PN 115417 - Genie Industries
Contents
1. could result in death or serious injury o Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate oY injury co Indicates a potentially hazardous situation which if not avoided zza may result in property damage other protective clothing if the situation E Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes zj Be aware of potential crushing hazards EJ 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 tha2. 12 5 78 no 962 750 106 660 1342 s0 1 N el a slo a o 17 s 12 8 908 560 1206 1080 1464 1440 1952 1220 1654 T 1 5 1280 1240 31681 1570 2047 2010 2725 1700 2304 vr 16 i0 1978 1950 2643 2370 3213 3160 4284 2670 3620 2 12 6 2225 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 03 Class 12 9 DRY DRY Y d c DI 1 d c DI d c DI 1 D Oo C3 O WER O Ou OO afa c ojo age o o co CO D i B B B B w o a ga o N w go Gel o o m Sa a ol ca hy A N o a ai u c Glo n N N OJJ po oF Po 2 an oo oJ 2 Sol ta R a a ER N A W DV a ro a DV N 5 CO O Nh NI a MJ Nz a N 2 i o OFS A 9 Co CO A A E foe foe n2 ol 91 n e A NI 4 C3 No O C2 O 91 n w O ow Ajo alo DB po Oo NI F ofto N co olo BIN clio ges u olo Sib Am ola AYA o clo DQ e i io ajn MIN Qi P R o N Bla al co V o b i Qo ALA WE A iun a A A A N e gt EN ojoj o W z jol et sro NIN 9 9 91 R Baj o ojo U a A w M N A m o n o Q Em
3. anie A TEREX COMPANY Serial Number Range Genie Lift ton EE Part No 115417 Rev A1 October 2010 April 2009 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 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 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 awp techpub terex com A TEREX CON li GL 4 e GL 8 e GL 10 e GL 12 MEANY Serial Number Information Genie Industries offers the following Service Manuals for this model Title Part No Genie Lift Parts amp Service Manual First Edition from serial number 1395 103 to 1301 23434 22186 Genie L
4. 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 operators manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Section 1 Safety Rules April 2009 SAFETY RULES Personal Safety Workplace Safety be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Any person working on or around a machine must Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following M 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 ADANGER ndicates 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
5. 115417 A TEREX CO GL 4 GL 8 GL 10 GL 12 MPANY 6 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e 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 Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 12 w Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 9 7 Perform an equalizing charge OR fully charge the batteries and allow the battery to rest at least 6 hours 8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 9 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e 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 charged Proceed to step 10 amp 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 1 217 Replace the battery 10 Check the battery acid level If
6. A o E o a A N Dv o Ei N A AI a u I N N Q R E gt I lt oo Di Bike ol amp GN oo Po AY N o gt a mon corny Gop do NI ofo O ATO ba ein Copco OT AY Co PO al O JO AO Co oO INN Kei ki ts AJON O1f co no QIN N OWN amp O17 G9 m NIN o oj O I O1 O O JO O1 o Po A Ao ND oa co 4 A EN oa 4 eo a ono RININ DOBOK Ke Aen 5 o m AIN NI 1 lo ono ab ef Gol NI co O mo m 85 56 583 Genie A TEREX COMPAN 2 4 GL 4 GL 8 GL 10 GL 12 Part No 115417 April 2009 Section 3 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey MI 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 perform each procedure as presented and scheduled could result in death serious injury or substantial damage EI Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine M Use only Genie approved replacement parts M Machines that have been out of service for a period longer than 3 m
7. Load Platform Length 23 in 23 in 23 in 23 in 58 4 cm 58 4 cm 58 4 cm 58 4 cm Width 22 in 22 in 22 in 22 in 55 9 cm 55 9 cm 55 9 cm 55 9 cm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie GL 4 GL 8 GL 10 GL 12 A TEREX COMPANY Part No 115417 April 2009 Section 2 Specifications REV A SPECIFICATIONS Performance Specifications Model GL 4 GL 8 GL 10 GL 12 Standard Forks Maximum working height 5 ft 11 in 10 ft 0 5 in 11 ft 8 in 13 ft 9 5 in Forks up 1 8m 3 1m 3 6m 4 2m Maximum working height 4 ft 1 5 in 8ft3in 9 ft 10 5 in 12 ft Forks down 1 3m 2 5m 3m 3 7m Boom Maximum working height 5 ft 1 5 in 9 ft 3 in 10 ft 10 5 in 13 ft 1 6m 2 8m 3 3m 4m Load Platform Maximum working height 5 ft 1 5 in 9 ft 3 in 10 ft 10 5 in 13 ft 1 6m 2 8m 3 3m 4m Standard Base 3 5 in 3 5 in 3 5 in 3 5 in Minimum working height 8 9 cm 8 9 cm 8 9 cm 8 9 cm Straddle Base 2 in 2 in 2 in 2 in Minimum working height 5 1 cm 5 1 cm 5 1 cm 5 1 cm Load capacity Standard forks 500 Ibs 400 Ibs 350 Ibs 350 Ibs at 14 in 36 cm load center 227 kg 182 kg 159 kg 159 kg Boom 500 Ibs 400 Ibs 350 Ibs 350 Ibs at 12 in 30 5 cm load center 227 kg 182 kg 159 kg 159 kg Boom 300 Ibs 240 Ibs 210 Ibs 210 Ibs at 20 in 51 cm load center 136 kg 109 kg 95 kg 95 kg Airborne noise emissions by machinery Maximum sound level at normal operating workstations A weighted Manual winc
8. Part No 115417 April 2009 Section 3 Scheduled Maintenance Procedures REVA B 4 Inspect the Carriage Hold down Bar Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Detection of damage to the carriage hold down bar assembly is essential to safe machine operation An unsafe working condition exists if the system is damaged and does not operate properly 1 Fully lower the carriage 2 Rotate the carriage hold down bar over the carriage 3 Raise the carriage Result The carriage should not move Component Damage Hazard Do not apply too much force on the carriage Raise it only enough to check the resistance against the hold down bar 4 Visually inspect the assembly for damage Part No 115417 A TEREX CO GL 4 GL 8 GL 10 GL 12 MPANY CHECKLIST B PROCEDURES B 5 Inspect All Welds Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Weld inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage may result in an unsafe operating condition 1 Visually inspect the welds in the following locations Base and base components Legs Carriage Forks Boom if equipped Section 3 Scheduled Maintenance Procedures April 2009 CHECKLIST B PROCEDURES B 6 Clean the Channels Genie spec
9. Remove the carriage from the outer frame Proceed to step 21 Note After removing the carriage note the location of the roller wheel buttons on the carriage roller wheels 16 GL 8 GL 10 and GL 12 models Remove the mounting fasteners from the lower inner frame casting and remove the lower casting from the inner frame 17 Remove the carriage from the inner frame Note After removing the carriage note the location of the roller wheel buttons on the carriage roller wheels Section 4 Repair Procedures April 2009 REPAIR PROCEDURES 18 Remove the mounting fasteners from the lower inner frame casting and remove the lower casting from the inner frame 19 Tag and disconnect the wiring from the electric winch 20 Remove the electric winch mounting fasteners and remove the electric winch from the machine 21 Remove the carriage from the inner frame Note After removing the carriage note the location of the roller wheel buttons on the carriage roller wheels 22 If necessary remove the hold down bar winch mounting plate limit switch mounting bracket handle and loading wheel bracket Note For proper cable routing see Repair procedure 1 6 How to Replace the Lifting Cable A TEREX COMI GL 4 GL 8 GL 10 GL 12 REVA 1 3 How to Disassemble the Manual Winch Note Refer to the illustration on page 4 6 for an exploded view of the winch assembly 1 Fully lower the carriage 2 Remove the
10. Scheduled Maintenance Procedures April 2009 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 appear 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 EJ Es A TEREX CON 3 2 GL 4 GL 8 GL 10 GL 12 MPANY 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 three types of maintenance inspections that must be performed according to a schedule daily quarterly and annual The Scheduled Maintenance Procedures and the Maintenance Inspection Report have been divided into three subsections A B and C 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 Annual or every 1000 hours A B C Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenan
11. container after use Note Contact your authorized Genie distributor or Genie Industries if replacement manuals or decals are needed Part No 115417 October 2010 Section 3 e Scheduled Maintenance Procedures REV B 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 Inspection 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 Genie Lift Operator s Manual Refer to the Operator s Manual on your machine 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 Genie Li
12. in death or serious injury Remove all rings watches and other jewelry 4 Remove the battery and battery charger from the machine Models with counterweight base 5 Support the base counterweights with a proper lifting device 6 Remove the counterweight retaining fasteners from the base and remove the counterweight from the base All models 7 Using proper lifting techniques lay the machine over onto a table or other suitable work surface 8 Remove the legs from the machine Part No 115417 REX CON GL 4 GL 8 GL 10 GL 12 MANY REPAIR PROCEDURES 9 GL 4 models Remove the cable mounting fastener from the handle bracket GL 8 GL 10 and GL 12 models Remove the cable mounting fastener from the upper inner frame casting 10 Remove the mounting fasteners from the electric winch cover 11 Tag and disconnect the wiring from the electric winch cover and remove the electric winch cover from the machine 12 Remove the old cable following instructions in the Owner s Manual for Rule Winches Rule part number W 1013 Owner Manual for Rule Winches Genie part number 85220 ACAUTION POTY injury hazard Cables can fray Always wear adequate hand protection when handling cable 13 Remove the base mounting fasteners from the outer frame channels and remove the base from the machine 14 Remove the limit switch mounting fasteners and remove the limit switch from the machine 15 GL 4 models
13. jam nut from the winch drum bolt Remove the winch drum cover from the machine Remove the cable retaining fastener from the winch drum and remove the cable from the drum ACAUTION POTY injury hazard Cables can fray Always wear adequate hand protection when handling cable Remove the handle adaptor nut and spring Remove the handle adaptor from the machine 5 Remove the handle from the pinion shaft 6 Remove the drum bolt and remove the drum from winch 7 Remove the retaining ring from the pinion shaft 8 Slide the pinion shaft toward the carriage and remove the pressure plate ratchet gear and brake face 9 Remove the pinion shaft from the winch housing 10 Remove both pinion bushings Use a soft metal drift equal to the outside diameter of each bushing and tap with rubber mallet 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 April 2009 Section Ae Repair Procedures REV A 1 4 How to Assemble the Manual Winch ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable Note Refer to the illustration on page 4 6 for an exploded view of the winch assembly 1 Place one side of the winch housing over a vise Open the vise until it is wider than the outside diameter of the pin
14. 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 April 2009 REPAIR PROCEDURES 1 1 How to Disassemble the GL Models Equipped with a Manual Winch 1 Remove the load handling attachment from the carriage 2 Fully lower the carriage Models with counterweight base 3 Support the base counterweights with a proper lifting device 4 Remove the counterweight retaining fasteners from the base and remove the counterweight from the base All models 5 Using proper lifting techniques lay the machine over onto a table or other suitable work surface 6 Remove the legs from the machine 7 Remove the jam nut from the winch drum bolt and remove the winch drum cover 8 Remove the cable retaining fastener from the winch drum and remove the cable from the drum ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable A TEREX CON 4 2 GL 4 GL 8 GL 10 GL 12 REVA 9 GL 4 models Remove the cable mounting fastener from the handle bracket GL 8 GL 10 and GL 12 models Remove the cable mounting fastener from the upper inner frame casting ACAUTION POTY injury hazard Cables can fr
15. repair service problem solved M Be sure that all necessary tools and test equipment are available and ready for use A TEREX COMPANY Part No 115417 GL 4 GL 8 GL 10 GL 12 5 1 Section be Schematics April 2009 Electrical Symbols Legend Models With Electric Winch DOWN WHT prd BLK HANDLE ASSEMBLY CIRCUITS CROSSING NO CONNECTION 6V DC BATTERY U9 A M BATTERY CHARGER CB2 e o CIRCUIT BREAKER Ca RED EMERGENCY STOP BUTTON NORMALLY CLOSED Se CONNECTION NO TERMINAL LS20 LIMIT SWITCH CONNECTOR WINCH 5 2 A TEREX COMPANY QD1 T QUICK DISCONNECT m E QUICK DISCONNECT d O Olb U U SOLENOID REVA GL 4 GL 8 GL 10 GL 12 Part No 115417 Section be Schematics April 2009 Wiring Diagram REVA Models With Electric Winch RD WH ki BK P1 LS20 EMERGENCY CARRIAGE STOP UP CN BK BK RD Q9 Q10 UPPER LOWER SOLENOID SOLENOID WH BK Fil v Aa J 2 Jr m n E BN85 CARRIAGE UP ERGO SE BK 4 BK BK BK BK BN86 f e CARRIAGE DOWN T WH A BK Q Q HANDLE ASSEMBLY M8 dona
16. steps in procedure 1 6 RL NN A ANN S E Fa ae al a Cable slot e e NV he PN AS ei ANA SN Carriage is raised for illustrative purpose only Part No 115417 April 2009 Section Ae Repair Procedures REV A 4 GL 4 models Remove the cable mounting fastener from the handle bracket Pull all the cable out of the machine GL 8 GL 10 and GL 12 models Remove the cable mounting fastener from the upper inner frame casting Pull all the cable out of the machine 5 GL 4 models Attach the new cable to the handle bracket Note When installing the cable be sure the cable thimble swagged end is centered below the upper pulley GL 8 GL 10 and GL 12 models Attach the new cable to the upper inner frame casting Note When installing the cable be sure the cable thimble swagged end is centered below the upper pulley Facing the carriage side of the machine 6 Thread the cable through the cable slot and then through the carriage pulley from front to back Pull all the cable through the pulley GL 8 GL 10 and GL 12 models 7 Thread the cable through the upper inner frame pulley from back to front Pull all the cable through the pulley 8 From front to back thread the cable through the cable slot in front of the carriage pulley through the lower inner frame pulley Pull all the cable through the pulley Part No
17. the handle adaptor spring and handle adaptor mounting nut Tighten the mounting nut Do not overtighten the nut 9 Lubricate the outside of the drum spacer that goes through the cable drum with automotive grease Insert the drum spacer into the cable drum 10 Install the cable drum so that the drum gears mesh with the ratchet gears on the pinion shaft 11 Install the drum bolt through the winch housing and drum with the head of the drum bolt on the small bushing side of winch 12 From the winch side of the machine wrap the cable 1 time counterclockwise around the winch drum Thread the cable through the oblonged hole and attach it to the winch drum with the cable retaining fastener 13 While holding the cable tie on the drum rotate the winch until all the cable is spooled onto the drum neatly and evenly Be sure there are at least 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 Section 4 Repair Procedures April 2009 Manual Winch Assembly REVA o og o Genie A TEREX COMPANY 4 6 GL 4 GL 8 GL 10 GL 12 Part No 115417 April 2009 Section Ae Repair Procedures REVA Index No Description Ratchet Pawl Kit 2 Cable Drum 3 Carriage Bolt 4 Hex Nut 5 Gear Cover 6 Cable Keeper 7 Drum Sp
18. 115417 A TEREX COM GL 4 GL 8 GL 10 GL 12 REPAIR PROCEDURES All models 9 From front to back thread the cable through the handle weldment pulley Pull all the cable through the pulley 10 From the winch side of the machine wrap the cable 1 time counterclockwise around the winch drum Thread the cable through the oblonged hole and attach it to the winch drum with the cable retaining fastener 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 Section 4 Repair Procedures April 2009 REPAIR PROCEDURES Models with electric winch 1 Remove the load handling attachment from the carriage Fully lower the carriage 3 Pushin the red Emergency Stop button to the off position 4 Disconnect the battery 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 5 Remove the battery and battery charger from the machine Remove the winch cover fasteners 7 Tag and disconnect the winch wiring and remove the winch cover 8 Remove the old cable following instructions in the Owner s Manual for Rule Winches Rule part number W 1013 Owner Manual for Rule Winches Genie part number 85220 ACAUTION Bodily injury hazard Cables can fray Always wear adequate h
19. S Y WINCH e U9 ELECTRICAL COMPONENT LEGEND BATTERY Item Description B2 Battery BN Button BN85 Carriage up AC INPUT BN86 Carriage down LS20 Carriage up limit switch P1 Emergency stop button at ground controls QD1 Quick di t E SS Q sSdeod eiie Q9 Upper solenoid B2 Q10 Lower solenoid e M8 Electric winch U9 Battery charger WIRE COLOR LEGEND Color Description BK Black RD Red WH White TEREX COMPANY Part No 115417 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 G
20. acer 8 Screw 9 Lock Nut 10 Winch Frame 11 Winch Handle Assembly 12 Flat Washer Part No 115417 MANUAL WINCH ASSEMBLY Index No Description 13 Lock Pin 14 Handle Adapter Nut 15 Winch Handle Spring 16 Handle Adapter 17 Pinion Shaft Bushing 18 Pressure Plate 19 Ratchet Gear 20 Disc Brake 21 Drive Shaft Assembly 22 Retaining Ring 23 Pinion Shaft Bushing GL 4 GL 8 GL 10 GL 12 4 7 Section 4 Repair Procedures April 2009 REPAIR PROCEDURES 1 5 How to Replace the Lifting Pulley 1 Fully lower the carriage 2 Unwind the cable from the winch drum Do not remove the cable ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable 3 Remove the pulley mounting fastener and remove the pulley from the machine 4 Wrap the cable around the new pulley and install the pulley on to the machine Note Be sure not to twist the cable when installing the new pulley 4 8 GL 4 GL 8 GL 10 GL 12 REVA 1 6 How to Replace the Lifting Cable Models with manual winch 1 Fully lower the carriage 2 Remove the jam nut from the winch drum bolt and remove the winch drum cover 3 Remove the cable retaining fastener from the winch drum and unwind the cable from the winch drum ACAUTION Bodily injury hazard Cables can fray Always wear adequate hand protection when handling cable The numbers on the illustration correspond to the
21. and protection when handling cable 9 Install the new cable following the instructions in the Owner s Manual for Rule Winches 10 Connect the winch wiring and install the winch cover on to the machine A TEREX COMI GL 4 GL 8 GL 10 GL 12 REVA 1 7 How to Replace the Glide Buttons 1 Remove the load handling attachment from the carriage 2 Fully lower the carriage Models with counterweight base 3 Support the base counterweights with a proper lifting device 4 Remove the counterweight retaining fasteners from the base and remove the counterweight from the base Models with electric winch 5 Pushin the red Emergency Stop button to the off position 6 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 7 Remove the battery and battery charger from the machine All models 8 Using proper lifting techniques lay the machine over onto a table or other suitable work surface 9 Remove the legs from the base Part No 115417 April 2009 Section Ae Repair Procedures REV A 10 Remove the base mounting fasteners from the outer frame channels Then remove the base from the machine 11 GL 8 GL 10 GL 12 Slide the inner frame out the bottom of the outer frame approximately 6 inches 15 cm 12 Use a soft metal drift to remove the glide butt
22. ation 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 N 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 3 Scheduled Maintenance Procedures April 2009 pum m m M i This page intentionally left blank 3 4 GL 4 GL 8 GL 10 GL 12 Part No 115417 April 2009 Section 3 Scheduled Maintenance Procedures Maintenance Inspection Report Serial number Date 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 Inspection A Quarterly Inspection A B Annual Inspection A B C Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedur
23. ay Always wear adequate hand protection when handling cable 10 Remove the base mounting fasteners from the outer frame channels and remove the base from the machine 12 GL 4 models Remove the carriage from the outer frame GL 8 GL 10 and GL 12 Remove the inner frames from the outer frame Remove the carriage from the outer frame Proceed to step 15 Note After removing the carriage note the location of the roller wheel buttons on the carriage roller wheels 13 Remove the mounting fasteners from the lower inner frame casting and remove the lower casting from the inner frame 14 Remove the carriage from the inner frame Note After removing the carriage note the location of the roller wheel buttons on the carriage roller wheels 15 If necessary remove the hold down bar winch mounting plate handle and loading wheel bracket Note When installing the cable be sure the cable thimble is centered below the upper pulley GL 8 GL 10 and GL 12 models Note For proper cable routing see Repair procedure 1 6 How to Replace the Lifting Cable Part No 115417 April 2009 Section Ae Repair Procedures REV A 1 2 How to Disassemble the GL Models Equipped with an Electric Winch 1 Remove the load handling attachment from the carriage 2 Fully lower the carriage 3 Disconnect the battery from the machine AWARNING Electrocution burn hazard Contact with electrically charged circuits could result
24. ce 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 115417 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 specifications and the requirements listed in the responsibilities manual anie 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 Rev A 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 oper
25. cification Pnuematic tires 50 psi 3 4 bar Part No 115417 April 2009 Section 3 e Scheduled Maintenance Procedures Checklist B Procedures REVA B 1 Inspect the Battery Models with Electric Winch Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine performance 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 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 3 Be sure that the battery retainers and cable connections are tight 4 Fully charge the battery Allow the battery to rest 24 hours before performing this procedure to allow the battery cells to equalize 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Part No
26. crew 8 Stair Roller Mount Bracket Left Side 21 Base 9 Brake Cam Spacer 22 Brake Pedal 10 Screw 23 Screw 11 Nylock Nut 24 Nylock Nut 12 Brake Cam 25 Brake Linkage Plate 13 Brake Pivot Plate Genie Section Ae Repair Procedures MMN REAR WHEEL BRAKE ASSEMBLY OPTION Part No 115417 A TEREX COMPANY GL 4 GL 8 GL 10 GL 12 Section 4 Repair Procedures April 2009 R ZIZI LANE This page intentionally left blank A TEREX COMPANY 4 14 GL 4 GL 8 GL 10 GL 12 Part No 115417 April 2009 Section 5 Schematics Schematics About This Section An illustration legend precedes the electrical schematics Electrical Schematics AWARNING Electrocution burn hazard Observe and Obey Contact with electrically charged circuits could result in death or M Troubleshooting and repair procedures shall be serious injury Remove all rings completed by a person trained and qualified on watches and other jewelry the repair of this machine General Repair Process M Immediately tag and remove from service a damaged or malfunctioning machine Malfunction _ discovered H Repair any machine damage or malfunction before operating the machine Before Troubleshooting Identify Troubleshoot symptoms H Read understand and obey the safety rules and operating instructions printed in the Genie Lift Operator s Manual Perform Return to
27. enie Holland Phone 31 183 581 102 Fax 31 183 581 566 Service Manual Genie Lift from serial number 1395 103 to 1301 23434 and from GL02 23435 Part No 115417 Rev A1 G QIR REX
28. es in this section to learn how to perform these inspections If any inspection receives an N remove the machine from use 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 A 1 Manuals and Decals B 1 Battery A 2 Pre operation B 2 Electrical wiring inspection B 3 Electric winch A 3 Function tests maintenance A 4 Inspect the channels B 4 Carriage hold down A 5 Inspect cable B 5 Inspect welds and pulleys B 6 Clean channels A 6 Inspect casters B 7 Inspect and lubricate and wheels manual winch ChecklistC RevA Y NR C 1 Casters and wheels C 2 Winch friction disks C 3 Inspect painted Sufacs Comments Genie Part No 115417 A TEREX COMPANY GL 4 GL 8 GL 10 GL 12 Section 3 Scheduled Maintenance Procedures October 2010 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 safet
29. ft Operator s Manual Refer to the Operator s Manual on your machine Part No 115417 A TEREX COM GL 4 GL 8 GL 10 GL 12 PANY CHECKLIST A PROCEDURES A 4 Inspect the Channels Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Detection of damage to the inner and outer frame channels is essential for safe machine operation An unsafe working condition exists if the channels are damaged and do not operate smoothly free of hesitation and binding A daily check of the channels allows the inspector to identify changes in the operating condition of the unit that might indicate damage 1 Visually inspect each channel for the following Dents gauges or abrasions Bends or warping Excessive wear 2 Raise and lower the carriage through a complete cycle Result The carriage and inner frame if equipped should raise and lower smoothly free of hesitation and binding Section 3 Scheduled Maintenance Procedures October 2010 CHECKLIST A PROCEDURES A 5 Inspect the Cable and Cable Pulleys Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Detection of damage to the cable or pulleys is essential for safe machine operation An unsafe working condition exists if these components are damaged and do not operate smoothly A daily check of this system allows the inspector to ident
30. h 90 dB 90 dB 90 dB 90 dB Electric winch 95 dB 95 dB 95 dB 95 dB Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY Part No 115417 GL 4 GL 8 GL 10 GL 12 2 3 Section 2 Specifications April 2009 SPECIFICATIONS REVA SAE FASTENER TORQUE CHART e This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade 5 7 Grade 8 C2 Black Oxide Bolts DRY DRY LUBED Nm in ibs_ Nm Nm inis Nm _ CO CA 10 10 1 120 135 120 135 160 18 140 158 LUBED LUBED LUBED d R I J m gt U es Nm U 13 23 T 257 28 42 26 77 4 37 66 4 2 745 60 813 1684 521 w L1 5 738 5 1016 80 1084 110 149 03 126 20 54 867 58 115 00 122 320 2 106 1 one 12 50 1084 110 149 18 1 122 10 62 10 16 10 230 140 88 vs M 101 188 50 205 160 277 210 288 180 244 18 330 176 10 12 6 244 0 88 00 271 sa 10 200 21 270 366 280 379 380 515 320 433 6 20 298 300 406 50 420 420 569 80 am 8 9 320 438 280 583 450 610 610 827 510 om 14 550 474 470 687 500 678 670 9068 560 78 e 480 650 640 867 680 922 910 1288 770 10
31. ifications require that this procedure be performed every 250 hours or quarterly whichever comes first Clean inner if equipped and outer frame channels are essential to good machine performance and safe operation Extremely dirty conditions may require that the channels be cleaned more often 1 Raise the carriage to the maximum height 2 Visually inspect the inner if equipped and outer frame channels for debris or foreign material If necessary use a mild cleaning solvent to clean the channels 3 If needed lubricate the inner if equipped and outer channels with a dry silicone spray or silicone wax A TEREX CON GL 4 e GL 8 GL 10 GL 12 MPANY REVA B 7 Inspect and Lubricate the Manual Winch Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Carefully lubricate the pivot point on the ratchet pawl with 30W oil ACAUTION odily Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake disc or the winch pressure plate leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 2 Inspect the brake disks for excessive wear Rep
32. ift Parts amp Service Manual Second Edition from serial number GLO2 23435 35572 Note Genie Lift Service Manual 115417 and Genie Lift Part s Manual 115418 replaces Genie Lift Parts and Service Manual 35572 Copyright 1989 by Genie Industries 115416 Rev A April 2009 Third Edition First Printing Genie is a registered trademarks of Genie Industries in the USA and many other countries es Printed on recycled paper Printed in U S A Part No 115417 April 2009 INTRODUCTION Serial Number Legend Genie Redmond WA 98052 USA Model Name GL Serial Number GL08 12345 Manufacture Date 01 02 08 Electrical Schematic N A GL 09 12345 Country of manufacture USA Sequence number Model Year Serial label Serial label stamped on base Part No 115417 GL 4 GL 8 GL 10 e GL 12 iii April 2009 E This page intentionally left blank A TEREX COMPANY iv GL 4 GL 8 GL 10 e GL 12 Part No 115417 April 2009 Part No 115417 A TEREX COMPANY GL 4 GL 8 GL 10 GL 12
33. ify changes in the operating condition that might indicate damage 1 Visually inspect all cable components for the following Frayed or broken wire strands Kinks in the cable Corrosion Paint or foreign materials Split or cracked swaged end Cable is properly secured to the winch Cable is properly secured to the upper inner frame casting GL8 GL10 and GL 12 Cable is properly secured to the cable anchor GL4 Cable is on all pulleys No broken or damaged pulleys No unusual or excessive pulley wear A TEREX COMI GL 4 GL 8 GL 10 GL 12 REV B A 6 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 Casters 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 fashion Extremely dirty conditions may require that the wheels and casters be inspected more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 Unlock the brake if equipped and move the machine on a firm smooth surface and check that the casters and wheels roll smoothly free of hesitation and binding 3 Models with Pneumatic Wheel Check the tire pressure with an air pressure gauge and add air as needed Spe
34. ion shaft bushing 2 Insert a soft metal drift through the opposite bushing hole Tap the drift with a rubber mallet to push the bushing into place Note Use a piece of flatbar in between the drift and the bushing to prevent any damage to the bushing Note Repeat steps 1 and 2 to insert the other bushing 3 Carefully lubricate the pivot point on the ratchet pawl with 30W oil ACAUTION Body Injury Hazard Overlubrication of the ratchet pawl may result in oil coming in contact with the surface of the winch brake disc or the winch pressure plate leading to an unsafe working condition Do not allow any oil on the brake or pressure plate 4 Install the winch housing onto the machine Be sure the winch drum is towards the right 5 Insert the threaded end of the pinion shaft through the large bushing Then insert the other end of the pinion shaft through the small bushing 6 Push the pinion shaft toward the small bushing Install the brake disk ratchet gear and pressure plate Note The teeth on the ratchet gear must curve away from the drum Part No 115417 A TEREX COM GL 4 GL 8 GL 10 GL 12 4 5 REPAIR PROCEDURES 7 Pushthe pinion shaft toward the large bushing Install the pinion shaft retaining ring Note Push the ratchet pawl outwards while pushing the pinion shaft through the large bushing Be sure the ratchet pawl is in firm contact with the ratchet gear and all parts move freely 8 Install
35. lace if pad is less than 1 16 inch 1 5 mm thick 3 Inspect the pinion shaft bushings for excessive wear Replace if wall thickness of bushing is less than specified Bushing Specification Small bushing 0 172 inch 4 34 mm Large bushing 0 109 inch 2 76 mm Part No 115417 April 2009 Section 3 e Scheduled Maintenance Procedures AA Checklist C Procedures C 1 C 2 Lubricate the Casters and Wheels Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Extreme dirty conditions may require that the casters and wheels be inspected and lubricated more often 1 Visually inspect each caster and wheel for cuts cracks or unusual wear 2 Move the machine on firm smooth surface and check that the casters and wheels roll smoothly free of hesitation and binding 3 Pump a lithium based grease into the caster or wheel until it can be seen coming out of the bearing gap Part No 115417 A TEREX CO GL 4 GL 8 GL 10 GL 12 MPANY Replace the Manual Winch Friction Disks Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the winch is essential to good machine performance and safe operation An unsafe working condition exists if the winch has excessive wear and or does not operate smoothly free of hesitation and binding 1 Replace the winch brake disks and lubrica
36. needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill 11 Install the vent caps and neutralize any electrolyte that may have spilled Section 3 Scheduled Maintenance Procedures April 2009 CHECKLIST B PROCEDURES B 2 Inspect the Electrical Wiring Models With Electric Winch 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 hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed pinched corroded and loose wires Control panel Battery pack Remote control Channel frame A TEREX COMI GL 4 GL 8 GL 10 GL 12 REV A B 3 Perform Electric Winch Maintenance Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Required maintenance procedures and additional winch information is available in the Owner Manual for Rule Winches Rule part number W 1013 Owner Manual for Rule Winches Genie part number 85220
37. on 13 Press the new glide button in place until it is fully seated Part No 115417 A TEREX CO GL 4 GL 8 GL 10 GL 12 REPAIR PROCEDURES 1 8 How to Adjust the Brake if equipped Note Refer to the illustration on page 4 12 for an exploded view of the brake 1 5 Rotate the brake pedal to the up or unlocked position Loosen the clamping bolts from all three of the brake cams Rotate both of the wheel brake cams until they contact the tires Tighten the brake cam clamping bolts With the pedal up rotate the brake cam rod until there is approximately 4 inch of gap between the wheel and the wheel brake cam Tighten the center brake cam clamping bolt Check the brake for proper activation 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 MPANY Section 4 Repair Procedures April 2009 Rear Wheel Brake Assembly option REVA 4 12 GL 4 GL 8 GL 10 GL 12 Part No 115417 April 2009 REVA Index Index No Description No Description Screw 14 Brake Linkage Spring 2 Lock Washer 15 Axle Tube 3 Nut 16 Spring Retaining Washer 4 Stair Roller Mount Bracket Right Side 17 Screw 5 Stair Roller Spacer 18 Flat Washer 6 Stair Roller 19 Solid Rubber Wheel 7 Brake Cam Rod 20 S
38. onths must complete the quarterly inspection MI Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a firm level surface Carriage in the stowed position Casters locked Red Emergency Stop button pushed in to the off position if equipped Brakes locked if equipped Part No 115417 A TEREX CO GL 4 GL 8 GL 10 GL 12 3 1 MPANY 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 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 3
39. rnserenserennsens 4 8 A 1 7 Howto Replace the Glide Buttons ossesesseeesseeesenrssirrserrenrnnsrrnnserennene 4 10 A 1 8 Howto Adjust the Brake if equipped aaa aaa aaa sanaaaacca 4 11 Section5 Rev Schematics lueft en RPP 5 1 A Electrical Symbol Legend Models with Electric Winch ssesesss 5 2 A Wiring Diagram Models with Electric Winch sssssssssssesssrssersnssrnnnsrnserrnserrnnernn 5 3 Genie A TEREX COMPANY viii GL 4 e GL 8 GL 10 e GL 12 Part No 115417 April 2009 Section 2 Specifications Specifications REVA Machine Specifications Model GL 4 GL 8 GL 10 GL 12 Stowed Height 51t7 5 in 5 ft 7 5 in 6 ft 6 5 in 6 ft 6 5 in 1 7m 1 7m 2m 2m Ground Clearance 0 7 in 0 7 in 0 7 in 0 7 in 1 8 cm 1 8 cm 1 8 cm 1 8 cm Standard Base Width stowed 24 8 in 24 8 in N A N A 62 9 cm 62 9 cm Length stowed 12 in 12 in N A N A 30 5 cm 30 5 cm Length operating 34 8 in 34 8 in N A N A 88 3 cm 88 3 cm Straddle Base Width stowed 28 8 in 28 8 in 28 8 in 28 8 in 73 cm 73 cm 73 cm 73 cm Width extended 43 5 in 43 5 in 43 5 in 43 5 in 1 4m 1 4m 1 4m 1 4m Length stowed 19 3 in 19 3 in 19 3 in 19 3 in 48 9 cm 48 9 cm 48 9 cm 48 9 cm Length operating 43 in 43 in 43 in 43 in 1m 1m 1m 1m Counterweight Base Width stowed 28 8 in 28 8 in 28 8 in N A 73 cm 73 cm 73 cm Width extended 43 5 in 43 5 in 43 5 in N A 1 1m 1 1m 1 1m Length opera
40. t your workshop or work area is properly ventilated and well lit A TEREX COMPANY vi GL 4 e GL 8 GL 10 e GL 12 Part No 115417 October 2010 Table of Contents Introduction Important Information Rec ii Serial N rmbet InfOrmmaltiOlr aa asza O E teet O ccrta es neret d PPE rane pt ii Serial Number Legend iii Section 1 Safety Rules General Safety Rules tic 2 ad EA A a PAMW PA elie aes V Section2 Rev Specifications A Machine Specifications AANEREN 2 1 Performance Specifications isinisisi edes ate a GA PAK 2 3 SAE and Metric Fasteners Torque Chart 2 4 Section 3 Rev Scheduled Maintenance Procedures INrOdUCHON RPO 3 1 Pre delivery Preparation Report iacet AEO e EAR ee EUR RE 3 3 Maintenance Inspection Report ssssssseeeeeene een 3 5 B Checklist A Procedures A 1 Inspect the Manuals and Decals sssssssessssrrnressrrnnnnrnnrannnnrnnnannanrennnnnenna 3 6 A 1 Perform Pre operation Inspection essssssesesrirrsensernnnanssnrnnnnnrsnnnnnaesnnnannnnne 3 7 A 2 Perform Function Tests ssssssssseeeenm eene 3 7 A 3 Inspect the Channels A 3 7 A 4 Inspect the Cable and Cable Pulleys ssseseeeemme 3 8 A 5 Inspect the Casters and Wheels AA 3 8 Genie A TEREX COMPANY Part No 115417 GL 4 e GL 8 GL 10 e GL 12 vil April 2009 E TABLE OF CONTENTS Section3 Rev Scheduled Main
41. te the winch shaft Refer to Repair procedure 1 3 How to Disassemble the Manual Winch Section 3 Scheduled Maintenance Procedures April 2009 CHECKLIST C PROCEDURES C 3 Inspect the Painted Surfaces Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Inspecting the painted surfaces of your machine is essential to safe operation An unsafe working condition exists if there is damage to the painted surfaces that is not corrected 1 Visually inspect all painted surfaces for the following conditions Blistering Rust Peeling Fading Corrosion Note Replace any component if it is damaged 3 14 GL 4 GL 8 GL 10 GL 12 A TEREX COMPANY REV A Part No 115417 April 2009 Section Ae Repair Procedures REV A Observe and Obey H Repair procedures shall be completed by a person trained and qualified on the repair of this machine Hl Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating the machine Before Repairs Start MI Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine H Be sure that all necessary tools and parts are available and ready for use M Use only Genie approved replacement parts H Read each procedure completely and adhere to the instruc
42. tenance Procedures continued A Checklist B Procedures B 1 Check the Battery models with electric winch sseeeeeessss 3 9 B 2 Inspect the Electrical Wiring models with electric winch 3 10 B 3 Perform Electric Winch Maintenance A 3 10 DA Inspect the Carriage Hold down Bar 3 11 B 5 Inspect All Woelds cita tet o eint etn suu EE ak Ela 3 11 B 6 Clean the Channels eeeeu aaa aaa aaa aaa aaa nennen nennen 3 12 B 7 Inspect and Lubricate the Manual Winch eeeeeeeeeeee ea aaaa aaa esinnae 3 12 A Checklist C Procedures C 1 Lubricate the Casters and Wheels sesseessseesnessnerereserrnsererserenrsrennsne 3 13 C 2 Replace the Manual Winch Friction Disk 3 13 C 3 Inspected the Painted Surfaces 0 ccccceccceeeeceeeeeeeeeeeeeeeeeeeneeeeeseeeesenaeees 3 14 Section4 Rev Repair Procedures niifejolifoi o ee LEER 4 1 A 1 1 Howto Disassemble the GL Models Equipped with a Manual Winch sssssesssssessssrrrresserrnrrnrsrrrnnessrnnnnnenne 4 2 A 1 2 Howto Disassemble the GL Models Equipped with an Electric Winch A 4 3 A 1 3 Howto Disassemble the Manual Winch ssssessssrsesssrinrrensrnnnessnnnnnnensennnnas 4 4 A 1 4 Howto Assemble the Manual Winch eseeee 4 5 A 1 5 Howto Replace the Lifting Pulley seeeeem 4 8 A 1 6 Howto Replace the Lifting Cable ssesosseessseesseneneseesererrsnrrnssr
43. ting 28 5 in 28 5 in 285 in N A 72 4 cm 72 4 cm 72 4 cm 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 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY Part No 115417 GL 4 GL 8 GL 10 GL 12 2 1 Section 2 Specifications April 2009 SPECIFICATIONS REV A Machine Specifications cont Model GL 4 GL 8 GL 10 GL 12 Machine Weight Standard base 113 Ibs 132 Ibs N A N A 51 kg 60 kg Straddle base 126 Ibs 145 Ibs 149 Ibs 154 Ibs 57 kg 66 kg 68 kg 70 kg Counterweight base 392 Ibs 411 Ibs 433 Ibs N A 178 gk 186 kg 196 kg Standard base 117 Ibs 136 Ibs N A N A pneumatic caster option 53 kg 60 kg Straddle base 130 Ibs 149 Ibs 153 Ibs 158 Ibs pneumatic caster option 59 kg 68 kg 69 kg 72 kg Straddle base 137 Ibs 158 Ibs 162 Ibs 167 lbs 4 point caster option A 62 kg 72 kg 74 kg 76 kg Straddle base 139 Ibs 160 Ibs 164 Ibs 169 Ibs 4 point caster option B 63 kg 73 kg 75 kg 77 kg The electric winch option will add an additional 103 Ibs 47 kg to the above machine weights Forks Length 22 5 in 22 5 in 22 5 in 22 5 in 57 2 cm 57 2 cm 57 2 cm 57 2 cm Width 20 5 in 20 5 in 20 5 in 20 5 in 52 1 cm 52 1 cm 52 1 cm 52 1 cm
44. tions Attempting shortcuts may produce hazardous conditions MI Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Carriage in the stowed position Casters locked Red Emergency Stop button in the off position if equipped Brake locked if equipped All external AC power supply disconnected from the machine models with electric winch Part No 115417 A TEREX CO GL 4 GL 8 GL 10 GL 12 4 1 MANY Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend A ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury 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 a potentially hazardous AWARNING 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
45. y 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 Checkto make sure that the operator s and safety manuals are present and complete in the storage container on the platform A TEREX COMI 3 6 GL 4 GL 8 GL 10 GL 12 REV B 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 W 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 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 XK 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
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