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Service Manual - Genie Industries

1. Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES 5 Raise the platform approximately 3 feet 1 m above the top of the base 6 Place a jack stand on the top of the base centered under the platform Adjust the jack stand to 24 inches 61 cm a platform b jack stand c base 7 Lower the platform onto the jack stand just enough to take the weight off the lifting chains Crushing hazard Keep away from AWARNING lowering platform 8 Inspect each idler wheel for the following excessive wear on the side flanges unusual wear movement side to side in excess of 0 040 inches 1 mm any movement of wheel front to back DE a idler wheel b spacer c lifting chain If idler wheel inspection results in a measurement that is not within specification refer to Repair procedure 5 2 How to Assemble the Mast 9 Raise the platform and remove the jack stand and the support blocks Then lower the platform 10 Install the mast covers and adjust the sequencing cable See B 7 Adjust the Sequencing Cables Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 4 Scheduled Maintenance Procedures C 3 Lubricate the Lifting Chains Lubricated chains are essential to good machine performance
2. seee 5 7 4 Steer Handle Interlock Light Will Not Turn On 5 9 5 Level Sensor Interlock Light Will Not Turn On 5 11 6 Machine Will Not Lift AC Models ssseeeneenene 5 13 T Machine Will Not Lift But Power Unit Will Operate AC Models 5 16 8 Machine Will Not Lift DC Models ee eue aaa aaa aaa aaa Ln Ynn nL nno 5 18 9 Machine Will Not Lift But Power Unit Will Operate DC Models 5 21 10 Machine Will Not Lower Up Function Operates sssssesss 5 23 11 Base Will Not Raise With Steer Handle sese 5 25 vi Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition TABLE OF CONTENTS Section Five Troubleshooting Flow Charts continued 12 Platform Will Not Hold In Up Position sseeee ooo aaa aaa aaa aaaaaca 5 26 13 Power Unit Will Not Lift Rated Load sss 5 27 14 A Auxiliary Platform Lowering Will Not Operate eeeeeeeees 5 28 15 Power Wheel Assist Will Not Operate Models with Power Wheel Assist Option sseeese 5 29 Section Six Schematics INTOdUCTION ERR 6 1 Symbols Legend aaa LE 6 2 Electrical Schematic CWP amp StockPicker AC Models essessssss 6 3 Electrical Schematic CWP amp StockPicker DC Models o n 6 4 Electrical Sc
3. LJ SPECIFICATIONS Platform function speed maximum maximum CWP 8S AC DC SP 12S AC DC Platform Up 15 seconds 15 seconds Platform Up 17 seconds 17 seconds Platform Down 17 seconds 17seconds Platform Down 19 seconds 19 seconds CWP 12S AC DC SP 15S AC DC Platform Up 17 seconds 17 seconds Platform Up 21 5 seconds 21 5 seconds Platform Down 19 seconds 19 seconds Platform Down 20 seconds 20 seconds CWP 15S AC DC Maximum hydraulic pressure All Models Platform Up 21 5 seconds 21 5 seconds 2700 psi 186 bar Platform Down 20 seconds 20 seconds Maximum hydraulic pressure All Models 2700 psi 186 bar Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 2 3 Section 2 Specifications Service Manual First Edition SPECIFICATIONS Bolt Torque Specifications Size Threads SAE Grade 5 Bolts amp SAE Grade 8 Bolts per inch Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters 10 24 43 5 60 7 32 49 6 68 8 1 4 20 96 11 144 16 28 120 14 168 19 5 16 18 17 23 25 34 24 19 28 25 34 3 8 16 30 41 45 61 24 35 48 50 68 7 16 14 50 68 70 95 20 55 75 80 109 1 2 13 75 102 110 149 20 90 122 120 163 9 16 12 110 149 150 204 18 120 163 170 231 5 8 11 150 204 220 298 18 170 231 240 326 3 4 10 260 353 380 515 16 300 407 420 570 7 8 9
4. CWP amp StockPicker Models NORMALLY T P OPEN VALVE Q O Vil PRESSURE RELIEF VALVE C gt PUMP HYDRAULIC POWER UNIT PLATFORM LIFT CYLINDER DOWN VALVE b w ll y 6 6 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Hydraulic Schematic CWP amp StockPicker Models with Power Wheel Assist Section 6 Schematics T c H HL M K7 ka JJ d acl Q gt KA H re POWER ASSIST LIT 0 MOTOR re al POWER ASSIST MANIFOLD NORMALLY P OPEN VALVE I gem PRESSURE RELIEF VALVE ae S M DA UMP L J it J L ij HYDRAULIC POWER UNIT DOWN gt VALVE n PLATFORM LIFT md CYLINDER o Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Section 6 Schematics Service Manual First Edition cac mc JfA ss Z Z M R This page intentionally left blank 6 8 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures Observe and Obey M Repair procedures shall be completed by a person trained a
5. wire of the 13 pole terminal strip Ut in the base control box Continued on the next page Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series 5 19 Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 8 While pushing in the control activate switch and activating the up function hold both PE switches and check for power at the motor Continued from the previous page contactor coil positive terminal red wire Put Neg lead of the voltage meter on the negative terminal green yellow wire 12V DC no the voltage meter at terminal 10 green yellow wire of the 13 pole terminal strip J1 in the base control box 12V DC Repair open circuit in the green yellow wire Perform a continuity test tinuit across the motor Suu Paie moror contactor coil continuity While pushing in the control activate switcl and activating the up ov DC function hold both switches and check for power at the N O side of the motor contactor number 4 weld cable to 12 volt motor 12V DC no Perform a continuity test continuit across the 12 volt motor continuity Check the condition of the battery OR consult Genie Industries Service Department Replace the motor contactor because of damaged contacts Replace the motor brushes OR the 12 volt DC motor Relocate the Neg lead of
6. EMERGENCY STOP SWITCH PLATFORM ES GROUND EMERGENCY STOP SWITCH GROUND KS KET SWITCH AUX DWN AUXILIARY DOWN SWITCH MC MOTOR CONTACTOR PB POWER TO PLATFORM 6 4 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 6 Schematics Electrical Schematic CWP amp StockPicker DC Models with Power Wheel Assist r I D CONTROL BOX I I RED PESTE HANDLE S I EE sze GONTROLS I I i si I ES BASE WHT i E FT T Bk KS o mk I L xav DC POWER INPUT GBNYEL I s i NEGITIVE 12V DC INPUT 2 TE 1 BLK I I LU posiTiVe 12v DC INPUT a NU Ar I I i I H RED GRNYEL 1 t CHARGE 1 i i 4 WHT i BATTERY Le 1 DRIVE 1 1 1 I GRN YEL MANIFOLD t LED Lee I S I D s ax m S f gt i UN SL omo po sk BLK I om 5 war I 3 BAABATTERIES WHT i Mo YSANYEL BLK GRN I I I I I i LEDA LEDs Fm 1 1 1 NOV SOL I C un N GRNvEL RU V GRNYEL I wore RED 1 POWER INDICATOR ria
7. While pushing in and holding control activate switch check for power at terminal 3 of control activate switch contact 12V DC Continued on the next page ue Replace the P C board Replace 16 6 cable because of open in red OV DC wire OR repair open in quick disconnect under base control box Replace Emergency Stop ov DC switch N C contact block Replace red wire because of open circuit between Emergency 0v De Stop switch contact block and control activate switch contact block OV DC Replace control activate switch N O contact block Chart 6 Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 6 While pushing in and holding the control Continued from the previous page OV DC activate switch check for power at terminal 4 of the up switch contact 12V DC While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 3 of up switch contact While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 13 orange wire of the 13 pole terminal strip J1 in base control box ov DC 12V DC While pushing in the control activate switch and activating the up function hold both switches and check for power a
8. cia T 4 T circuits Connection connect no terminal Battery Emergency Stop AL button normally closed ry ety Relay contact Resistor Relay Contactor Relay Coil Transformer normally open Hydraulic Symbols Cylinder Pressure gauge Filter Fixed displacement Check valve pump 0 035 Relief valve Orifice with size Solenoid operated 2 pos 3 way directional valve MOT T i Om Solenoid operated Pump prime mover dump valve engine or motor 6 2 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 6 Schematics Electrical Schematic CWP amp StockPicker AC Models RED r BLK WHT GRN DWN SOL WHT BLK V eielgleojo oo THERMAL DEVICE ES GROUND 23 VEL BLK NEGATIVE 12 VDC INPUT 16 0 VAC INPUT BLK aj m L POSITIVE 12 VDC INPUT WHT BK A CENTER TAP INPUT GRNYEL 7 16 0 VAC INPUT 3 BLU WHT 4 WHT WHT czai s one a 1 i EI E U IM i E MC BLK 8 AA BATTERIES BLK va LED4 LED3 I WHT i i MOTOR X s x4 6 BLU i GRN YEL GR YEL
9. switches and check for voltage at the down valve solenoid at the barrel end 12V DC of the lift cylinder Put Pos lead of the voltage meter on the white black wire and Neg lead on the green yellow grounding wire OV DC Repeat the test but relocate the Neg lead of the voltage meter at the ground terminal 10 green yellow wire of the 13 pole terminal strip J1 in the base control box 12V DC ov DC Check the voltage at terminal 3 on the down N O contact block located in the platform control box ov DC 12V DC Continued on the next page Chart 10 Check the resistance of infinite the N C down valve coil ohms Replace the N C valve coil because of an open circuit 7 ohms Pull the manual lowering nm The N C down valve is knob red knob at the owers damaged or possibly contaminated Consult Genie Industries Service Department barrel end of the lift cylinder platform will not lower The flow control valve at the barrel end of the lift cylinder is possibly contaminated Consult Genie Industries Service Department Check for a loose connection at the grounding stud in the base control box OR check for a bad pin connection at the quick disconnect under the base control box OR replace 16 6 cable because of an open circuit in the green yellow grounding wire Replace the red jumper wire because of an open circuit Part No 38139 Genie C
10. the platform and base Then lower the platform onto the blocks AWARNING Stockpicker Super Series Models Attach an overhead crane or similar lifting device to the platform Crushing hazard Keep away from descending platform 2 Remove the mounting fasteners from the platform 3 Pull the platform away from the mast and remove it from the machine AWARNING If a platform is being replaced be sure that all appropriate safety and instructional decals are applied to the new platform 6 2 How to Install a Fiberglass Platform CWPS Models 1 Remove the platform See 6 1 How to Remove the Platform 2 Support the platform with a lifting device then place the platform against the mounting angles 3 Install the mounting fasteners If a platform is being replaced be sure that all appropriate safety and instructional decals are applied to the new platform AWARNING Platform 6 3 Platform Control Box How to Test the Contactors 1 Fully lower the platform turn the key switch off and disconnect the power supply Loosen the platform control box lid fasteners and open the control box Observe the markings on the contactor to be checked The N O marking designates the switch as normally open and N C designates the switch as normally closed Connect a continuity tester to the exposed screw terminals Result Normally open contactors should have no continuity Normally closed contactors shou
11. 430 583 600 814 14 470 637 660 895 1 8 640 868 900 1221 12 700 949 1000 1356 Torque specifications for lubricated bolts are 25 less than the dry torque specifications for each bolt size These bolt torque specifications are for general use only Specification may vary depending on application of bolt 2 4 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Scheduled Maintenance Inspections Observe and Obey M 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 and annually as specified on the Maintenance Inspection Report Failure to properly complete each AWARNING inspection when required may result in death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine MI Repair any machine damage or malfunction before operating machine M Keep records on all inspections for three years FI Machines that have been out of service for a period longer than 3 months must have a quarterly inspection About This Section Schedule There are three types of maintenance inspections that must be performed according to a schedule daily quarterly and annual To account for repeated procedures
12. 7 Repair Procedures Service Manual First Edition MAST ASSEMBLY 5 1 Lift Cylinder How to Remove the Lift Cylinder This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the mast See 5 2 How to Remove the Mast Assembly 2 Remove the socket head retaining bolt from the clevis block on the lift cylinder rod end a a topofno 1 column b retainingbolt c clevis block 3 Disconnect and plug the lift cylinder hydraulic hoses Cap the fittings on the lift cylinder Bodily injury hazard Spraying ACAUTION 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 4 Remove the cylinder mounting fasteners from the cylinder barrel end 5 Loosen the cylinder bracket mounting fasteners bracket mounting fasteners cylinder mounting fasteners hydraulic cylinder cylinder mounting plate Q OQ gw 6 Support the cylinder and carefully slide it out of the bottom of the mast Crushing hazard The lift cylinder ACAUTION will fall unless it is properly supported Genie CWP Super Series amp Genie StockPicker Sup
13. AC where it connects to the brown transformer wire 110V AC Continued on the next page Plug into a different power supply and recheck the voltage Repair or replace the pig tail and or the 12 3 cable Replace the key switch Trace the black wire from terminal 1 back to the key switch and repair open in wire Replace the Emergency Stop button Repair open in the yellow transformer wire betwee the Emergency Stop button and the transformer OR replace the transformer because of a faulty thermal fuse Chart 1 Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition Be CHART 1 Check the voltage at ov ac Repair the transformer terminals 1 and 3 of 13 wires OR replace the IS terminal strip J1 transformer ut Pos lead of voltage meter on terminal 1 and Neg lead on terminal 3 Continued from the previous page 14 to 16V AC Check the voltage on both sides of the 5amp P C board fuse Put i Neg lead of voltage Replace the 5amp fuse meter on terminal 10 ground terminal of 13 pole terminal strip J1 If there is voltage on both sides of the fuse and the power light is not turned on replace P C board OR consult Genie Industries Service Department 5 4 Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edi
14. OV DC Repair open circuit in the wire Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Machine Will Not Lift But Power Unit Will Operate DC Models Be sure the power unit reservoir is full and the breather cap has been installed While pushing in the control activate switch and activating the up function hold both switches and check for input voltage at the N O OV DC valve coil on the power unit Put Pos lead of the voltage meter on the red wire and Neg lead on the green yellow grounding wire 12V DC a the N O valve coil 7 ohms Tee in a 3000 psi pressure gauge at the pressure port fitting 1800 to stamped P of the power 2000 psi unit Push in the control activate switch activate the up function hold both switches and check the pressure less tnan 1800 psi On the power unit remove the return to tank hose off of the T port fitting and plug the hose fitting leaving the 3000 psi gauge teed in at the port fitting Push in the control activate switch activate the up function hold both switches and 1800 to A 2000 psi check the pressure less than 1800 psi Continued on the next page Chart 9 Replace or repair the red wire between the motor contactor coil and the N O valve coil because of an open circuit Replace the N O valve
15. anchors and pulleys hydraulic power unit cylinder hoses fittings sequencing cables and pulleys lifting chains and idler wheels adjustable glide pads mast columns and counterweight s mast covers nuts bolts and other fasteners platform entry mid rail s and or gate breather cap foot pads dents or damage to machine corrosion or oxidation cracks in welds or structural components If equipped Models with Power Wheel Assist Option steer handle hydraulic motor and hoses hydraulic manifold If equipped Models with Outreach Option locking bracket handle and handle lock outreach extension arms chain and sprocket TABLE A PROCEDURES A 4 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous conditions impair machine functions and damage machine components 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas hydraulic power unit reservoir valves fittings hydraulic cylinder flow control valve ground area under the machine all hydraulic hoses and fittings hydraulic manifolds If equipped CWPS Models with Power Wheel Assist Option hydraulic motor and hoses Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 4 3 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 5 Test the Base
16. cable quick disconnect from base under the base control box and inspect the male and female connectors for damage good Check for power at the base mounted 10 pole terminal strip 12V DC Pull apart the quick disconnect at the top of the level sensor an check for power at the black wire wire harness side Put Neg lead of voltage meter on green wire wire harness side 12V DC Continued on the next page black wires located at the OV DC OV DC Replace the P C board Repair or replace connectors Replace 18 7 cable because of open in black wire Relocate Neg lead of voltage meter at terminal 10 which is a grounding terminal green yellow wire of 13 pole terminal strip J1 in the base control box 12V DC Repair open circuit in the green grounding wire from 10 pole terminal Strip to level sensor OR replace 18 7 cable because of open circuit i the green wire Chart 5 Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 5 Reconnect the quick Replace the defective d the disconnect at the top of p page the level sensor an check for power at the white wire located at the 10 pole base mounted terminal strip connected with a orange wire If the power was just turned on wait 1 second before performing this test Replace 18 7 c
17. contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear 2 Remove the battery vent caps and check the specific gravity with a hydrometer 3 Check the battery acid level If needed replenish with distilled water to cover the battery plates Do not overfill 4 Install the battery vent caps If equipped Set the battery charger AC Selector switch to the proper voltage 6 Plug charger in and set timer to the auto position and observe charger ammeter after one hour to confirm charging amperage has dropped If the amperage does not drop test battery condition and confirm charger is operating correctly 7 Remove the battery vent caps Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 8 Install the battery vent caps TABLE B PROCEDURES B 4 Clean and Lubricate the Columns Clean and properly lubricated columns are essential to good machine performance and safe operation Extremely dirty conditions may require that the columns be cleaned and lubricated more often 1 Raise the platform to the maximum height 2 Visually inspect the inner and outer channels of the columns for debris or foreign material If necessary use a mild cleaning solvent to clean the columns AWARNING This procedure will require the use of additional access equipment Do not place ladders or scaf
18. does not meet this specification see Repair procedure 7 4 How to Adjust the Platform Outreach Chain 4 12 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 4 Scheduled Maintenance Procedures C 1 Inspect the Wheels Extremely dirty conditions may require that the casters and wheels be inspected more often 1 Visually inspect each wheel for cuts cracks or unusual wear 2 Move the machine on a flat smooth surface and check that the wheels roll smoothly Table C Procedures C 2 Inspect the Mast Assembly for Wear Detection of excessive or unusual wear in the mast assembly is essential for safe machine operation An unsafe working condition exists if the mast assembly has excessive wear and or does not operate smoothly free of hesitation and binding 1 Remove the mast covers 2 Raise the platform until 3 to 5 inches 7 6 to 12 7 cm of each column is visible 3 Visually inspect the top of each column for clearance between the roller wheels and the adjacent column surface Result There should be an equal amount of distance between the roller wheel and the column on each side If mast inspection results in a measurement that is not within specification refer to Repair procedure 5 4 How to Adjust the Shim Pads 4 Loosen but do not remove the adjustment nut on the sequencing cable located at the top of the first column
19. hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 5 Tag and disconnect the electrical wiring from the valve coil 6 Remove the cover from the junction box on the motor Then tag and disconnect the electrical wiring in the junction box Loosen the squeeze connector on the junction box and pull the wiring out through the squeeze connector 7 Support the hydraulic power unit with a lifting device 8 Remove the power unit mounting fasteners then remove the power unit from the machine Crushing hazard The power unit AWARNING will fall unless it is properly supported If a new power unit is installed the pressure relief valve must be properly adjusted See 3 6 How to Adjust the Pressure Relief Valve 3 4 How to Remove the Hydraulic Power Unit DC Models 1 Fully lower the platform turn the machine off remove the key and disconnect the power supply 2 Lower the base with the steer handle Remove the power unit cover 4 Tag disconnect and plug the hydraulic hoses Cap the fittings on the power unit Bodily injury hazard Spraying ACAUTION 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 5 Tag and disconnect the electrical wiring from the valve coil 6 Tag and disconnect the electrical wiring from the motor start sol
20. or missing chain leafs and pins tight or kinked joints in the chain missing or damaged idler wheels and related components 3 Inspect the chain terminations near the bottom of each column to confirm that each termination has a lock nut 4 6 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 4 Inspect the chain terminations near the bottom of each column to confirm that the chain tensioner bracket is centered in the inspection hole chain tensioner bracket adjustment nut hidden from view termination rod hidden from view column Q OQ TABLE A PROCEDURES A 14 Inspect the Breather Cap The hydraulic reservoir is a breathing type reservoir The breather cap has an internal air filter that can clog and may cause the power unit to operate improperly If the breather cap is not properly installed and checked daily impurities can enter the hydraulic system and cause component damage 1 Be sure the breather cap is installed on the hydraulic power unit reservoir and is not damaged Do not remove it Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 4 7 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table B Procedures B 1 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to
21. power unit 6 Remove the magnet from the reservoir and clean it using a mild solvent 7 Install the magnet then the reservoir 8 Apply pipe thread sealant to the drain plug or the hose on Power Wheel Assist models and re install it in the reservoir 9 Fill the reservoir with hydraulic oil until the level is visible in the sight gauge on the side of the reservoir Do not overfill Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES 10 Replace the breather cap with a new one 11 Raise and lower the platform through three complete cycles Add hydraulic oil if needed to allow platform to reach full height Component Damage Hazard Do ACAUTION not allow the hydraulic reservoir to completely empty when raising the platform Pressurized air in the hydraulic system can damage hydraulic components Hydraulic System Hydraulic fluid Dexron equivalent Hydraulic reservoir capacity AC models DC models 2 8 liters 2 8 liters 3 quarts 3 quarts Hydraulic System Capacity includes reservoir C 5 Replacing the Auxiliary Platform Lowering Batteries 1 Turn the machine off and remove the key 2 Loosen the two ground control box cover fasteners 3 Open the base control box and locate the battery pack 4 Remove the fasteners that hold the battery pack in place
22. power switch to the Auro position Result The charger ammeter should be on A 9 Inspect the Columns for Damage Detection of damage to columns is essential for safe machine operation An unsafe working condition exists if the columns are damaged and do not operate smoothly free of hesitation and binding A daily check of the columns allows the inspector to identify changes in the operating condition of the column assembly that might indicate damage 1 Visually inspect each column for the following dents gouges cracks or abrasions bends or warping excessive wear 2 Raise and lower the platform through a complete cycle Result Platform should raise and lower smoothly free of hesitation and binding TABLE A PROCEDURES A 10 Check the Sequencing Cables Detection of damage to sequencing cables or components is essential for safe machine operation An unsafe working condition exists if the sequencing components are damaged and do not operate smoothly A daily check of the sequencing system allows the inspector to identify changes in the operating condition that might indicate damage 1 Visually inspect the cables and components for the following frayed or broken wire strands kinks in the cable corrosion paint or foreign materials broken or damaged pulleys unusual or excessive pulley wear split or cracked threaded swage ends 2 Check to be sure of the following cables are on the pulleys upper and low
23. reservoir Component damage hazard Do ACAUTION not continue to operate the machine if the hydraulic pump is cavitating 15 Install the breather cap and the power unit cover Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures 3 7 How to Check the Resistance of a Valve Coil 1 Fully lower the platform turn the machine off and remove the key 2 Connectthe leads from an ohmmeter to the valve coil terminals Valve coil specifications Solenoid operated N O valve 10V 5 9 to 7 20 Lowering valve 10V 7 8 to 9 5 Q located at base of cylinder HYDRAULIC POWER UNITS 3 8 How to Test the Motor Start Solenoid DC Models Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Electrocution hazard Disconnect AWARNING the ground cable from the battery before performing this procedure 1 Label and disconnect all the wiring from the motor start solenoid 2 Connect the leads from an ohmmeter to each terminal combination and check for continuity Test Desired result Small post to ground 13 to 17 Q 2 large posts no continuity infinite O Small post to any large post no continuity infinite a high amp power contact terminal large post b solenoid activate coil terminal
24. 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 Electrocution hazard Contact with AWARNING hot or live circuits may cause death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires all base wiring inside of the ground control box inside of the base junction box hydraulic power unit all external machine electrical cables inside of the platform control box DC models battery pack AC power supply cord B 2 Inspect All Welds 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 platform base mast brace mounting brackets foot pads power wheel assist if equipped 4 8 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 3 Check the Battery DC Models 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 Batteries contain acid Avoid AWARNING spilling or
25. suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Please write or fax to the Technical Publications Team Genie Industries PO Box 69 Redmond WA 98073 0069 USA If you have any questions please call Genie Industries Genie North America Telephone 206 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Sales Fax 206 883 3475 Service Fax 206 556 8649 Genie Europe Telephone 44 01636 605030 Fax 44 01636 611090 Genie Industries Copyright 1996 by Genie Industries First Edition First Printing July 1996 GenieQ is a registered trademark of Genie Industries Registered 2009987 Printed on recycled paper Printed in U S A This machine complies with ANSI SIA A92 3 1990 ii Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie CWP Super Series Operator s Manual and the Genie StockPicker Super Series Operator s Manual will cause death or serious injury Many of the hazards identified in the operators manuals 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
26. 5 Carefully slide the battery pack out of the holder The wires connected to the battery pack are very small Be careful not to damage the wires AC models Remove the old batteries from the pack CWP 8S 3 1 quarts 29 liters 7 Insert new batteries into the pack CWP 12S 3 1 quarts 2 9 liters CWP 15S 3 1 guarts 2 9 liters Make Sure IME llenas installed correctly by following the SP 12S 3 1 quarts 2 9 liters diagram on the inside of the SP 15S 3 1 quarts 2 9 liters battery pack DC models 8 Install the battery pack into the ground control box and tighten the fasteners CWP 8S 3 1 quarts 2 9 liters CWP 12S 3 1 quarts 2 9 liters 9 Close the ground control box cover and tighten CWP 15S 3 1 quarts 2 9 liters the fasteners SP 12S 3 1 quarts 2 9 liters SP 15S 3 1 quarts 2 9 liters 4 16 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie CWP Super Series Operator s Manual and the Genie StockPicker Super Series Operator s Manual Observe and Obey M Be sure that all necessary tools and test equipment are available and ready for use MI Troubleshooting and repair procedures shall be completed by a person trained and qualified on M Read each appropiate flow chart thoroughly t
27. ATFORM 23 Thread the chain through the upper sprocket housing around the sprocket and then back through the housing 24 Thread the chain through the lower sprocket housing around the sprocket and back through the housing Make sure the chain does not become twisted 25 Connect the two ends of the chain together with a new master link Do not re use the old master link 26 Slide the platform mounting column onto the inner frame assembly 27 Install the column outreach locking bracket onto the platform mounting column 28 Install the upper sprocket housing to the column When fasteners are installed be sure the center bolt is in between the two chains inside the housing 29 Pull the slack out of the chain by pulling on the lower sprocket housing 30 Install the lower sprocket housing 31 Adjust the chain See 7 4 How to Adjust the Outreach Chain 32 Install the outreach back onto the machine Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Distributed By 4 Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 4 Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England
28. ES GROUND i i aot BLK TBk ks BK i i L 12v DC POWER INPUT onm i i NEGATIVE 12V DC INPUT FEX i WHT M i POSITIVE 12V DC INPUT alt i CHARGE 31 f i s i wur i BATTERY f f LED LED2 i i 5 ona i o K H mE C i hil i i WHT i Me SEINE r d BAABATTERIES i i ip i RED BLK il one wer i i LED LED i i i I i NN 2 alk i NOV SOL BLK GRN i KB i wur GRN YEL o i wc i GRN YEL how i POWER INDICATOR i ro I roli 4 GRNYEL oto i i ja wur ojo i is onc ojo GR vow BATTERY INDICATOR i olo DWN SOL i M7 FOR AUXILIARY LOWERING i 12 BLU A o wer i i RED 6 RED one BE revoc OUTPUT 5 BLK iz Bik WE 2 i s revocoureur 9 rev ae 919 ET i i BLK i i DC MODEL LOW 12V DG OUTPUT 3 BLU AUX DOWN Ls YEL 5 GI i H BATTERY INDICATOR i E i BLU BLK i i GROUND 10 GRN YEL i Lay BK u i WHT i i 12V DC MOTOR SOLENOID OUTPUT H RED i PLATFORM CONTROLS i i i2 i BLU i 6 f i 1 SEC TIME DELAY 12V DC OUTPUT i i Fe m ES PLATEORM O i i 13 ORG i i 12V DC UP SIGNAL INPUT i is i i ir i 4_ GRNYEL PB i i1 wur LEGEND 1 RIGHT FOOT PAD SWITCH S2 TILT LEVEL SENSOR 83 STEERING HANDLE SWITCH S4 LEFT FOOT PAD SWITCH DWN SOL DESENT VALVE SOLENOID NOV SOL NORMALLY OPEN VALVE SOLENOID CAS CONTROL ACTIVATE SWITCH ES PLATFORM
29. I i I I I 4 caver RED 5 Iw T i wer r fofo 1 1 Ii ojo ST LOW BATTERY INDICATOR LL O olo E GWNSOL E7 FOR AUXILIARY LOWERING le au veL wer I Le nep E ax I I a li i REE ons Foto savDc oureur TI Flex ge RTE i e tvocourrur 2 RED B RED WHT DC MODEL LOW yevocourpur 2 ALL BLU AUX DOWN is ve i I BATTERY INDICATOR I mm I mono PT PLATFORM CONTROLS a SL wm i I i I mu BIK BLK 12V DC MOTOR SOLENOID OUTPU hn RED i I 1 1 I rz ax 1sec TIME DELAY 1evocouTeur E 16 r I I I I I s ORG a I 12V DC UP SIGNAL INPUT U s ona m I I E LIBE L4 GRNYEL p mh Di WHT i I 1 LEGEND S1 RIGHT FOOT PAD SWITCH S2 TILT LEVEL SENSOR 53 STEERING HANDLE SWITCH S4 LEFT FOOT PAD SWITCH S5 DIRECTION REVERSING SWITCH S6 FWD REV SWITCH FUNC SOL DRIVE MANIFOLD FUNCTION SOLENOID VALVE M1 SOL DRIVE MANIFOLD REVERSE SOLENOID VALVE M2 SOL DRIVE MANIFOLD FORWARD SOLENIOD VALVE DWN SOL DESCENT VALVE SOLENOID NOV SOL NORMALLY OPEN VALVE SOLENOID CAS CONTROL ACTIVATE SWITCH ES PLATFORM EMERGENCY STOP SWITCH PLATFORM ES GROUND EMERGENCY STOP SWITCH GROUND KS KET SWITCH AUX DWN AUXILIARY DOWN SWITCH MC MOTOR CONTACTOR PB POWER TO PLATFORM Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 6 5 Section 6 Schematics Service Manual First Edition A Hydraulic Schematic
30. Operation Testing the base for proper operation is essential for safe machine operation An unsafe working condition exists if the base fails to operate properly The base should operate smoothly and be free of hesitation jerking and binding 1 Liftthe base with the steer handle Result The foot pads should be 1 2 to 1 inch 1 5 to 2 54 cm off the ground 2 Push the base steer handle to the stowed position Result The base should lower putting the two foot pads in firm contact with the ground Raise the platform slightly 4 Attempt to raise the base with the steer handle Result The base should not raise A 6 Check the Auxiliary Platform Lowering Operation The auxiliary platform lowering is powered by a secondary battery pack that is located in the ground control box The auxiliary platform lowering can be activated from the ground or platform controls Detection of an auxiliary lowering malfunction is essential for safe machine operation An unsafe working condition exists if the auxiliary platform lowering function does not operate in the event of a main power failure 1 Raise the platform slightly 2 Disconnect the power from the machine 3 Activate the auxiliary platform lowering button at the ground controls Result Platform should lower 4 Reconnect the power and raise the platform slightly 5 Disconnect the power from the machine 6 Pushin the control activate button and rotate the u
31. POWER INDICATOR fax 7 GRN YEL i4 Nr i1 LOW BATTERY INDICATOR 3 K7 FOR AUXILIARY LOWERING j2 RED 16 12 VDC OUTPUT BLK i k 12 VDC OUTPUT 2 RED 5 DC MODEL LOW 12 VDC OUTPUT BLU AUX DOWN BATTERY INDICATOR T BLU GROUND GRN YEL eu PLATFORM CONTROLS 12 VDC MOTOR RELAY OUTPUT 11 RED i 3 1 SEC TIME DELAY 12 VDC OUTPUT 12 BE i2 17 BLK 12 VDC UP SIGNAL INPUT 13 ORG j1 WHT pg Ta GRN YEL BLK NOV SOL GRN YEL LEGEND S1 RIGHT FOOT PAD SWITCH NSOR 2 TILT LEVEL SE S3 STEERING HANDLE SWITCH 4 LEFT FOOT PAD SWITCH DWN SOL DESCENT VALVE SOLENOID NOV SOL NORMALLY OPEN VALVE SOLENOID CAS CONTROL ACTIVATE SWITCH ES PLATFORM EMERGENCY STOP SWITCH PLATFORM ES GROUND EMERGENCY STOP SWITCH GROUND KS KET SWITCH AUX DWN AUXILIARY DOWN SWITCH MC MOTOR CONTACTOR PB POWER TO PLATFORM PTI Part No 40460 Genie CWP Super Series 8 Genie StockPicker Super Series Section 6 Schematics Service Manual First Edition jee ns Sa SS Saas i Electrical Schematic CWP amp StockPicker DC Models CONTROL BOX i RED BLK i i i PC BOARD RAE i Ja aa i
32. Platform Lowering Operation A 8 Inspect the Battery and Battery Charger DC Models A 9 Inspect the Columns for Damage A 10 Check the Sequencing Cables A 11 Check the Interlock System for Proper Operation A 12 Test the Power and Function Controls A 13 Inspect the Lifting Chains and Idler Wheels A 14 Inspect the Breather Cap 3 2 Genie CWP Super Series amp Genie Stock Picker Super Series Part No 40460 Service Manual First Edition Section 3 Scheduled Maintenance Inspections E MAINTENANCE TABLES Table B Dealer Tools are New parts service required required suggested Complete all procedures in Table A B 1 Inspect the Electrical Wiring a B 2 Inspect All Welds B 3 Check the Battery DC Models B 4 Clean and Lubricate the Columns B 5 Test the Lifting Capacity B 6 Test the Power To Platform Operation B 7 Adjust the Sequencing Cables B 8 Check the Chain Adjustment CWPS Models Equipped with Platform Outreach Option Table C ra ra za ra ra Ea Complete all procedures in Table A and Table B C 1 Inspect and Lubricate the Wheels je C 2 Inspect the Mast Assembly for Wear C 3 Lubricate the Lifting Chains o EB C 4 Replace the Hydraulic Oil je C 5 Replace the Auxiliary Platform Lowering Batteries o ra za ra ra ra EE EI EI EI Part No 40460 Genie CWP Super Series amp Genie Stock Picke
33. Power and Function Controls e eeeeaaaa aaa Ye aaa aaa FFF dnon 4 6 A 13 Inspect the Lifting Chains and Idler Wheels 4 6 A 14 Inspect the Breather Cap 4 7 B 1 Inspect the Electrical Wiring eee eee aaa aaa aaa aaa aaa aaa n 4 8 B 2 Inspect All WEldS vise siew miam A A A OE AE PA LTD FYNO 4 8 B 3 Check the Battery DC Models eeeeu aaa aaa aaa aaa adia ae 4 9 B 4 Clean and Lubricate the Columns eee eee aaa aaa aaa aaa aaa 4 9 B 5 Test the Lifting Capacity esse ien aannaaien a 4 10 B 6 Test the Power To Platform Operation eeeaa aaa aaa aaa aaa aaa aaana ach 4 10 B 7 Adjust the Sequencing Cables 4 11 B 8 Check the Chain Adjustment CWPS Models Equipped with Platform Outreach Option ss 4 12 C 1 Inspect and Lubricate the Wheels ssssssssseeee n 4 13 C 2 Inspect the Mast Assembly for Wear 4 13 C 3 Lubricate the Lifting Chains eeees eee a aaa aaa aaa aaa aaa awanse 4 15 C 4 Replace the Hydraulic Oil aa i A Ed a 4 15 C 5 Replace the Auxiliary Platform Lowering Batteries 42 11112 111 4 16 Section Five Troubleshooting Flow Charts laiia eli en a a PP ne 5 1 1 Power Light Will Not Turn On AC Models cceeeeeeeeeeeeeeeeeeeeseeeeeeeeeneees 5 3 2 Power Light Will Not Turn On DC Models sesm 5 5 3 Foot Pad Interlock Lights Will Not Turn On
34. Technical Genie CWP SYRER Genie StockPicker Seize Service Manual Introduction Service Manual First Edition Genie CWP SERIES Genie StockPicker SURE Important Read understand and obey the safety rules and operating instructions in the Genie CWP Super Series Operator s Manual and the Genie StockPicker Super Series Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals 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 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 Industries of any errors and send in
35. WP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition e CHART 10 Continued from the previous page Activate the down function and check the Replace the N O down voltage at terminal 4 blu contact block because of wire of the N O down an open circuit contact block Check the voltage at He pin 2 for a defect terminal 2 on the N O in the quick disconnect auxilary down contact under the base control block in the base control box OR replace the 16 6 box cable because of an ope circuit in the blue wire Inspect pin 5 for a defect in the quick disconnect under the base control box OR replace the 16 6 cable because of an ope circuit Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Base Will Not Raise With Steer Handle Be sure the platform is fully lowered Be sure to pump the foot pedal with slow even strokes Check the base lift Adjust the base lift lockout release cable for incorrect lockout release cable proper adjustment See Repair procedure How to Adjust the Base lift lockout Release correct Cable Remove the steering Adjust the base lift handle switch S3 lockout release cable mounting plate and check incorrect See Repair procedure for proper cable How to Adjust the Base adjustment on the base lift locko
36. able because of open circuit i orange wire OR repair defective pins in the quick disconnect under base control box OR tighten the orange wire al the 10 pole terminal strip base mounted Check for power at terminal 5 of the13 pole terminal na J1 Put Neg lead of voltage meter at terminal 10 ground terminal Replace P C board OR consult Genie Industries Service Department 5 12 Genie CWP Super Series 8 Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Machine Will Not Lift AC Models Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the power light and all interlock display lights are on Be sure the ground control box circuit breaker has been reset Check for power at terminal 9 red wire of 1 pole terminal strip J1 Put Neg lead of voltage meter on terminal 10 grounding terminal 12V DC Check for power at terminal 1 of Emergency Stop switch contact in platform control box Put Neg lead of voltage meter on terminal 10 green yellow wire of 13 pole terminal strip J1 in base control box 12V DC Emergency Stop switch should be pulled up for the contact to close Check for power at terminal 2 of Emergency Stop switch contact 12V DC Check for power at terminal 4 of control activate switch 12V DC
37. alve See Repair procedure How to Adjust the Pressure Relief Valve and then perform pressure test again less than 1800 psi Consult Genie Industries Service Department Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series 5 17 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 8 Machine Will Not Lift DC Models Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the power light and all interlock display lights are on Check for power at terminal 9 red wire of 1 pole terminal strip J1 Put Neg lead of voltage meter on terminal 10 ground terminal 12V DC Check for power at terminal 1 of Emergency Stop switch contact in platform control box Put Neg lead of voltage meter on terminal 10 green yellow wire of 13 pole terminal strip J1 in base control box OV DC 12V DC Emergency Stop switch should be pulled up for the contact to close Check for power at terminal 2 of Emergency Stop switch contact OV DC 12V DC Check for power at terminal 4 of control activate switch OV DC 12V DC While pushing in and holding the control activate switch check for power at terminal 3 of the control activate switch contact OV DC 12V DC Continued on the next page ov DC Replace the P C board Replace 16 6 ca
38. and safe operation Extremely dirty conditions may require that the chains be cleaned and lubricated more often 1 Raise the platform to the maximum height 2 Lubricate each chain with a dry type spray lubricant This procedure will require the use AWARNING of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the proper skills and tools may result in death or serious injury Dealer service is strongly recommended TABLE C PROCEDURES C 4 Replace the Hydraulic Oil Replacement of the hydraulic oil is essential for good machine performance and service life Dirty oil and a dirty suction strainer 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 1 Fully lower the platform 2 Remove the plastic cover from the power pack 3 Remove the drain plug from the hydraulic reservoir and completely drain the reservoir into a container Properly discard of oil 4 Models with Power Wheel Assist Option Remove the hose on the bottom of the reservoir and drain oil into a suitable container Bodily injury hazard Spraying ACAUTION 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 5 Remove the reservoir from the hydraulic
39. assembly from the machine Installation Reassemble in the reverse order of disassemble procedure Do not install the motor cover until the relief valve adjustment is complete Refer to 3 6 How to Adjust the Pressure Relief Valve Component damage hazard Do ACAUTION not overtighten the hydraulic fittings Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures Mast Assembly CWP 8 CWP 12S SP 12S I LA Y Sin TN OTE cl E a CWP 15S SP 15S I EZ Mast Components a carriage b number 2 column c number 1 column d number 2 column idler wheel assembly number 3 column number 3 column idler wheel assembly number 4 column number 4 column idler wheel assembly 7O gt 0 Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 7 17 Section
40. ble because of open in red wire OR repair open in quick disconnect under base control box Replace Emergency Stop switch N C contact block Replace the red wire because of open circuit between the Emergency Stop switch contact block and the control activate switch contact block Replace the control activate switch N O contact block Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts ESS CHART 8 While pushing in and Replace the red wire holding the control because of open cir cuit activate switch check for between the control power at terminal 4 of the activate switch contact up switch contact block and the up switch contact block Continued from the previous page While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 3 of the up switch contact Replace the up switch N O contact block While pushing in the control activate switch Reta Home e dk orange re OR epa bd pen in the quici sa m disconnect under base orange wire of the 13 control box pole terminal au dl J1 in the base control box While pushing in the Replace P C board OR control activate switch consult Genie Industries and activating the up service Department function hold both switches and check for power at terminal 11 red
41. cause serious injury or damage to the machine AWARNING Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 7 1 Section 7 Repair Procedures Service Manual First Edition Base Assembly 1 1 Interlocks The base interlock switches indicate that the foot pads are in firm contact with the ground How to Remove a Base Interlock Switch 1 Fully lower the platform turn the machine off and remove the key 1 2 Base Components How to Adjust the Steer Handle Interlock Cable 1 Lower the base with the steer handle 2 Remove the base cover to access the cable 3 Check to be sure the cable is properly connected to the latch plates 2 Lower the base with the steer handle 3 Remove the foot pad switch holder fasteners j 4 Pull the foot pad switch holder out of the base immmm m tube A a steer handle cable b lock nut c measurement d latch plate e spring f cable mounting plate 4 Checkto be sure the cable is attached to the a Switch holder fasteners cable mounting bracket with a lock nut on each ls holder cover side There should be 21 2 to 25 s inches 6 6 to 5 Remove the wires from the switch Take note of 6 8 cm between the cable mounting plate an
42. coil Inspect the mast for a mechanical bind such as the hold down bar not releasing properly or foreign objects that could have fallen in between the columns Remove the N C down valve and inspect valve for contamination or Activate the up function and check for voltage at the N C valve coil down valve coil white black wire at the barrel end of the lift cylinder ov DC damage OR consult Genie Industries Service Department 12V DC Replace defective N O contact block for down function in the platform control box Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition Be CHART 9 On the power unit remove and inspect the N O valve for contamination or damage Clean repair or replace valve and then perform pressure test again Continued from the previous page less than 1800 psi Adjust the pressure relief valve See Repair procedure How to Adjust the Pressure Relief Valve and then perform pressure test again less than 1800 psi Consult Genie Industries Service Department 5 22 Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Machine Will Not Lower Up Function Operates While pushing in the control activate switch and activating the down function hold both
43. d the location of the wires the latch plate 6 Remove the fasteners that attach the switch to the foot pad switch holder Note how many threads of the footpad switch are above the switch mounting plate This will provide a starting point for footpad Switch installation T 2 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures 5 Locate the steer handle interlock cable mounting bracket on the bottom side of the number 1 column number 1 column steer handle interlock cable cable striker bracket slider bracket spring lock nut cable mounting bracket Q D Q O0 OU 6 Loosen the mounting fasteners on the cable mounting bracket and the cable striker bracket on the number 2 column Do not remove the fasteners 7 From the bottom of the number 1 column make a reference mark 6 inches 15 2 cm up from the bottom BASE ASSEMBLY Slide the cable mounting bracket up until the top of the bracket is even with the reference mark from step 7 Tighten the mounting fasteners At the top of the cable mounting bracket make a reference mark on the number 2 column 4 inches 10 cm above the top of the cable mounting bracket 10 Slide the cable striker bracket down until the top of the bracket is even with the reference mark from step 9 The spring will need to be compres
44. ding to the operator s manual from base under the base control box and inspect the male and female connectors for damage Check for power at the base mounted 10 pole terminal strip Remove the foot pad switch access covers on the end of the base weldment and check for power at the common terminal of each foot pad switch Continued on the next page Replace the P C board black wires located at the OV DC Repair or replace connectors Replace 18 7cable because of open in black wire Repair open circuit in the black wire or replace 16 2 cable from the base mounted 10 pole terminal strip to common terminal at Si or S4 Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 3 While the footpad switch is being activated check for power at the N O terminal Continued from the previous page Check for power at the base mounted 10 pole terminal strip white wire from S1 or white wire from S4 At the 13 pole terminal strip J1 check for power at terminal 7 red wire from switch 4 and and at terminal 4 white wire from switch 1 Replace P C board OR consult Genie Industries Service Department Remove the foot pad inuity Replace the footpad switch and perform a switch continuity test Repair open in white wire or replace 18 7 cabl
45. e Repair open in wire 5 8 Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Steer Handle Interlock Light Will Not Turn On Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the power light is on Be sure the unit is set up according to the operator s manual Check the power light light on Refer to either Chart 1 or Chart 2 Check for 12 volts DC at A black a on the 13 pole terminal stri J1 Put Pos lead of oV DC voltage meter on terminal 8 and Neg lead on terminal 10 ground terminal Replace the P C board Disconnect the power op ly Unplug the 18 7 cable quick disconnect from base under the base control box and inspect the male and female connectors for damage Repair or replace connectors Check for power at the Replace 18 7 cable black wires located at the OV DC becas of an open base mounted 10 pole circuit in the black wire terminal strip Remove the steering Repair open circuit in the handle switch access black wire from the cover on the top of the base mounted 10 pole base weldment and terminal strip to common check for power at the terminal of the steering common terminal of the handle switch S3 steering handle switch Continued on the next page C
46. enoid 7 Support the hydraulic power unit with a lifting device 8 Remove the power unit mounting fasteners then remove the power unit from the machine Crushing hazard The power unit AWARNING will fall unless it is properly supported If a new power unit is installed the pressure relief valve must be properly adjusted See 3 6 How to Adjust the Pressure Relief Valve Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures i SSS HYDRAULIC POWER UNITS 3 5 How to Remove the Hydraulic Pump 1 Fully lower the platform turn the machine off and remove the key 2 Lowerthe base with the steer handle Remove the power unit cover 4 Remove the drain plug from the hydraulic reservoir and completely drain the reservoir into a container Properly discard of oil 5 Remove the power unit See 3 3 How to Remove the Power Unit AC Models or 3 4 How to Remove the Power Unit DC Models 6 Support the hydraulic reservoir with a lifting device 7 Remove the mounting fasteners from the reservoir Then remove the reservoir from the power unit It may be necessary to tap the side of the reservoir with a soft rubber mallet to loosen it 8 Remove the mounting fasteners from the pump Then remove the pump from the power unit When installing the reservoir be sure not to damage the o ring Part No 40460 Genie CWP Super Series a
47. er Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures EE i O W MAST ASSEMBLY 5 2 How to Remove the Mast Assembly This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended AWARNING 1 Fully lower the platform turn the machine off and remove the key 2 Lower the base with the steer handle 3 Remove the platform See 7 1 How to Hemove the Platform 4 Remove the power pack See 4 1 How to Change a Power Pack 5 Tag disconnect and cap the lift cylinder hydraulic hoses Plug the cylinder ports ACAUTION 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 6 Remove the level sensor assembly mounting fasteners 7 Remove the steer handle interlock cable mounting fasteners from the side of the mast 8 Attach an overhead crane to the lifting eye located on the back of the mast 9 Remove the base cover 10 Remove the four base mounting fasteners 11 Carefully lift the mast out of the base Crushing hazard The mast will fall ACAUTION unless it is properly supported 12 Place two saw horses under the mast 13 Lower the bot
48. er cable ends are properly secured upper and lower mounting brackets are properly secured A 11 Check the Interlock System for Proper Operation 1 Lower the platform 2 Pull the steer handle 5 to 6 inches 13 to 16 cm away from the machine Result The steer handle interlock display light should be off 3 Raise the base with the steer handle Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES Result All four interlock display lights should be off 4 Place a 1 2 inch 1 2 cm block under one of the foot pads 5 Lower the base with the steer handle Be sure the steer handle is in the stowed position Result The foot pad indicator lights and the steer handle indicator light should be on The level sensor light should be off because the machine is not level 6 Twist to release the red Emergency Stop button at the platform controls 7 Pushin the control activate button and rotate the up down switch to the up position then the down position Result Platform up function should not operate 8 Raise the base and remove the block Lower the base A 12 Test the Power and Function Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to ope
49. er is seen then the won t Replace the auxiliary symptom would be that lower down N O contact block the auxillary lowering from located in the base from the platform would base control box OR repair the work and not from the wire from terminal 9a of base control box 13 pole terminal strip J1 5 28 Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Power Wheel Assist Will Not Operate Models with Power Wheel Assist Be sure the base foot pads are not contacting the ground Remove the S3 steering handle switch access cover on the top of the Replace steering handle base weldment and switch because of an check for power at the open circuit N C terminal of the steering handle switch black wire Check for power at the l function solenoid on the dr open in the black power assist manifold 12V DC Check for power at the common terminal black Repair open in the black wire of the backup wire switch on the handle Check for power at the Replace backup switch N C terminal of the SPDT because of an backup switch open circuit Continued on the next page Chart 15 Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts ee qe WO Z RE EE E CHART 15 Continued from the previous page Check for power at t
50. f Valve eueuaaaa aaa ananasa czaaaaaaa 7 14 3 7 How to Check the Resistance of a Valve Coil 7 15 3 8 How to Test the Motor Start Solenoid DC Models 1 7 15 Power Pack 4 1 How to Change a Power Pack 7 16 Mast Assembly Mast IIUstratlo s issues 7 17 5 1 How to Remove the Lift Cylinder e ee esse eee asa aaa aaa nana eaaaaaaeanaa 7 18 5 2 How to Remove the Mast Assembly eseua aaa aaa aaa aaa aecnaa 7 19 5 3 How to Adjust the Lifting Chains sssrinin intuens 7 22 5 4 How to Adjust the Glide Pads sssseeeea aaa aaa aaa aaa aaa aaa a aaa aaa Yn Fon 7 22 5 5 How to Inspect the Lifting Chains eee sssee eee aaa aaa aaa aaa acca 7 23 Platform 6 1 How to Remove the Platform ih ei tee dte Peer Ere t e 7 25 6 2 How to Install a Fiberglass Platform seemA 7 25 6 3 Platform Control Box 7 25 6 4 How to Adjust the Platform Outreach Chain GWPS Models nissan and ees eed eerie 7 26 6 5 How to Replace the Outreach Chain CWPS Models 2222 11111111222 7 26 vill Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 2 Specifications Specifications Height working maximum CWP 8 13 ft 11 in 4 2 m CWP 12 17 ft3 in 5 3 m CWP 15 20 ft 8 in 6 3 m Heig
51. f the 3 pole terminal strip J2 back to the Emergency Stop button and repair the wire Chart 2 Part No 38139 Genie CWP Super Series 8 Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 2 Check the voltage on Se d Leu SE both sides of the 5amp p pags P C board fuse Put Neg lead of voltage meter on terminal 10 ground terminal of 13 pole terminal strip J1 If there is voltage on both sides of the fuse and the power light is not turned on replace P C board OR consult Genie Industries Service Department Replace the 5amp fuse 5 6 Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 3 Foot Pad Check the power light Refer to either Chart 1 or Interlock Chart 2 i i light o Lights Will ca Not Turn On Check for power at terminal 8 black wire on Be sure the the 13 pole terminal strip keyswitch is in the appropriate J1 Put Pos lead of voltage meter on terminal 8 and Neg lead on terminal 10 ground position terminal Be sure the Emergency Stop oe are pulled Disconnect the power up tot e on ap ly Unplug the 18 7 position cable quick disconnect Be sure the power light is on Be sure the steer handle is locked in the up position Be sure the unit is set up accor
52. fold on or against any part of the machine Performing this procedure without the proper skills and tools may result in death or serious injury Dealer service is strongly recommended 3 If needed lubricate the inner and outer channels of the columns with a dry silicone spray or silicone wax Genie part no 90337 Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 5 Test the Lifting Capacity Proper lifting capacity is essential to safe machine operation Improper lifting capacity adjustment could allow machine to be overloaded and may cause death or serious injury This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Place the maximum load capacity in the platform Refer to the operator s manual or the load capacity decal on the machine to determine the maximum load capacity Be sure the load is secure 2 Raise the platform slightly Result The hydraulic power unit should raise the platform Fully lower the platform 4 Add an additional 30 pounds 14 kg to the platform Secure the additional weight 5 Raise the platform slightly Result The hydraulic power u
53. hart 4 Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 4 Continued from the While the steering handle Remove the steering Replace steering handle previous page tch switch is being activated OV DC handle switch and inuity switch check for power at the perform a continuity test normally open terminal At the 13 pole terminal strip J1 located in the base control box check OV DC agi ns _ for power at terminal 6 circuitin blue e blue wire from switch 3 Replace P C board OR consult Genie Industries Service Department 5 10 Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Level Sensor Interlock Light Will Not Turn On Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the power light is on Be sure the unit is set up according to the operator s manual Check the power light Llight off Refer to either Chart 1 or Chart 2 light on Check for 12 volts DC at terminal 8 black wire on the 13 pole terminal strip J1 Put Pos lead of voltage meter on terminal 8 and Neg lead on terminal 10 ground terminal 12V DC Disconnect the power op ly Unplug the 18 7
54. he A CAUTION mounting fasteners are removed the platform outreach will become unbalanced and may fall if it is not properly supported 9 Lay the outreach onto a work bench or table with the chain assembly facing up Be sure the work bench or table is of ample capacity 10 Place a block of wood under the inner frame assembly to support it while removing the chain Crushing hazard The platform AWARNING outreach will collapse if a suitable block or brace is not used 11 Remove the lower sprocket housing mounting fasteners Do not allow the chains to become twisted 12 Remove the upper sprocket housing mounting fasteners Do not allow the chains to become twisted 13 Remove the fasteners from the column outreach locking bracket 14 Slide the platform mounting column off of the inner frame assembly and set it aside 15 Locate the two allen head screws in the chain slider block 16 Remove the roller wheel on the same side of the allen head screws 17 Remove the two allen head screws 18 Locate the master link in the chain Use a screwdriver to pry the link apart 19 Pull the chain out of the slider block and both sprocket housings 20 Install the new chain through the slider block first 21 Push the chain through the slider block until approximately 2 inches 5 1 cm of the chain is extended past the slider block 22 Install the two allen head screws into the slider block then install the roller wheel PL
55. he common terminals of the 0V DC rocker switch DPDT 12V DC Activate the rocker switch for forward travel and check for power at ov DC the white wire on the rocker switch goes to motor contactor 12V DC Check for power atthe OV DC motor contactor 12V DC Check for power at the wire to the forward OV DC solenoid at the rocker switch 12V DC Check for power at the forward solenoid at the OV BE power assist manifold 12V DC Remove foward reverse and function valves from power assist manifold and inspect for damage good Consult Genie Industries Service Department Service Manual First Edition Repair wire between the backup switch and the rocker switch Replace the rocker switch DPDT because of an open circuit Repair white wire or replace 16 4 cable because of an open circuit Replace rocker switch DPDT because of an open circuit Repair or wire or replace 16 4 cable because of an open circuit Repair or replace damaged valve Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 6 Schematics Observe and Obey M 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 M Repair any machine damage or malfunction bef
56. he repair of this machine Attempting shortcuts may produce hazardous conditions M Immediately tag and remove from service a damaged or malfunctioning machine M Be aware of the following hazards and follow generally accepted safe workshop practices M Repair any machine damage or malfunction before operating the machine DANGER Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 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 Perform all troubleshooting ona firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series 5 1 Section 5 Troubleshooting Flow Charts Service Manual First Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts 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 The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Sche
57. hematic CWP amp StockPicker DC Models with Power Wheel Assist 6 5 Hydraulic Schematic CWP amp StockPicker Models ccccceeeeeeeeeeeeeeeeeetteeeees 6 6 Hydraulic Schematic CWP amp StockPicker Models with Power Wheel Assist 6 7 Section Seven Repair Procedures I iroJUCUO PR ER 7 1 Base Assembly Ped IMIeMOCKS 22 72 tente 7 2 1 2 Base Components issues 7 2 1 3 Hydraulic Manifold Components IWPS Models with Power Wheel Assist 7 4 1 4 How to Check the Resistance of a Valve Coil 7 5 Ground Control Box 2 1 Howto Test the Transformer AC Models sss 7 6 2 2 Howto Test the AC Contactor AC Models ssessssee 7 6 Hydraulic Power Units 3 1 Hydraulic Power Unit Components AC Models sssssse 7 8 3 2 Hydraulic Power Unit Components DC Models 1 21111 11 7 10 3 3 How to Remove the Hydraulic Power Unit AC Models 7 12 3 4 How to Remove the Hydraulic Power Unit DC Models 1 1 7 12 3 5 How to Remove the Hydraulic Pump 7 13 Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Vii Service Manual First Edition EEE E TABLE OF CONTENTS Section Seven Repair Procedures continued 3 6 How to Adjust the Pressure Relie
58. ht platform maximum CWP 8 7 ft 11 in 2 4 m CWP 12 11 ft3 in 3 4m CWP 15 14 ft 8 in 4 5 m Lift capacity All models 350 lbs 159 kg Lift capacity with outreach option 300 lbs 136 kg Power source DC models 12V AC models 110V or 220V Machine weight AC DC models CWP 8 740 830 lbs 336 376 kg CWP 12 800 890 lbs 363 404 kg CWP 15 880 970 lbs 399 440 kg Height stowed 63 in 160 cm Width 291 2 in 75 cm Length 59 in 149 9 cm Ambient operating 20 F to 135 F temperature 29 C to 57 C Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Current Protection Rating 220V AC models 8A fuse circuit breaker 5A fuse printed circuit board 15A fuse circuit breaker 5A fuse printed circuit board 175A fuse power unit 5A fuse printed circuit board 110V AC models DC models Specifications Platform dimensions 27 x 26 x 443 4 in 69 x 66 x 113 7 cm Standard platform I x w x h gated or sliding mid rail 22 x 18 x 443 4 in 56 x 46 x 117 cm Gated ultra narrow platform Ix w x h 26 x 20 x 443 4 in 66x51x113 7 cm Gated narrow platform Ix w xh 29 x 261 2 x 431 2 in 74 x 67 x 110 cm Standard fiber platform Ix w xh 26 x 22 x 431 2 in 66 x 56 x 110 cm Narrow fiber platform Ix w xh 30 x 28 x 431 2 in 76 x 71 x 110 cm 3 sided entry platform Ix w xh 30 x 28 x 431 2 in 76 x 71 x 110 cm Ex
59. ification uu a eden tante da DI a 2 4 Scheduled Maintenance Inspections Introduction sot RE EET TETTE EET UTE 3 1 Table A c id ee aes Mn Rime EE HR trs ler oies 3 2 Table Bia yw A ree EF RHAFF EF ad p estet uid docent ee kt es eue a 3 3 TAGS Ca Tp 3 3 Maintenance Inspection Report 3 4 Scheduled Maintenance Procedures LIMO QU lero e sez Cm 4 1 A 1 Inspect the Operator s and Responsibility Manuals 4 2 A 2 Inspect the Decals and Placards cccccceeeceeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneaeeess 4 2 A 3 Inspect for Damage and Loose or Missing Parts 22211111 4 3 A 4 Check for Hydraulic Leaks 2 0 2 cceeeeceeeeeeeeeeeeeeeeeeeaeeeeceeeeeseaeeeesaaeeseeneeeeeeaeees 4 3 A 5 Test the Base Operation ue 4 4 A 6 Check the Auxiliary Platform Lowering Operation 4 4 A 7 Check the Manual Platform Lowering Operation ssssss 4 4 A 8 Inspect the Battery and Battery Charger DC Models 1112222211111111 4 4 A 9 Inspect the Columns for Damage essen 4 5 A 10 Check the Sequencing Cables 4 5 A 11 Check the Interlock System for Proper Operation sssssssss 4 5 Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series V Service Manual First Edition a Z ZZ TABLE OF CONTENTS Section Four Scheduled Maintenance Procedures continued A 12 Test the
60. il ao RE eset te te i Activates N O dump valve 6 RESGNVOIT wee H 3 quarts 2 8 liters 7 DraimiplUQ p Drains reservoir 8 Sight GAUGE reet tr tte ta Hydraulic fluid level 9 Breather Cap eee Literie annt ers Reservoir vent 10 Piek UD MOT esata R ER R nn Filters hydraulic fluid 11 ONO ii EH E Seals reservoir 12 WU CI eit et Sailor 0 7 to 1 gallons per minute at 2000 psi 2 6 to 3 76 liters per minute at 138 bar 13 Check valve siennes One way valve for pump output 14 Motor seal iisiii finies Seals motor from contaminants 15 Motor Dealing eene Aligns motor shaft into pump 7 10 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures HYDRAULIC POWER UNITS eS 2 Se ey T Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 7 11 Section 7 Repair Procedures Service Manual First Edition HYDRAULIC POWER UNITS 3 3 How to Remove the Hydraulic Power Unit AC Models 1 Fully lower the platform turn the machine off remove the key and disconnect the power supply 2 Lower the base with the steer handle Remove the power unit cover 4 Tag disconnect and plug the hydraulic hoses Cap the fittings on the power unit Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen
61. in 1 8 inch 3 175 mm to even with each other Starting at the number 1 column torque the upper and lower glide pad bolts to 12 in lbs 1 356 Nm Hold the glide pad bolt and tighten the lock nut Be sure the glide pad bolt does not turn Repeat step 5 for each remaining upper and lower glide pad bolt on one side of the mast Start at the number 1 column and adjust each column working toward the carriage Repeat step 5 for all of the upper and lower glide pad bolts on the other side of the mast Make sure glide pad bolts are adjusted evenly on each side to maintain squareness of the columns Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition 9 5 How to Inspect the Lifting Chains Inspection Wear Rust and Corrosion Tight Joints Procedure Count out 16 chain links and measure pin to pin centerline dimension with a steel tape Note Be sure to measure a section of chain that moves over the idler wheels Visually inspect the chains for rust and corrosion Section 7 Repair Procedures i Z W SSS Inspection Failure When the length of the 16 links pin to pin measure more than 8 25 inches for 1 2 inch chain or 10 31 inches for 5 8 inch chain Evidence of rust or corrosion MAST ASSEMBLY Inspection Remedy Replace both chains on that column section Replace entire chain Do not repair just the affected portion of the chai
62. l 7 ohms Tee in pressure gauge at Inspect the mast for a ee port stamped mechanical bind such as of power unit Push in 1800 to the hold down bar not the control activate 2000 psi releasing properly or switch activate the up foreign objects that could function hold both have fallen in between switches and check the columns pressure less than 1800 psi On the power unit remove the return to tank hose off of the T port Activate the up function Remove the N C down fitting and plug the hose 1800 to and check for voltage at valve and inspect valve fitting leaving 3000 psi 2000 psi the N C valve coil down for contamination or gauge teed in at the P PS valve coil white black damage OR consult port fitting Push in the wire at the barrel end of Genie Industries Service control activate switch the lift cylinder Department activate the up function hold and check the pressure 12V DC Replace defective N O less than 1800 psi contact block for down function in platform Continued on the next control box page 5 16 Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts aa ZZ CHART 7 On the power unit remove and inspect the N O valve for contamination or damage Clean repair or replace valve and then perform pressure test again Continued from the previous page less than 1800 psi Adjust the pressure relief v
63. latform 5 outreach will collapse if a suitable block or brace is not used Locate the two fasteners which hold the lower sprocket housing onto the outreach Service Manual First Edition Loosen but do not remove both sprocket housing fasteners Push downward on the sprocket housing to remove any excess slack in the chain Tighten the sprocket housing fasteners Check the chain adjustment Refer to maintenance procedure B 8 Check the Chain Adjustment If chain cannot be adjusted to specification refer to 7 5 How to Replace the Outreach Chain 7 5 How to Replace the Outreach Chain CWPS Models 1 2 Fully lower the platform turn the key switch off Fully lower the base and disconnect the power supply Remove the platform See 7 1 How to Hemove the Platform Remove the fasteners on platform control box cover to access the control box mounting fasteners Remove the platform control box mounting fasteners Remove the platform control box from the outreach and set it aside Extend the outreach approximately 14 inches 36 cm and lock the handle in position Be sure the handle is locked Attach a overhead crane to the center brace pivot pin on the outreach Remove the fasteners that hold the outreach to the carriage 7 26 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures Crushing hazard When t
64. ld have full continuity Push the small triangular button on the top of the contactor and check the continuity Result Normally open contactors should have full continuity Normally closed contactors should have no continuity Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Section 7 Repair Procedures cured ee ane O W A O Z ZE I PLATFORM How to Test Power to Platform GFCI outlet 1 2 Fully lower the platform turn the key switch off Be sure the AC power supply is properly connected Connect an AC voltage tester or a small hand tool to the platform GFCI receptacle Test the voltage or test the hand tool operation Result The voltage should be 115V AC nominal or the hand tool should operate normally Push the black TEST button on the GFCI receptacle Result The voltage should be OV or the hand tool should not operate Push the red RESET button on the GFCI receptacle Result The voltage should be 115V AC nominal or the hand tool should operate normally 7 4 How to Adjust the Platform Outreach Chain CWPS Models 1 2 3 Fully lower the platform Turn the power off and remove the key Fully extend the platform outreach and lock the handle into position Be sure the handle is locked Place a block of wood between the carriage and the platform outreach to prevent the outreach from collapsing when the fasteners are loosened AWARNING Crushing hazard The p
65. ler wheel Visually inspect chain anchors M threaded 7 rod Visually inspect chain idler wheels Visually inspect chain link plates for cracks Misalignment of flats on all V heads Wear on pin heads or noticeable wear in the profile of the outside link plate AES RZ link plate wear Broken chain anchor fingers Replace both chains on that column section Do not repair just the affected portion of the chain Replace both chains on that column section Do not repair just the affected portion of the chain Check alignment of chain anchors and idler wheels Replace chain anchor Bent or damaged anchor Replace chain anchor Twisted or misaligned chain anchor Re align chain anchor to ensure even loading of chain Threaded rod not visible in inspection hole Idler wheels have badly worn flanges Replace chain anchor and threaded rod Replace idler wheel and check chain alignment Idler wheels have grooves worn into chain contact surface Cracks in any chain link plate Replace idler wheel Replace both chains on that column section Replace entire chain Do not repair just the affected portion of the chain Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures 6 1 How to Remove the Platform 1 CWP Models Place support blocks between
66. ls like battery gases 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 am Be sure that your workshop or work area F E is well ventilated and safely and NA i m adequately illuminated 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 load capacity Be sure any forklift overhead crane or Be sure that fasteners intended for FN 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 cs other fluids Use an approved container w Please be mindful of the environment iv Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Introduction Section One Section Two Section Three Section Four Table of Contents Important Infonmation 2 22 s w aa OE AEO dere w ret wa sde il Safety Rules General Safety Rules iii iii Specifications GWP Super S ries Models te et eren e ett EE ede ete 2 1 StockPicker Super Series Models ssssssssseeeenns 2 2 Performance Specifications 2 3 Bolt Torque Spec
67. lumn 7 20 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures 22 Slide the column out the bottom of the mast 23 Follow steps 19 through 22 for each remaining column If the chains are removed be sure to mark the location and label each chain before removal How to Assemble the Mast This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Thoroughly clean all columns 2 Secure the number 1 column to the saw horses and lay the chains out on the floor at the top 3 Apply a generous amount of Boe lube wax Genie part number 90337 to the inside and outside channels of each column 4 Slide the number 2 column into the number 1 column Be sure not to damage the slide block 5 Lay the number 2 column chains onto the floor Do not allow the chains to become twisted or dirty 6 Pick up the number 1 column chains and lay them inside the number 2 column Be sure not to twist the chains 7 Slide the number 3 column into the number 2 column Be sure not to damage the slide block 8 When the column is almost all the way in guide the number 1 column chains into the chain tension rocker on the number 3 column 9 Ins
68. matics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction Identify discovered Troubleshoot symptoms problem still exists Perform repair Return to service problem solved 5 2 Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Power Light Will Not Turn On AC Models Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the ground control box PC board fuse is not blown Check the power supply OV AC with a voltage meter 110V AC Check the voltage at OV AC terminal 3 on the key switch Put Pos lead of voltage meter on terminal 3 and Neg lead on the white wire from the pig tail 110V AC Check the voltage at ee terminal 4 on the key switch 110V AC Check the voltage at terminal 1 on the ov AC Emergency Stop button 110V AC Check the voltage at terminal 2 on the OV AC Emergency Stop button 110V AC Check the voltage at the black transformer wire OV
69. motor contactor 110V AC While pushing in the control activate switch and activating the up function hold both Replace the motor switches and check for contactor because of power at the N O damaged contacts terminals white and black wires on the motor contactor 110V AC Check the motor wiring OR consult Genie Industries Service Department CHART 6 Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 7 Machine Will Not Lift But Power Unit Will Operate AC Models Be sure the power unit reservoir is full and the breather cap has been While pushing in the control activate switch and activating the up function hold both switches and check for ov DC input voltage at the N O valve coil on the power unit Wait 1 second before checking voltage Put Pos lead of the voltage meter on the black wire and Neg lead on the green yellow grounding wire While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 12 black wire of the 13 pole terminal strip J1 This is a 1 second ON time delayed terminal 12V DC Replace or repair black ov DC Replace P C board installed j wire because of an open BE circuit infinite NRA of ohms Replace N O valve coi
70. mp Genie StockPicker Super Series 7 13 Section 7 Repair Procedures Service Manual First Edition HYDRAULIC POWER UNITS 3 6 How to Adjust the Pressure Relief Valve 1 Remove the power unit cover Remove the breather cap from the reservoir 3 Fill the reservoir up to the sight glass with Dexron ATF hydraulic oil equivalent Install the breather cap 5 Follow the appropriate operator s manual to set up the machine 6 Place the maximum load capacity in the platform Refer to the operator s manual or the load capacity decal on the machine to determine the maximum load capacity Be sure the load is secure 7 Hold the relief valve screw and loosen the lock nut 8 While activating the platform up function turn the relief valve screw clockwise just until the platform begins to raise 9 Fully lower the platform 10 Add an additional 30 pounds 14 kg to the platform Secure the additional weight 11 Raise the platform slightly 12 The power unit should not be able to lift the platform If the power unit lifts the platform turn the relief valve counterclockwise until the adjustment is correct 13 Hold the relief valve screw and tighten the lock nut Be sure the relief valve screw does not turn 14 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic
71. n Remove chain and inspect for cracked plates see inspection of cracked plates If no cracks are found lubricate chain with motor oil SAE 40 and re install chain Visually inspect the chains for lubrication Inspect chain link joints for easy movement When external surfaces are not protected with a layer of oil Joints that do not flex freely or are bound up Lubricate chain with motor oil SAE 40 If rust and corrosion is found refer to Failure Remedy for rust and corrosion If link plates or pins are bent or deformed replace entire chain Replace both chains on that column Do not repair just the affected portion of the chain Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 7 23 Section 7 Repair Procedures Service Manual First Edition MAST ASSEMBLY Inspection Raised or Turned Pins Chain Side Chain Anchors SA PUER anchors Idler Wheels idler wheel Cracked Link Plates Procedure Visually inspect for raised pins Inspection Failure Raised pins N th ch AlE Inspection Remedy Replace both chains on that column section Do not repair just the affected portion of the chain Visually inspect for turned pins by insuring all the flats on the V heads are aligned Visually inspect for wear patterns on heads of link pins and outside link plates where they contact the id
72. nce of a Valve Coil 1 Fully lower the platform turn the machine off and remove the key 2 Connectthe leads from an ohmmeter to the valve coil terminals Valve coil specifications Solenoid operated N O valve 10V 6 5 to 7 2 Q Solenoid operated N C valve 10V 7 8 to 9 5 Q Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 7 5 Section 7 Repair Procedures Service Manual First Edition Ground Control Box 2 1 How to Test the Transformer AC Models 1 Fully lower the platform turn the key switch off and disconnect the power supply 2 Open the ground control box and locate the transformer 3 Label and then disconnect all wiring from the transformer 4 Connect the leads from an ohmmeter to the following terminal combinations and check the resistance a yellow wire b black wire c white wire d brownwire e bluewire f red wire No 1 g red yellow wire h red wire No 2 Test Desired result brown wire to blue wire 20 to 22 Q black wire to white wire 16 to 19 Q yellow wire to white wire 16 to 19 Q red yellow wire to red wire 1 0 5 to 1 5 O red yellow wire to red wire 2 0 5 to 1 5 O red wire 1 to red wire 2 0 5 to 1 5 Q yellow wire to black wire 0 5 to 1 50 all other wire combinations no continuity infinite 2 2 2 How to Test the AC Contactor AC Models 1 Fully lower the platform turn the key switch off and discon
73. nd qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie CWP Super Series Operator s Manual and the Genie StockPicker Super Series Operator s Manual MI Be sure that all necessary tools and parts are available and ready for use M Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions 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 General Repair Process Identify Troubleshoot symptoms problem still exists Perform repair Return to service problem solved Symbols Legend sr Indicates the presence of a hazard LE that will cause death or serious injury Indicates the presence of a hazard that may cause death or serious injury Indicates the presence of a hazard ACAUTION A that will or may
74. ndicate damage 4 Re check the tension on each sequencing 1 Lower the platform cable 2 Check the tension on each sequencing cable by 5 Repeat adjustment for each cable as required grasping the cable halfway down the column and pulling the cable from one side then to the other Measure the total distance between the two points this is the maximum deflection Raise and lower the platform through three complete cycles and re check deflection a adjustment tension nut b threaded swage end c Sequencing cable Specification Maximum Deflection 11 2 to 21 2 inches 3 8 to 6 4 cm Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 4 11 Section 4 Scheduled Maintenance Procedures Service Manual First Edition E UM EZ Z TABLE B PROCEDURES B 8 Check the Chain Adjustment CWPS Models Equipped with Platform Outreach Detection of a improperly adjusted platform outreach chain is essential for safe machine operation Failure to detect an improperly adjusted platform outreach chain could result in unsafe operating conditions and may cause injury and component damage 1 Fully lower the platform 2 Fully extend the outreach and lock the handle 3 Locate the two chains between the lower sprocket and the lower brace 4 Grasp the two chains and lightly pinch them together Result There should be a minimum of a 1 4 inch 6 4 mm gap between the chains If the result
75. nect the power supply 2 Open the ground control box and locate the AC contactor 3 Label and then disconnect all wiring from the contactor 4 Connect the leads from an ohmmeter to the following terminal combinations and check the continuity resistance terminal no 1 terminal no 8 terminal no 6 terminal no 2 terminal no 4 terminal no 0 oOaQ 070 9 Test Desired result terminal 0 to 1 80 to 85 Q all other terminal combinations no continuity infinite Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures mra z This page intentionally left blank Part No 40460 Genie CWP Super Series 8 Genie StockPicker Super Series 7 7 Section 7 Repair Procedures Service Manual First Edition Hydraulic Power Units 3 1 Hydraulic Power Unit Components AC Models Index No Description Function 1 115 230V AC electric motor Single phase 2850 3450 rpm 50 60 Hz 2 CapacitOl aiu Na ciae TU eu Motor start circuit 3 Pressure relief valve Hydraulic relief valve adjustment 4 Solenoid operated N O dump valve Diverts pump output back to reservoir during motor start up 5 TOV DC Coil aa doc cies AA ienna Activates N O dump valve 6 RESSO pa 3 quarts 2 8 liters 7 Drainiplug eri reet tena Drains reservoir 8 Sight ga
76. nit should not be able to raise the platform If the hydraulic power unit is unable to lift rated load or lifts more than rated load see Repair procedure 3 6 How to Adjust the Pressure Relief Valve B 6 Test the Power To Platform Operation AC power to the platform is intended to be an extension cord to the platform for using hand tools 1 Connect an appropriate extension cord to the AC power supply cord at the base of the machine 2 Inthe platform plug a power drill or similar tool into the AC outlet Result The tool should operate normally GFCI outlet may require that the outlet be reset with the reset button Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 4 Scheduled Maintenance Procedures ja m See A TABLE B PROCEDURES B 7 3 Hold the threaded swage end of the cable from i turning and adjust the tension nut to obtain Adjust the Seguencing Cables correct tension deflection Turn the adjustment nut clockwise to increase the MI ine proper CIE RD TD tension or counterclockwise to decrease the cables is essential for safe machine operation An unsafe working condition exists if the seguencing tensi cables are improperly adjusted A frequent check Component damage hazard Do of the sequencing cables allows the inspector to ACAUTION not exceed the recommended identify changes in the operating condition that tension might i
77. ore operating the machine Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie CWP Super Series Operator s Manual and the Genie StockPicker Super Series Operator s Manual MI Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section Electrical Schematics Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics 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 AWARNING General Repair Process Malfunction discovered Identify L gt Troubleshoot symptoms Perform repair Return to service solved Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 6 1 Section 6 Schematics Service Manual First Edition Symbols Legend Electrical Symbols TB20 118 980 Wire color Terminal with cable number 15AMP Circuit breaker Solenoid or relay coil LA OP BLK 21 rex i s Light T circuits connect at terminal Circuits crossing Diode no connection
78. p down switch in the down direction Result Platform should lower A 7 Check the Manual Platform Lowering Operation Detection of a manual lowering malfunction is essential for safe machine operation An unsafe working condition exists if the manual lowering function does not operate in the event of a main and auxiliary power failure 1 Raise the platform slightly 2 Activate the manual lowering valve located at the bottom of the hydraulic cylinder Result Platform should lower A 8 Inspect the Battery and Battery Charger DC Models Proper battery and charger 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 Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water AWARNING 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 4 4 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 3 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 4 Install the vent caps If equipped Set the battery charger AC Selector switch to the proper voltage 6 Set the
79. r Super Series 3 3 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Inspection Report Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this page to use for eachinspection 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 maintenance tables in this section and the step by step procedures in section 4 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 unacceptable R repaired Comments Checklist A YN R Checklist B Refer to Table A Refer to Table B A 1 Operator s B 1 Electrical wiring and Responsibility manuals B 2 Welds A 2 Decals and placards B 3 Battery A 3 Damage loose or B 4 and lubricate missing parts columns A 4 Hydraulic leaks B 5 Lifting capacity A 5 Testbase operation B 6 Power to platform operation A 6 Auxiliary lowering operation B 7 Sequencing cables A 7 Manuallowering B 8 ay BUU operation a moues
80. rate properly or either Emergency Stop button fails to stop all the machine functions Each function should operate smoothly and be free of hesitation jerking and unusual noise 1 Turn the key switch to the on position and pull out the red Emergency Stop button to the on position Result The power light should be on 2 Twist to release the red Emergency Stop button at the platform controls 3 Push in the control activate button and rotate to the up position then the pown position Result Platform up and down functions should operate smoothly 4 Push in the Emergency Stop button at the platform controls to the orr position and test up and down functions Result Up down functions should not operate 5 Twistto release the red Emergency Stop button at the platform controls 6 Push in the Emergency Stop button at the ground controls to the orr position Then test up and down functions Result Up down functions should not operate A 13 Inspect the Lifting Chains and Idler Wheels Maintaining the lifting chains and idler wheels in good condition is essential to safe machine operation Failure to find and replace damaged chains or idler wheels could result in unsafe operating conditions and may cause component damage 1 Raise the platform approximately 3 feet 1 m 2 Visually inspect the chains and idler wheels near the top of each column for the following excessive wear corrosion or damage broken
81. read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations MI You have the appropriate tools lifting equipment and a suitable workshop Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series lii Introduction Service Manual First Edition 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 number one priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Indicates the presence of a hazard that will cause death or serious injury Indicates the presence of AWARNING a hazard that may cause death or serious injury Indicates the presence of ACAUTION a hazard that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information other protective clothing if the situation G 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 Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materia
82. sed with the slider bracket when the cable striker bracket is pulled down Tighten the mounting fasteners 11 Raise the platform 12 Pull the steer handle away from the machine to be sure the steer handle remains in the locked position Re adjust if necessary Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 7 3 Section 7 Repair Procedures Service Manual First Edition Torque 25 35 ft lbs 34 41 Nm 25 35 ft lbs 34 41 Nm 25 35 ft lbs 34 41 Nm BASE ASSEMBLY 1 3 Hydraulic Manifold Components CWPS Models with Power Wheel Assist Index Schematic No Description Item Function 1 Check Valve aceites Ont System pressure 1 11 2 2 position 3 way spool valve AM HNN Ste 3 2 position 3 way spool valve Sr Forward nein onec diess 4 2 position 3 way spool valve Jesse AITUNCHONS i nant Plug Torque Specifications 25 35 ft lbs 34 41 Nm Description Hex Size Torque Description Hex Size Torque SAE No 2 1 8 50 in lbs 6 Nm SAE No 8 5 16 50 ft lbs 68 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 10 9 16 55 ft lbs 75 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 12 5 8 75 ft lbs 102 Nm 7 4 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures a mai BASE ASSEMBLY 1 4 How to Check the Resista
83. setting See incorrect Valve See Repair Maintenance procedure procedure How to Adjust Test the Lifting Capacity the Pressure Relief Valve correct Consult Genie Industries Service Department Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series 5 27 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 14 Auxiliary Check the low auxiliary battery indicator red Replace the 8 1 5V AA Platform LED light fon itis H showing a low voltage Loweri ng condition Will Not off Operate Check the auxiliary lowering battery holder to make sure that the e PH TAR batteries have been installed yes Disconnect the main Check for power at Check the auxiliary power source Check for terminal 1 of the 3 pole lowering battery holder power at terminal 9 and OV DC terminal strip J2 in the wires red wire connects 9A of the 13 pole terminal base control box Put the to terminal 1 and black strip J1 in the base positive lead of the wire connects to terminal control box voltage meter on terminal oV DC 2 for loose connections 1 and the negative lead at the J2 terminal strip on terminal 2 the OR check for defects in grounding terminal the battery holder and its wires 12V DC 12V DC Replace the P C board Correct the loose OR contact Genie connections at the J2 Industries Service terminal strip OR replace Department the battery holder If pow
84. small post 3 Connect 12V DC to the small post and a ground wire to the case of the solenoid then test the following terminal combinations Test Desired result 2 large posts continuity zero Q Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 7 15 Section 7 Repair Procedures Service Manual First Edition Power Pack 4 1 How to Change a Power Pack 1 Fully lower the platform and disconnect the machine from the power source Lower the base with the steer handle Remove the power unit cover Separate both quick disconnect couplers from the ground control box Unplug the quick disconnects DC models Disconnect the battery cables from the motor Remove the breather cap from the hydraulic power unit and install a pipe plug into the filler hole Label disconnect and plug the hydraulic hoses from the power unit Bodily injury hazard Sprayin ACAUTION 105 RAR 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 Support the power unit assembly and remove the mounting bolts Crushing hazard When mounting ACAUTION bolts are removed power unit assembly will become unbalanced and may fall if not properly supported 10 Remove the power unit assembly 11 Remove the ground control box assembly mounting bolts Remove the control box
85. st the steer handle interlock cable See 1 2 How to Adjust the Steer Handle Interlock Cable Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Section 7 Repair Procedures Service Manual First Edition MAST ASSEMBLY 5 3 How to Adjust the Lifting Chains 1 Fully lower the machine and check to see if all the columns except the carriage are even at the top The chains are adjusted correctly if all the columns are even at the top To adjust column chains 2 Markthe column to be adjusted 3 Raise the platform 6 feet 2 m 4 Turn the adjustment lock nuts evenly on both chain terminals clockwise to raise the column or counterclockwise to lower the column 5 Fully lower the machine and recheck the alignment of the columns Re adjust if necessary 6 Checkto make sure the chain terminals on each column have equal tension and the lock nuts are tight 7 Check to be sure the chain tension rockers are centered in the inspection hole of the column 5 4 How to Adjust the Glide Pads 1 Fully lower the platform turn off the machine and remove the key Locate the upper and lower glide pad bolts below each top roller wheel bolt on both sides of the columns Hold each glide pad bolt and loosen the lock nut on all the glide pads Turn all the glide pad bolts clockwise until the glide pads make contact with the column Adjust both sides of the mast Be sure the sides of the columns are with
86. t terminal 11 red wire of the 13 pole terminal strip J1 in the base control box ov DC 12V DC While pushing in the control activate switch and activating the up function hold both switches and check for power at the motor contactor coil terminal 1 red wire Put Neg lead of the voltage meter on terminal 0 green yellow wire OV DC 12V DC Continued on the next page Replace the red wire because of open circuit between the control activate switch contact block and the up switch contact block OV DC Replace up switch N O contact block Replace 16 6 cable because of open in orange wire OR repair open in quick disconnect under base control box Replace P C board OR consult Genie Industries Service Department Relocate Neg lead of the voltage meter at terminal 10 green yellow wire of AE the13 pole terminal strip Repair open circuit in red wire J1 12V DC Repair open circuit in green yellow wire Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts previous page Continued from the Perform a continuity test no across the motor continuit contactor coil terminals 1 and 0 Replace the motor contactor continuity Check for 110 volts AC at the common terminals white and black wires of AE da faulty circuit the
87. t the Decals and Placards Maintaining all of the safety and instructional decals and placards in good condition is essential for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using a 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 Refer to the Decals section in the Genie CWP Super Series Operator s Manual or the Genie StockPicker Super Series Operator s Manual and use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed 4 2 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 3 Inspect for Damage and Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including electrical cables and wiring electrical cable
88. t to access the mounting screws 8 Remove the control box and AC outlet and set aside 9 Remove the steer handle interlock cable bracket from the mast 10 Remove the adjustment nuts from all the sequencing cables 11 Slide the carriage towards the top enough to remove the tension on the lifting chain 12 Slide the column that is under the carriage towards the top about 6 inches 15 2 cm to access the idler wheel mounting fasteners 13 Hold the idler wheel axle from turning by placing a small screwdriver in the hole of the axle Remove the axle mounting fasteners then remove the idler wheel assembly When the idler wheel assemblies are removed be sure to label the location of each idler wheel assembly 14 Remove the adjustment nuts from the chain tension rocker on the carriage 15 Slide the carriage out the bottom of the mast assembly 16 Lay the chains out on the floor at the top of the mast Do not allow the chains to become twisted or dirty 17 Remove the adjustment nuts from the chain tension rocker on the top column 18 Slide the column out the bottom of the mast 19 Push the next column towards the top of the mast to access the idler wheel assembly mounting fasteners 20 Hold the idler wheel axle from turning by placing a screwdriver in the hole of the axle Remove the axle mounting fasteners then remove the idler wheel assembly 21 Remove the adjustment nuts from the chain tension rocker on the co
89. tall the adjustment nuts onto the number 1 column chains 10 Lay the number 3 column chains on the floor Do not allow the chains to become twisted or dirty MAST ASSEMBLY 11 Pick up the number 2 column chains and lay them inside the number 3 column Be sure not to twist the chains 12 Follow steps 4 through 11 for each remaining column and the carriage 13 After all the columns are together the idler wheel assemblies need to be installed 14 Rotate the mast over onto the carriage side 15 Remove the tension from the lifting chains by pushing the top column toward the bottom of the mast 16 Install the idler wheel assembly into the top of the number 2 column Tighten the mounting fasteners Push or pull the columns to increase the space for mounting the idler wheel assembly Be sure the removal hole in the idler wheel axle is accessible Be sure all idler wheels rotate with no excessive side to side movement and be sure that they do not rub on the inside of the column Replace worn shims if necessary 17 Follow steps 15 and 16 for each remaining idler wheel assembly 18 Be sure that all of the idler wheel axle mounting fasteners are flush with the column Component damage hazard The ACAUTION roller wheels will become damaged if the idler wheel axle mounting fasteners are not flush with the column 19 Reassemble the machine Then adjust the lifting chains See 5 3 How to Adjust the Lifting Chains 20 Adju
90. the Maintenance Tables 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 Table or Checklist Daily A Quarterly every 150 hours or three months A B Annual A B C Maintenance Tables The maintenance tables contained in this section provide summary information on the specific physical requirements for each inspection Complete step by step instructions for each scheduled maintenance procedure are provided in section 4 Scheduled Maintenance Procedures 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 Store completed forms for three years Part No 40460 Genie CWP Super Series amp Genie Stock Picker Super Series 3 1 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Tables Table A Dealer Tools are New parts service required required suggested A 1 Inspect the Operator s and Responsibility Manuals A 2 Inspect the Decals and Placards A 3 Inspect for Damage and Loose or Missing Parts A 4 Check for Hydraulic Leaks ra ra A 5 Test the Base Operation A 6 Check the Auxiliary Platform Lowering Operation A 7 Check the Manual
91. tion Section 5 Troubleshooting Flow Charts Power Light Will Not Turn On DC Models Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the battery cables are connected Be sure the ground control box PC board fuse is not blown Check the battery pack ov DC voltage 12V DC Check the voltage at terminal 3 on the key switch Put Pos lead of voltage meter on terminal 3 and Neg lead on terminal 10 of 13 pole terminal strip J1 12V DC Check the voltage at terminal 3 on the key M switch 12V DC Check the voltage at ones terminal 4 on the key switch 12V DC Check the voltage at terminal 1 on the ov DC Emergency Stop button 12V DC Check the voltage at terminal 2 on the 0V DG Emergency Stop button 12V DC Check the voltage at terminal 3 black wire of 0V DC 3 pole terminal strip J2 Continued on the next page Charge the battery OR check the battery condition and replace a bad battery Trace the black input wire back to the motor start solenoid and repair open in the wire Trace the black wire from terminal 3 back to the fuse and check for damage Replace the key switch contact block Trace the black wire from terminal 1 back to the key switch and repair open in wire Replace the Emergency Stop button Trace the black wire from terminal 3 o
92. tom of the mast onto one saw horse and continue to lower the mast until the top is resting on the second saw horse The mast should be resting on the platform side The level sensing system will not operate correctly if the number 1 column is not perpendicular to the base front to back and side to side Consult Genie Industries Service Department Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series Section 7 Repair Procedures Service Manual First Edition MAST ASSEMBLY How to Disassemble the Mast This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the mast See How to Remove the Mast Assembly 2 Remove the mounting fasteners from the cylinder mounting plates 3 Remove the retaining bolt from the clevis block on the lift cylinder rod end a top of no 1 column b retaining bolt c clevis block 4 Support the cylinder and carefully slide it out of the bottom of the mast 5 Carefully rotate the mast until it is resting on the back of the number 1 column 6 Remove the mast covers CWPS Models with Platform Outreach Remove the outreach assembly from the carriage 7 Remove the cover from the platform control box and AC outle
93. tra large platform Ix w xh Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 2 1 Section 2 Specification S Service Manual First Edition SPECIFICATIONS Specifications Platform Specifications Height working maximum Width 31 in 79 cm SP 12 17 ft 3 in 5 3 m Length 42 in 107 cm SP 15 20 ft 8 in 6 3 m Height 45 in 114 cm Height platform maximum Ambient operating 20 F to 1359F SP 12 11 ft 3 in 3 4m temperature 29 C to 57 C SP 15 14 ft 8 in 4 5m Airborne noise emissions 80 dB Machine lift capacity 500 Ibs 227 kg Maximum sound level at normal operating workstations Platform capacity 400 Ibs 181 kg A weighted Material storage compartment capacity 150 Ibs 68kg Current Protection Rating 220V AC models 8A fuse circuit breaker Power source 5A fuse printed circuit board DC models 12V 110V AC models 15A fuse circuit breaker AC models 110V or 220V 5A fuse printed circuit board DC models 175A fuse power unit Machine weight AC DC models 5A fuse printed circuit board SP 12 850 940 Ibs 386 427 kg SP 15 930 1020 Ibs 425 463 kg Height stowed 751 2 in 192 cm Width 31 in 79 cm Length SP 12 70 in 178 cm SP 15 701 2 in 179 cm 2 2 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Platform function speed Section 2 Specifications IL LLL R
94. uge ue eere teet cuc Hyaraulic fluid level 9 Breather Cap ied etes eni Reservoir vent 10 Lelis GUINEA PCE Filters hydraulic fluid 11 O LDT Re FFAN Seals reservoir 12 PUttip is D ARR eerie 0 5 to 0 6 gallons per minute at 2000 psi 1 89 to 2 27 liters per minute at 138 bar 13 Check valve uide uen One way valve for pump output 14 Mot r Seal suucaszsctw ee eerte us une Seals motor from contaminants 15 Motor bearing tritt Aligns motor shaft into pump 7 8 Genie CWP Super Series amp Genie StockPicker Super Series Part No 40460 Service Manual First Edition Section 7 Repair Procedures HYDRAULIC POWER UNITS AO O Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 7 9 Section 7 Repair Procedures cum ee east HYDRAULIC POWER UNITS Service Manual First Edition 3 2 Hydraulic Power Unit Components DC Models Index No Description Function 1 12V DC electric motor ssssessessss 12V DC standard duty 1 terminal 180 amp at 2650 psi 183 bar 2 Electric motor starter solenoid Relay connecting power supply to electric motor 3 Pressure relief valve esses Hyaraulic relief valve adjustment 4 Solenoid operated N O dump valve Diverts pump output back to reservoir during motor start up 5 10V DG Co
95. use death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION that will or may cause serious injury or damage to the machine Indicates special operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 40460 Genie CWP Super Series amp Genie StockPicker Super Series 4 1 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table A Procedures A 1 Inspect the Operator s and Responsibility Manuals Maintaining the operator s and responsibility manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided at the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to be sure the storage container and lid are present and in good condition 2 Check to make sure that the operator s and responsibility manuals are present and complete in the storage container at the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacement manuals are needed A 2 Inspec
96. ut Release lift lockout plate Cable Chart 11 Part No 38139 Genie CWP Super Series amp Genie StockPicker Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 12 Platform Will Not Hold In Up Position Activate the platform up function while latform simultaneously activating baie u Inspect the hydraulic the manual lowering R system for valve Test the unit contamination platform wont hold up On the power unit remove the return to tank hose off the T port fitting and put it into a bucket leaking Replace or repair down and activate the platfom valve up function Check for leaking from the hose not leaking While platform is drifting gt is the motor spinning S or repair check backwards Remove and rebuild the hydraulic lift cylinder OR contact Genie Industries Service Department Genie CWP Super Series amp Genie StockPicker Super Series Part No 38139 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 13 Power Unit WAR ine m ES ee the chen OR H H ote on DC models the check battery condition Will Not Lift low battery indicator red voltage and replace bad battery Rated Load LED light would be on OR use the appropriate indicating a low voltage power cord OR consult situation Genie Industries Service Department Check the pressure relief Adjust the pressure relief valve
97. with outreach A 8 Battery and charger DC models A9 Columns Checklist C A 10 Sequencing cables Refer to Table C A 11 Interlock system C 1 Casters and wheels operation C 2 Mastassembly A 12 Powerand C 3 Lifting chains function controls C 4 Hydraulic oil A 13 Lifting chains and idler wheels C 5 Auxiliary platform lowering batteries A 14 Breather cap Genie CWP Super Series amp Genie Stock Picker Super Series Part No 40460 Service Manual First Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of these machines M Scheduled maintenance inspections shall be completed daily frequently every 3 months and annually as specified on the maintenance report Failure to properly complete each AWARNING inspection when required may result in death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating machine M Keep records on all inspections for three years 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 Indicates the presence of a hazard A DANGER that will ca

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