Genie Runabout GR-8 Manuale utente

Part No. 72965

Rev B2

January 2007

Service Manual

(from serial number GR-101 to GR05-4999)

August 2005

GR-8 • GR-12 • GR-15 Part No. 72965

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 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.

72965 Rev B August 2005

First 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.

www.genieindustries.com

e-mail: [email protected]

Introduction

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15

iii

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

100 lb / 445 kg

2005

Model year

Serial Number Legend

August 2005

GR-8 • GR-12 • GR-15 Part No. 72965

This page intentionally left blank.

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15

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.

Section 1 • Safety Rules

Safety Rules

August 2005

GR-8 • GR-12 • GR-15 Part No. 72965

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 .

Section 1 • Safety Rules

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15

Table of Contents

Introduction

Important Information .........................................................................................

Serial Number Legend ......................................................................................

iii

Section 1 Safety Rules

General Safety Rules ........................................................................................

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 - 7

Section 3 Rev Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1

Pre-delivery Preparation Report .................................................................. 3 - 3

Maintenance Inspection Report ................................................................... 3 - 5

BChecklist 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

April 2006

GR-8 • GR-12 • GR-15 Part No. 72965

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 - 9

B-3 Inspect the Tires and Wheels (including castle nut torque) ............... 3 - 10

B-4 Check the Lifting Chain Adjustments ................................................ 3 - 10

B-5 Clean and Lubricate the Columns..................................................... 3 - 11

B-6 Adjust the Sequencing Cables .......................................................... 3 - 11

B-7 Test the Emergency Stop ................................................................. 3 - 12

B-8 Test the Key Switch .......................................................................... 3 - 13

B-9 Test the Automotive-style Horn (if equipped) .................................... 3 - 13

B-10 Test the Drive Brakes ....................................................................... 3 - 14

B-11 Test the Drive Speed - Stowed Position ........................................... 3 - 14

B-12 Test the Drive Speed - Raised Position ............................................ 3 - 15

B-13 Test the Flashing Beacon (if equipped) ............................................ 3 - 15

B-14 Test the Alarm Package (if equipped)............................................... 3 - 16

B-15 Perform Hydraulic Oil Analysis ......................................................... 3 - 17

B-16 Inspect the Hydraulic Tank Cap Venting System .............................. 3 - 17

CChecklist C Procedures

C-1 Replace the Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil .................................................... 3 - 18

C-2 Grease the Platform Overload Mechanism (if equipped) .................. 3 - 18

C-3 Test the Platform Overload System (if equipped) ............................. 3 - 19

CChecklist D Procedures

D-1 Calibrate the Platform Overload System (if equipped) ...................... 3 - 21

D-2 Inspect the Mast Assembly for Wear ................................................ 3 - 22

D-3 Lubricate the Lifting Chains .............................................................. 3 - 24

D-4 Replace the Hydraulic Tank Return Filter ......................................... 3 - 24

BChecklist E Procedure

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 25

viii

August 2005

Part No. 72965 GR-8 • GR-12 • GR-15

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

BPlatform Components

2-1 Platform ............................................................................................. 4 - 5

2-2 Platform Extension ............................................................................. 4 - 5

BMast Components

3-1 Mast ................................................................................................... 4 - 6

3-2 Glide Pads ....................................................................................... 4 - 10

3-3 Lifting Chains ................................................................................... 4 - 11

3-4 Lift Cylinders .................................................................................... 4 - 14

BGround Controls

4-1 Control Relays ................................................................................. 4 - 15

4-2 Circuit Board .................................................................................... 4 - 16

4-3 Controller Adjustments ..................................................................... 4 - 17

4-4 Level Sensor .................................................................................... 4 - 19

BHydraulic Pump

5-1 Function Pump ................................................................................. 4 - 22

BManifolds

6-1 Function Manifold Components

(before serial number GR01-225) .................................................... 4 - 24

6-2 Function Manifold Components

(from serial number GR01-225 to GR01-248) .................................. 4 - 26

6-3 Function Manifold Components

(after serial number GR01-248) ....................................................... 4 - 28

6-4 Valve Adjustments - Function Manifold ............................................. 4 - 30

6-5 Valve Coils ....................................................................................... 4 - 33

BHydraulic Tank

7-1 Hydraulic Tank ................................................................................. 4 - 35

April 2006

GR-8 • GR-12 • GR-15 Part No. 72965

Section 4 Rev Repair Procedures, continued

BSteer Axle Components

8-1 Yoke and Drive Motor ...................................................................... 4 - 36

8-2 Steer Cylinder .................................................................................. 4 - 38

ANon-steer Axle Components

9-1 Wheel Brake .................................................................................... 4 - 40

APlatform Overload Components

10-1 Platform Overload System ............................................................... 4 - 41

Section 5 Rev Troubleshooting Flow Charts

A Introduction .................................................................................................. 5 - 1

Chart Chart

Number Title

A 1 All Functions Will Not Operate ........................................................... 5 - 3

A 2 Pump Motor Will Not Operate............................................................ 5 - 5

A 3 All Function Inoperative, Power Unit Starts and Runs ....................... 5 - 6

A 4 Ground Controls Inoperative, Platform Controls Operate Normally ... 5 - 7

A 5 Platform Controls Inoperative, Ground Controls Operate Normally ... 5 - 8

A 6 Platform Up Function Inoperative ...................................................... 5 - 9

A 7 Platform Down Function Inoperative................................................ 5 - 10

A 8 Steer Left Function Inoperative ....................................................... 5 - 11

A 9 Steer Right Function Inoperative ..................................................... 5 - 12

A 10 All Drive Functions Inoperative, All Other

Functions Operate Normally ............................................................ 5 - 13

A 10A Brake Release Function Inoperative................................................ 5 - 14

A 11 Drive Forward Function Inoperative................................................. 5 - 15

A 12 Drive Reverse Function Inoperative ................................................ 5 - 16

A 13 Machine Will Not Drive at Full Speed .............................................. 5 - 17

A 14 Machine Drives At Full Speed With Platform Raised ....................... 5 - 18

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