227656
227656
227656
Introduction
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.
Compliance
Machine Classification
Group B/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.
Printed in U.S.A.
Revision History
Revision Date Section Procedure / Schematic Page / Description
A 4/2011 New release
REFERENCE EXAMPLES:
REFERENCE EXAMPLES:
INTRODUCTION
Safety Rules
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.
SAFETY RULES
Read each procedure thoroughly. This Be sure that all tools and working areas
manual and the decals on the machine, are properly maintained and ready for
use signal words to identify the following: use. Keep work surfaces clean and free of
debris that could get into machine components and
Safety alert symbol—used to alert cause damage.
personnel to potential personal
injury hazards. Obey all safety Be sure any forklift, overhead crane or
messages that follow this symbol other lifting or supporting device is fully
to avoid possible injury or death. capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
Indicates an imminently hazardous
are in good condition and of ample capacity.
situation which, if not avoided, will
result in death or serious injury. Be sure that fasteners intended for one
Indicates a potentially hazardous time use (i.e., cotter pins and self-locking
situation which, if not avoided, nuts) are not reused. These components
could result in death or serious may fail if they are used a second time.
injury. Be sure to properly dispose of old oil or
Indicates a potentially hazardous other fluids. Use an approved container.
situation which, if not avoided, Please be environmentally safe .
may cause minor or moderate Be sure that your workshop or work area
injury. is properly ventilated and well lit.
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.
Table of Contents
Introduction
Important Information ......................................................................................... ii
Revision History ................................................................................................ iii
Serial Number Legend ...................................................................................... v
Section 2 Specifications
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
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
Section 6 Schematics
Introduction .................................................................................................. 6 - 1
Electrical Component and Wire Color Legend ............................................. 6 - 2
ECM Pin-out legend ..................................................................................... 6 - 3
Limit Switch and Sensor Legend .................................................................. 6 - 4
Electrical Symbols Legend ........................................................................... 6 - 5
Specifications
Machine Specifications Tires and wheels
SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
-10 62 ft-lbs / 84 Nm
Seal-Lok™ Fittings
(hose end - ORFS) -12 84 ft-lbs / 114 Nm
-8 40 ft-lbs / 54.2 Nm
SPECIFICATIONS
Torque Procedure
Seal-Lok™ fittings
a
1 Replace the O-ring. The O-ring must be
replaced anytime the seal has been broken. c b
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.
Figure 1
Note: The O-rings used in the Parker Seal Lok™
fittings and hose ends are custom-size O-rings. a hex nut
They are not standard SAE size O-rings. They are b reference mark
available in the O-ring field service kit (Genie part c body hex fitting
number 49612). 3 Working clockwise on the body hex fitting,
2 Lubricate the O-ring before installation. make a second mark with a permanent ink
marker to indicate the proper tightening
3 Be sure that the face seal O-ring is seated and position. Refer to Figure 2.
retained properly.
Note: Use the JIC 37° Fittings table on the
4 Position the tube and nut squarely on the face previous page to determine the correct number of
seal end of the fitting and tighten the nut finger flats for the proper tightening position.
tight.
Note: The marks indicate that the correct
5 Tighten the nut or fitting to the appropriate tightening positions have been determined. Use
torque per given size as shown in the table. the second mark on the body hex fitting to
properly tighten the joint after it has been
6 Operate all machine functions and inspect the
loosened.
hoses and fittings and related components to
confirm that there are no leaks.
JIC 37° fittings
b
1 Align the tube flare (hex nut) against the nose a
of the fitting body (body hex fitting) and tighten c
b
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 Figure 2
fitting with a permanent ink marker. Refer to
Figure 1. a body hex fitting
b reference mark
c second mark
SPECIFICATIONS
Maintenance Schedule
Indicates that tools will be required to
perform this procedure. 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
Indicates that new parts will be required
Section and the Maintenance Inspection Report
to perform this procedure.
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
Indicates that a cold motor or pump will perform a scheduled inspection.
be required to perform this procedure.
Inspection Checklist
Fundamentals Instructions
It is the responsibility of the dealer to perform the Use the operator’s manual on your machine.
Pre-delivery Preparation.
The Pre-delivery Preparation consists of completing
The Pre-delivery Preparation is performed prior to the Pre-operation Inspection, the Maintenance items
each delivery. The inspection is designed to discover if and the Function Tests.
anything is apparently wrong with a machine before it
is put into service. Use this form to record the results. Place a check in
the appropriate box after each part is completed.
A damaged or modified machine must never be used. Follow the instructions in the operator’s manual.
If damage or any variation from factory delivered
condition is discovered, the machine must be tagged If any inspection receives an N, remove the machine
and removed from service. from service, repair and reinspect it. After repair, place
a check in the R box.
Repairs to the machine may only be made by a
qualified service technician, according to the Legend
manufacturer's specifications. Y = yes, completed
Scheduled maintenance inspections shall be N = no, unable to complete
performed by qualified service technicians, according R = repaired
to the manufacturer's specifications and the Comments
requirements listed in the responsibilities manual.
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
Checklist A Procedures
A-1 3 Open the operator's manual to the decals
inspection section. Carefully and thoroughly
Inspect the Manuals and Decals inspect all decals on the machine for legibility
Genie specifications require that this procedure be and damage.
performed every 8 hours or daily, whichever Result: The machine is equipped with all
comes first. required decals, and all decals are legible and
Maintaining the operator’s and safety manuals in in good condition.
good condition is essential to safe machine Result: The machine is not equipped with all
operation. Manuals are included with each required decals, or one or more decals are
machine and should be stored in the container illegible or in poor condition. Remove the
provided in the platform. An illegible or missing machine from service until the decals are
manual will not provide safety and operational replaced.
information necessary for a safe operating
condition. 4 Always return the manuals to the storage
container after use.
In addition, maintaining all of the safety and
instructional decals in good condition is mandatory Note: Contact your authorized Genie distributor or
for safe machine operation. Decals alert operators Genie Industries if replacement manuals or decals
and personnel to the many possible hazards are needed.
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.
CHECKLIST A PROCEDURES
A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever
comes first. comes first.
Completing a Pre-operation Inspection is essential Completing the function tests is essential to safe
to safe machine operation. The Pre-operation machine operation. Function tests are designed to
Inspection is a visual inspection performed by the discover any malfunctions before the machine is
operator prior to each work shift. The inspection is put into service. A malfunctioning machine must
designed to discover if anything is apparently never be used. If malfunctions are discovered, the
wrong with a machine before the operator performs machine must be tagged and removed from
the function tests. The Pre-operation Inspection service.
also serves to determine if routine maintenance
procedures are required. Complete information to perform this procedure is
available in the appropriate operator's manual.
Complete information to perform this procedure is Refer to the Operator's Manual on your machine.
available in the appropriate operator's manual.
Refer to the Operator's Manual on your machine.
A-4
Perform 30 Day Service
CHECKLIST A PROCEDURES
Checklist B Procedures
B-1
Inspect the Battery
a
F9 b
250A Fuse
CHECKLIST B PROCEDURES
Genie specifications require that this procedure be 6 Remove the fasteners securing the rear chassis
performed every 250 hours or quarterly, whichever cover to the chassis at the non-steer end of the
comes first. machine. Remove the chassis cover. Lay the
cover and fasteners to the side.
Maintaining electrical wiring in good condition is
essential to safe operation and good machine 7 Inspect the drive motors connections for burnt,
performance. Failure to find and replace burnt, chafed, pinched cables and loose connections.
chafed, corroded or pinched wires could result in 8 Install the rear chassis cover at the non-steer
unsafe operating conditions and may cause end of the machine and securely install the
component damage. fasteners.
Electrocution/burn hazard. Contact 9 Install the cables onto the ground terminal of the
with electrically charged circuits battery, and securely tighten.
could result in death or serious
injury. Remove all rings, watches 10 Inspect the battery pack for burnt, chafed and
and other jewelry. pinched cables.
1 Open and remove the turntable covers from the 11 Inspect the following areas for burnt, chafed,
machine. corroded and loose wires:
2 Turn the key switch to ground control and pull • Ground control panel
out the red Emergency Stop button to the on • Battery charger
position at both the ground and platform
• Hydraulic power unit
controls.
12 Turn the key switch to ground control and pull
Note: Rotate the red Emergency Stop button at out the red Emergency Stop button to the on
platform control one quarter turn in a clockwise position at the ground control.
direction to restore the power supply. The red
Emergency Stop button returns automatically to Note: Rotate the red Emergency Stop button at
the out, or on position. platform control one quarter turn in a clockwise
direction to restore the power supply. The red
3 Raise the jib boom until the platform is Emergency Stop button returns automatically to
approximately 8 feet / 2.4 m from the ground. the out, or on position.
CHECKLIST B PROCEDURES
CHECKLIST B PROCEDURES
B-4 B-5
Test the Emergency Stop Test the Horn
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever
comes first. comes first.
A properly functioning Emergency Stop is essential The horn is activated at the platform controls and
for safe machine operation. An improperly sounds at the ground as a warning to ground
operating red Emergency Stop button will fail to personnel. An improperly functioning horn will
shut off power and stop all machine functions, prevent the operator from alerting ground
resulting in a hazardous situation. personnel of hazards or unsafe conditions.
1 Turn the key switch to ground control and pull 1 Turn the key switch to platform control and
out the red Emergency Stop button to the on pull out the red Emergency Stop button to the
position at both the ground and platform on position at both the ground and
controls. platform controls.
Note: Rotate the red Emergency Stop button at Note: Rotate the red Emergency Stop button at
platform control one quarter turn in a clockwise platform control one quarter turn in a clockwise
direction to restore the power supply. The red direction to restore the power supply. The red
Emergency Stop button returns automatically to Emergency Stop button returns automatically to
the out, or on position. the out, or on position.
2 Push in the red Emergency Stop button at the 2 Push down the horn button at the platform
ground controls to the off position. controls.
3 Check the machine functions from the ground Result: The horn should sound.
controls.
Result: The machine functions should not
operate.
4 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
5 Push the red Emergency Stop button at the
platform controls to the off position.
6 Check the machine functions from the platform
controls.
Result: The machine functions should not
operate.
Note: The red Emergency Stop button at the
ground controls will stop all machine operations,
even if the key switch is turned to the platform
control.
CHECKLIST B PROCEDURES
B-6
Test the Key Switch a
CHECKLIST B PROCEDURES
B-7
Test the Drive Brakes
2 Turn the key switch to platform control and pull 7 Measure the distance between the test line and
out the red Emergency Stop button to the on your machine reference point. Refer to
position at both the ground and platform Section 2, Specifications.
controls. Note: The brakes must be able to hold the machine
Note: Rotate the red Emergency Stop button at on any slope it is able to climb.
platform control one quarter turn in a clockwise
direction to restore the power supply. The red
Emergency Stop button returns automatically to
the out, or on position.
3 Lower the platform to the stowed position.
4 Press the drive function select button.
CHECKLIST B PROCEDURES
B-8
Test the Drive Speed -
Stowed Position
a
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first. a drive function select button BN130
Proper drive functions are essential to safe 5 Choose a point on the machine i.e. contact
machine operation. The drive function should patch of a tire, as a visual reference for use
respond quickly and smoothly to operator control. when crossing the start and finish lines.
Drive performance should also be free of
hesitation, jerking and unusual noise over the 6 Bring the machine to top drive speed before
entire proportionally controlled speed range. reaching the start line. Begin timing when your
reference point on the machine crosses the
Note: Perform this procedure with the machine on start line.
a firm, level surface that is free of obstructions.
7 Continue at full speed and note the time when
1 Create start and finish lines by marking two your reference point on the machine passes
lines on the ground 40 feet / 12.2 m apart. over the finish line. Refer to Section 2,
Specifications.
2 Turn the key switch to platform control and pull
out the red Emergency Stop button to the on
position at both the ground and platform
controls.
Note: Rotate the red Emergency Stop button at
platform control one quarter turn in a clockwise
direction to restore the power supply. The red
Emergency Stop button returns automatically to
the out, or on position.
3 Lower the platform to the stowed position.
4 Press the drive function select button.
CHECKLIST B PROCEDURES
B-9
Test the Drive Speed -
Raised Position
CHECKLIST B PROCEDURES
B-10
Test the Flashing Beacon
(if equipped)
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first.
CHECKLIST B PROCEDURES
1 Turn the key switch to ground control and pull 8 Press and hold the function enable switch on
out the red Emergency Stop button to the on the joystick. Move the joystick off center, hold
position at both the ground and platform for a moment and then release it. Move the
controls. joystick off center in the opposite direction, hold
for a moment and then release it.
Note: Rotate the red Emergency Stop button at
platform control one quarter turn in a clockwise Result: The motion alarm will sound when the
direction to restore the power supply. The red joystick is moved off center in either direction.
Emergency Stop button returns automatically to 9 Press and hold the function enable switch on
the out, or on position. the joystick. Press and hold the thumb rocker
switch for a moment to the left position and then
2 Raise the platform approximately 1 ft / 30.5 cm. release it. Press and hold the thumb rocker
Result: When raising the platform, the motion switch for a moment to the right position and
alarm will sound. then release it.
Result: The motion alarm will sound when the
3 Lower the platform to the stowed position.
rocker switch is moved off center in either
Result: When lowering the platform, the motion direction.
alarm will sound.
4 Turn the key switch to platform controls.
5 Press the lift function select button.
CHECKLIST B PROCEDURES
B-12 B-13
Perform Hydraulic Oil Analysis Inspect the Breather Cap
Genie specifications require that this procedure be
performed every 250 hours or quarterly, whichever
comes first. Perform this procedure more often if
Genie specifications require that this procedure be dusty conditions exist.
performed every 250 hours or quarterly, whichever
comes first. A free-breathing hydraulic tank cap is essential for
good machine performance and service life. A dirty
Replacement or testing of the hydraulic oil is or clogged cap may cause the machine to perform
essential for good machine performance and poorly. Extremely dirty conditions may require that
service life. Dirty oil may cause the machine to the cap be inspected more often.
perform poorly and continued use may cause
component damage. Extremely dirty conditions 1 Open the turntable cover at the hydraulic power
may require oil changes to be performed more unit side of the machine.
often. Refer to Section 2, Specifications. 2 Locate and remove the breather cap from the
Before replacing the hydraulic oil, the oil may be hydraulic tank.
tested by an oil distributor for specific levels of 3 Check the breather cap for proper venting.
contamination to verify that changing the oil is
necessary. Result: Air passes through the breather cap.
If the hydraulic oil is not replaced at the two Proceed to step 5.
year inspection, test the oil quarterly. Replace Result: If air does not pass through the cap,
the oil when it fails the test. See E-1, Test or clean or replace the cap. Proceed to step 4.
Replace the Hydraulic Oil.
Note: When checking the hydraulic tank breather
cap for venting, air should pass freely through the
cap.
4 Using a mild solvent, carefully wash the cap
venting system. Dry using low pressure
compressed air. Repeat this procedure
beginning with step 3.
5 Install the breather cap onto the hydraulic tank.
CHECKLIST B PROCEDURES
B-14
a
Inspect the Rear Axle
Free-wheeling
1 Secure the steer end of the machine to a forklift 6 Move the free-wheel selector switch to the left.
or similar device using a connecting bar no
Result: The parking brakes will set and the horn
greater than 3 ft / 1 m in length. Set the brakes
will not sound.
on forklift.
7 Using a fork lift or similar device, apply force to
2 Open the turntable cover at the ground control
the machine.
side of the machine.
Result: The machine will not move freely.
3 Using the illustration as a guide, locate the
free-wheel selector switch on the top of the
ground control box.
4 Move the free-wheel selector switch to the right
to set the machine to free-wheel condition.
Result: The parking brakes will release and the
horn will sound softly.
5 Remove the wheel chocks and, using a fork lift
or similar device, apply force to the machine.
Result: The machine will move freely.
Component damage hazard. The
machine can be damaged if it
breaks free from the forklift. Do not
attempt to test the free-wheeling
function unless a connecting bar
of adequate size and strength is
used to secure the GR-J to the
forklift or similar device.
CHECKLIST B PROCEDURES
CHECKLIST B PROCEDURES
B-16
Inspect the Mast Wear Pads
Checklist C Procedure
C-1 Models equipped with the platform overload option
are provided with additional machine components:
Calibrate the Platform Overload an adjustable spring-loaded subassembly, a limit
System (if equipped) switch harness, an electronic module which
receives the overload signal and interrupts power,
and an audio/visual warning indication to alert the
operator of the overload.
Genie specifications require that this procedure be Refer to Repair Procedure 2-2, How to Calibrate
performed every 500 hours or six months, the Platform Overload System (if equipped).
whichever comes first OR when the machine fails
to lift the maximum rated load.
Calibrating the platform overload system regularly
is essential to safe machine operation. Continued
use of an improperly operating platform overload
system could result in the system not sensing an
overloaded platform condition. Machine stability
could be compromised resulting in the machine
tipping over.
CHECKLIST C PROCEDURES
C-2
Replace the Hydraulic Tank
Breather Cap - Models with
Optional Hydraulic Oil
Checklist D Procedure
D-1
Replace the Hydraulic Tank
Return Filter
Checklist E Procedure
E-1 4 Place a suitable container under the hydraulic
tank. Refer to Section 2, Specifications.
Test or Replace the Hydraulic Oil
5 Locate and remove the hydraulic tank filler cap.
Set the filler cap to the side.
6 Remove the drain plug and drain all of the oil
Genie specifications require that this procedure be into a suitable container.
performed every 2000 hours or every two years, 7 Clean up any oil that may have spilled. Properly
whichever comes first. discard the used oil.
Replacement or testing of the hydraulic oil is Note: To clean the inside of the hydraulic tank
essential for good machine performance and using a mild solvent, it may be helpful to remove
service life. Dirty oil may cause the machine to the hydraulic power unit from the tank. Refer to
perform poorly and continued use may cause Repair Procedure 6-1, How to Remove the
component damage. Extremely dirty conditions Function Pump.
may require oil changes to be performed more
often. 8 Install the drain plug onto the hydraulic tank and
torque to specification.
Before replacing the hydraulic oil, the oil may be
tested by an oil distributor for specific levels of
Torque specification
contamination to verify that changing the oil is
necessary. If the hydraulic oil is not replaced at Hydraulic tank drain plug 44 in-lbs
the two year inspection, test the oil quarterly. 5 Nm
Replace the oil when it fails the test.
Note: Perform this procedure with the machine in 9 Fill the tank with hydraulic oil until the fluid is at
the stowed position. the full indicator on the hydraulic tank. Do not
overfill.
1 Open the turntable covers of the machine.
10 Install the filler cap onto the hydraulic tank, and
2 Disconnect the battery pack from the machine. securely tighten. Do not over tighten.
Electrocution/burn hazard. Contact 11 Activate the pump to fill the hydraulic system
with electrically charged circuits with oil and bleed the system of air.
could result in death or serious
Component damage hazard. The
injury. Remove all rings, watches
pump can be damaged if operated
and other jewelry.
without oil. Be careful not to empty
3 Remove the fasteners securing the chassis side the hydraulic tank while in the
cover next to the tank to the chassis. Remove process of filling the hydraulic
the side cover. Lay the side cover and system. Do not allow the pump to
fasteners to the side. activate.
Repair Procedures
About This Section
Most of the procedures in this section should only
be performed by a trained service professional
in a suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Observe and Obey:
Perform disassembly procedures to the point
Repair procedures shall be completed by a where repairs can be completed. Then to
person trained and qualified on the repair of this reassemble, perform the disassembly steps in
machine. reverse order.
Immediately tag and remove from service a Symbols Legend
damaged or malfunctioning machine.
Safety alert symbol—used to alert
Repair any machine damage or malfunction personnel to potential personal
before operating the machine. injury hazards. Obey all safety
messages that follow this symbol
Before Repairs Start: to avoid possible injury or death.
Read, understand and obey the safety rules Indicates an imminently hazardous
and operating instructions in the appropriate situation which, if not avoided, will
operator's manual on your machine. result in death or serious injury.
Be sure that all necessary tools and parts are Indicates a potentially hazardous
situation which, if not avoided,
available and ready for use.
could result in death or serious
Use only Genie approved replacement parts. injury.
Read each procedure completely and adhere to Indicates a potentially hazardous
the instructions. Attempting shortcuts may situation which, if not avoided,
produce hazardous conditions. may cause minor or moderate
injury.
Unless otherwise specified, perform each repair
procedure with the machine in the following Indicates a potentially hazardous
configuration: situation which, if not avoided,
may result in property damage.
• Machine parked on a firm, level surface
Indicates that a specific result is expected after
• Platform in the stowed position
performing a series of steps.
• Key switch in the off position with the key
removed Indicates that an incorrect result has occurred
after performing a series of steps.
• 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
Platform Controls
The platform controls, used to operate the machine 1-1
from the platform. The platform controls are used
to operate the various machine functions. Circuit Boards
The platform controls consist of an electronic How to Remove the Platform
circuit board, joystick, alarm, buttons and LEDs.
Controls Circuit Board
For further information or assistance, consult the
Genie Service Department. 1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Remove the fasteners securing the top plate
assembly to the platform control box. Carefully
remove the top plate assembly from the box to
expose the circuit boards.
3 Tag and disconnect the wire harness
connectors from the platform controls circuit
board.
Electrocution/burn hazard. Contact
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches
and other jewelry.
Component damage hazard.
Electrostatic discharge (ESD) can
damage printed circuit board
components. Maintain firm contact
with a metal part of the machine
that is grounded at all times when
handling printed circuit boards OR
use a grounded wrist strap.
4 Remove the fasteners securing the platform
controls circuit board to the top plate assembly.
Set the fasteners to the side.
5 Remove the platform controls circuit boards
from the top plate assembly.
PLATFORM CONTROLS
1-2
Controller Adjustments h
a
g
How to Activate or Deactivate b
the Motion Alarm
The alarm is activated at the platform controls and
sounds at the ground as a warning to ground
personnel. An improperly functioning alarm will f e d c
prevent the operator from alerting ground
personnel of hazards or unsafe conditions. a joystick function enable switch
b thumb rocker switch
1 Turn the key switch to platform control and pull c joystick
d jib boom function button BN97
out the red Emergency Stop button to the on e lift function and turntable rotate
position at both the ground and platform function button BN63
controls. f drive function button BN130
g function indicator lights
Note: Rotate the red Emergency Stop button at h red Emergency Stop button P2
platform control one quarter turn in a clockwise
direction to restore the power supply. The red 5 Press and hold the drive function button for
Emergency Stop button returns automatically to 3 seconds.
the out, or on position. Result: All 3 indicator lights will flash for 3
2 Simultaneously press and hold all three function seconds and turn off.
buttons for 3 seconds. 6 Push in the red Emergency Stop button at
Result: A beep sounds and three function platform controls to confirm the procedure.
indicator lights will flash one after another. Result: The motion alarm will sound during all
3 Simultaneously press and hold the drive machine movements.
function and the lift function buttons for 3 Note: To deactivate the motion alarm, perform this
seconds. procedure beginning with step 1.
Result: All three function indicator lights will stop
flashing.
4 Briefly press and release the drive function
button to turn the motion alarm on or off.
Result: The drive indicator light will be on if the
motion alarm is activated.It will be off if the
motion alarm is deactivated.
PLATFORM CONTROLS
PLATFORM CONTROLS
4 Using the illustration as a guide, move the Result: All three function indicator lights will
joystick fully to the left, then return the joystick flash three times. Joystick calibration is
to the neutral position. complete.
Note: Do not squeeze or activate the joystick
function enable switch. No machine function
should operate while performing the joystick
calibration procedure.
PLATFORM CONTROLS
2 Turn the key switch to off position and push in a joystick function enable switch
the red Emergency Stop button to the off b thumb rocker switch
position at both the ground and platform c joystick
d jib boom function button BN97
controls. e lift function and turntable rotate
function button BN63
3 Tag and disconnect the steer angle sensor wire
f drive function button BN130
harness from the machine wire harness. g function indicator lights
h red Emergency Stop button P2
4 With a multimeter set to read 4K±0.2 ohms,
connect the leads to the green and black wires 8 Simultaneously press and hold the lift function
of the potentiometer. and jib boom function buttons for 3 seconds.
Result: The reading is 4K±0.2 ohms. Result: All three function indicator lights will stop
Proceed to step 5. flashing.
Result: The reading is not 4K±0.2 ohms. 9 Press and hold the joystick function enable
See 10-4, How to Replace the Steer Angle switch and activate the thumb rocker switch
Sensor. turning the wheels fully to the left.
5 Connect the steer angle sensor wire harness to 10 Press the drive function button for 1 second to
the machine wire harness. validate the left side steering limit.
6 Turn the key switch to platform control and pull 11 Press and hold the joystick function enable
out the red Emergency Stop button to the on switch and activate the thumb rocker switch
position at both the ground and platform turning the wheels fully to the right.
controls.
12 Press the jib boom function button for 1 second
Note: Rotate the red Emergency Stop button at to validate the right side steering limit.
platform control one quarter turn in a clockwise
direction to restore the power supply. The red 13 Press and hold the joystick function enable
Emergency Stop button returns automatically to switch and activate the thumb rocker switch
the out, or on position. placing the wheels in line with the chassis.
7 Simultaneously press and hold all three function 14 Press the lift function button for 1 second.
select buttons for 3 seconds. 15 Press the drive function button for 3 seconds.
Steer Sensor calibration is complete.
Result: A beep sounds and three function
indicator lights will flash one after another.
Platform Components
2-1 7 Remove the fasteners securing the outlet
mounting plate to the platform. Set the
Platform mounting plate assembly and fasteners to the
side.
How to Remove the Platform 8 Attach a lifting strap of suitable capacity from an
1 Push in the red Emergency Stop button to the overhead crane to the bottom of the platform.
off position at both the ground and platform Support the platform. Do not apply any lifting
controls. pressure.
2 Disconnect the battery pack from the machine. Component damage hazard. The
platform railings can be damaged
3 Remove the fasteners securing the top plate if they are used to lift the platform.
assembly to the platform control box. Do not attach the lifting strap to
4 Tag and disconnect the wire harness the platform railings or put
connectors from the platform controls circuit pressure on the railings.
boards. 9 Remove the platform mounting pins retaining
Electrocution/burn hazard. Contact fasteners. Set the fasteners to the side.
with electrically charged circuits 10 Remove the pins securing the platform to the jib
could result in death or serious boom.
injury. Remove all rings, watches
and other jewelry. 11 Remove the platform from the machine.
PLATFORM COMPONENTS
2-2 a b c
Platform Overload System
PLATFORM COMPONENTS
8 Turn the adjusting screw of the number 1 11 Turn the key switch to the ground control.
overload sensor 10° in a counterclockwise
12 Test all machine functions from the ground
direction.
controls.
Result: The overload indicator lights are
Result: All ground control functions should not
flashing at the ground and platform controls,
operate.
and the alarm is sounding intermittently.
Proceed to step 9. 13 Using a suitable lifting device, remove the test
weight from the platform.
Result: The overload indicator lights are off at
the ground and platform controls and the alarm Result: The platform overload indicator light
does not sound intermittently. Repeat the should be off at both the ground and platform
procedure beginning with step 8. controls and the alarm should not sound.
9 Turn the adjusting screw of the number 2 14 Test all machine functions from ground controls.
overload sensor 10° in a counterclockwise
direction. Result: All ground control functions should
operate normally.
Result: The overload indicator lights are
flashing at the ground and platform controls, 15 Turn the key switch to the platform control.
and the alarm is sounding continuously. 16 Test all machine functions from the platform
Proceed to step 10. controls.
Result: The overload indicator lights are off at Result: All platform control functions should
the ground and platform controls and the alarm
operate normally.
does not sound continuously. Repeat the
procedure beginning with step 9.
10 Test all machine functions from the platform
controls.
Result: All platform control functions should not
operate.
Jib Components
3-1
Jib Cylinder
Mast Components
4-1 3 Turn the key switch to off position and push in
the red Emergency Stop button to the off
Mast Assembly position at both the ground and platform
controls.
How to Remove the Mast 4 Open and remove the turntable covers.
Assembly
5 Remove the fasteners securing the mast head
Bodily injury hazard. This cover to the mast. Set the fasteners to the side.
procedure requires specific repair
6 Remove the mast head cover from the mast
skills, lifting equipment and a
head.
suitable workshop. Attempting this
procedure without these skills and 7 Tag and disconnect the proximity sensor. Lay
tools could result in death or the proximity sensor to the side.
serious injury and significant
component damage. Dealer 8 Tag, disconnect and plug the hydraulic hose at
service is strongly recommended. the top of the lift cylinder. Remove the hose
connector from the lift cylinder. Plug the lift
Note: When removing a hose assembly or fitting, cylinder.
the O-ring on the fitting and/or hose end must be Bodily injury hazard. Spraying
replaced and then torqued to specification during hydraulic oil can penetrate and
installation. Refer to Section 2, Hydraulic Hose and burn skin. Loosen hydraulic
Fitting Torque Specifications. connections very slowly to allow
the oil pressure to dissipate
Note: Perform this procedure with the machine on
gradually. Do not allow oil to squirt
a firm, level surface that is free of obstructions, and
or spray.
the machine in stowed position.
a
1 Check the condition of the wear pads. Refer to
h
Maintenance Procedure B-16, Inspect the Mast b
Wear Pads. g
2 Using Illustration 1 as a guide, create a safety
f
steel plate using the dimensions specified.
25 e c
mm 50
mm
m
2 x Ø18 mm
30
0m d
a
10 mm
m
0m
13 Illustration 2
mm
85
a mast head cover
b mast head cover fasteners
Illustration 1 c mast head
d jib boom
a safety steel plate e proximity sensor
f lift cylinder
g mast head fasteners
h lift cylinder fasteners
MAST COMPONENTS
P
platform railings can be damaged
if they are used to lift the
assembly. Do not attach the lifting
strap to the platform railings or put
pressure on the railings.
10 Remove the fasteners securing the mast head Illustration 3
to the mast assembly. Set the fasteners to the a stops
side. b mast assembly
11 Raise the mast head, jib boom and platform 14 Using the mast head fasteners, install the safety
assembly and move the assembly steel plate onto the top of the mast assembly.
approximately 20 inches / 50 cm towards the Securely tighten the fasteners. Do not over
non-steer end of the machine. tighten.
Crushing hazard. The mast head,
jib boom and platform assembly a
could become unbalanced and fall
when removed from the machine. a
Component damage hazard.
c
Cables and hose can be damaged
if they are kinked or pinched.
Note: During removal the mast head, jib boom and
platform assembly, the overhead crane strap will
need to be carefully adjusted for proper balancing.
A properly balanced lifting strap is essential when b
removing the assembly from the machine.
12 Remove the fasteners securing the lift cylinder
to the mast head. Set the fasteners to the side.
13 Using Illustration 3 as a guide, remove the Illustration 4
fasteners securing the stops to the mast
assembly and remove the stops. Set the a M16 shackles
b mast assembly
fasteners and stops to the side. c safety steel plate
MAST COMPONENTS
MAST COMPONENTS
TOP
P P P P
1 8
BOTTOM
4 5 6 7
Illustration 1
1 number 1 mast
2 shims
3 wear pads
4 fasteners Ground Controls Side
5 stops Steer End
6 number 2 mast
7 number 3 mast
8 number 4 mast
9 cover plate
Platform
(Non-Steer End) Power Unit Side
P
Illustration 2
MAST COMPONENTS
P
procedure without these skills and
P
tools could result in death or
P
serious injury and significant
component damage. Dealer
P
service is strongly recommended.
1 Remove the mast assembly. See 4-1, How to
Remove the Mast Assembly. a c
b d
2 With the 'P' mark facing upwards, use a clamp
to secure the mast assembly to the workbench. Illustration 3
Securely tighten the clamp. Do not over tighten. a number 1 mast
b number 2 mast
3 Working from the top of the mast assembly, pull
c number 3 mast
the number 2, 3 and 4 mast sections d number 4 mast
approximately 12 inches / 30 cm. Out of mast 1,
use a permanent marker to indicate the face 6 Working from the bottom of the mast assembly,
closest to the platform with the 'P' mark on the pull the number 4 mast half way out.
number 2, 3 and 4 mast sections corresponding
7 Attach a lifting strap from an overhead crane to
to the 'P' mark on mast 1. Refer to Illustration 3.
the number 4 mast section. Remove the
4 Working from the top of the mast assembly, number 4 mast while carefully pulling it out from
push the number 2, 3 and 4 mast sections fully the bottom of the number 3 mast. With the 'P'
into the number 1 mast. mark facing upwards, place the number 4 mast
on a level workbench capable of supporting it.
5 Remove the fasteners securing the safety steel
plate to the mast assembly. Remove the safety Crushing hazard. The mast
steel plate. Set the fasteners and safety steel section could become unbalanced
plate to the side. and fall if not properly supported
when removed from the mast
assembly.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper
balancing.
MAST COMPONENTS
8 Slide the number 2 mast and the number 3 14 Working from the bottom of the number 2 mast,
mast towards the top of the number 1 mast to pull the number 3 mast half way out.
gain the access to the stops at the bottom of
15 Attach a lifting strap from an overhead crane to
the number 1 mast.
the number 3 mast section. Remove the
9 Remove the fasteners securing stops to the number 3 mast while carefully pulling the it out
inside of the number 1 mast. Remove the from the bottom of the number 2 mast. With the
stops. Set the fasteners and stops to the side. 'P' mark facing upwards, place the number 3
mast on a level workbench capable of
10 Push the number 3 mast fully into the number 2
supporting it.
mast. Working from the bottom of the number 1
mast, pull the number 2 mast and the number 3 Crushing hazard. The mast
mast half way out. section could become unbalanced
and fall if not properly supported
11 Attach a lifting strap from an overhead crane to
when removed from the mast
the number 2 mast section. Remove both the
assembly.
number 2 mast and the number 3 mast while
carefully pulling the assembly out from the Note: During removal, the overhead crane strap
bottom of the number 1 mast. With the 'P' mark will need to be carefully adjusted for proper
facing upwards, place the number 2 mast and balancing.
the number 3 mast assembly on a level
workbench capable of supporting it. 16 Using Illustration 1 as a guide, tag and remove
the outer wear pads and shims from the bottom
Crushing hazard. The mast of the number 4 mast section. Set the shims to
sections could become the side. Discard the wear pads.
unbalanced and fall if not properly
supported when removed from the Note: For ease of mast reassembly, make careful
mast assembly. note of the location, order and orientation of the
shims.
Note: During removal, the overhead crane strap
will need to be carefully adjusted for proper Note: Use a hammer and chisel if necessary to
balancing. gently loosen the wear pads from the mast.
12 Slide the number 3 mast towards the top of the 17 Using Illustration 1 as a guide, carefully tag and
number 2 mast to gain the access to the stops remove the outer wear pads and shims from
at the bottom of the number 2 mast. the bottom of the number 3 mast section. Set
the shims to the side. Discard the wear pads.
13 Remove the fasteners securing stops to the
inside of the number 2 mast. Remove the Note: For ease of reassembly of the mast, make
stops. Set the fasteners and stops to the side. careful note of the location, order and orientation of
the shims.
MAST COMPONENTS
18 Using Illustration 1 as a guide, tag and remove 21 Using Illustration 1 as a guide, tag and remove
the inner wear pads from the top of the number the outer wear pads and shims from the bottom
3 mast section. Set the shims to the side. of the number 1 mast section. Set the shims to
Discard the wear pads. the side. Discard the wear pads.
Note: For ease of mast reassembly, make careful Note: For ease of mast reassembly, make careful
note of the location, order and orientation of the note of the location, order and orientation of the
shims. shims.
Note: Use a hammer and chisel if necessary to Note: Use a hammer and chisel if necessary to
gently loosen the wear pads from the mast. gently loosen the wear pads from the mast.
19 Using Illustration 1 as a guide, tag and remove 22 Using Illustration 1 as a guide, tag and remove
the outer wear pads and shims from the bottom the inner wear pads and shims from the top of
of the number 2 mast section. Set the shims to the number 1 mast section. Set the shims to the
the side. Discard the wear pads. side. Discard the wear pads.
Note: For ease of mast reassembly, make careful Note: For ease of mast reassembly, make careful
note of the location, order and orientation of the note of the location, order and orientation of the
shims. shims.
Note: Use a hammer and chisel if necessary to Note: Use a hammer and chisel if necessary to
gently loosen the wear pads from the mast. gently loosen the wear pads from the mast.
MAST COMPONENTS
How to Assemble the Mast, 2 Install six 12 mm wear pads, and the
corresponding shims removed in the mast
GR-26J disassembly process, onto the bottom of mast
Bodily injury hazard. This sections 1, 2, 3 and 4.
procedure requires specific repair 3 Using Illustration 1 as a guide, install two 10
skills, lifting equipment and a mm wear pads, and the corresponding shims
suitable workshop. Attempting this removed in the mast disassembly process, onto
procedure without these skills and the top of mast sections 1, 2 and 3.
tools could result in death or
serious injury and significant 4 Install six 12 mm wear pads, and the
component damage. Dealer corresponding shims removed in the mast
service is strongly recommended. disassembly process, onto the top of mast
sections 1, 2 and 3.
1 Using Illustration 1 as a guide, install two 10
mm wear pads, and the corresponding shims 5 Using Illustration 2 as a guide, apply grease
removed in the mast disassembly process, onto onto the inner faces of the mast sections 1, 2
the bottom of mast sections 1, 2, 3 and 4. and 3.
a b a Grease Specification
a b
TOP
P
Illustration 1 b a
MAST COMPONENTS
Illustration 3
a grease
b mast section (mast 4 shown)
MAST COMPONENTS
TOP
P P
1 5
BOTTOM
3 4
Illustration 1
Illustration 2
MAST COMPONENTS
P
procedure without these skills and
P
tools could result in death or
serious injury and significant
component damage. Dealer
service is strongly recommended.
1 Remove the mast assembly. See 4-1, How to
Remove the Mast Assembly.
a b
2 With the 'P' mark facing upwards, use a clamp
to secure the mast assembly to the workbench. Illustration 3
Securely tighten the clamp. Do not over tighten.
a number 1 mast
3 Working from the top of the mast assembly, pull b number 2 mast
the number 2 mast section approximately
7 Attach a lifting strap from an overhead crane to
12 inches / 30 cm. Out of mast 1, use a
the number 2 mast section. Remove the
permanent marker to indicate the face closest
number 2 mast while carefully pulling the it out
to the platform with the 'P' mark on the number
from the bottom of the number 1 mast. With the
2 mast section corresponding to the 'P' mark on
'P' mark facing upwards, place the number 2
mast 1. Refer to Illustration 3.
mast on a level workbench capable of
4 Remove the fasteners securing the safety steel supporting it.
plate to the mast assembly. Remove the safety
Crushing hazard. The mast
steel plate. Set the fasteners and safety steel
section could become unbalanced
plate to the side.
and fall if not properly supported
5 Remove the fasteners securing stops to the when removed from the mast
inside of the number 1 mast. Remove the assembly.
stops. Set the fasteners and stops to the side.
Note: During removal, the overhead crane strap
6 Working from the bottom of the number 1 mast, will need to be carefully adjusted for proper
pull the number 2 mast half way out. balancing.
MAST COMPONENTS
8 Using Illustration 1 as a guide, tag and remove How to Assemble the Mast,
the outer wear pads and shims from the bottom
of the number 2 mast section. Set the shims to GR-20J
the side. Discard the wear pads. Bodily injury hazard. This
Note: For ease of mast reassembly, make careful procedure requires specific repair
note of the location, order and orientation of the skills, lifting equipment and a
shims. suitable workshop. Attempting this
procedure without these skills and
Note: Use a hammer and chisel if necessary to tools could result in death or
gently loosen the wear pads from the mast. serious injury and significant
component damage. Dealer
9 Using Illustration 1 as a guide, tag and remove
service is strongly recommended.
the outer wear pads and shims from the bottom
of the number 1 mast section. Set the shims to 1 Using Illustration 1 as a guide, install two 10
the side. Discard the wear pads. mm wear pads, and the corresponding shims
removed in the mast disassembly process, onto
Note: For ease of mast reassembly, make careful
the bottom of mast sections 1 and 2.
note of the location, order and orientation of the
shims.
Illustration 1
a wear pad 10 mm
b mast section (mast 1 shown)
MAST COMPONENTS
2 Install six 12 mm wear pads, and the 6 Using Illustration 3 as a guide, apply grease
corresponding shims removed in the mast onto the outer faces of the mast sections 1 and
disassembly process, onto the bottom mast 2.
sections 1 and 2.
7 Carefully assemble the mast sections using the
3 Using Illustration 1 as a guide, install two 10 mast disassembly procedure in reverse order.
mm wear pads, and the corresponding shims See 4-1, How to Disassemble the Mast,
removed in the mast disassembly process, onto GR-20J.
the top of mast section 1.
4 Install six 12 mm wear pads, and the
corresponding shims removed in the mast
disassembly process, onto the top mast
section 1.
5 Using Illustration 2 as a guide, apply the grease a
onto the inner faces of the mast section 1.
Grease Specification b
a grease
b mast section (mast 2 shown)
a b
b a
Illustration 2
a grease
b mast section (mast 1 shown)
MAST COMPONENTS
4-2 a
Lift Cylinder h
b
g
How to Remove the Lift Cylinder
f
Bodily injury hazard. This
procedure requires specific repair e c
skills, lifting equipment and a
suitable workshop. Attempting this
procedure without these skills and d
tools could result in death or
serious injury and significant
component damage.
Note: When removing a hose assembly or fitting, a mast head cover
the O-ring on the fitting and/or hose end must be b mast head cover fasteners
replaced and then torqued to specification during c mast head
d jib boom
installation. Refer to Section 2, Hydraulic Hose and e proximity sensor
Fitting Torque Specifications. f lift cylinder
g mast head fasteners
Note: Perform this procedure with the machine on h lift cylinder fasteners
a firm, level surface that is free of obstructions, and
the machine in stowed position. 6 Remove the nut securing the bottom of the lift
cylinder to the chassis. Set it to the side.
1 Block the wheels at the non-steer end of the
machine. 7 Raise the machine slightly. Remove the blocks
from under the chassis and lower the machine
2 Open and remove the turntable covers of the onto the ground. Remove the jack.
machine.
8 Remove the fasteners securing the mast head
3 Center a lifting jack under the drive chassis at cover to the mast. Remove the mast head
the steer end of the machine. cover. Set the mast head cover and fasteners
4 Raise the steer end of the machine to the side.
approximately 10 inches / 25 cm to access the 9 Tag and disconnect the proximity sensor. Lay
nut at the bottom of the lift cylinder. the proximity sensor to the side.
5 Place blocks under the chassis for support.
Lower the machine onto the blocks.
Crushing hazard. The chassis
could fall if not properly supported.
MAST COMPONENTS
10 Tag, disconnect and plug the hydraulic hose at 13 Raise the mast head, jib boom and platform
the top of the lift cylinder. Remove the hose assembly and move the assembly
connector from the lift cylinder. Plug the lift approximately 20 inches / 50 cm towards the
cylinder. non-steer end of the machine.
Bodily injury hazard. Spraying Crushing hazard. The mast head,
hydraulic oil can penetrate and jib boom and platform assembly
burn skin. Loosen hydraulic could become unbalanced and fall
connections very slowly to allow when removed from the machine.
the oil pressure to dissipate
Component damage hazard.
gradually. Do not allow oil to squirt
Cables and hose can be damaged
or spray.
if they are kinked or pinched.
11 Attach a lifting strap of suitable capacity from an
overhead crane to the mast head, jib boom and Note: During removal the mast head, jib boom and
platform assembly. Support the assembly. Do platform assembly, the overhead crane strap will
not apply any lifting pressure. need to be carefully adjusted for proper balancing.
Component damage hazard. The 14 Remove the fasteners securing the lift cylinder
platform railings can be damaged to the mast head. Set the fasteners to the side.
if they are used to lift the 15 Attach a lifting strap from an overhead crane to
assembly. Do not attach the lifting the lift cylinder.
strap to the platform railings or put
pressure on the railings. 16 Carefully remove the lift cylinder from the
machine.
12 Remove the fasteners securing the mast head
to the mast assembly. Set the fasteners to the Crushing hazard. The lift cylinder
side. could become unbalanced and fall
if not properly supported when
removed from the machine.
Component damage hazard. The
lift cylinder can be damaged if it
falls.
Ground Controls
5-1 6 Securely install the level sensor pigtail into the
machine wire harness, disconnected in step 3.
Level Sensor
7 Remove the plastic cap from the end of the
The tilt alarm sounds when the incline of the level sensor calibration wire.
chassis exceeds 2° to the side, front or rear. 8 Using a length of wire approximately
40 inches / 1 m long, connect the level sensor
How to Install and Calibrate the calibration wire to the negative post of the
Level Sensor battery.
Tip-over hazard. Failure to install Result: The green LED underneath the level
or calibrate the level sensor as sensor flashes several times and stops. The
instructed will compromise level sensor calibration is complete.
machine stability and cause the
Result: The green LED underneath the level
machine to tip over, resulting in
sensor does not flash. Check the calibration
death or serious injury. Do not
wire connection. Contact Genie Industries
install or calibrate the level sensor
Service Department.
other than specified in this
procedure. Note: The green LED is on during normal machine
operation and it only goes out when the tilt angle of
Note: Perform this procedure with the machine on
the machine exceeds 2°.
a firm, level surface that is free of obstructions, and
the machine in stowed position. 9 After the green LED stops flashing, disconnect
the calibration wire from the battery, and
1 Open the turntable cover at the ground control
securely install the plastic cap removed in
side of the machine.
step 7.
2 Locate the level sensor which is mounted on
the turntable base below the battery charger.
3 Tag and disconnect the level sensor pigtail from
the machine wire harness.
4 After noting the orientation of level sensor
assembly, remove the fasteners securing the
base of level sensor assembly to the chassis.
5 Install the new level sensor onto the machine.
Install and securely tighten the fasteners. Do
not over tighten.
Hydraulic Pump
6-1 How to Remove the Function
Function Pump Pump
Note: When removing a hose assembly or fitting,
The hydraulic pump is attached to the motor which
the O-ring on the fitting and/or hose end must be
makes up the hydraulic power unit.
replaced and then torqued to specification during
How to Test the Function Pump installation. Refer to Section 2, Hydraulic Hose and
Fitting Torque Specifications.
See 7-2, How to Adjust the System Relief Valve.
Note: Perform this procedure with the machine in
stowed position.
1 Disconnect the battery pack from the machine.
2 Open and remove the turntable cover at the
hydraulic power unit side of the machine.
3 Tag and disconnect the wire harness
connectors from the function manifold.
4 Tag and disconnect the cables from the motor.
e
b
d
Illustration 1
a motor
b function manifold
c hydraulic tank
d connector fittings
e hydraulic hoses
HYDRAULIC PUMP
Function Manifold
7-1
Function Manifold Components
The function manifold is mounted underneath the hydraulic power unit.
Index Schematic
No. Description Item Function Torque
1 Filter,
Filter cap .................................................... H ......................... Suction filter ............................ 37 ft-lbs / 50 Nm
2 Solenoid valve, 2 position 4 way ............... B ......................... Steer/Turntable directional ..... 18 ft-lbs / 25 Nm
3 Check valve ............................................... I .......................... Blocks flow from auxiliary
pump to function pump . 29 ft-lbs / 40 Nm
4 Solenoid valve, 2 position 2 way ............... D ......................... Platform up ............................. 18 ft-lbs / 25 Nm
5 Solenoid valve, 2 position 4 way ............... C ......................... Turntable rotate left/right ........ 18 ft-lbs / 25 Nm
6 Solenoid valve, 2 position 2 way ............... E ......................... Platform down and jib down ... 18 ft-lbs / 25 Nm
7 Relief valve,
930 psi / 64 bar .......................................... G ......................... Platform up ............................. 18 ft-lbs / 25 Nm
8 Solenoid valve, 2 position 4 way ............... A ......................... Steer left/right ......................... 18 ft-lbs / 25 Nm
9 Relief valve,
2030 psi / 140 bar ...................................... F ......................... System relief ........................... 18 ft-lbs / 25 Nm
FUNCTION MANIFOLD
F
9
B
Y117 2
Y116
A
8
I
G 3
7
D
4
E Y21 Y22
Y118
6
C
5
FUNCTION MANIFOLD
7-2
Valve Adjustments -
Function Manifold
FUNCTION MANIFOLD
FUNCTION MANIFOLD
Hydraulic Tank
8-1 7 Place a suitable container under the hydraulic
tank. Refer to Section 2, Specifications.
Hydraulic Tank
8 Locate and remove the hydraulic tank filler cap.
The primary functions of the hydraulic tank are to Set the filler cap to the side.
cool and deaerate the hydraulic fluid during 9 Remove the drain plug and drain all of the oil
operation. into a suitable container.
How to Remove the Hydraulic 10 Clean up any oil that may have spilled. Properly
discard the used oil.
Tank
11 Install the drain plug onto the hydraulic tank and
Component damage hazard. The tighten to finger tight.
work area and surfaces where this
procedure will be performed must 12 Install the filler cap onto the hydraulic tank and
be clean and free of debris that tighten to finger tight.
could get into the hydraulic
13 Remove the clamp securing the hydraulic
system.
power unit to the chassis. Set the clamp to the
Note: Perform this procedure with the machine in side.
stowed position.
14 Carefully remove the hydraulic tank along with
1 Disconnect the battery pack from the machine. hydraulic power unit from the machine and
place it on a clean work bench.
2 Open and remove the turntable cover at the
hydraulic power unit side of the machine. 15 Remove the fasteners securing the function
manifold to the hydraulic tank. Set the fasteners
3 Working next to the hydraulic tank, remove the to the side.
fasteners securing the chassis side cover to the
chassis. Remove the side cover. Lay the side 16 Remove the clamp securing the hydraulic
cover and fasteners to the side. power unit to the hydraulic tank. Set the clamp
to the side.
4 Tag and disconnect the wire harness
connectors from the function manifold. 17 Remove the hydraulic power unit from the
hydraulic tank.
5 Tag and disconnect the cables from the motor.
6 Tag, disconnect and plug the hydraulic hoses at Torque specifications
the function manifold. Cap the fittings on the Hydraulic oil reservoir drain plug 44 in-lbs
manifold. 5 Nm
Bodily injury hazard. Spraying Manifold to tank fasteners 40 in-lbs
hydraulic oil can penetrate and 4.5 Nm
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to squirt
or spray.
Turntable Components
9-1
Turntable Rotation Motor
TURNTABLE COMPONENTS
TURNTABLE COMPONENTS
9-2
Battery
TURNTABLE COMPONENTS
9-3 d a
Battery Charger
Charger
Electrocution/burn hazard. Contact c
with electrically charged circuits
could result in death or serious
injury. Remove all rings, watches a power cable
and other jewelry. b charger cutout harness connector
c LED
1 Turn the key switch to off position and push in d charger-to-battery wires
the red Emergency Stop button to the off
position at both the ground and platform 8 Locate and remove the nut holding the ground
controls. control box closed, and open the ground control
box.
2 Open and remove the turntable cover at the
ground control side of the machine. 9 Remove the fasteners securing the top of the
battery charger to the machine. Set the
3 Tag and disconnect the cables connected to the fasteners to the side.
ground terminal of the battery.
10 Close the ground control box and install the nut.
4 Tag and disconnect the black and red battery
charger wires from the battery. 11 Remove the fasteners securing the bottom of
the battery charger to the machine. Set the
5 Tag and disconnect the power cable from the fasteners to the side.
battery charger.
12 Lower the battery charger towards the tilt
6 Locate the LED at the bottom of the bulkhead. sensor, and remove the battery charger from
Tag and disconnect the LED wire harness the machine.
connector.
7 Tag and disconnect the charger cutout harness
connector.
10-3 10-4
Steering Rod Steer Angle Sensor
How to Remove the Steering Rod How to Replace the Steer Angle
1 Remove the steer cylinder. See 10-2, How to Sensor
Remove the Steer Cylinder. 1 Adjust the wheels at the steer end of the
2 Remove the top cir-clips securing the steering machine so they are in straight driving position.
rod to the steer yoke at both the ends of the 2 Turn the key switch to off position and push in
steering rod. the red Emergency Stop button to the off
3 Lift the steering rod up and off of the yoke, and position at both the ground and platform
remove the steering rod from the machine. controls.
3 Tag and disconnect the steer angle sensor wire
harness from the machine wire harness.
4 Remove the plastic cap above the steer yoke
pivot. Set the cap to the side.
5 Carefully remove the sensor activator pin from
the steer yoke pivot. Set the pin to the side.
Note: Inspect the sensor activator pin to confirm it
is not broken or twisted. If the sensor activator pin
is broken or twisted, it must be replaced. Note the
installation and orientation of the old sensor to be
sure the new one is installed correctly.
8 Using the illustration as a guide, mount the 11 Install the bottom plate and it's fasteners on the
potentiometer on to the plate and securely steer yoke pivot.
tighten with the nut.
12 Install the sensor activator pin on to the steer
yoke pivot.
a
Note: Be sure the sensor activator pin is engaged
b into the sensor.
11 Tag and disconnect the cables from the drive 16 Place a 2 x 4 x 6 inch / 5 x 10 x 15 cm long
motor assembly. wood block under the left drive motor.
12 Loosen the castle nut of the wheel at the Note: The wood block will support to the drive
non-steer end of the machine. Do not remove motor assembly when the fasteners are removed.
the castle nut.
17 Remove the fasteners securing the left drive
Note: To remove the right drive motor assembly, motor assembly to the chassis. Set the
first it is necessary to remove the left drive motor fasteners to the side.
assembly.
18 Carefully remove the left drive motor assembly
13 Center a lifting jack under the drive chassis at from the machine. Place it onto a suitable
the non-steer end of the machine. workbench capable of supporting it.
14 Raise the machine approximately Bodily injury hazard. The
6 inches / 15 cm. Place blocks under the drive motor assembly may fall if
chassis for support. Lower the chassis onto the not properly supported when
blocks. removed from the machine.
Crushing hazard. The chassis
could fall if not properly supported.
15 Remove the castle nut from the wheel at the
non-steer end of the machine. Remove the
wheel from the machine.
Note: A properly sized puller may be needed to
remove the wheel from the tapered shaft.
11-2 a b c d e
Drive Brake
3 Raise the jib boom to the maximum height. 9 Remove the fasteners securing the steel bar to
the chassis. Set the fasteners to the side.
4 Turn the key switch to off position and push in
the red Emergency Stop button to the off 10 Turn over the steel bar and cut the zip ties
position at the ground control. attaching the two wire harness connectors to
the steel bar. Lay the steel bar to the side.
5 Open the turntable cover at the ground control
side of the machine. 11 Remove the fasteners securing the drive brake
to the drive motor assembly. Set the fasteners
6 Tag and disconnect the cables from the ground
to the side.
terminal of the battery.
12 Carefully remove the drive brake from the drive
7 Remove the fasteners securing the rear chassis
motor assembly.
cover to the chassis at the non-steer end of the
machine. Remove the chassis cover. Lay the
cover and fasteners to the side. Torque specifications
8 Tag and disconnect the two wire harness Brake mounting fasteners, dry 75 ft-lbs
connectors at the steel bar. 102 Nm
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Be aware of the following hazards and follow
Troubleshooting and repair procedures shall be generally accepted safe workshop practices.
completed by a person trained and qualified on
Crushing hazard. When testing
the repair of this machine.
or replacing any hydraulic
Immediately tag and remove from service a component, always support
damaged or malfunctioning machine. the structure and secure it
from movement.
Repair any machine damage or malfunction
before operating the machine. Electrocution/burn hazard. Contact
with electrically charged circuits
Unless otherwise specified, perform each could result in death or serious
repair procedure with the machine in the injury. Remove all rings, watches
following configuration: and other jewelry.
• Machine parked on a firm, level surface
Bodily injury hazard. Spraying
• Platform in the stowed position hydraulic oil can penetrate and
• Key switch in the off position with the key burn skin. Loosen hydraulic
removed connections very slowly to allow
the oil pressure to dissipate
• The red Emergency Stop button in the off
gradually. Do not allow oil to
position at both ground and platform controls
squirt or spray.
• Wheels chocked
• All external AC power supply disconnected
from the machine
FAULT CODES
problem
still exists
a Error Source: First two digits indicates the
Return to Inspect Perform
affected machine area or component.
service problem and test repair • '01' Controller interface board
solved
• '02' Controller logic board
• '08' Platform controls circuit board
• '16' Diagnostic display
b Third digit always an alphabet "A" when fault
code is displayed.
c Error Type: Last two digits indicates the fault
number.
The codes listed in the Fault Code Chart
describe malfunctions and can aid in
troubleshooting the machine by pinpointing the
area or component affected.
Schematics
About This Section
There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.
Electrical Schematics
problem
still exists
Diode
Toggle Switch
Solenoid Valve
Parking Brake
Connector
Battery
Key Switch
Fuse
Electric Motor
Flashing Beacon
Sensor
LED (hydraulic oil temperature) Joystick Controller
BK V/J
GR 2
S21
RD 1
BR
OR
GR
BL
RD
BK
WH
GR\YL
RD-2
BL-2
BR-1
G6 1
BL-4
4
G7 GR/YL-2
G8
RD-3
3
6
J3
6 BN9 15
14
5 BN57 GR/YL
L4 L79 2 B- LS3
4 BN97 7
3 BN128 1
6
2 BN129
BR-1
1
BL-4 9
1 GR/YL-2
F9B BL-13
7 RD-11
BL-10
RD-3 8 U6
RD-12
OR-14
Y-7
13
OR-15
Y-5 1
OR-16
F9A Y-6
Y-9
OR-16
18
Y-8
19
Y-7
Y-8
Y-6
20 B+
OR-15 21
Y-5
Y-9
22 M5
BL-13
6 OR-14 24
D2 D1
12
BL-10
31 P
RD-11
J2
4 3 RD-12
J1 2 1 2
35 M7A A2 A1
FB1 1 T1
OR-4
OR-3
OR-2
OR-1
S4 PP-22 2
26 F1 F2
Y121 1 F2
RD-6
KS1 PP-5
GROUND
Y116
PLATFORM
RD-6
A2 A1
PP-4
RD-7 RD-23
T2
Y117 RD-6 23
F2 F1
PP-22
PP-3 16
PP-5
Y118 RD-6 34
PP-2
PP-4
28 M7
PP-3
25
Y21 RD-6
PP-2 F1
32
PP-1 PP-1
30
Y22 RD-6 PP-7 TS75 87A
30
2 2 12
87
U53 1
R29
1500Ώ
1
RD
GR
85 86
U54 CR89
3 2 1
- BK BK 29 P1
U9
WH
GR
BR
H2 RD RD
+
2 2
17
1 1
2 F6
250A
OR C 2 2
OUTPUT 3
+24V dc BR A 1 1
S7 11
BL B 3 3
GND
AC INPUT BK 10
REF
F9 -
+
5A
B9
12-2V
ES0525C
BL-2
RD-2
BR
GR/YL
WH
BK
RD
BL
GR
OR
L30
1
4
C P2
6 3 RD BK
2 BK
D 2 1 1 RD BK LS31
4 BK
SW6R
SW6L
SW5
JC1
BK
BK LS11
6 1
10
11
12
BK
8
BR-10 BK LS18
A Y-2
RD
GY-9
GR-7
2 Y102
10
5
1 RD
U3A BK GR/YL Y101
8
1 Y-14
Y-13
Y-12
Y-15
BN130
OR-6
BN97
BN63
B
BN5
BN8
4
BK
BL-3
BK
OR/BK-8 U10
1 2 3 4 5 6
14
7 BK J2
J1
6 1 BK-20 14
1 7
BK-19
E BK-18 +
H1
RD-17
RD-16 -
GR/YL
L68
10
5 2
RD-5
L48
BK-23
L81
4
1
RD-4
L1
BK-22
WH-1
L82
F 8
BK-21
6 3 1
L17 4 3
2 1
J3
PLATFORM
CONTROLLER
ES0525C
BK V/J
GR 2
S21
RD 1
BR
OR
GR
BL
RD
BK
WH
GR\YL
RD-2
BL-2
BR-1
G6 1
BL-4
4
G7 GR/YL-2
G8
RD-3
3
6
J3
6 BN9 15
14
5 BN57 GR/YL
L4 L79 2 B- LS3
4 BN97 7
3 BN128 1
6
2 BN129
BR-1
1
BL-4 9
1 GR/YL-2
F9B BL-13
7 RD-11
BL-10
RD-3 8 U6
RD-12
OR-14
Y-7
13
OR-15
Y-5 1
OR-16
F9A Y-6
Y-9
OR-16
18
Y-8
19
Y-7
Y-8
Y-6
20 B+
OR-15 21
Y-5
Y-9
22 M5
BL-13
6 OR-14 24
D2 D1
12
BL-10
31 P
RD-11
J2
4 3 RD-12
J1 2 1 2
35 M7A A2 A1
FB1 1 T1
OR-4
OR-3
OR-2
OR-1
S4 PP-22 2
26 F1 F2
Y121 1 F2
RD-6
KS1 PP-5
GROUND
Y116
PLATFORM
RD-6
A2 A1
PP-4
RD-7 RD-23
T2
Y117 RD-6 23
F2 F1
PP-22
PP-3 16
PP-5
Y118 RD-6 34
PP-2
PP-4
28 M7
PP-3
25
Y21 RD-6
PP-2 F1
32
PP-1 PP-1
30
Y22 RD-6 PP-7 TS75 87A
30
2 2 12
87
U53 1
R29
1500Ώ
1
RD
GR
85 86
U54 CR89
3 2 1
- BK BK 29 P1
U9
WH
GR
BR
H2 RD RD
+
2 2
17
1 1
2 F6
250A
OR C 2 2
OUTPUT 3
+24V dc BR A 1 1
S7 11
BL B 3 3
GND
AC INPUT BK 10
REF
F9 -
+
5A
B9
12-2V
ES0525C
BL-2
RD-2
BR
GR/YL
WH
BK
RD
BL
GR
OR
L30
1
4
C P2
6 3 RD BK
2 BK
D 2 1 1 RD BK LS31
4 BK
SW6R
SW6L
SW5
JC1
BK
BK LS11
6 1
10
11
12
BK
8
BR-10 BK LS18
A Y-2
RD
GY-9
GR-7
2 Y102
10
5
1 RD
U3A BK GR/YL Y101
8
1 Y-14
Y-13
Y-12
Y-15
BN130
OR-6
BN97
BN63
B
BN5
BN8
4
BK
BL-3
BK
OR/BK-8 U10
1 2 3 4 5 6
14
7 BK J2
J1
6 1 BK-20 14
1 7
BK-19
E BK-18 +
H1
RD-17
RD-16 -
GR/YL
L68
10
5 2
RD-5
L48
BK-23
L81
4
1
RD-4
L1
BK-22
WH-1
L82
F 8
BK-21
6 3 1
L17 4 3
2 1
J3
14
7
8
1
PLATFORM
J1 U3B CONTROLLER
ES0525C
M
Auxiliary pump Variable speed motor Fixed displacement pump Check valve
Y117
B
Y116
A
G I
Y21 Y22
E Y118
D
C
Hydraulic Schematic
N O
(GR26-J ONLY)
TURNTABLE
ROTATE
Y119
P
+
1450 psi 1450 psi
100 bar 100 bar
TP
A DR B
L
LIFT CYLINDER
P2 P3 P5 P6 T2 P1 P4
C
A
Y117
Y118
B
Y116 E
Y22 Y21
D
H
B10 = 100
930 psi
F 64 bar
G
I
2030 psi
Q 140 bar
FUNCTION MANIFOLD
T1
AUXILIARY
M POWER UNIT
PUMP
A = Steer select
B = Steer/Turntable Directional
C = Turntable select
D = Platform up
E = Platform down
F = System relief
VALVE ACTIVATION G = Platform up/down relief
FUNCTION
Y21 Y22 Y101 Y102 Y116 Y117 Y118 Y121 H = Filter
STEER RIGHT I = Check valve
STEER LEFT J = Turntable rotate right relief
K = Turntable rotate left relief
TURNTABLE ROTATE RIGHT
L = Test port
TURNTABLE ROTATE LEFT M = Lift cylinder select
MAST CYLINDER RAISE N = Jib up
MAST CYLINDER LOWER O = Jib down
JIB CYLINDER RAISE P = Jib up/down flow control
JIB CYLINDER LOWER Q = Check valve
HS0255C
800.536.1800
Fax 425.883.3475