thread Size Flats
-4 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

Section 2 • Specifications
REV B
September 2016
Part No. 227123 GRC 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
September 2016
2 - 6 GRC Part No. 227123
SPECIFICATIONS
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
516 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
619 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
745 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
85.4 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 chart is to be used as a guide onlyunless notedelsewhere inthis manual•
LUBED DRY
Class 10.9Class 8.8
DRY
SIZE THREAD
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20 80 9 100 11.3 110 12.4 140 15.8 130 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
9320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
7590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
61460 1979 1950 2643 2370 3213 3160 4284 2670 3620
12 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYLUBED
• This chart is to be usedas a guide onlyunless noted elsewhere in this manual•
A574 High Strength
Black Oxide Bolts
Grade 8
LUBED
1/4
LUBED DRY LUBED DRY
1 1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
5/16
3/8
7/16
1/2
10.9 12.98.84.6

Section 3 • Scheduled Maintenance ProceduresSeptember 2016
Part No. 227123 GRC 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, 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
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 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.

Section 3 • Scheduled Maintenance Procedures September 2016
3 - 2 GRC Part No. 227123
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.
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. Maintain completed
forms for a minimum of 4 years or in compliance
with employer, jobsite and governmental
regulations and requirements.