Genie Lift Guard GRC-12 Manual de usuario

Service Manual

Part No. 227123

Rev B1

September 2016

GRC -12

Serial Number Range

from GRC11-1000

to GRC16-2369

from GRC16P-2370

to GRC16P-4599

from GRCP-4600

September 2016

GRC Part No. 227123

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 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications

are subject to change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

227123 Rev B October 2011

Second Edition, Second Printing

"Genie" is a registered trademark of Terex South

Dakota in the U.S.A. and many other countries.

"GR" is a trademark of Terex South Dakota. Inc.

Printed on recycled paper

Printed in U.S.A.

www.genielift.com

e-mail: [email protected]

Serial Number Information

Genie offers the following Service Manuals for this

model:

Title Part No.

Genie Runabout Contractor Service Manual,

First Edition

(before serial number 999) ................................. 115370

Introduction

September 2016

Part No. 227123 GRC

Serial Number Legend

iii

INTRODUCTION

Model: Serial number:

Model year:

Elec/Hydr Schematic:

Manufacture date:

Power supply voltage/Pneumatic Pressure:

Maximum Wind Speed:

Maximum allowable inclination of the chassis:

Gradeability:

Maximum platform height:

Maximum allowable side force:

Machine unladen weight:

Max Load:

Occupants and Equipment must not exceed:

Indoor:

Outdoor:

Nominal Power:

GRC16P-1234

2016

01/02/2010

GRC 16 P - 1234

1 43

Model: Serial number:

Elec/Hydr Schematic:

Year of Manufacture :

Power supply voltage/Pneumatic Pressure:

Maximum Wind Speed:

Maximum allowable inclination of the chassis:

Gradeability:

Maximum platform height:

Maximum allowable side force:

Machine unladen weight:

Max Load:

Occupants and Equipment must not exceed:

Indoor:

Outdoor:

Nominal Power:

GRP-12345

2016

GR P - 12345

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial label (behind covers)

6 Serial number stamped on chassis

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label (behind covers)

5 Serial number stamped on chassis

September 2016

GRC Part No. 227123

This page intentionally left blank.

September 2016

Part No. 227123 GRC

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.

Safety Rules

September 2016

GRC Part No. 227123

SAFETY RULES

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an approved fire

extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

Be sure that your workshop or work area

is properly ventilated and well lit.

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Indicates an imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

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.

September 2016

Part No. 227123 GRC

Table of Contents

Introduction

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

Serial Number Information .................................................................................

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

iii

Section 1 Safety Rules

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

Section 2 Rev Specifications

B Machine Specifications ................................................................................ 2 - 1

Performance Specifications ......................................................................... 2 - 2

Hydraulic Specifications ............................................................................... 2 - 2

Manifold Component Specifications ............................................................. 2 - 3

Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 4

SAE and Metric Fasteners Torque Charts ................................................... 2 - 6

Section 3 Rev Scheduled Maintenance Procedures

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

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

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

AChecklist A Procedures

A-1 Inspect the Manuals and Decals ......................................................... 3 - 6

A-2 Perform Pre-operation Inspection ....................................................... 3 - 7

A-3 Perform Function Tests ...................................................................... 3 - 7

A-4 Perform 30 Day Service ..................................................................... 3 - 8

A-5 Grease the Steer Yokes ..................................................................... 3 - 8

vii

September 2016

GRC Part No. 227123

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

BChecklist B Procedures

B-1 Inspect the Batteries ........................................................................... 3 - 9

B-2 Inspect the Electrical Wiring ............................................................. 3 - 12

B-3 Inspect the Tires and Wheels (including castle nut torque) ............... 3 - 13

B-4 Test the Emergency Stop ................................................................. 3 - 13

B-5 Test the Key Switch .......................................................................... 3 - 14

B-6 Test the Automotive-style Horn (if equipped) .................................... 3 - 14

B-7 Inspect the Voltage Inverter (if equipped) ......................................... 3 - 15

B-8 Test the Drive Brakes ....................................................................... 3 - 16

B-9 Test the Drive Speed - Stowed Position ........................................... 3 - 17

B-10 Test the Drive Speed - Raised Position ............................................ 3 - 18

B-11 Test the Slow Drive Speed ............................................................... 3 - 19

B-12 Test the Flashing Beacons ............................................................... 3 - 20

B-13 Test the Motion Alarm (if equipped) .................................................. 3 - 20

B-14 Perform Hydraulic Oil Analysis ......................................................... 3 - 22

B-15 Inspect the Breather Cap .................................................................. 3 - 22

B-16 Inspect the Electrical Contactor ........................................................ 3 - 23

AChecklist C Procedures

C-1 Replace the Hydraulic Tank Breather Cap -

Models with Optional Hydraulic Oil ................................................... 3 - 24

AChecklist D Procedures

D-1 Replace the Hydraulic Tank Return Filter ......................................... 3 - 25

AChecklist E Procedure

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 26

viii

September 2016

Part No. 227123 GRC

TABLE OF CONTENTS

Section 4 Rev Repair Procedures

Introduction .................................................................................................. 4 - 1

APlatform Controls

1-1 Circuit Board ...................................................................................... 4 - 3

1-2 Joystick .............................................................................................. 4 - 4

1-3 Platform Controls Alarm ..................................................................... 4 - 4

1-4 Platform Emergency Stop Button ....................................................... 4 - 5

AGround Controls

2-1 Software Revision Level ..................................................................... 4 - 7

2-2 Machine Setup ................................................................................... 4 - 8

2-3 Level Sensor ...................................................................................... 4 - 9

AHydraulic Pump

3-1 Function Pump ................................................................................. 4 - 12

AFunction Manifold

4-1 Function Manifold Components ........................................................ 4 - 14

4-2 Valve Adjustments - Function Manifold ............................................ 4 - 16

4-3 Valve Coils ....................................................................................... 4 - 20

ABrake Release Hand Pump Components

5-1 Brake Release Hand Pump Components ......................................... 4 - 22

September 2016

GRC Part No. 227123

TABLE OF CONTENTS

Section 4 Rev Repair Procedures, continued

AHydraulic Tank

6-1 Hydraulic Tank ................................................................................. 4 - 23

ASteer Axle Components

7-1 Yoke and Drive Motor ...................................................................... 4 - 24

7-2 Steer Cylinder .................................................................................. 4 - 26

7-3 Steer Bellcrank ................................................................................. 4 - 26

ANon-steer Axle Components

8-1 Drive Brake ...................................................................................... 4 - 27

APlatform Components

9-1 Platform ........................................................................................... 4 - 28

9-2 Platform Extension ........................................................................... 4 - 28

AMast Components

10-1 Mast ................................................................................................. 4 - 30

10-2 Wear Pads ....................................................................................... 4 - 41

10-3 Lift Cylinder ...................................................................................... 4 - 42

10-4 Lift Cylinder Wear Block ................................................................... 4 - 44

10-5 Mast Coil Cord ................................................................................. 4 - 44

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