Genie GR-8 GR-12 GR-15 Service Manual 72965 – PDF DOWNLOAD

Description

Genie GR-8 GR-12 GR-15 Service Manual 72965 – PDF DOWNLOAD

Language : English
Pages : 132
Downloadable : Yes
File Type : PDF

Table of Contents:

Genie GR-8 GR-12 GR-15 Service Manual 72965 – PDF DOWNLOAD

Table of Contents.............................................................................  7
Section 1 • Safety Rules......................................................................  5
	Safety Rules..............................................................................  5
Section 2 • Specifications - Rev B............................................................ 13
	Machine Specifications.................................................................... 13
	Performance Specifications................................................................ 14
	Hydraulic Specifications.................................................................. 14
	Manifold Component Specifications......................................................... 15
	Hydraulic Hose and Fitting Torque Specifications.......................................... 16
	SAE and Metric Fasteners Torque Charts.................................................... 19
Section 3 • Scheduled Maintenance Procedures.................................................. 21
	Introduction.............................................................................. 21
	Pre-delivery Preparation Report........................................................... 23
	Maintenance Inspection Report............................................................. 25
	Checklist A Procedures - Rev B............................................................ 26
		A-1  Perform Pre-operation Inspection................................................. 26
		A-2  Perform Function Tests........................................................... 26
		A-3  Perform 30 Day Service........................................................... 27
		A-4  Grease the Steer Yokes........................................................... 27
	Checklist B Procedures - Rev B............................................................ 28
		B-1  Inspect the Batteries............................................................ 28
		B-2  Inspect the Electrical Wiring.................................................... 29
		B-3  Inspect the Tires and Wheels (including castle nut torque)....................... 30
		B-4 Check the Lifting Chain Adjustments............................................... 30
		B-5 Clean and Lubricate the Columns................................................... 31
		B-6 Adjust the Sequencing Cables...................................................... 31
		B-7 Test the Emergency Stop........................................................... 32
		B-8 Test the Key Switch............................................................... 33
		B-9 Test the Automotive-style Horn (if equipped)...................................... 33
		B-10 Test the Drive Brakes............................................................ 34
		B-11 Test the Drive Speed - Stowed Position........................................... 34
		B-12 Test the Drive Speed - Raised Position........................................... 35
		B-13 Test the Flashing Beacon (if equipped)........................................... 35
		B-14 Test the Alarm Package (if equipped)............................................. 36
		B-15 Perform Hydraulic Oil Analysis................................................... 37
		B-16 Inspect the Hydraulic Tank Cap Venting System.................................... 37
	Checklist C Procedures - Rev C............................................................ 38
		C-1 Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil...... 38
		C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 38
		C-3 Test the Platform Overload System (if equipped) .................................. 39
	Checklist D Procedures - Rev C............................................................ 41
		D-1 Inspect the Mast Assembly for Wear................................................ 41
		D-2 Lubricate the Lifting Chains...................................................... 42
		D-3 Replace the Hydraulic Tank Return Filter.......................................... 43
	Checklist E Procedure - Rev B............................................................. 44
		E-1 Test or Replace the Hydraulic Oil................................................. 44
Section 4 • Repair Procedures................................................................. 47
	Introduction.............................................................................. 47
	Platform Controls - Rev B................................................................. 48
		1-1 Circuit Board..................................................................... 48
		1-2 Controller Adjustments............................................................ 49
	Platform Components - Rev A............................................................... 51
		2-1 Platform.......................................................................... 51
		2-2 Platform Extension................................................................ 51
	Mast Components - Rev B................................................................... 52
		3-1 Mast.............................................................................. 52
		3-2 Glide Pads........................................................................ 56
		3-3 Lifting Chains.................................................................... 57
		3-4 Lift Cylinder..................................................................... 60
	Ground Controls - Rev B................................................................... 61
		4-1 Control Relays.................................................................... 61
		4-2 Circuit Board..................................................................... 62
		4-3 Controller Adjustments............................................................ 63
		4-4 Level Sensor...................................................................... 65
	Hydraulic Pump - Rev B.................................................................... 68
		5-1 Function Pump..................................................................... 68
	Manifolds - Rev B......................................................................... 70
		6-1 Function Manifold Components (before serial number GR01-225)...................... 70
		6-2 Function Manifold Components (from serial number GR01-225 to GR01-248)............ 72
		6-3 Function Manifold Components (after serial number GR01-248)....................... 74
		6-4 Valve Adjustments - Function Manifold............................................. 76
		6-5 Valve Coils....................................................................... 79
	Hydraulic Tank - Rev B.................................................................... 81
		7-1 Hydraulic Tank.................................................................... 81
	Steer Axle Components - Rev B............................................................. 82
		8-1 Yoke and Drive Motor.............................................................. 82
		8-2 Steer Cylinder.................................................................... 84
	Non-steer Axle Components - Rev A......................................................... 86
		9-1 Wheel Brake....................................................................... 86
	Platform Overload Components.............................................................. 87
		10-1 Platform Overload System......................................................... 87
Section 5 • Troubleshooting Flow Charts....................................................... 89
	Introduction.............................................................................. 89
	Chart 1 All Functions Will Not Operate - Rev A............................................ 91
	Chart 2 Pump Motor Will Not Operate - Rev A............................................... 93
	Chart 3 All Functions Inoperative, Power Unit Starts and Runs - Rev A..................... 94
	Chart 4 Ground Controls Inoperative, Platform Controls Operate Normally - Rev A........... 95
	Chart 5 Platform Controls Inoperative, Ground Controls Operate Normally - Rev A........... 96
	Chart 6 Platform Up Function Inoperative - Rev A.......................................... 97
	Chart 7 Platform Down Function Inoperative - Rev A........................................ 98
	Chart 8 Steer Left Function Inoperative - Rev A........................................... 99
	Chart 9 Steer Right Function Inoperative - Rev A..........................................100
	Chart 10 All Drive Functions Inoperative, All Other Functions Operate Normally - Rev A....101
	Chart 10A Brake Release Function Inoperative - Rev A......................................102
	Chart 11 Drive Forward Function Inoperative - Rev A.......................................103
	Chart 12 Drive Reverse Function Inoperative - Rev A.......................................104
	Chart 13 Machine Will Not Drive At Full Speed - Rev A.....................................105
	Chart 14 Machine Drives at Full Speed With Platform Raised - Rev A........................106
Section 6 • Schematics........................................................................107
	Introduction..............................................................................107
	Ground Controls Layout and Electrical Component Legend - Rev B............................108
	Electrical Symbols and Wire Color Legends - Rev B.........................................109
	Electrical Schematic - ANSI Models (before serial number GR02-1800) - Rev C...............110
	Electrical Schematic - ANSI Models (from serial number GR02-1800 to GR03-2407) - Rev C....112
	Electrical Schematic - ANSI Models (from serial number GR03-2408 to GR03-2432) - Rev B....114
	Electrical Schematic - ANSI Models (after serial number GR03-2432) - Rev B................116
	Electrical Schematic - CE Models (before serial number GR02-1800) - Rev C.................118
	Electrical Schematic - CE Models (from serial number GR02-1800 to GR03-2407) - Rev C......120
	Electrical Schematic - CE Models (from serial number GR03-2408 to GR03-2432) - Rev B......122
	Electrical Schematic - CE Models (from serial number GR03-2433 to GR04-4000) - Rev B......124
	Electrical Schematic - CE Models (after serial number GR04-4000) - Rev B..................126
	Hydraulic Symbols Legend - Rev B..........................................................128
	Hydraulic Schematic (before serial number GR01-249) - Rev B...............................129
	Hydraulic Schematic (after serial number GR01-248) - Rev B................................130

S.S 04/24