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Summary of Contents for Genie Genie Lift
- Page 1 Service Manual Serial Number Range Genie Lift from 1395 to 1301-23434 from GL02-23435 to GL16G-80150 from GL16G-80151 to GL16G-83799 from GLG-83800 Part No. 115417 Rev A2 September 2016...
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Page 2: Introduction
Contact Us: Internet: www.genielift.com E-mail: awp.techpub@terex.com Copyright © 1989 by Genie Industries 115417 Rev A, April 2009 Third Edition, First Printing 'Genie'' is registered trademark of Terex South Dakota. in the U.S.A. and many other countries. Genie Lift Part No. 115417... -
Page 3: Revision History
Section – Maintenance, B-3 Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section – Fault Codes, All charts the update. Section – Schematics, Legends and schematics Part No. 115417 Genie Lift... -
Page 4: Serial Number Legend
2 Model year 5 Serial label 3 Facility code 6 Serial number (stamped on base) From September 1, 2016 1 Model 4 Serial label 2 Facility code 5 Serial number (stamped on base) 3 Sequence number Genie Lift Part No. 115417... -
Page 5: Safety Rules
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. Part No. 115417 Genie Lift... - Page 6 Be sure that your workshop or work area warrants it. is properly ventilated and well lit. 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. Genie Lift Part No. 115417...
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Page 7: Table Of Contents
B-3 Perform Electric WinchMaintenance ............. 25 B-4 Inspect the Carriage Hold-down Bar ............. 26 B-5 Inspect All Welds ................... 26 B-6 Clean the Channels ..................27 B-7 Inspect and Lubricate the Manual Winch ............27 Part No. 115417 Genie Lift... - Page 8 1-8 How to Adjust the Brake (if equipped) ............40 Rear Wheel Brake Assembly (option) ..............41 Section 5 Schematics ......................42 Electrical Symbols Legend - Models With Electric Winch........43 Wiring Diagram - Models With Electric Winch ............. 44 viii Genie Lift Part No. 115417...
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Page 9: Specifications
* The 10 inch pneumatic rear wheel option will add 1 inch / 2.5 cm to these specifications. * The 4 point caster option B will add 1 inch / 2.5 cm to these specifications. * The counterweight base will add 1 inch / 2.5 cm to these specifications. Part No. 115417 Genie Lift... - Page 10 Load Platform 23 in 23 in 23 in 23 in Length 58.4 cm 58.4 cm 58.4 cm 58.4 cm 22 in 22 in 22 in 22 in Width 55.9 cm 55.9 cm 55.9 cm 55.9 cm Genie Lift Part No. 115417...
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Page 11: Performance Specifications
95 kg Airborne noise emissions by machinery Manual winch 90 dB 90 dB 90 dB 90 dB Electric winch 95 dB 95 dB 90 dB 90 dB Maximum sound level at normal operating workstations (A-weighted) Part No. 115417 Genie Lift... -
Page 12: Sae And Metric Fasteners Torque Charts
Service Manual September 2016 Specifications SAE and M etric F asteners Tor que C harts Genie Lift Part No. 115417... -
Page 13: Scheduled Maintenance Procedures
Use only Genie approved replacement parts. Machines that have been out of service for a Indicates that a specific result is expected period longer than 3 months must complete the after performing a series of steps. - Page 14 Maintenance Inspection Repor Make copies of the to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with your employer, jobsite and governmental regulations and requirements. Genie Lift Part No. 115417...
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Page 16: Pre-Delivery Preparation Report
Service Manual September 2016 Pre-Delivery Preparation Report Pre-Deliv ery Prepar ati on Repor t Fundamentals Instructions It is the responsibility of the owner or dealer to Use the operator’s manual on your machine. perform the Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery. - Page 17 September 2016 Service Manual This page intentionally left blank. Part No. 115417 Genie Lift...
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Page 18: Maintenance Inspection Report
• If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a check in the "R" box. Legend Y = yes, acceptable N = no, remove from service R = repaired Genie Lift Part No. 115417... - Page 19 September 2016 Service Manual This page intentionally left blank. Part No. 115417 Genie Lift...
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Page 20: Checklist A Procedures
Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Result: The machine is equipped with all first. -
Page 21: Perform Pre-Operation Inspection
A-3 Per form F uncti on Tes ts Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes first. -
Page 22: Inspect The Channels
A-5 Ins pect the C able and Cable Pulley s Inspect the Channels Inspect the Cable and Cable Pulleys Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Genie specifications require that this procedure be first. -
Page 23: Inspect The Casters And Wheels
Checklist A Procedures A-6 Ins pect the C as ters and Wheels Inspect the Casters and Wheels Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first. Maintaining the casters and wheels in good condition is essential to safe operation and good performance. -
Page 24: Checklist B Procedures
Result: All battery cells display an adjusted specific gravity of 1.277 or higher. The battery is fully charged. Proceed to step 12. Genie specifications require that this procedure be Result: One or more battery cells display a performed every 250 hours or quarterly, whichever specific gravity of 1.217 or below. -
Page 25: Inspect The Electrical Wiring - Models With Electric Winch
Inspect the Electrical Wiring - Perform Electric Winch Models with Electric Winch Maintenance Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie requires that this procedure be performed Required maintenance procedures and additional... -
Page 26: Inspect The Carriage Hold-Down Bar
B-4 Ins pect the C arriage Hol d-down Bar B-5 Ins pect All W elds Inspect the Carriage Hold-down Inspect All Welds Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. -
Page 27: Clean The Channels
B-7 Ins pect and Lubricate the M anual Winc h Clean the Channels Inspect and Lubricate the Manual Winch Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. -
Page 28: Checklist C Procedures
Checklist C Procedur es C-1 Lubricate the C asters and W heels Lubricate the Casters and Wheels Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Regular application of lubrication to the Caster or Wheel is essential to good machine performance and service life. -
Page 29: Replace The Manual Winch Friction Disks
C-3 Inspec t the Pai nted Surfac es Inspect the Safety Brake System Inspect the Painted Surfaces (if equipped) Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Inspecting the painted surfaces of your machine is... -
Page 30: Repair Procedures
Use only Genie approved replacement parts. Read each procedure completely and adhere Indicates a potentially hazardous to the instructions. Attempting shortcuts may situation which, if not avoided, produce hazardous conditions. -
Page 31: Base Assembly
(GL-8,GL-10 and GL-12 models). Bodily injury hazard. Cables can Note: For proper cable routing, see Repair fray. Always wear adequate How to Replace the Lifting Cable Procedure, hand protection when handling cable. Part No. 115417 Genie Lift... -
Page 32: How To Disassemble The Gl - Models Equipped With An Electric Winch
W-1013). Owner Manual for Rule Winches Remove the battery and battery charger from the machine. Genie part number 85220 Bodily injury hazard. Cables can Models with counterweight base: fray. Always wear adequate Support the base counterweights with a hand protection when handling proper lifting device. -
Page 33: How To Disassemble The Manual Winch
Component damage hazard. Place a block between the walls of the winch housing to prevent the housing from bending while removing the bushings. 11 If necessary, remove the winch housing from the machine. Part No. 115417 Genie Lift... -
Page 34: How To Assemble The Manual Winch
Do not allow any oil on the brake or pressure plate. Genie Lift Part No. 115417... - Page 35 4 wraps of cable on the winch drum. Component damage hazard. Improperly wound cable may result in poor winch performance and accelerate cable wear. Be sure the cable winds onto the winch drum evenly. Part No. 115417 Genie Lift...
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Page 36: Manual Winch Assembly
Handle Adapter Gear Cover Pinion Shaft Bushing Cable Keeper Pressure Plate Nylock Nut Ratchet Gear Screw Disk Brake Lock Nut Drive Shaft Assembly Winch Frame Retaining Ring Winch Handle Assembly Pinion Shaft Bushing Flat Washer Genie Lift Part No. 115417... -
Page 37: How To Replace The Lifting Pulley
Note: Be sure not to twist the cable when installing the new pulley. Cable slot GL-8, GL-10 and GL12 Cable slot Carriage is raised for illustrative purpose only GL-4 Part No. 115417 Genie Lift... - Page 38 11 While holding the cable tie on the drum, rotate the winch until all the cable is spooled onto the drum. Be sure there are at least 4 wraps of cable on the winch drum. Genie Lift Part No. 115417...
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Page 39: How To Replace The Glide Buttons
Remove all rings, part number W-1013). watches and other jewelry. Owner Manual for Rule Winches Remove the battery and battery charger from Genie part number 85220 the machine. Bodily injury hazard. Cables can fray. Always wear adequate All models:... -
Page 40: How To Adjust The Brake (If Equipped)
Note: Apply enough force to the brake pedal to lock the brakes in place. After the brakes are engaged, the brakes should hold the wheels in place with enough force to keep the wheels from turning. Genie Lift Part No. 115417... -
Page 41: Rear Wheel Brake Assembly (Option)
Stair Roller Solid Rubber Wheel Brake Cam Rod Screw Stair Roller Mount Bracket, Left Side Base Brake Cam Spacer Brake Pedal Screw Screw Nylock Nut Nylock Nut Brake Cam Brake Linkage Plate Brake Pivot Plate Part No. 115417 Genie Lift... -
Page 42: Schematics
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. Genie Lift Part No. 115417... -
Page 43: Electrical Symbols Legend - Models With Electric Winch
September 2016 Service Manual Electrical Symbols Legend - Models with Electric Winch Elec trical Symbols Legend - Models With El ectric Wi nc h Part No. 115417 Genie Lift... -
Page 44: Wiring Diagram - Models With Electric Winch
Service Manual September 2016 Wiring Diagram - Models with Electric Winch Wiring Diagram - Models With Elec tric Winc h Genie Lift Part No. 115417 Servic e M anual September 2016 Genie Lift Part No. 115417...
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