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from SN 08-101 to 11-999, Runabout Contractor (PN 115370)

1. 1 Electrical Schematic Part 2 of 2 GN 1 1 GNYL GN YL EN4 AC A BK 2 2 BK BK AC OUTLET oum ET WH 3 3 LB LB BOX QD4A L RD RD RD 4 4 RD OR BK l 3 7 WH CR48 4 POWER RELAY TO US 85 E STOP 004 6 6 RD BK 2 EMERGENCY WH BK te e STOP a BL 2 2 BL RD POWER TO PLATFORM amp oR 5 5 OR 3 3 RD POWER TO GROUND s RD es ee BL 1 1 r WH GROUND PIOS H PIO2 BK 2 2 BK DATALINK HIGH rOPIO4 OR 5 5 OR DATA LINK LOW O PIO5 Li J o ToS 24V DC gt PETTITTE 1 4 1Nc U3 D7 svec 4 PLATFORM CONTROLS VOLTAGE i PRINTED CIRCUIT BOARD REGULATOR LEVEL n SENSOR E 4 8 CIRCUIT x
2. 6 4 A Electrical Symbols Legend stii once pate tete tee lee ia 6 5 A Electrical Schematic ssssssssssessseeeeeee eene enne 6 6 A Hydraulic Component Reference and Symbol Legend 6 9 A Flydraulic Sehernalio ucro te ce Ft pucri in renes 6 10 X GRC 12 Part No 115370 September 2008 Section 2 Specifications REVA Machine Specifications Specifications Tires and wheels Batteries Standard Tire size solid rubber 10x 3 in 25 4 2 5 Voltage 6V DC 7 Tire contact area 6 5 sq Group GC2 41 9 cm2 Type T 105 Castle nut torque dry 225 ft lbs 305 Nm Quantity 4 Castle nut torque lubricated 175 ft lbs Battery capacity maximum 225AH 237 Nm Reserve capacity 25A rate 447 minutes Batteries Maintenance free option Continuous improvement of our products is a Genie policy Product specifications are Voltage 6VDC subject to change without notice Group GC2 Type 6V AGM Quantity 4 Battery capacity maximum 200AH Reserve capacity 25 rate 380 minutes Fluid capacities Hydraulic tank 1 5 gallons 5 7 liters Hydraulic system 2 2 gallons including tank 8 3 liters Height stowed maximum GRC 12 66 8 in 1 69 m For operational specifications refer to the Operator s Manual Part No 115370 GRC 12 2 1 Section 2 Specifications
3. chassis b level sensor X indicator d mast Section 4 Repair Procedures September 2008 GROUND CONTROLS 4 Install the level sensor adjusting fasteners through the level sensor and springs and into the mount Tighten the fasteners and measure the distance between the level sensor and the level sensor mount Result The measurement should be approximately 3 8 inch 10 mm 5 Connect the chassis wire harness to the level sensor wire harness 6 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the calibration circles a adjusting fastener b calibration circles ground controls A TEREX CON REV A 7 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result The tilt sensor alarm should not sound 8 Center a lifting jack under the drive chassis at the ground controls side of the machine 9 Raise the machine approximately 2 inches 5 cm 10 Place a 0 65 x 6 x 6 inch 1 65 x 15 x 15 cm thick steel block under both wheels at the ground controls side of the machine 11 Lower the machine onto the blocks 12 Raise the platform approximately 1 foot 30 cm Result The level sensor alarm should not sound W Result
4. em EHE RELEASE FII lt ORY ai gu QN gt MANIFOLD E THE ORIFICE IS LOCATED l UNDERNEATH THE HOSE B1 FITTING ON THE LIFT CYLINDER L V S1 S2 B AC HP M1 M4 va ON boo ve M me gt 0 75 gpm NN J 28Umin i psi Theo see Hd z 1800 to 3500 pel CALL OUT LEGEND lie FUNCTION tem Description O MANIFOLD EE L9 creche wear crak Laem eT N D Check valve brake circuit E Drive forward reverse Steer left right A 4 2500 psi 15 L min 172 bar T BYPASS 10 MICRON WITH 25 psi 1 7 bar POWER UNIT a Relief valve system Hand pump manual brake release Check valve manual brake release Platform lowering valve HS0251A Orifice platform down circuit Flow regulator relief valve Platform up Genie TEREX COMPANY 6 10 GRC 12 Part No 115370
5. 3 5 Checklist A Procedures A 1 Inspect the Manuals and 3 6 2 Perform Pre operation 3 7 3 Perform Function Tests eerie creto 3 7 4 Perform 30 Day Service erre dt teneo rd 3 8 5 Grease the Steer 0000 3 8 Genie Part No 115370 A TEREX COMPANY GRC 12 vii September 2008 TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued A Checklist B Procedures B 1 Inspect the Batteries oic re teca ctore sees 3 9 B 2 Inspect the Electrical 0 3 11 B 3 Inspect the Tires and Wheels including castle nut torque 3 12 B 4 Test the Emergency Stop 3 12 B 5 Test the Key Switch reete Dee RE dun p Ear 3 13 B 6 Test the Automotive style Horn if 3 13 B 7 Inspect the Voltage Inverter if equipped 3 14 B 8 Test the Drive Brakes niece eniro ettet 3 15 B 9 Testthe Drive Speed Position 3 16 B 10 Test the Drive Speed Raised Position 3 17 B 11 Test the Slow Drive
6. Illustration 6 a wear pad b rivets number 3 mast d number 2 mast e number 1 mast Part No 115370 September 2008 Section 4 Repair Procedures REVA MAST COMPONENTS 18 Using the appropriate rivets securely install the 19 Attach a lifting strap from an overhead crane upper corner wear pads to the upper half of the to the number 4 mast and carefully slide the number 3 mast Refer to Illustration 7 number 4 mast onto the number 3 mast with the cylinder mount brackets facing the work table AWARNING Crushing hazard The number 4 mast could become unbalanced and fall if not properly supported Note During installation the overhead crane strap will need to be carefully adjusted for proper balancing 20 Slide the lower inner corner wear pads between the number 4 mast and the number 3 mast Align the holes on the wear pads to the rivet holes on the lower half of the number 4 mast and secure into place using the appropriate rivets Refer to Illustration 8 Illustration 7 a b wear pad rivet number 3 mast number 2 mast number 1 mast Illustration 8 number 4 mast rivet wear pads number 1 mast number 2 mast number 3 mast A TEREX COMPANY Part No 115370 GRC 12 4 23 Section 4 Repair Procedures September 2008 MAST COMPONENTS 21 Slide the number 4 mast towards the bottom of the number 3 mast and align
7. Q 5 o EN OY A NS Note alpha callouts refer i tes on to correspon the hydraulic schematic Note alpha numeric callouts f ponding notes on the electrical schematic A TEREX COMPANY Part No 115370 GRC 12 4 35 Section 4 Repair Procedures September 2008 FUNCTION MANIFOLD 6 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Note Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the system relief valve on the function manifold item a test port b system relief valve 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item A A TEREX CON REV A 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform Note Perform this test from the ground with the platform controls Do not stand in the platform 5 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 6 Press and hold the function enable switch 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hol
8. REVA How to Activate the Battery Drain Alarm Option 1 9 Note To deactivate the battery drain alarm option Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control At the platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC Release the lift function select and speed select buttons Result The diagnostic display will show the current software configuration Press the slow speed select button Result The ones digit setting will be activated and the current ones setting will flash in the diagnostic display Press the horn button Result A dot located at the lower right of the diagnostic display window will become illuminated This indicates that the battery drain alarm option has been activated Press and hold the speed select button for a minimum of 3 seconds or until the ones setting stops flashing Turn the key switch to the off position on a machine which has the option activated repeat this procedure When the ECM is in the SC mode and the option is deactivated there will not be an illuminated dot in the diagnostic display window
9. 0 3 18 B 12 Test the Flashing 2442 4421 3 19 B 13 Test the Motion Alarm if equipped 3 19 B 14 Perform Hydraulic Oil 3 20 B 15 Inspect the Breather 3 21 Checklist Procedure C 1 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic 3 22 A Checklist D Procedure D 1 Replace the Hydraulic Tank Return Filter 3 23 Checklist E Procedure E 1 Testor Replace the Hydraulic Oil 3 24 Genie A TEREX COMPANY viii GRC 12 Part No 115370 September 2008 Section 4 Rev TABLE OF CONTENTS Repair Procedures 4 1 Platform Controls 1 1 Circuit 4 2 1 2 Controller 4 3 1 3 Software Configuration 4 8 Platform Components MEE dune 4 12 2 2 Platform 4 12 Mast Components 3 1 e 4 14 S2 WearPads eire aste e DET 4 25 353 SB ERES 4 26 3 4 Lift Cylinder Wear aaaea 4 28 3 5 Mast Coll Cord m 4
10. g col a A E far i B z B ile Eh i B O oj A AYP olx wo NIS ANIC n ge CO l aj A eo E A zi a a Dv A NI io A D mi QIN EI ala S o o 2 oo D A o a A N N A m o a Oo 1 A o o zi a gt oo 00 9 9 gt nj AININ 92 N ojojo AT A 2 o A 91 A ye A A a A A Apc 85 September 2008 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to properly complete each inspection when required may cause death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning mach
11. Part No 115370 Section 4 Repair Procedures PLATFORM CONTROLS How to Determine the Battery Voltage The diagnostic display on the platform controls is used to indicate the battery voltage at all times when the machine is in normal operation Limp Mode If the battery level falls to less than 17 8V DC the single bar in the diagnostic display will be flashing and machine drive speed is limited to that of the raised drive speed Refer to Section 2 Specifications the battery level is 22 6V DC or higher the battery level is 21 6 to 22 5V DC the battery level is 20 7 to 21 5V DC the battery level is 19 7 to 20 6V DC the battery level is 17 8 to 19 6V DC the battery level is less than 17 8V DC Section 4 Repair Procedures September 2008 Platform Components 2 1 Platform How to Remove the Platform 1 Disconnect the platform controls from the control cable at the platform and remove the platform controls from the platform Set the platform controls to the side Carefully cut all cable ties securing the control cable to the platform Component damage hazard The control cable can be damaged if cut while removing the cable ties Attach a lifting strap of suitable capacity from an overhead crane and center it around the platform railing Support the platform Do not apply any lifting pressure Remove the fasteners securing the platform to the mast and set the fasteners to the
12. BOARD BN HALL EFFECT JC1 z 4 i a 7 NSENERATOR JOYSTICK S7 GY X CONTROLLER m E gt m 999 LEVEL SO S ios m SENSOR 8 3 Gd T oW ec eeseqenescccccd 4 62228 o amp N gt m 2 2 0 0 E 525 2 2 g c E 9 l SW5 SW6 FUNCTION ENABLE STEER 4 1 LEFT RIGHT pno o E 2 2 BK 4 2 E 2298 2 o 5 oji SS er e rac pinto ORD c2 A2 Bi C11 IN IN IN IN IN OUT z gk PLATFORM CONTROLS E M MEMBRANE DECAL z POUTI 0 LIFT LED L16 DRIVE LED 117 4 ELECTRONIC CONTROL MODULE 4 z POUTS O HIGH TORQUE LED L21 z 7 OUT OUT OUT C6 A6 B6 mm 4 4 G8 z lC o z POUT4 O DIAGNOSTIC 7 2 DISPLAY E T A H P P P 2m z PINI 4 HIGH TORQUE BN6 Y6 Y8 Y7 DRIVE PLATFORM PLATFORM PIN2 p 7 HORN BNS FORWARD ur DOWN l 4 DRIVE ENABLE BN8 E A l T z 4 ENABLE i apt AX SNOTE s E i poum ol L4 e e MACHINE SHOWN H1 PLATFORM P IN THE STOWED BK ALARM 4 0 POSITION WITH CONTROLLER THE POWER OFF 1 ES0126C fe MAR
13. no connection EX e Capacitor Emergency Stop button Battery charger Diode re zi oo CT lt pt ed Circuit breaker Noise suppression EH 6V DC battery inductor Circuit connection ches 87A Te 85 WH B 1 OR Control relay 2 KS1 Connector KEY PLATFORM SWITCH CONTROL BI 24 ehs A GROUND CONTROL Horn or alarm Key switch Hour meter e e EI s LED X ET swe Flashing beacon STEER LEFT RIGHT e 2 E 18 FUNCTION ierunt Pl Joystick Genio A TEREX COMPANY Part No 115370 GRC 12 6 5 Section 6 Schematics September 2008 A J M Ml Electrical Schematic Part 1 of 2 REVA QUICK DISCONNECT 1 KS1 EMERGENCY CN KEY SWITCH STOP B PLATFORM CONTROL H5 ALARM N CHO 4 LS7 POTHOLE GUARD SWITCH N CHO 4 Si Sj POTHOLE 56 GUARD DOWN SWITCH EIMIT SWITCH B1 4 HM GROUND CONTROL GROUND M sd CONTROLS BREAKER 4 AC INPUT POWER TO PLATFORM 110V 240V AC RE PoP NMOG dn w NOTE MACHINE SHOWN Wuviv IN THE STOWED P
14. 115370 Rev A September 2008 First Edition First Printing Genie is a registered trademark of Genie Industries in the USA and many other countries Runabout is a trademark of Genie Industries 4 Printed recycled paper Printed in U S A Part No 115370 September 2008 INTRODUCTION Serial Number Legend MANUFACTURED BY FABRIQUE PAR Genie Industries 18340 NE 76th Street Redmond WA 98052 USA TEREX SOMPANY Model 12 Serial number GRCO08 1234 Model year 2008 Manufacture date 4 14 08 Elec Hydr Schematic 50126 50251 Power supply voltage Pneumatic Pressure 85 264 VAC 60 50 Hz 900 W Nominal Power 8 3 Hp 6 2 kW Machine unladen weight 2 055 Ibs 932 kg Max Load 500 Ibs 227 kg Occupants and Equipment must not exceed 500 Ibs 227 kg Maximum allowable inclination of the chassis 1 5 Side 3 Rear Maximum Wind Speed Indoor N A 20u G RC 08 7 1 234 Maximum allowable side force 100 Ibs 445 N Maximum platform height 12 3 7 m Maximum Travel Height Full ht Maximum number of platform occupants 1 Baca Country of manufacture USA Model Sequence This machine complies with number EN 280 98 37 EC Model year PN 77172 Serial number stamped on chassis Serial label behind covers A TEREX COMPANY
15. Illustration 3 a b f Note While drilling the rivets out be careful not drill into the number 3 mast section number 4 mast rivet wear pads number 1 mast number 2 mast number 3 mast Note While drilling the rivets out be careful not enlarge the wearpad mounting holes 14 Attach a lifting strap from an overhead crane to the number 4 mast section and carefully remove the number 4 mast AWARNING Crushing hazard The number 4 mast section could become unbalanced 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 Section 4 Repair Procedures September 2008 MAST COMPONENTS 15 Slide the number 3 mast towards the bottom of the number 2 mast and align the upper and lower number 3 mast access holes to the upper and lower rivets on the number 2 mast Refer to Illustration 4 lt lt I Illustration 4 a wear pads b rivets number 3 mast d number 2 mast e number 1 mast 16 Using a drill carefully drill out the rivets securing the number 2 outer wear pads to the top half of the number 2 mast section Refer to Illustration 2 Note While drilling the rivets out be careful not drill into the number 2 mast section Note While drilling the
16. Part No 115370 GRC 12 iii September 2008 lt This page intentionally left blank iv GRC 12 Part No 115370 September 2008 Part No 115370 A TEREX COMPANY 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 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 September 2008 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
17. enie A TEREX COMPANY Serial Number Range GRC 12 from GRCO8 000101 115370 Rev 1 2011 January 2011 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 Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group A Type 2 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper opeation inspection and scheduled maintenance 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 Contact Us www genieindustries com e mail techpub Q terex com A TEREX COMPANY Copyright 2008 by Genie Industries
18. 120 362 1130 3176 3170 230 189 18 130 376 170 230 1180 244 240 325 200 271 zaa 10 20 27i 270 366 280 379 380 515 30 433 220 298 300 406 310 420 420 569 so am m 19 320 438 430 583 450 60 610 827 50 om 350 474 40 637 50 678 60 908 550 759 e 480 65 60 867 680 92 910 1233 70 104 2 50 78 70 962 750 1016 990 1342 80 1139 N slo o o 15 2 60 908 850 1205 1080 1464 1440 1952 120 1654 T 1260 1240 31681 1510 2047 2010 2725 1700 2304 16 1460_ 1979 1950 2643 2370 3218 3160 4284 2670 3620 2 312 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 8 8 Class 10 9 Class 12 9 DRY DRY reer 68 775 103 DRY DRY 2 125 8 110 108 147 337 304 535 525 713 600 458 622 612 830 536 727 715 970 0 570 562 762 583 791 778 1055 682 925 909 1293 2 6 GRC 12 Part No 115370 iz ile Eh ile 1 4 ee En On re A o e mE 1
19. The level sensor alarm does sound Adjust the level sensor retaining fasteners just until the level sensor alarm does not sound 13 Lower the platform to the stowed position 14 Raise the machine slightly 15 Remove the blocks from under both wheels 16 Lower the machine and remove the jack 17 Center a lifting jack under the drive chassis at the tank side of the machine Part No 115370 September 2008 Section 4 Repair Procedures REVA 18 Raise the machine approximately 2 inches 5 cm 19 Place a 0 79 x 6 x 6 inch 2 x 15x 15 cm thick steel block under both wheels at the tank side of the machine 20 Lower the machine onto the blocks 21 Raise the platform approximately 1 foot 30 cm Result The platform should stop and an alarm should sound Result The platform does not stop or the level sensor alarm does not sound Adjust the level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 22 Lower the platform to the stowed position 23 Raise the machine slightly 24 Remove the blocks from under both wheels 25 Lower the machine and remove the jack 26 Center a lifting jack under the drive chassis at the steer end of the machine 27 Raise the machine approximately 2 inches 5 cm 28 Place a 2 18 x 6 x 6 inch 5 54 x 15 x 15 cm thick steel block under both wheels at the steer end of the machine 29 Lower the machine onto the blocks Part No 11
20. burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Identify discovered symptoms gt Troubleshoot problem still exists Return to _ service problem solved Section 6 Schematics September 2008 Electrical Schematic Abbreviation and Wire Color Legends REV ELECTRICAL COMPONENT LEGEND WIRE COLOR LEGEND Item Description Color Description BK Black Button BK WH Black White BN5 Horn BN6 High torque BL Blue BN8 Drive enable BN Brown BNQ Lift enable GN Green CB2 GN BK Green Black cR e UR GN YL Green Yellow 5 Hom relay wi 2 option CR48 Power B to U5 ed GY Gray D7 Voltage regulator Platform controls circuit board LB X LightBlue EN4 Endosure AC outlet box OR Orange F6 Fuse 275A OR BK Orange Black Flashing beacons PP Purple Gauge RD Red G6 Hour meter RD BK Red Black G8 Diagnostic display WH White Ground Horn or alarm WH BK White Black H1 Horn YL Yellow H2 Automotive style horn option H5 Multifunction alarm Joystick controller Key switch LED or light L16 Lift L17 Drive L21 High torque Limit switch LS6 Platform down LS7 Pothole LS8 Pothole M5 Hydraulic power unit NC No
21. connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched Part No 115370 A TEREX COMPANY STEER AXLE COMPONENTS 8 3 Steer Bellcrank How to Remove the Steer Bellcrank 1 Remove the steer cylinder See 8 2 How to Remove the Steer Cylinder 2 Center a lifting jack under the drive chassis at the steer end of the machine 3 Raise the machine approximately 14 inches 36 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 4 Turn the yokes fully to one side of the machine 5 Remove the fasteners securing the bell crank to the steer yoke Note Observe and note the quantity and location of the spacers between the bellcrank and the steer links 6 Turn the yokes fully to the opposite side of the machine 7 Remove the fasteners securing the bell crank to the steer yoke Note Observe and note the quantity and location of the spacers between the bellcrank and the steer links 8 Remove the bellcrank from the machine Note Observe and note the quantity and location of the spacers between the bellcrank and the steer links Section 4 Repair Procedures September 2008 Non steer Axle Components 9 1 Drive Brake How to Remove a Drive Brake Note When removing a hose assembly or fitting th
22. function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC 5 Release the lift function select and drive function select buttons Result The diagnostic display will show the current software configuration 6 Press the lift function select button Result The tens digit setting will be activated and the current tens setting will flash in the diagnostic display Use the steering thumb rocker switch on the joystick to increase or decrease the value See 1 3 Machine Configuration Code Chart for configuration settings 7 Press and hold the lift function select button for a minimum of seconds to set the tens value A TEREX COMPANY PLATFORM CONTROLS gt lt a joystick controller JC1 with thumb steering rocker SW6 b function select button BN9 diagnostic display d red Emergency Stop button P2 e slow speed select button BN6 f blue arrow 8 Press the slow speed select button Result The ones digit setting will be activated and the current ones setting will flash in the diagnostic display Use the steering thumb rocker switch on the joystick to increase or decrease the value See 1 3 Machine Configuration Code Chart for configuration settings 9 Press and hold the slow speed select button for a minimum of 3 seconds o
23. lines on the ground 40 feet 12 2 m apart 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 Press the lift function select button Press and hold the function enable switch on the joystick Raise the platform approximately 4 feet 1 2 m from the ground Press the drive function select button Part No 115370 ATER COMPANY CHECKLIST B PROCEDURES Ce a lift function select button BN9 b drive function select button BN8 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications Section Scheduled Maintenance Procedures September 2008 CHECKLIST B PROCEDURES B 11 Test the Slow Drive Speed Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitati
24. 2 Red wire at platform controls 2 5 Level sensor power 57 output J KA A6 Platform up coil Y8 output A7 Drive reverse coil Y5 output A8 Motor controller U6 terminal 1 A9 Motor controller U6 terminal 3 4 c A10 Overload sensor PS2 input A11 Key switch to platform control input A12 Platform down TS66 input Relay layout B1 Platform data link high input a auto style horn 5 option Blue wire at b power relay CR48 B2 Plug ECM diagnostic display window B3 ECM ground output d electronic control module ECM U5 B4 Plug e motor controller U6 B5 Plug B6 Platform down coil Y7 output B7 Steer left coil 4 output B8 Automotive style horn H2 option output B9 Multi function alarm H5 output B10 Pothole limit switch input B11 Drive enable power up limit switch input B12 Platform up TS66 input C1 Platform data link low input Orange wire at platform controls C2 Power to ECM input C3 Plug C4 Plug C5 Jumper Drive forward 6 output C7 Steer right coil Y3 output C8 Parallel coil Y 1 not available on GS 1530 82 and GS 1930 32 C9 Work light L30 option C10 Jumper C11 Level sensor signal S7 input C12 Down limit switch LS66 input TEREX COMPANY Part No 115370 GRC 12 6 3 Section 6 Schematics September 2008 Wiring Diagram Ground and Platform Controls MOTOR CONTROLLER TERMINAL B H GROUND CONTR
25. Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 434 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 49 422 149 1820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual GRC 12 from serial number GRC08 000101 115370 Rev A1 G Part No EX COMPANY
26. September 2008 SPECIFICATIONS Performance Specifications Drive speed maximum REVA Hydraulic Specifications Hydraulic Oil Specifications Platform stowed fast 2 5 mph 40 ft 10 9 sec 4 km h 12 2 10 9 sec Platform stowed slow 1 1 mph 40 ft 24 8 sec 1 8 km h 12 2 24 8 sec Platform raised 0 5 mph 40 ft 55 sec 0 8 km h 12 2 m 55 sec Braking distance maximum 19 in x 6 in 48 15 cm High range on paved surface Gradeability 3096 Airborne noise emissions 70 dB Maximum sound level at normal operation workstations A weighted Function speed maximum from platform controls with 1 person in platform 10 to 14 seconds 14 to 18 seconds Platform up Platform down Rated work load at full height maximum 500 Ibs 227 kg Platform Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMI Hydraulic oil type Viscosity grade Chevron Rykon MV equivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron IlI oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140
27. The lift cylinder AWARNING could become unbalanced and fall if not properly supported when removed from the mast Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing mast cylinder pin cylinder retaining bolt a lower mast assembly b lift cylinder c hydraulic hose d hair pin clip e f A TEREX COMPANY Part No 115370 GRC 12 om MAST COMPONENTS lift cylinder manual lowering valve knob coil platform down solenoid valve orifice connector fitting hydraulic hose Section 4 Repair Procedures September 2008 MAST COMPONENTS 3 4 Lift Cylinder Wear Block How to Remove the Lift Cylinder Wear Block AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the mast See 3 1 How to Remove the Mast Assembly 2 Remove the mast See 3 3 How to Remove the Cylinder 3 Working at the barrel end of the cylinders remove the fasteners securing the number 2 cylinder to the number 1 cylinder 4 Separate the number 2 cylinder from the number 1 cylinder and remove the cylinder wear block at the rod end of the cylinders cap screw number
28. and platform controls x x a rightfault LED b leftfault LED 25VLED x d 21VLED Genie A TEREX COMPANY inverter Activate the tool Result The power tool should operate There may be a brief 0 5 second delay if the power tool has not been used in the previous 10 minutes If the left fault LED REV_POL is illuminated the inverter is connected to batteries with the incorrect polarity Correct the polarity issue with the red wire to battery positive and the black wire to battery negative The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks one time the power draw is too high The tool being used requires too much power to operate or is being used at or near the limit of the inverter for an extended period of time Reduce the power draw The inverter will then operate correctly and begin supplying AC power If the right fault LED 123 blinks two times the Ground Fault Interrupt GFI has been activated A short circuit or partial short exists between the AC hot and ground in the tool or outlet Check the tool for burnt chafed corroded and loose wires and inspect the tool for internal moisture Correct the short circuit or moisture issue OR inspect the wiring in the power to platform box The inverter will then operate correctly and begin supplying AC power If right fault LED 123 blinks three times the inverter is overheated Allow the inverter t
29. are installed SAE O ring Boss Port JIC 37 Fittings tube fitting installed into Aluminum swivel nut or hose connection SAE Dash size Torque SAE Dash size Thread Size Flats 4 11 ft lbs 14 9 Nm 4 7 16 20 2 6 23 ft lbs 31 2 Nm 6 9 16 18 1 1 4 8 40 ft lbs 54 2 Nm 8 3 4 16 1 10 69 ft lbs 93 6 Nm 10 7 8 14 1 12 93 ft lbs 126 1 Nm 12 1 1 16 12 1 16 139 ft Ibs 188 5 Nm 16 1 5 16 12 1 20 172 ft lbs 233 2 Nm 20 1 5 e 12 1 24 208 ft lbs 282 Nm 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Torque 4 16 ft lbs 21 7 Nm 6 35 ft lbs 47 5 Nm 8 60 ft lbs 81 3 Nm 10 105 ft lbs 142 4 Nm 12 140 ft lbs 190 Nm 16 210 ft lbs 284 7 Nm 20 260 ft lbs 352 5 Nm 24 315 ft lbs 427 1 Nm A TEREX COMPANY 2 4 GRC 12 Part No 115370 September 2008 Section 2 Specifications REVA SPECIFICATIONS Torque Procedure 3 Working clockwise on the body hex fitting make JIC 37 fittings 1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in Ibs 3 4 Nm 2 Make a reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 a second mark with a permanent ink m
30. charged Proceed to step 15 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery 15 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 16 Install the vent caps and neutralize any electrolyte that may have spilled A TEREX REV A All models 17 Check each battery pack and verify that the batteries are wired correctly 18 Inspect the battery charger plug and pigtail for damage or excessive insulation wear Replace as required 19 Connect the battery charger to a properly grounded 115V 60Hz or 230V 60Hz single phase AC power supply Result The charger should operate and begin charging the batteries W If simultaneously the charger alarm sounds and the LEDs blink one time correct the charger connections at the fuse and battery The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink two times the input voltage is too low or too high Correct the voltage issue The charger will then operate correctly and begin charging the batteries If simultaneously the charger alarm sounds and the LEDs blink three times the charger is overheated Allow the charger to cool The charger will then operate correctl
31. clothing and eye wear Models without maintenance free or sealed batteries 10 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Section Scheduled Maintenance Procedures September 2008 CHECKLIST B PROCEDURES 11 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C O Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 15 Result One or more battery cells display specific gravity of 1 217 or below Proceed to step 12 12 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours 13 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 14 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully
32. hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Part No 115370 A TEREX COMPANY PLATFORM CONTROLS iy b 4 G amp 99 8 amp a joystick controller JC1 with thumb steering rocker SW6 b horn button BN5 lift function select button BN9 d red Emergency Stop button P2 e drive function select button BN8 6 Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage 7 Usethe steering thumb rocker swi
33. number 2 mast number 3 mast number 4 mast September 2008 Section 4 Repair Procedures REVA 10 Attach a lifting strap from an overhead crane to the mast assembly and carefully rotate the mast 180 Set the mast assembly onto the work table and secure the mast to the table AWARNING Crushing hazard The mast assembly could become unbalanced and fall if not properly supported Note During installation the overhead crane strap will need to be carefully adjusted for proper balancing 11 Slide the number 4 mast towards the bottom of the number 3 mast and align the upper and lower number 4 mast access holes to the upper and lower rivets on the number 3 mast Refer to Illustration 2 Illustration 2 wear pads rivets number 4 mast number 3 mast number 2 mast number 1 mast 12 Using a drill carefully drill out the rivets securing the number 3 outer wear pads to the top half of the number 3 mast section Refer to Illustration 2 Note While drilling the rivets out be careful not drill into the number 2 mast section Note While drilling the rivets out be careful not enlarge the wearpad mounting holes Part No 115370 A TEREX COMPANY MAST COMPONENTS 13 Using a drill carefully drill out the rivets securing the number 4 inner wear pads to the bottom half of the number 4 mast section Refer to Illustration 3
34. number 2 mast Illustration 7 d number 1 mast number 3 mast rivet wear pads number 1 mast number 2 mast 20 Using a drill carefully drill out the rivets securing the number 1 outer wear pads to the top half of the number 1 mast section Refer to Illustration 2 Note While drilling the rivets out be careful not Note While drilling the rivets out be careful not drill into the number 1 mast section enlarge the wearpad mounting holes Note While drilling the rivets out be careful not enlarge the wearpad mounting holes 22 Attach a lifting strap from an overhead crane to the number 2 mast section and carefully remove the number 2 mast AWARNING Crushing hazard The number 2 mast section could become unbalanced 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 A TEREX COMPANY Part No 115370 GRC 12 4 19 Section 4 Repair Procedures September 2008 MAST COMPONENTS How to Assemble the Mast AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended 1 Thoroughly clean all mast sections 2 Attach a lifting strap from an over
35. pum m m M M This page intentionally left blank 3 26 GRC 12 Part No 115370 September 2008 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start 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 parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 115370 A TEREX COMPANY Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained ser
36. rivets out be careful not enlarge the wearpad mounting holes A TEREX CON REV A 17 Using a drill carefully drill out the rivets securing the number 3 inner wear pads to the bottom half of the number 3 mast section Refer to Illustration 5 lllustration 5 a number 3 mast b c wear pads d number 1 mast e number 2 mast Note While drilling the rivets out be careful not drill into the number 2 mast section Note While drilling the rivets out be careful not enlarge the wearpad mounting holes 18 Attach a lifting strap from an overhead crane to the number 3 mast section and carefully remove the number 3 mast AWARNING Crushing hazard The number 3 mast section could become unbalanced 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 Part No 115370 September 2008 Section 4 Repair Procedures REVA MAST COMPONENTS 19 Slide the number 2 mast towards the bottom of 21 Using a drill carefully drill out the rivets the number 1 mast and align the upper and securing the number 2 inner wear pads to the lower number 2 mast access holes to the upper bottom half of the number 2 mast section Refer and lower rivets on the number 1 mast Refer to to Illustration 7 Illustration 6 9 lt Illustration 6 a wear pads b rivets
37. side Remove the platform from the machine AWARNING Crushing hazard The platform could become unbalanced and fall when removed from the machine A properly centered lifting strap is essential when removing the platform from the machine Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing A TEREX COMI REV A 2 2 Platform Extension How to Remove the Platform Extension Deck 1 Remove the fasteners and spring securing the extension deck latch to the extension deck Set the fasteners spring and the latch to the side Remove the fasteners securing the platform wear pads to the main deck at the steer end of the machine Set the fasteners and the wear pads to the side Remove the fasteners securing the extension deck guide blocks to the extension deck and main deck Set the fasteners and the guide blocks to the side a extension deck latch b platform wear pad c extension deck guide block Part No 115370 September 2008 Section 4 Repair Procedures REVA PLATFORM COMPONENTS 4 Attach a lifting strap of suitable capacity from an overhead crane and center it around the extension deck railing Remove the extension deck from the machine Crushing hazard The extension AWARNING deck could become unbalanced and fall when removed
38. the lower number 4 mast access holes to the lower number 3 rivet holes Refer to Illustration 9 22 Working at the top of the number 4 mast carefully slide the lower corner wear pads between the number 4 mast and the number 3 mast Refer to Illustration 9 23 Align the the rivet holes on the wear pads to the number 4 mast access holes and to the number 3 mast rivet holes Refer to Illustration 6 24 Using the appropriate rivets securely install the lower corner wear pads to the lower half of the number 3 mast Refer to Illustration 9 Note After installing the first rivet move and align the number 4 mast access hole to the second hole on the wear pad and install the second rivet Refer to Illustration 9 9 Illustration 9 wear pad rivets number 4 mast number 3 mast number 2 mast number 1 mast 25 Attach a lifting strap from an overhead crane to the mast assembly and carefully rotate the mast 180 Set the mast assemblty onto the work table and secure the mast to the table AWARNING Crushing hazard The mast assembly could become unbalanced and fall if not properly supported Note During installation the overhead crane strap will need to be carefully adjusted for proper balancing 4 24 A TEREX COMI REVA 26 Using Illustration 10 as a guide stagger the mast assembly 27 Slide the lower inner corner wear pads between mast sectiopns1 and 2 2 and 3
39. to avoid possible injury or death A Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes A TEREX COMI vi GRC 12 Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and 2 combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach 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 all tools and working areas 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 any forklift overhead crane or Be sur
40. 28 Ground Controls 1 LOVE SOMSOM ERR 4 29 Hydraulic Pump 5 1 UNCON Pump d rtt ED o Exe a Qaa Eee edu ues 4 32 Function Manifold 6 1 Function Manifold 4 34 6 2 Valve Adjustments Function Manifold 4 36 6 3 E 4 40 Hydraulic Tank PAL Hydraulic 4 42 Part No 115370 A TEREX COMPANY September 2008 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued A Steer Axle Components 8 1 Yokeand Drive Molor idet eid edocet Ert aetas 4 43 8 2 Steer Cylinder sssssssssssssssesesesene nennen nnne 4 45 8 8 Steer Bellcrank teet c a er 4 45 A Non steer Axle Components 9 1 Drive Brake are ergo eee ptus rude dide PEL Ame 4 46 A Brake Release Hand Pump Components 10 1 Brake Release Hand Pump 4 47 Section 5 Rev Fault Codes 5 1 Fault Code Chart nennen 5 3 Section 6 Rev Schematics A 07 e 6 1 Electrical Component and Wire Color 6 2 A Relay Layout and ECM Pin out 6 3 A Wiring Diagram Ground and Platform
41. 3 cylinder number 2 cylinder number 1 cylinder cylinder wear block a b A TEREX COMI REV A 3 5 Mast Coil Cord How to Remove the Mast Coil Cord AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the mast See 3 1 How to Remove the Mast Assembly 2 Loose the strain relief nut at the top of the outlet junction box 3 Remove the cover from the AC outlet junction box Tag and disconnect the coil cord wires from the control cable wires 4 Cut the connectors from the coil cord wires and pull the coil cord from the strain relief 5 Working at the rod end of the mast cut the zip tie securing the coil cord and the spring to the number 4 cylinder mount bracket 6 Working at the barrel end of the mast cut the zip tie securing the coil cord and spring to the L bracket 7 Remove the coil cord and the spring from the mast assembly Part No 115370 September 2008 Section 4 Repair Procedures REVA 4 1 Level Sensor The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor The tilt alarm sounds when the incline of the chass
42. 5370 A TEREX COMPANY GROUND CONTROLS 30 Raise the platform approximately 1 foot 30 cm Result The level sensor alarm should not sound W Result The level sensor alarm does sound level sensor is faulty and must be replaced Repeat this procedure beginning with step 1 31 Raise the machine slightly 32 Remove the blocks from under both wheels 33 Lower the machine and remove the jack 34 Center a lifting jack under the drive chassis at the non steer end of the machine 35 Raise the machine approximately 2 inches 5 cm 36 Place a 2 4 x 6x6 inch 6 1 x 15 x 15 cm thick steel block under both wheels at the non steer end of the machine 37 Raise the platform approximately 1 foot 30 cm O Result The platform should stop and an alarm should sound Result The platform does not stop or the level sensor alarm does not sound The level sensor is faulty and must be replaced Repeat this procedure beginning with step 1 38 Lower the platform to the stowed position 39 Raise the machine slightly 40 Remove the blocks from under both wheels 41 Lower the machine and remove the jack 4 31 Section 4 Repair Procedures September 2008 Hydraulic Pump 5 1 Function Pump The hydraulic pump is attached to the motor which makes up the hydraulic power unit How to Test the Hydraulic Pump Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to sp
43. 800 mA 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil Part No 115370 A TEREX COMPANY FUNCTION MANIFOLD COIL MULTI METER 100 9 RESISTOR BATTERY i eee 1 1 I ON Fi bb Les PN Vp See cee dedi ttt be b IESUS multimeter 9V DC battery 10Q resistor coil ao oo Note Dotted lines in illustration indicate a reversed connection as specified in step 6 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than mA are different by a minimum of 20 The coil is good W Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Section 4 Repair Procedures September 2008 Hydraulic Tank 7 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool and deaerate the hydraulic fluid during
44. ECM and the platform controls and level sensor wiring 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 6 Raise the platform approximately 8 feet 2 4 m from the ground 7 Placea lifting strap from an overhead crane under the platform Support the platform Do not apply any lifting pressure Component damage hazard The platform railings can be damaged if they are used to lift the platform Do not attach the lifting strap to the platform railings 8 Inspect the center chassis area for burnt chafed and pinched cables 9 Open the battery tray cover 10 Inspect the battery tray for burnt chafed and pinched cables 11 Close the battery tray cover 12 Remove the strap from the platform 13 Lower the platform to the stowed position and turn the machine off Section Scheduled Maintenance Procedures September 2008 CHECKLIST B PROCEDURES B 3 Inspect the Tires and Wheels including castle nut torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition including proper castle nut torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashio
45. EV A C a joystick controller JC1 with thumb steering rocker SW6 b horn button BN5 c liftfunction select button BN9 d red Emergency Stop button P2 Press the drive function select button Press and hold the horn button Result The diagnostic display will show the raised drive speed percentage Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications for function speeds Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Part No 115370 September 2008 Section 4 Repair Procedures REVA How to Adjust the Slow Drive Speed Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform con
46. G se injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray AC outlet box junction box mast retaining fasteners lift cylinder coil lift cylinder solenoid valve mast mast cover 0 9 Part No 115370 September 2008 Section 4 Repair Procedures REVA MAST COMPONENTS 5 Remove the fasteners securing the lower rear 10 Using an overhead crane attach a sling access cover to the chassis and remove the cover Set the cover and the fasteners to the side 6 Tag and disconnect the wire harness from the equipped with the appropriate sized hooks to the lifting eyes located inside the mast assembly Support the mast Do not apply any lifting pressure platform down valve coil at the base of the lift 11 Working at the non steer end of the lower cylinder 7 Remove the retaining nut securing the platform chassis remove the mast retaining fasteners and set the fasteners to the side down coil to the platform down solenoid valve 12 Carefully pull the cables and hydraulic hoses and remove the coi
47. MAST COMPONENTS 7 Slide the number 2 mast towards the bottom of 11 Using the appropriate rivets securely install the the number 1 mast and align the lower number upper corner wear pads to the upper half of the 2 mast access holes to the lower number 1 rivet number 2 mast Refer to Illustration 4 holes Refer to Illustration 3 8 Working at the top of the number 2 mast carefully slide the lower corner wear pads between the number 2 mast and the number 1 mast Refer to Illustration 3 9 Align the the rivet holes on the wear pads to the number 2 mast access holes and to the number 1 mast rivet holes Refer to Illustration 3 10 Using the appropriate rivets securely install the lower corner wear pads to the lower half of the number 1 mast Refer to Illustration 3 Note After installing the first rivet move and align the number 2 mast access hole to the second hole on the wear pad and install the second rivet Refer to Illustration 3 Illustration 4 a wear pad b rivet number 2 mast d number 1 mast Illustration 3 a wear pad b rivets number 1 mast d number 2 mast TEREX COMPANY Part No 115370 GRC 12 4 21 Section 4 Repair Procedures September 2008 MAST COMPONENTS 12 Attach a lifting strap from an overhead crane to the number 3 mast and carefully slide the number 3 mast onto the number 2 mast with the cylinder mount brackets facing the work table AWARNING Crushing haza
48. OLS re la Bgm lum 7A CIRCUIT KEY SWITCH 3 BREAKER HOUR METER MOTOR CONTROLLER wy TERMINAL 1 6 PINCONNECTOR py PIN 1 RD ECM PIN B12 TS66 zh PLATFORM UP DOWN ECM PIN A12 DOWN TOGGLE SWITCH CR48 TERMINAL OR ECM PIN 11 1 gt EMERGENCY STOP Occ ee cee PLATFORM CONTROLS BK RD amia 5 ALARM GO L i JC1 GY 9 TEREX COMPANY P2 EMERGENCY STOP REVA TO COIL CORD Part No 115370 September 2008 Section 6 Schematics Electrical Symbols Legend REVA N C N C H O N O H C b Q OH 1 tes 5 2 Limit switch CIRCUIT BOARD i t gt S7 m LEVEL 1 SENSOR 2 MM oe Level sensor Button or switch Wire with description or color t 09 Solenoid valve with diode Pr Toggle switch Circuits crossing 99
49. OSITION WITH THE POWER OFF HM NMOG HOLIMS AJJ MS Ms NMOd dN H3MOd HOLIMS QD1 9 HOLIMS IM 8 MIU il B9 B10 4 B11 C5 C10 C12 OUT IN N N N N IN F6 275a FUSE 5 aem H 2 18 m 22 Luo L 09 CHARGER GN AQ OUT BK 1 A8 OUT US ELECTRONIC CONTROL MODULE A1 WH 4 1 OUT OUT OUT OUT OUT B8 B3 C7 B7 A7 FB SS el etc ye ee Oa crm FLASHING 9 9 BEACONS OPTION le CR5 a HORN RELAY 30 H2 OPTION 9 M co Y3 Y4 Y5 STEER STEER DRIVE RIGHT LEFT REVERSE B5 4 6V BATTERY RD 06 motor des d INPUT CONTROLLER 1 BK t 1 U13 DC AC INVERTER OPTION E H2 AUTO STYLE zm Ex bx kx OPTION ES0126C Genie TEREX COMPANY 6 6 GRC 12 Part No 115370 September 2008 Section 6 Schematics REVA
50. RRRRR RR RR ERR RRRR RR N E RR RR RR RR RR Part No 115370 a A TEREX COMPANY GRC 12 6 7 Section 6 Schematics September 2008 mec c M M 5 This page intentionally left blank 6 8 GRC 12 Part No 115370 September 2008 Section 6 Schematics Hydraulic Component Reference and REV A Symbols Legend 2 E Orifice Check valve Brake Variable speed motor aa e A Solenoid operated Hydraulic cylinder Fixed displacement pump gt 3 position 4 Y8 directional valve Solenoid operated 2 position 4 way directional valve Y6 M aaa Bi directional motor Solenoid operated Relief valve 3 position 4 way directional valve Filter 7 Q Q v Solenoid operated 2 2 position 2 way Priority flow regulator ee Pilot operated directional valve Hand pum normally closed needle valve with manual override 2 Pd ts Brake manifold 7 Lift cylinder RO Function manifold Part No 115370 GRC 12 6 9 Section 6 Schematics May 2008 Hydraulic Schematic REV LIFT CYLINDER STEER STEER LEFT RIGHT LEFT RIGHT LEFT RIGHT DRIVE DRIVE U MOTOR MOTOR
51. They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Environ MV 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below 0 F 17 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Part No 115370 September 2008 Section 2 Specifications REVA Function pump Type Gear Displacement per revolution 0 244 cu in 4cc Flow rate 2500 psi 172 bar 4 gpm 15 L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Function manifold System relief valve pressure maximum 3500 psi 241 bar Lift relief valve pressure 1800 to 3500 psi 124 to 241 bar SPECIFICATIONS Manifold Component Specifications Plug
52. aintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annually or 500 hours Inspection A B C Annually or 1000 hours Inspection A B C D Two year or 2000 hours Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures this section to learn how to perform these inspections If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable no remove from service repaired Checklist A Rev A Y NR ChecklistB RevA Y NR B RevA A 1 Inspect the manuals and decals 2 Pre operation inspection A 3 Function tests Perform after 40 hours A 4 30 day service Perform every 100 hours BRE A 5 Grease steer yokes Comments Part No 115370 TEREX COMPANY B 4 Emergency stop B 5 Key switch B 6 Horn if equipped B 7 Inverter if equipped B 8 Drive brakes B 9 Drive speed stowe
53. and 3 and 4 Align the holes on the wear pads to the rivet holes on the lower half of mast sections 2 3 and 4 Secure the wear pads into place using the appropriate rivets Refer to Illustration 10 Illustration 10 number 4 mast rivet wear pad limit switch number 1 mast number 2 mast number 3 mast O 28 Carefully collapse the mast assembly 29 Attach a lifting strap from an overhead crane to the lift cylinder Working from the lower half of the mast assembly carefully slide the lift cylinder into the mast assembly aligning the rod ends of the cylinder to the cylinder mast mounting brackets at the upper half of the mast assembly AWARNING Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported Note During installation the overhead crane strap will need to be carefully adjusted for proper balancing Part No 115370 September 2008 Section 4 Repair Procedures REVA 30 Working at the upper half of the mast assembly securely install the lift cylinder nylock nuts onto the lift cylinder Torque to 300 ft Ibs 406 Nm 31 Working from the lower half of the mast assembly install the mast cylinder pin into the mounting holes of the number 1 mast and the lift cylinder 32 Install the hair pin clips onto each side of the mast cylinder pin 33 Securely install the lift cylinder retaining bolt onto the lower cylinder block Do not over tighten t
54. arker to indicate the proper tightening position Refer to Figure 2 Use the JIC 37 Fittings table on the previous page to determine the correct number of flats for the proper tightening position The marks indicate that the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened d lt OEC Figure 2 a body hex fitting b reference mark second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Figure 1 a hydraulic hose b hex nut c reference mark d body hex fitting Part No 115370 GRC 12 Section 2 Specifications September 2008 SPECIFICATIONS REVA SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade5 2 Grade8 69 Black Oxide Bolts DRY DRY LUBED Nm_ in lbs Nm Nm inis LUBED LUBED LUBED I 2 m gt muss 13 23 14 257 23 22 26 274 37 66 4 i 745 60 s3 1084 58 921 73 75 1016 1084 0 149 03 16 20 894 867 835 115 o 122 320 362 108 742 one 12 1084 no 149 18 90 122
55. atform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine Part No 115370 A TEREX COMPANY PLATFORM CONTROLS _ d joystick controller JC1 lift function select button BN9 diagnostic display window red Emergency Stop button P2 yellow arrow 3 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 Result The diagnostic display at the platform controls will show the battery condition See 1 3 How to Determine the Battery Voltage 4 Press the lift function select button 5 Slowly move the joystick in the direction indicated by the yellow arrow Result The software revision level will appear in the diagnostic display 6 Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Section 4 Repair Procedures September 2008 PLATFORM CONTROLS How to Adjust the Lift Speed ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be perf
56. ck to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced A TEREX COMI REV A 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Part No 115370 September 2008 Section Scheduled Maintenance Procedures REVA A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Insp
57. ct button 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line Part No 115370 A TEREX COMPANY CHECKLIST B PROCEDURES amp 999 gu 5 a drive function select button BN8 6 Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine crosses the test line 7 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb Section Scheduled Maintenance Procedures September 2008 CHECKLIST B PROCEDURES REVA B 9 Test the Drive Speed 2 Stowed Position 1 NEY Genie specifications require that this procedure be 455 performed every 250 hours or quarterly whichever e comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of eS 5 hesitation jerking and unusual noise over the entire proportionally controlled speed range a drive function select button BN8 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the mach
58. d B 10 Drive speed raised B 11 Drive speed slow B 12 Flashing beacons B 13 Alarm if equipped B 14 Hydraulic oil analysis B 1 Batteries B 2 Electrical wiring B 3 Tires and wheels B 15 Breather cap ChecklistC RevA Rev Y NR C 1 Breather cap models with optional oil Checklist D Rev A Y NR D 1 Tank return filter Checklist E Rev A Y NR E 1 Hydraulic oil Section Scheduled Maintenance Procedures September 2008 Checklist A Procedures A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards 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 1 Che
59. d the system relief valve with a wrench and remove the cap schematic item I 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure ADANGER Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap 11 Repeat steps 5 through 7 to confirm the relief valve pressure Part No 115370 September 2008 Section 4 Repair Procedures REVA How to Adjust the Platform Lift Relief Valve Note Be sure that the hydraulic oil level is at the FULL mark on the hydraulic tank 1 Locate the system relief valve on the function manifold item S Tm us S S GS SS a test port b system relief valve lift relief valve 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold schematic item A 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform Note Perform this test from the ground with the platform controls Do not stand in the platform Part No 115370 A TEREX COMPANY FUNCTION MANIFOLD 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platf
60. dentify gt Troubleshoot discovered symptoms A problem still exists 4 Return to 0 0 Perform service problem repair solved 5 2 GRC 12 LED Diagnostic Readout The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers remain on when a fault code is displayed The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected Part No 115370 September 2008 Section 5 Fault Codes REVA Fault Code Problem Fault Code Chart Possible Causes Solution Internal ECM error ECM Platform communication error Undefined platform DIP switch settings Chassis up down toggle closed at start up Pothole guard failure Limit switch failure Platform left turn switch fault Platform right turn switch fault Platform drive enable switch fault Platform joystick fault Forward coil fault Reverse coil fault Up coil fault Down coil fault Steer right coil fault Steer left coil fault Brake coil fault Series parallel coil fault Low battery voltage EPROM not programmed Malfunctioning control cable OR malfunctioning platform controls DIP switch settings incorrect Malfunctioning up down switch Malfunctioning poth
61. distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil Part No 115370 September 2008 Section 3 Scheduled Maintenance Procedures M y REVA CHECKLIST B PROCEDURES B 15 Inspect the Breather Cap Genie specifications require that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist A free breathing hydraulic tank cap is essential for good machine performance and service life A dirty or clogged cap may cause the machine to perform poorly Extremely dirty conditions may require that the cap be inspected more often 1 Remove the breather cap from the hydraulic tank 2 Checkfor proper venting O Result Air passes through the breather cap Result If air does not pass through the clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat step 2 4 Install the breather cap onto the hydraulic tank A TEREX COMPANY Part No 115370 GRC 12 3 21 Section Scheduled Maintenance Procedures Se
62. e Yoke and Drive Motor Assembly Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications 1 Block the wheels at the non steer end of the machine 2 Remove the cotter pin from the wheel castle nut at the steer end of the machine Note Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 6 inches 15 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel Part No 115370 A TEREX Steer Axle Components 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 8 Support and secure the yoke assembly to an appropriate lifting device 9 Remove the retaining fastener from the steer link at the yoke assembly Note Observe and note th
63. e ds 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 A other fluids Use an approved container Please be environmentally safe Sure that your workshop or work area is properly ventilated and well lit Part No 115370 September 2008 Introduction Section 1 Section 2 Rev A Section 3 Rev A Table of Contents Important nformiatiOTi uiuit encierra eret etna eene vv e nae d li Serial Number Legend ERE eus iii Safety Rules General Safety 4 22 0 nennen entere nennen nnne nns Specifications Machine Specifications 002 1 0 2 1 Performance Specifications 20 04442 0 0 0 2 2 Hydraulic Specifications cente loce i nee etna weenie 2 2 Manifold Component 2 93 Hydraulic Hose and Fitting Torque Specifications 2 4 SAE and Metric Fasteners Torque Charts 2 6 Scheduled Maintenance Procedures DEUM 3 1 Pre delivery Preparation Report 3 3 Maintenance Inspection Report
64. e fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications 1 Block the wheels at the steer end of the machine 2 Remove the cotter pin from the wheel castle nut at the non steer end of the machine Note Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Center a lifting jack under the drive chassis at the non steer end 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel A TEREX COMI REV A 7 Tag disconnect and plug the hydraulic hose from the brake Cap the fitting on the brake AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Place a lifting jack under the brake for support 9 Remove the fasteners that attach the brake to the drive chassis Remove the brake Crushing hazard The brake will ACAUTION fall if not properly supported when the mounting fasteners are removed Torque specifications Brake mounting fasteners dry 75 ft lbs 102 Nm Brake mounting fasteners lubricated 56 ft lbs 76 Nm Pa
65. e hydraulic tank return filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter Remove the filter with an oil filter wrench 2 Applyathin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand 4 Use a permanent ink marker to write the date and number of hours from the hour meter onto the filter Part No 115370 A TEREX 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 6 Activate and hold the platform up toggle switch 7 Inspect the filter and related components to be sure that there are no leaks 8 Clean up any oil that may have spilled Torque specifications Hydraulic tank drain plug dry 40 in Ibs 4 5 Nm Hydraulic tank drain plug lubricated 30 in Ibs 3 4 Nm Section Scheduled Maintenance Procedures September 2008 Checklist E Procedure E 1 Test or Replace the Hydraulic Oil Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Be
66. e quantity and location of the spacers when disconnecting the steer link from the yoke assembly 10 Remove the retaining fastener from the rear of the yoke pivot shaft Note The pivot shaft retaining fastener is located below the main deck 11 Lower the yoke assembly out of the chassis Esos ACAUTION P09 injury hazard The yoke motor assembly may fall if not properly supported when removed from the machine Section 4 Repair Procedures September 2008 STEER AXLE COMPONENTS How to Remove a Drive Motor 1 Block the wheels at the non steer end of the machine 2 Remove the cotter pin from the wheel castle nut of the motor to be removed at the steer end of the machine Note Always replace the cotter pin with a new one when removing the castle nut 3 Loosen the wheel castle nut Do not remove it 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushing hazard The chassis AWARNING could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel A TEREX COMI REV A 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually D
67. ecification during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the high pressure hydraulic hose from the hydraulic pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 32 A TEREX COMPANY REV A 4 Activate the platform up function from the ground controls Result If the pressure gauge reads 3200 psi 221 bar immediately stop The pump is good Result If pressure fails to reach 3200 psi 221 bar the pump is bad and will need to be serviced or replaced Component damage hazard There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed 3200 psi 221 bar When testing the pump activate the pump in one second intervals until 3200 psi 221 bar is confirmed Do not over pressurize the pump 5 Remove the pressure gauge and reconnect the hydraulic hose Torque to specification AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connectio
68. ection Troubleshoot and correct DIP switch settings Charge batteries ECM has been erased Static strap may be missing from the machine Replace static strap Part No 115370 Genie GRC 12 Section 5 Fault Codes September 2008 M M ey This page intentionally left blank 5 4 GRC 12 Part No 115370 September 2008 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine 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 Part No 115370 A TEREX COM Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and
69. ection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Part No 115370 A TEREX COM CHECKLIST A PROCEDURES A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Section Scheduled Maintenance Procedures September 2008 CHECKLIST A PROCEDURES A 4 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 40 hours of usage After this interva
70. ee 3 3 How to Remove the Lift Cylinder 4 Remove the mast coil cord See 3 4 How to Remove the Mast Coil Cord 5 Remove the fasteners securing the AC outlet junction box to the upper half of the mast and remove the junction box Set the junction box and the fasteners to the side 6 Remove the fasteners securing the work trays to the upper half of the mast and remove the work trays Set the trays and the fasteners to the side 7 Remove the fasteners securing the down limit switch assembly to the limit switch bracket and remove the limit switch assembly Set the limit switch assembly and the fasteners to the side 8 With the chassis mount side up stagger the mast assembly to gain access to the rivets securing the inner wear pads to the bottom half of the number 2 number 3 and number 4 mast sections REVA A TEREX COMI GRC 12 Part No 115370 9 Using a drill carefully drill out the rivets securing the number 2 inner wear pads to the bottom half of the number 2 mast section the number 3 inner wear pads to the bottom half of the number 3 mast section and the number 4 inner wear pads to the bottom half of the number 4 mast section Refer to Illustration 1 Note While drilling the rivets out be careful not drill into the opposing mast section Note While drilling the rivets out be careful not enlarge the wearpad mounting holes Chassis Mount Side Illustration 1 rivet wear pads number 1 mast
71. entially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 3 Scheduled Maintenance Procedures September 2008 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be required to perform this procedure Ae 2 A TEREX COMPANY Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have bee
72. fold Components The function manifold is mounted next to the hydraulic power unit Index Schematic No Description Item Function Torque Coil nut items E Fand I sd petet i 5 ft lbs 7 Nm 1 Diagnostic nipple Bes eet Selves Testing 2 Check CISC cater ete ee tertie Steer circuit 18 ft lbs 24 Nm Relief valve 1800 to 3500 psi 124 to 241 bar Lift 2 2 2 20 ft lbs 27 Nm 4 Check valve 10 psi 0 7 bar Drive 20 ft lbs 27 Nm 5 Solenoid valve 3 position 4 way E ug Drive forward reverse 25 ft lbs 34 Nm 6 Solenoid valve 3 position 4 way Steer left right 25 ft lbs 34 Nm 7 Flow regulator and relief valve 0 75 gpm 2 8 L min 1500 psi 103 bar enin Steer circuit 26 ft lbs 35 Nm 8 Solenoid valve 2 position 4 way Platform up 25 ft lbs 34 Nm 9 Relief valve 3500 psi 241 bar maximum se System relief 20 ft lbs 27 Nm 4 34 GRC 12 Part No 115370 September 2008 Section 4 Repair Procedures REVA FUNCTION MANIFOLD
73. fore replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Open the power unit module tray A TEREX COMI REV A 3 Tag and disconnect the hydraulic tank return hard line from the hydraulic filter head and remove the hard line from the tank Cap the fitting on the filter head 4 Tag and disconnect the hydraulic pump inlet hard line and remove the hard line from the tank Cap the fitting on the pump 5 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine 6 Drain all of the oil into a suitable container Refer to Section 2 Specifications for capacity information AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Clean up any oil that may have spilled Properly discard the used oil 8 Clean the inside of the
74. from the machine A properly centered lifting strap is essential when removing the extension deck from the machine Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing A TEREX COMPANY Part No 115370 GRC 12 4 13 Section 4 Repair Procedures September 2008 Mast Components 3 1 Mast How to Remove the Mast Assembly AWARNING 200 injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure on a firm level surface Note Perform this procedure with the mast in the stowed position 1 Remove the Platform See 2 1 How to Remove the Platform 2 Tag and disconnect the power to platform wire harness at the quick disconnect near the Electronic Control Module ECM 3 Tagand disconnect the up limit switch cable near the Electronic Control Module ECM A TEREX COMI REV A 4 Tag disconnect and plug the lift cylinder hose at the function manifold Cap the fitting AWARNIN
75. gency Stop button at the platform controls to the off position Result No machine functions should operate Note The red Emergency Stop button at the ground controls will stop all machine operation even if the key switch is switched to platform control Part No 115370 September 2008 Section Scheduled Maintenance Procedures REVA B 5 Test the Key Switch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation Note Perform this procedure from the ground using the platform controls Do not stand in the platform 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control 3 Checkthe platform up down function from the ground controls Q Result The machine functions should not operate 4 Turn the key switch to ground control 5 Checkthe machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position 7 Test the machine functions from the ground a
76. he bolt 34 Using the appropriate fasteners install the limit Switch assembly onto the lower half of the mast assembly Do not over tighten the fasteners Refer to Illustration 10 35 Securely install the hydraulic lift hose onto the lift cylinder Refer to the note below for torque specifications Note When installing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Part No 115370 A TEREX COM MAST COMPONENTS 3 2 Wear Pads Wear pads on the GRC 12 are used to provide a uniform fit between the mast sections as the mast assembly extends and retracts Over time it may be necessary to replace the wear pads to ensure good machine performance How to Replace Wear Pads 1 See 3 1 How to Remove the Mast Assembly and How to Disassemble a Mast 2 See 3 1 How to Assemble a Mast Section 4 Repair Procedures September 2008 MAST COMPONENTS REVA 3 3 Lift Cylinder The lift cylinder is equipped with a normally closed solenoid valve to prevent movement in the event of a hydraulic line failure How to Remove the Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious inj
77. head crane to the number 1 mast and place the number 1 mast onto a work table capable of supporting a complete mast assembly AWARNING Crushing hazard The number 1 mast could become unbalanced and fall if not properly supported Note During installation the overhead crane strap will need to be carefully adjusted for proper balancing 3 Secure the number 1 mast to the work table 4 Using the appropriate rivets securely install the upper corner wear pads to the upper half of the number 1 mast Refer to Illustration1 Illustration 1 a wear pad b rivet number 1 mast A TEREX COMP REVA 5 Attach a lifting strap from an overhead crane to the number 2 mast and carefully slide the number 2 mast onto the number 1 mast with the cylinder mount brackets facing the work table AWARNING Crushing hazard The number 2 mast could become unbalanced and fall if not properly supported Note During installation the overhead crane strap will need to be carefully adjusted for proper balancing 6 Slide the lower inner corner wear pads between the number 2 mast and the number 1 mast Align the holes on the wear pads to the rivet holes on the lower half of the number 2 mast and secure into place using the appropriate rivets Refer to Illustration 2 Illustration 2 number 2 mast rivet wear pads number 1 mast ao oo Part No 115370 September 2008 Section 4 Repair Procedures REVA
78. hydraulic tank using a mild solvent Allow the tank to dry completely Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners Torque to specification Torque specifications 35 in lbs 4Nm Hydraulic tank retaining fasteners dry Hydraulic tank retaining fasteners lubricated 26 in lbs 2 9 Nm Part No 115370 September 2008 Section 3 Scheduled Maintenance Procedures M REVA CHECKLIST E PROCEDURE 10 Install the hydraulic pump inlet hard line into the tank Install the fitting onto the pump and torque to specification Refer to Section 2 Specifications 11 Install the hydraulic pump return hard line into the tank Install the fitting onto the hydraulic filter head and torque to specification Refer to Section 2 Specifications 12 Fill the tank with hydraulic oil until the fluid is at the FULL indicator on the hydraulic tank Do not overfill 13 Activate the pump to fill the hydraulic system with oil and bleed the system of air Component damage hazard The pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system Do not allow the pump to cavitate 14 Repeat steps 12 through 13 until the hydraulic system and tank are both full A TEREX COMPANY Part No 115370 GRC 12 3 25 Section Scheduled Maintenance Procedures September 2008
79. ine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 115370 A TEREX COMPANY About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a pot
80. ine crosses the Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two start line lines on the ground 40 feet 12 2 m apart 7 Continue at full speed and note the time when 2 Turn the key switch to platform control and pull your reference point on the machine passes out the red Emergency Stop button to the on over the finish line Refer to Section 2 position at both the ground and platform Specifications controls Lower the platform to the stowed position 4 Press the drive function select button 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines A TEREX COMPANY 3 16 GRC 12 Part No 115370 September 2008 Section Scheduled Maintenance Procedures REVA B 10 Test the Drive Speed Raised Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two
81. is exceeds 1 5 to the side or 3 to the front or rear How to Install and Calibrate the Level Sensor ADANGER Tip over hazard Failure to install or calibrate the level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure Note Perform this procedure with the machine on a firm level surface that is free of obstructions Note Perform this procedure with the platform in the stowed position If you are not installing a new level sensor proceed to step 6 1 Tag and disconnect the level sensor wire harness from the chassis wire harness 2 Remove the level sensor adjusting fasteners Remove the level sensor from the machine Part No 115370 A TEREX COMPANY Ground Controls 3 Place the new level sensor onto the level sensor base with the X on the level sensor closest to the mast of the machine and the Y on the level sensor closest to the steer end of the machine ip The level ADANGER Tip over hazard The level sensor must be installed with the X on the level sensor closest to the mast of the machine and the Y on the level sensor closest to the steer end of the machine Failure to install the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury
82. it from movement ADANGER Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Bodilv iniurv h ae AWARNING E injury hazard Spraying Platform in the stowed position hydraulic oil can penetrate and Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Part No 115370 TEREX COMPANY burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Section 5 Fault Codes September 2008 FAULT CODES About This Section When a malfunction is discovered the fault code chart in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process Malfunction I
83. l Set the coil and retaining nut to the side free while removing the mast from the machine AWARNING Crushing hazard The mast 8 Remove the platform down solenoid valve from the lift cylinder Set the valve to the side and plug the cylinder port Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Remove the fasteners securing the top mast cover to the top of the mast Set the cover and fasteners to the side A TEREX COMPANY Part No 115370 GRC 12 assembly could become unbalanced and fall if not properly supported when removed from the machine Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 13 Place the mast assembly on a suitable structure capable of supporting it Section 4 Repair Procedures September 2008 MAST COMPONENTS How to Disassemble the Mast AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer Service is strongly recommended Remove the mast See 2 1 How to Remove the Platform 2 Remove the mast See 3 1 How to Remove the Mast Assembly 3 Remove the lift cylinder S
84. l refer to the maintenance checklists for continued scheduled maintenance The 30 day maintenance procedure is a one time procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures B 3 Inspect the Tires and Wheels including castle nut torque D 1 Replace the Hydraulic Tank Return Filter A TEREX COMI REVA A 5 Grease the Steer Yokes Genie specifications require that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance and service life Continued use of an insufficiently greased steer yoke will result in component damage 1 Locate the grease fitting on the top of the steer yoke 2 Pump multipurpose grease into the steer yoke until the steer yoke is full and grease is being forced past the bearings Repeat this step for the other steer yoke Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Part No 115370 September 2008 Section Scheduled Maintenance Procedures Checklist B Procedures REVA B 1 Inspect the Batteries Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine perfor
85. mance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Raise the platform approximately 3 feet 1 m 3 Open the battery cover Rest the cover against the chassis 4 Lower the platform until the mast just contacts the battery cover AWARNING C ushing hazard Keep hands clear of the battery cover when lowering the platform 5 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 6 Be sure that the battery hold downs and cable connections are tight Part No 115370 A TEREX COM U9 Battery Charger batteries B5 275A fuse F6 quick disconnect QD1 battery charger U9 ao oo 7 Besure that the battery separator wire connections are tight if equipped 8 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 9 Puton protective
86. n 1 Check the tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Remove the cotter pin and check each castle nut for proper torque Refer to Section 2 Specifications Note Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 4 Install a new cotter pin Bend the cotter pin to lock it in place A TEREX COMI REVA B 4 Test the Emergency Stop Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation Note As a safety feature selecting and operating the ground controls will override the platform controls except the platform red Emergency Stop button 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push in the red Emergency Stop button at the ground controls to the off position Result No machine functions should operate 3 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 4 Push down the red Emer
87. n divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with employer jobsite and governmental regulations and requirements Part No 115370 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s
88. nd platform controls Result No machine functions should operate Part No 115370 A TEREX COMPANY CHECKLIST B PROCEDURES B 6 Test the Automotive style Horn if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 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 2 Push down the horn button at the platform controls Result The horn should sound Section Scheduled Maintenance Procedures September 2008 CHECKLIST B PROCEDURES REVA B 7 3 Connect an appropriate power tool to the Inspect the Voltage Inverter if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first x The inverter is activated whenever the power is on and an electrical tool is connected to the inverter and turned on 1 Inspect the inverter plug and pigtail for damage or excessive insulation wear Replace as required 2 Turn the key switch to the on position and pull out the red Emergency Stop button to the on position at both the ground
89. ns very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 115370 September 2008 Section 4 Repair Procedures p M REVA HYDRAULIC PUMP How to Remove the Hydraulic Pump Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic supply hard line at the pump Cap the fitting on the pump 2 Tag disconnect and plug the high pressure hose at the pump Cap the fitting on the pump AWARNING siad injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pump mounting bolts Carefully remove the pump Tip over hazard After replacing the hydraulic pump it is critical to return the function speed settings to original factory specifications Failure to restore the machine to original factory specifications could cause the machine to tip over resulting in death or serious injury A TEREX COMPANY Part No 115370 GRC 12 4 33 Section 4 Repair Procedures September 2008 Function Manifold REV 6 1 Function Mani
90. o cool The inverter will then operate correctly and begin supplying AC power If the battery 25 volt fault LED 25V blinks one time the battery voltage is over 30V Operate the machine to lower the voltage level The inverter will then operate correctly and begin supplying AC power If the battery 21 volt fault LED 21V blinks one time the battery voltage is less than 20V DC The inverter will continue to operate until the battery voltage falls to 17 8V DC Part No 115370 September 2008 Section Scheduled Maintenance Procedures REVA B 8 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when not fully operational Note Perform this procedure with the machine on a firm level surface that is free of obstructions Note Be sure the platform extension deck is fully retracted and the platform is in the stowed position 1 Mark atest line on the ground for reference 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 3 Lower the platform to the stowed position 4 Press the drive function sele
91. o not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched 8 Remove the drive motor mounting fasteners Remove the motor Torque specifications Drive motor mounting fasteners dry 75 ft lbs 101 7 Nm Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm Part No 115370 September 2008 Section 4 Repair Procedures REVA 8 2 Steer Cylinder How to Remove the Steer Cylinder Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Block the wheels at the non steer end of the machine 2 Remove the steer cylinder hose guard bracket from the machine 3 Remove the pin retaining fasteners from the steer cylinder barrel end pivot pin Remove the pin Note Observe and note the quantity and location of the spacers when removing the pivot pin 4 Remove the pin retaining fasteners from the steer cylinder rod end pivot pin Remove the pin Note Observe and note the quantity and location of the spacers when removing the pivot pin 5 Remove the steer cylinder from the machine 6 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings AWARNING injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic
92. ode the platform controls are used to operate the various machine functions When the ECM is in the speed tuning mode PS is shown in the diagnostic display window or software configuration mode SC is shown in the diagnostic display window the platform controls are used to adjust the function speed parameters or the machine configuration The platform controls consist of an electronic circuit board joystick alarm buttons and LEDs For further information or assistance consult the Genie Industries Service Department sas SS joystick controller JC1 alarm H1 platform controls circuit board U3 red Emergency Stop button P2 A TEREX COMI REVA 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the retaining fasteners securing the bottom to the platform control box Open the control box Remove the ties securing the wire harness Remove the alarm and red Emergency Stop button from the platform control box 5 Carefully disconnect the three wire harness connectors from the platform controls circuit board AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and othe
93. ole switch OR obstruction in pothole guard linkage Malfunctioning limit switch OR wire disconnected from limit switch Malfunctioning steer left microswitch Malfunctioning steer right microswitch Malfunctioning drive enable switch Joystick potentiometer not centered Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil DIP switch settings are incorrect Batteries discharged Replace ECM Troubleshoot control cable OR troubleshoot platform controls Correct DIP switch settings Troubleshoot up down Switch Troubleshoot pothole switch OR remove obstruction Troubleshoot limit switch OR inspect wire connection Troubleshoot steer left microswitch Troubleshoot steer right microswitch Troubleshoot drive enable switch Verify potentiometer setting Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire conn
94. on jerking and unusual noise over the entire proportionally controlled speed range Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull 7 out the red Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position Press the slow speed select button 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines A TEREX COMPANY REV A 994 7 12 a slow speed select button BN6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications Part No 115370 September 2008 Section e Scheduled Maintenance Procedures REVA B 12 Test the Flashing Beacons Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Flashing beacons are used to alert operators and ground personnel of machine proximity and motion The flashing beacons are located on b
95. on select button BN9 Software Configuration b diagnostic display ls controls red Emergency Stop button P2 1 Remove the platform controls from the platform drive function select button BN8 2 Place the platform controls close to the 6 Release the lift function select and speed select diagnostic display on the power unit side of the buttons machine Result The diagnostic display will show the 3 Pull out the red Emergency Stop button to the current configuration on position at the ground controls 7 Push the red Emergency Stop button to the 4 Push in the red Emergency Stop button to the off position at both the ground and platform off position at the platform controls controls and turn the key switch to the off position 5 Atthe platform controls press and hold the lift function select and speed select buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display at the platform controls and the ECM will show SC A TEREX COMPANY 4 8 GRC 12 Part No 115370 September 2008 Section 4 Repair Procedures REVA How to Change the Software Configuration 1 Pull out the red Emergency Stop button to the on position at the ground controls 2 Push in the red Emergency Stop button to the off position at the platform controls 3 Turn the key switch to platform control 4 Atthe platform controls press and hold the lift
96. operation It utilizes an internal suction strainer for the pump supply line and has an external return line filter How to Remove the Hydraulic Tank Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system Note When removing a hose assembly or fitting the fitting and or hose end must be torqued to specification during installation Refer to Section 2 Hyaraulic Hose and Fitting Torque Specifications Note Perform this procedure with the platform in the stowed position 1 Tag disconnect and plug the hydraulic supply hard line at the pump Cap the fitting on the pump Remove the hard line from the tank A TEREX COMI REV A 2 Tag disconnect and plug the return hard line at the hydraulic filter Cap the fitting on the filter AWARNING sa injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine Torque specifications 35 in Ibs 4Nm Hydraulic tank retaining fasteners dry Hydraulic tank retaining fasteners lubricated 26 in lbs 2 9 Nm Part No 115370 September 2008 Section 4 Repair Procedures REVA 8 1 Yoke and Drive Motor How to Remove th
97. orm controls 6 Press and hold the function enable switch 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap hydraulic schematic item 1 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure ADANGER Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap 11 Repeat steps 4 through 7 to confirm the relief valve pressure 12 Place maximum rated load into the platform Secure the load to the platform Refer to Section 2 Specifications 13 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 37 Section 4 Repair Procedures September 2008 FUNCTION MANIFOLD 14 Hold the lift relief valve with a wrench and remove the cap schematic item C 15 While activating the platform up function adjust the internal hex socket clockwise just until the platform fully raises 16 Fully lower the platform 17 Add an additional 50 pounds 22 7 kg to the platform Secu
98. ormed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls 2 Pushin the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 6 Press the lift function select button A TEREX COMPANY REV A e 99986 C Oa a joystick controller JC1 with thumb steering rocker SW6 b horn button BN5 lift function select button 9 d red Emergency Stop button P2 7 Usethe steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position 4 4 GRC 12 Part No 115370 September 2008 Section 4 Repair Procedures REVA How to Adjust the Stowed Drive Speed ADANGER Tip over
99. oth sides of the mast 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls O Result The beacons should flash Turn the key switch to platform controls Result The beacons should flash Part No 115370 A TEREX COMPANY CHECKLIST B PROCEDURES B 13 Test the Motion Alarm if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Alarms are used to alert operators and ground personnel of machine proximity and motion The motion alarm is located in the ground control box and when activated will sound at 60 beeps per minute 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Raise the platform approximately 1 foot 0 3 m O Result When raising the platform the motion alarm should sound 3 Lower the platform to the stowed position O Result When lowering the platform the motion alarm should sound 4 Turn the key switch to platform controls 5 Pressthe lift function select button 6 Press and hold the function enable switch on the joystick Move the joystick off center hold for a moment and then release it Move the joystick off center in the opposite direction hold for a moment and then release it Result The motion alarm should s
100. ound when the joystick is moved off center in either direction 7 Pressthe drive function select button Section Scheduled Maintenance Procedures September 2008 CHECKLIST B PROCEDURES 8 Press and hold the function enable switch on the joystick Move the joystick off center hold for a moment and then release it Move the joystick off center in the opposite direction hold for a moment and then release it Result The motion alarm should sound when the joystick is moved off center in either direction 9 Press and hold the function enable switch on the joystick Press and hold the thumb rocker Switch for a moment to the left position and then release it Press and hold the thumb rocker Switch for a moment to the right position and then release it Result The motion alarm should sound when the rocker switch is moved off center in either direction A TEREX COMI REV A B 14 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Refer to Section 2 Specifications Before replacing the hydraulic oil the oil may be tested by an oil
101. ptember 2008 Checklist C Procedure REVA C 1 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load The hydraulic tank is a vented type tank The breather cap has an internal air filter that can become clogged or over time can deteriorate If the breather cap is faulty or improperly installed impurities can enter the hydraulic system which may cause component damage Extremely dirty conditions may require that the cap be inspected more often 1 Remove and discard the hydraulic tank breather cap 2 Install and new cap onto the tank A TEREX COMPANY 3 22 GRC 12 Part No 115370 September 2008 Section 3 Scheduled Maintenance Procedures Checklist D Procedure REVA D 1 Replace the Hydraulic Tank Return Filter Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Beware of hot oil Contact with hot ACAUTION oil may cause severe burns Note Th
102. r 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 6 Carefully remove the platform controls circuit board retaining fasteners 7 Carefully remove the platform controls circuit board from the platform control box lid Part No 115370 September 2008 Section 4 Repair Procedures REVA 1 2 Controller Adjustments Platform lift speed stowed drive speed raised drive speed and slow drive speed are adjustable to compensate for wear in the hydraulic pump and drive motors The function speeds are determined by the percentage of total controller output For further information or assistance consult the Genie Industries Service Department ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills could result in death or serious injury Note Select a test area that is firm level and free of obstructions How to Determine the Software Revision Level 1 Remove the pl
103. r until the ones setting stops flashing 10 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Part No 115370 GRC 12 4 9 Section 4 Repair Procedures September 2008 PLATFORM CONTROLS Machine Configuration Code Chart A mark in the four right columns indicates that the machine configuration at left includes this feature Machine Function Code at Diagnostic Display Lift Drive Cut Out Non slab Motion GRC 12 REVA Machine Option Feature Definitions Non slab Option For the GRC to function correctly each model is configured with this option Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out In addition to an alarm sounding lift and drive functions are disabled when the platform is raised above the down limit switch and the incline of the chassis exceeds the rating on the serial plate Configured on all machines Battery Drain Alarm When the machine is turned on and in the stowed position and no function is activated for 2 minutes an alarm will sound once every 3 seconds When this option is configured a dot in the diagnostic display window will remain continuously illuminated when the ECM is in the SC mode OR when the platform up function is activated Part No 115370 September 2008
104. rd The number 3 mast could become unbalanced and fall if not properly supported Note During installation the overhead crane strap will need to be carefully adjusted for proper balancing 13 Slide the lower inner corner wear pads between the number 3 mast and the number 2 mast Align the holes on the wear pads to the rivet holes on the lower half of the number 3 mast and secure into place using the appropriate rivets Refer to Illustration 5 Illustration 5 a number 3 mast b rivet wear pads d number 1 mast e number 2 mast A TEREX COMI REV A 14 Slide the number 3 mast towards the bottom of the number 2 mast and align the lower number 3 mast access holes to the lower number 2 rivet holes Refer to Illustration 6 15 Working at the top of the number 3 mast carefully slide the lower corner wear pads between the number 3 mast and the number 2 mast Refer to Illustration 6 16 Align the the rivet holes on the wear pads to the number 3 mast access holes and to the number 2 mast rivet holes Refer to Illustration 6 17 Using the appropriate rivets securely install the lower corner wear pads to the lower half of the number 2 mast Refer to Illustration 6 Note After installing the first rivet move and align the number 3 mast access hole to the second hole on the wear pad and install the second rivet Refer to Illustration 6 E gt gt
105. re the additional weight 18 Attempt to raise the platform Result The power unit should not be able to lift the platform W Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the platform will not raise 19 Install the relief valve cap 20 Remove the weight from the platform 21 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or the platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic tank Component damage hazard Do not continue to operate the machine if the hydraulic pump is cavitating A TEREX COMI REV A How to Adjust the Steer Relief Valve Note Be sure that the hydraulic oil level is at the FuLL mark on the hydraulic tank 1 Locate the steer relief valve on the function manifold schematic item G a test port b steer relief valve 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port schematic item A on the function manifold 3 Remove the platform controls from the platform Note Perform this test from the ground with the platform controls Do not stand in the platform Part No 115370 September 2008 Section 4 Repair Procedures p i REVA FUNCTION MANIFOLD 4 Turn the key switch to platform control and pull out the red Emergency Stop but
106. rmally closed NO Normally op NCHO Normally closed held open NOHC Normally open held closed Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls Quick disconnect 901 Battery quick disconnect Control cable to ground QD4 Control cable to platform Switch SW5 Function enable SW6 Steer left right E Tilt level sensor 1266 Platform up down toggle switch Electronic component U3 Platform controls printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter opti Vvavecol ae Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up Genie TEREX COMPANY 6 2 GRC 12 Part No 115370 May 2008 Section 6 Schematics Relay Layout and ECM Pin out Legend REV F FL 9 7000000550509 AMOOOCOCOCCU 1 EN ECM PIN OUT LEGEND Item Description A1 Flashing beacon FB1 output A2 Ground from platform controls input White wire at platform controls Plug A4 Power from platform controls to ECM input 4
107. rt No 115370 September 2008 Section 4 Repair Procedures Brake Release Hand Pump Components REVA 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the hydraulic power unit Index Schematic No Description Item Function Torque 1 Hand pump uec Joe Manual brake release 30 ft Ibs 41 Nm 2 Needle valve pilot operated Manual brake release enable 45 50 in lbs 5 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic A TEREX COMPANY Part No 115370 GRC 12 4 47 Section 4 Repair Procedures September 2008 pum ec e M This page intentionally left blank 4 48 GRC 12 Part No 15370 Section 5 Fault Codes Fault Codes September 2008 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 the repair of this machine Crushing hazard When testing or replacing any hydraulic component always support the structure and secure
108. side specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tagand disconnect the wiring from the coil to be tested 2 Testthe coil resistance using a multimeter set to resistance Refer to the Valve Coil Resistance Specification table W Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil A TEREX COMI REV A Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 7 7 C that your air temperature increases or decreases from 68 F 20 C Valve Coil Resistance Specifications Description Specification Solenoid valve 3 position 4 way 18
109. specifications and the requirements listed in the responsibilities manual enie A TEREX COMPANY Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevA Genie Industries USA 18340 NE 76th Street PO Box 97030 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed no unable to complete R repaired Comments 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 Section Scheduled Maintenance Procedures September 2008 pum m m M M This page intentionally left blank 3 4 GRC 12 Part No 115370 September 2008 Section e Scheduled M
110. tch on the joystick to increase or decrease the stowed drive speed percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Section 4 Repair Procedures September 2008 PLATFORM CONTROLS How to Adjust the Raised Drive Speed A DANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Pull out the red Emergency Stop button to the on position at the ground controls Push in the red Emergency Stop button to the off position at the platform controls Turn the key switch to platform control 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage A TEREX COMI 9 9m O N 9 R
111. to 210 20V DC with diode schematic items E Solenoid valve 3 position 4 way 25 to 280 20V DC with diode schematic item F Solenoid valve 2 position 4 way 18 to 210 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 7 5 to 10 50 with manual override 12V DC with diode schematic item N Part No 115370 September 2008 Section 4 Repair Procedures REVA How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 6 3 How to Test a Coil 2 Connect a 100 resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Note The battery should read 9V DC or more when measured across the terminals Resistor 10Q Genie part number 27287 3 Seta multimeter to read DC amperage Note The multimeter when set to read DC amperage should be capable of reading up to
112. ton to the on position at both the ground and platform controls 5 Activate the function enable switch and press and hold the steer thumb rocker switch to the right Allow the wheels to completely turn to the right Continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 6 Press and hold the steer thumb rocker switch to the left Allow the wheels to completely turn to the left Continue holding the switch while observing the pressure reading on the pressure gauge 7 Turnthe machine off Hold the steer relief valve stem with a wrench and loosen the locknut schematic item G 8 Adjust the internal valve stem Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Component damage hazard Do not adjust the relief valve pressures higher than specifications 9 Tighten the locknut 10 Repeat steps 5 through 6 to confirm the relief valve pressure A TEREX COMPANY Part No 115370 GRC 12 4 39 Section 4 Repair Procedures September 2008 FUNCTION MANIFOLD 6 3 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values out
113. torque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft Ibs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm Valve Coil Resistance Steer relief valve pressure poe E Note The following coil resistance specifications are at ar an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 7 7 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 3 position 4 way 18 to 210 20V DC with diode schematic item E Solenoid valve 3 position 4 way 25 to 280 20V DC with diode schematic item F Solenoid valve 2 position 4 way 18 to 210 20V DC with diode schematic item H Solenoid valve 2 position 2 way N C 7 5 to 10 50 with manual override 12V DC with diode schematic item N Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Part No 115370 GRC 12 2 3 Section 2 Specifications September 2008 SEES SPECIFICATIONS REVA Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with JIC 37 flared fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings
114. trol 4 Atthe platform controls press and hold the lift function select and horn buttons and pull out the red Emergency Stop button to the on position Result The diagnostic display will show PS 5 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Part No 115370 A TEREX PLATFORM CONTROLS a joystick controller JC1 with thumb steering rocker SW6 horn button BN5 lift function select button BN9 red Emergency Stop button P2 slow speed select button BN6 6 Press hold the slow speed select button Result The diagnostic display will show the slow drive speed percentage 7 Use the steering thumb rocker switch on the joystick to increase or decrease the stowed high torque drive speed percentage Refer to Section 2 Specifications for function speeds 8 Turn the key switch to the off position Note Any change in software settings will not take effect until the key switch is turned to the off position Section 4 Repair Procedures September 2008 PLATFORM CONTROLS REVA 1 3 Software Configuration The Electronic Control Module ECM contains SS 995 9 programming for all configurations of the Genie GRC The machine can be adjusted to a different configuration using the buttons at the platform How to Determine the a liftfuncti
115. ury and significant component damage Dealer Service is strongly recommended Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications a number 4 mast cylinder mount bracket 1 Remove the mast See 3 1 How to Remove the b number 3 mast cylinder mount Mast Assembly bracket c number 2 mast cylinder mount 2 Remove the nylock nuts securing the lift bracket cylinder to the cylinder mast mount brackets 8 d inside th half of th e lift cylinder ocated inside the top half of the mast f mast assembly assembly Set the nylock nuts to the side 3 Tag disconnect and plug the hydraulic hose on the lift cylinder Cap the fittings on the cylinder 4 Remove the lift cylinder retaining bolt from the lower cylinder block and set to the side A TEREX COMPANY 4 26 GRC 12 Part No 115370 September 2008 Section 4 Repair Procedures REVA 5 Remove the hair pin clips securing the mast cylinder pin to the lower half of the mast assembly Set the clips to the side 6 Supportthe lift cylinder and use a soft metal drift to remove the mast cylinder pin from the lower mast assembly 7 Attach a lifting strap from an overhead crane to the cylinder and carefully slide the lift cylinder out of the mast assembly Crushing hazard
116. vice professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps Section 4 Repair Procedures September 2008 Platform Controls The platform controls used to operate the machine from the platform or while standing on the ground can also be used to tune the performance of the machine Moving the joystick or activating a button sends a signal to the Electronic Control Module ECM When the ECM is in the function m
117. y and begin charging the batteries Note For best results use an extension of adequate size with a length no longer than 50 feet 15 m Note If you have any further questions regarding the battery charger operation please contact the Genie Industries Scissor Service Department Part No 115370 September 2008 Section Scheduled Maintenance Procedures REVA B 2 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the underside of the chassis for damaged or missing ground straps 2 Inspect the following areas for burnt chafed corroded and loose wires Mast cable Platform controls Power to platform wiring 3 Inspect the following areas for burnt chafed corroded and loose wires Ground control panel Hydraulic power unit Part No 115370 A TEREX COM CHECKLIST B PROCEDURES 4 Inspect for a liberal coating of dielectric grease in all wiring connections between the

from SN 08-101 to 11-999, Runabout Contractor (PN 115370)

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