Operator's ManualSerial Number RangeGR-12 from GR10-20000 CEGR-15GR-20withMaintenanceInformationOriginal InstructionsSixth EditionThird PrintingPart No. 133572

Introduction

Symbol and Hazard Pictorials Definitions

General Safety

Personal Safety

Work Area Safety

Legend

Controls

Inspections

GR-12 • GR-15 • GR

Operating Instructions

Transport and Lifting Instructions

Maintenance

Specifications

Genie GR-12 Operator's Manual

November 2005

Machine Specifications

Performance Specifications

Manifold Component Specifications

Hydraulic Hose and Fitting Torque Specifications

Maintenance Inspection Report

A-1 Perform Pre-operation Inspection

A-3 Perform 30 Day Service

B-1 Inspect the Batteries

B-2 Inspect the Electrical Wiring

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

B-5 Clean and Lubricate the Columns

B-7 Test the Emergency Stop

B-8 Test the Key Switch

B-10 Inspect the Voltage Inverter (if equipped)

B-11 Test the Drive Brakes

B-12 Test the Drive Speed - Stowed Position

B-13 Test the Drive Speed - Raised Position

B-14 Test the Slow Drive Speed

B-15 Test the Flashing Beacons

B-17 Perform Hydraulic Oil Analysis

B-18 Inspect the Breather Cap

C-1 Grease the Platform Overload Mechanism (if equipped)

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

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

D-2 Inspect the Mast Assembly for Wear

D-3 Inspect and Lubricate the Lifting Chains

E-1 Test or Replace the Hydraulic Oil

Circuit Boards

Controller Adjustments

Software Configuration

Platform

Mast

Glide Pads

Lift Cylinder

Level Sensor

Function Pump

Function Manifold Components

Valve Adjustments - Function Manifold

Valve Coils

Hydraulic Tank

Yoke and Drive Motor

Steer Cylinder

Drive Brake

Brake Release Hand Pump Components

Lift Guard GR-12

Hydraulic Oil Specifications

Torque Procedure

Section 3 Scheduled Maintenance Procedures

Maintenance Schedule

Pre-Delivery Preparation Report

Scheduled and Programmed Maintenance Inspection Report

Commissioning Procedures

Quarterly Maintenance Procedures

Q-2 Battery Inspection

Q-3 Inspect the Electrical Wiring

Q-5 Inspect the Voltage Inverter (if equipped)

Q-6 Test the Flashing Beacons (if equipped)

Q-8 Inspect the Tires and Wheels (including castle nut torque)

Q-9 Check the Lifting Chain Adjustments

Q-11 Adjust the Sequencing Cables

Q-12 Visual Inspection of the Hydraulic Oil

Q-13 Test the Drive Brakes

Q-14 Test the Drive Speed – Stowed Position

Q-15 Test the Drive Speed - Raised Position

Annual Maintenance Procedures

Programmed Maintenance Procedures

P1-2 Inspect and Lubricate the Lifting Chains

P2-2 Test or Replace the Hydraulic Oil

Section 4 Repair Procedures

Platform Controls

Circuit Board

Joystick

Platform Emergency Stop Button

Ground Controls

Software Revision Level

Machine Setup

Level Sensors

Hydraulic Pump

How to Remove the Hydraulic Pump

Function Manifold

Valve Adjustments – Function Manifold

Non-Steer Axle Components

Steer Axle Components

Steer Bellcrank

Platform Components

Platform Extension Deck

Work Tray

Mast Components

How to Disassemble the Mast

How to Assemble the Mast

Lifting Chains

How to Inspect the Lifting Chains

Platform Overload Components

Platform Overload Recovery Message

Obstruction Sensing System

Battery Charger

Selecting a Charge Profile

Batteries

Diagnostics

GCON I/O Map without Load Sense

GCON I/O Map with Load Sense

Diagnostic Trouble Codes (DTC)

Troubleshooting "HXXX" and "PXXX" Faults

Fault Inspection Procedure

Type "HXXX" Faults

Type "PXXX" Faults

Type "UXXX" Faults

Type "FXXX" Faults

Type "CXXX" Faults

Charger Fault Codes

Charger Error Codes

Section 6 Schematics

Electrical Component and Wire Color Legends

Wiring Diagram Ground and Platform Controls

Electrical Symbol Legend

Hydraulic Symbols Legend

to GR16P

from serial numbers GR16P-44174 to GR16P-46499 and QS16P-2469 to QS16P

Electrical Schematic, QSR, AS/CE from serial number QS11-1000 to QS11-1015

Hydraulic Schematics

function test

tools required

software update

Lift Guard GR-15

Lift Guard GR-20


Contents Table Of Contents Introduction Symbol and Hazard Pictorials Definitions General Safety Personal Safety Work Area Safety Legend Controls Inspections GR-12 • GR-15 • GR Operating Instructions Transport and Lifting Instructions Maintenance Specifications	Operator's ManualSerial Number RangeGR-12 from GR10-20000 CEGR-15GR-20withMaintenanceInformationOriginal InstructionsSixth EditionThird PrintingPart No. 133572 Next / 52